Product Name:  
IWG75 HP  
Product Description:  
High pressure Internal  
Wastegate Actuator  
TS-06XX-XXXX  
Product Number:  
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IMPORTANT NOTES ON YOUR IWG75 HP INTERNAL WASTEGATE ACTUATOR  
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Consult your local specialist before setting your desired boost pressure, setting boost beyond your engines capability may result in  
engine damage.  
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Allow for adequate cool airflow around the top diaphragm housing  
RECOMMENDATIONS  
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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.  
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.  
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BASIC COMPONENTS OF YOUR IWG75 HP INTERNAL WASTEGATE ACTUATOR  
Swivel nipple  
(Can be removed to fit Dash 3 fitting)  
Washers  
Locking Collar  
Securing nuts  
Clevis locking nut  
Clevis  
MOUNTING YOUR HP IWG75  
Depending on the kit purchased, the IWG75 might not be provided with a bracket. You will need to either modify the existing bracket for  
the standard internal wastegate actuator or fabricate a bracket. The spacing between the mounting holes is 34mm. The fabricated  
bracket should be made from an appropriate material such as stainless steel that can handle high temperature and withstand high  
spring forces. Use the supplied nuts and spring washers to secure the IWG75 HP to the bracket.  
The Rod in the Universal IWG75 HP uses a ¼” UNF thread which can be used with a variety of different clevises to fix the end of the rod  
to the wastegate valve.  
When installing the clevis of the IWG75 HP onto the wastegate valve arm, make sure that there is 2mm of preload. Then use  
compressed air (from a regulated air pressure supply no higher than 4 bar (60psi) gauge). This is to pressurise the IWG75 HP so that  
the clevis can be hooked onto the wastegate valve arm easily. Remember to reinstall the standard R-Clip or circlip to secure the clevis  
to the wastegate valve arm. Then tighten the rod nut to secure the clevis onto the rod.  
Wastegate valve  
Clevis locking nut  
arm  
ACHIEVING YOUR TARGET BOOST PRESSURE  
There are various factors involved in achieving your target boost pressure including.  
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The size of the spring fitted in your wastegate actuator i.e. the boost pressure achieved by the wastegate actuator 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 exhaust manifold backpressure in your system.  
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Turbosmart recommends the ideal setup for achieving your target boost pressure is to use the wastegate actuator in  
conjunction with a Turbosmart boost controller.  
IMPORTANT NOTES ON SETTING THE WASTEGATE ACTUATOR SPRING PRESSURE  
A stiffer spring should only be used when necessary. The wastegate actuator allows for different combinations of spring pressures. All  
springs that are adaptable with the wastegate actuator are shown in the table below. The tuner can use a combination of the 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 identify the spring. Please see the following detailed instructions  
on setting your wastegate actuator spring pressure. The springs chosen should be rated to the lowest boost level desired.  
Notes:  
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As a rough guide it is possible to double the base pressure when accompanying a Turbosmart IWG75 with a Turbosmart boost  
controller if the system is adequately sized. Results will vary depending on every application.  
Check the spring combination in your IWG75. If more springs are required, they can purchased from your Turbosmart dealer by using  
the TS-xxx-xxxx part numbers shown below each spring.  
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Pressure rating  
Part number  
Colour  
10 PSI Inner  
TS-0505-2012  
BRN/ORG  
25 PSI Outer  
TS-0505-2013  
BRN/GRN  
30 PSI Outer  
TS-0505-2014  
BRN/RED  
Dimensions  
3
0mm OD, 82mm  
length  
44mm OD, 135mm  
length  
41mm OD, 130mm  
length  
Desired Boost  
Pressure  
PSI BAR  
KPa  
10  
25  
30  
35  
40  
0.69  
1.72  
2.07  
2.4  
68.95  
172  
207  
241  
2.76  
276  
Changing the springs  
WARNING! Fitting a higher pressure rated wastegate actuator spring may cause a higher than expected increase in boost pressure.  
Turbosmart recommends adjusting your boost controller back