Product Name:  
Gen V IWG (BorgWarner EFR)  
Gen V IWG  
Product Description:  
Product Number:  
TS-0620-4XXX  
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V1.00 Rev B  
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Document Version:  
IMPORTANT NOTES ON YOUR INTERNAL WASTEGATE ACTUATOR  
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Turbosmart accepts no responsibility whatsoever for incorrect installation of this product which is potentially hazardous and can cause serious  
engine damage or personal injury.  
Consult your local specialist before setting your desired boost pressure, setting boost beyond your engines capability may result in engine  
damage.  
Use only high-quality fittings ensuring maximum sealing reliability. Optional Turbosmart fitting kit available.  
RECOMMENDATIONS  
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Allow for adequate cool airflow around the diaphragm housing  
DO NOT Mount the wastegate so that the top diaphragm housing is less than 100mm from a heat source  
Turbosmart recommends that your wastegate is fitted by an appropriately qualified technician.  
Turbosmart recommends that the engines Air/Fuel ratio is checked while setting the desired boost pressure, as any increase in  
boost pressure can cause the engine to run “LEAN”, resulting in possible engine damage.  
Turbosmart recommends that boost pressure is set using a dynamometer and not on public roads.  
Turbosmart recommends that a boost gauge be permanently fitted to the vehicle.  
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KIT CONTENTS  
Please check that the following items have been provided in your Gen V Wastegate kit.  
Part  
1
Description  
Turbosmart Gen V IWG  
Rod Kit  
Use  
Main unit  
2
3x rods for fitment to BorgWarner EFR series turbos  
3x springs: 1x inner, 1x middle, 1x outer (1x spring pre-installed)  
2x 1/8” NPT nipple, 4x 1/8” NPT blanking plugs (1x pre-installed)  
Turbosmart sticker  
3
Spring kit  
4
Fitting kit  
5
Turbosmart Sticker  
Turbosmart Position Sensor  
IWG Actuator Collar Tool  
6
Turbosmart HE Sensor (Sensor Cap Model Only)  
Remove actuator collar to change spring  
7
Figure 1 - Kit Contents  
1
CONTENTS  
KIT CONTENTS..........................................................................................................................................................1  
TOOLS REQUIRED....................................................................................................................................................2  
SUGGESTED SEALANTS..........................................................................................................................................2  
GEN V WASTEGATE OVERVIEW..............................................................................................................................3  
FITTING YOUR GEN V WASTEGATE........................................................................................................................4  
HOW TO CHANGE YOUR GEN V WASTEGATE SPRING.........................................................................................6  
ACHIEVING YOUR TARGET BOOST PRESSURE ....................................................................................................7  
HOW TO USE A SENSOR CAP ON YOUR GEN V WASTEGATE .............................................................................8  
TROUBLESHOOTING................................................................................................................................................8  
TOOLS REQUIRED  
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10mm open end spanner  
Square drive ratchet wrench  
Torque wrench (3/8” drive)  
Non-marking spanners to tighten fittings  
3/16” hex key  
Turbosmart IWG collar tool  
SUGGESTED SEALANTS  
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Loctite 243 Thread locker  
Loctite 567 Thread Sealant  
2
GEN V WASTEGATE OVERVIEW  
“Top” Air Port  
HE Sensor  
1/8” NPT  
(Sensor model only)  
“
1
Bottom” Air Port  
/8” NPT  
Master Collar  
Mounting Studs  
Suit BW EFR  
Bracket)  
Ball Joint  
(
Preload Locking Nut  
Preload Adjuster Nut  
1
rods  
of 3 actuator  
(length depends  
on type of EFR  
turbo)  
Figure 2 – Gen V Wastegate Overview  
3
FITTING YOUR GEN V WASTEGATE  
Mounting your New Turbosmart Gen V IWG  
Wastegate  
1
Slide the actuator head through the BorgWarner mounting  
bracket, be sure the ball joint assembly has been removed form  
the actuator canister otherwise the unit cannot be assembled  
onto the bracket. Once mounted on the bracket, secure nuts to  
hold actuator in place, be sure at this point to determine the  
orientation of the actuator as it can be flipped 180º on the  
actuator bracket to allow for fitting clearance, or aligning the  
actuator to your liking without need to disassemble the actuator.  
CAUTION!  
Ensure nuts are tightened  
Install Rod of Choice  
3
Depending on the type of BorgWarner EFR turbocharger, they  
are available in different frame sizes, such as B1 and B2, and  
some are available in twin or single scroll configuration. As a  
result, we have provided all 3 rods that may be required for your  
turbocharger configuration. Simply select the rod length that  
allows for enough rod stick-out on the turbocharger actuator flap  
once installed. Generally, there is roughly ~5-10mm worth of  
stick-out on the wastegate clevis mount.  
Select rod that will provide enough stick out on wastegate  
through hole mount in order to correctly tighten nuts either side  
of wastegate actuator flap mount.  
Figure 3 – Install Actuator through bracket  
Figure 4 – Actuator secured onto bracket  
Install the ball joint  
2
Once the actuator has been mounted to the bracket, install the  
ball joint onto the main shaft out the actuator, orientation of the  
ball joint is not important. Use the flats machined into the ball joint  
to hold the ball joint in place as you tighten the nut on the main  
shaft to prevent unnecessary movement of the ball joint during  
operation.  
4
Once the correct rod has been confirmed, install 1x nut onto each  
end of the rod, install rod through the wastegate actuator flap arm  
first, then slide up and screw into the ball joint until bottoms out,  
then tighten with backup nut firmly.  
To apply 1mm/0.039” preload, simply turn the adjuster nut 1 full  
turn in the clockwise direction.  
To lock the actuator in this position, turn the locking nut by hand  
until finger tight, then proceed to tighten nut firmly to secure  
actuator in place. (6.5Nm / 4.8 ft lb)  
If a regulated air source is available on-hand, apply the air  
pressure of the spring installed to the actuator (5, 7 or 14psi) and  
observe the rod, the rod should begin to move slowly and freely  
over the range of travel as air pressure increases. If the rod does  
not move at all with increasing air pressure, proceed to  
troubleshooting.  
Applying Actuator Preload / Ensuring  
Wastegate Flap is Closed  
Start Engine and Check for Leaks  
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5
Congratulations, your Gen V wastegate is installed and ready for  
use. Double check all fittings, lines and mountings then proceed  
to start engine and check for leaks.  
CAUTION!  
This step is important  
In order to ensure the actuator does not suffer any  
stiction/temperature creep issues or the wastegate flap does not  
stay slightly open, it is important to apply a small amount (1mm/  
0.039”) of preload to the wastegate actuator.  
To correctly preload the wastegate, ensure wastegate flap is in  
the full closed position by holding the actuator flap as far closed  
as possible, wind the adjuster nut onto the back face of the  
actuator flap as shown below (in red) until hand tight  
5
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HOW TO CHANGE YOUR GEN V WASTEGATE SPRING  
The Gen V wastegate has a variety of springs to suit different boost levels. Turbosmart provides the Gen V wastegate pre-installed  
with a 14psi spring. With your wastegate 3 springs will be provided, 5psi inner, 7psi middle and 14psi outer. Different spring  
combinations may be required to suit different boost requirements and tuning.  
Remove Wastegate From Turbocharger  
Remove Top Cap (cont.)  
1
2
Remove boost pressure source hose from the wastegate  
Remove preload from wastegate by undoing preload nuts  
Remove ball joint locking nut  
Remove rod from actuator and turbo assembly  
Remove ball joint assembly  
Remove wastegate actuator from bracket  
CAUTION!  
Allow engine to cool down before removing your Gen V  
wastegate  
Remove Top Cap  
2
Prior to removing the Gen V wastegate cap, remove all fittings  
from the ports. Press down with light to medium load on the cap  
in a press or vice. Unscrew locking collar with the large end of  
the provided collar tool in an anti-clockwise direction until  
completely disengaged and slowly remove tension from the  
press or vice allowing the spring to expand, finally remove cap  
when the spring has stopped expanding.  
CAUTION!  
Use soft jaws to prevent cosmetic damage  
Configure wastegate with preferred spring combination of inner,  
middle and outer springs  
Familiarise Yourself with Cap and Body  
Notches  
3
Locate cap and body notches and grooves which dictate the  
alignment of the cap. These notches are used to locate the cap  
onto the body and must be aligned prior to compression of the  
cap onto the body  
CAUTION!  
Ensure notches are aligned and seated home correctly prior  
to exerting force to tighten collar, permanent damage will  
occur if these are not aligned correctly.  
6
Reinstall Gen V Wastegate  
5
Install wastegate actuator assembly to bracket  
Install ball joint assembly  
Install ball joint lock nut  
Install rod to ball joint and turbocharger  
ply wastegate preload  
ck adjuster nuts  
nnect wastegate signal lines and check for leaks  
an adjustable air source is available, connect to signal ports  
d check for smooth free operation of wastegate, if wastegate  
es not move with increasing air pressure, proceed to  
ubleshooting.  
Using a press or vice, compres
the notches are remaining alig
home onto the body, screw
clockwise direction. While still
collar further with the collar tool
ACHIEVING YOUR TARGET BOOST  
PRESSURE  
here are various factors involved in achieving your target  
boost pressure including.  
CAUTION!  
Maintain downward pressure on cap while tightening collar  
or non-repairable thread damage will occur.  
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The size of the spring fitted in your wastegate i.e. the boost  
pressure achieved by the wastegate spring only.  
The desired level of boost pressure and the difference  
between this and your wastegate spring pressure.  
The size of your turbocharger and wastegate and the resulting  
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exhaust manifold backpressure in your system.  
Turbosmart recommends the ideal setup for achieving your  
target boost pressure is to use the Gen V Wastegate in  
conjunction with a Turbosmart e-Boost controller.  
IMPORTANT NOTES ON SETTING THE WASTEGATE  
SPRING PRESSURE  
A stiffer spring should only be used when necessary. The Gen V  
Wastegate allows for different combinations of spring pressures.  
All springs that are adaptable with the Gen V Wastegate are  
shown in the table below. The tuner can use combinations of up  
to 3 springs to achieve the following base boost pressures. To  
aid in the identification of these springs they are supplied colour  
coded. If this colour coding is not clear please use the  
dimensions in the following table to identity the wastegate spring.  
Please see the following detailed instructions on setting your Gen  
V Wastegate’s spring pressure. The springs chosen should be  
rated to the lowest boost level desired.  
Reinstall fittings to the cap of the wastegate using fresh Loctite  
567 thread sealant.  
Table 1: Spring Chart  
Location  
Pressure  
Inner  
Middle  
7psi  
Outer  
14psi  
5psi  
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5
psi  
psi  
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7
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12psi  
14psi  
19psi  
21psi  
26psi  
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HOW TO USE A SENSOR CAP ON YOUR GEN V WASTEGATE  
Wiring  
CAUTION!  
7
To ensure longevity from the sensor, ensure adequate  
airflow is supplied directly to the sensor to avoid  
overheating or sensor failure.  
Your new Turbosmart sensor cap comes with sensor pre-  
installed into the cap with unterminated wires for you to fit the  
Turbosmart HE sensor has an operation temperature  
window of -40C up to 170ºC (340ºF) junction temperature,  
for temperatures outside of this window the VOUT will  
revert to less than 2.5V  
Temperature exposure above 260ºC (500ºF) can cause  
permanent damage to the sensor.  
Calibration*  
8
Rod Travel (mm)  
V
OUT  
0
2
4
6
8
0.439  
1.21  
1.58  
1.84  
2
Wire  
Red  
Note  
Rating  
Sensor Supply (Vsup  
)
4.5-5.5 Vdc  
0V  
10  
12  
14  
16  
18  
2.13  
2.21  
2.27  
2.32  
2.36  
Black Sensor Ground (V )  
0
White Sensor Output (Vout  
)
0-Vsupply  
Connect the wires to your data logger accordingly. Use a high-  
quality connection to reduce noise and calibration fluctuation.  
Ensure that the wiring is properly shielded from external heat  
sources.  
NOTE! For best results, each wastegate should be calibrated  
to your setup.  
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TROUBLESHOOTING  
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Wastegate not actuating - Confirm signal hose is plumbed to a pressure only source, confirm preload during installation  
Poor wastegate actuation - Ensure signal hose is not shared and is sourced as close to the compressor as possible, check seal  
on fittings  
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Poor wastegate actuation – Confirm no obstructions in actuator rod path  
Boost creeping at high rpm - Wastegate flow path is poor, wastegate is too small for the application, ensure ball joint is not  
seized  
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Failing the above, submit a technical request to tech@turbosmart.com.au with information of your engine configuration and  
photos of installation  
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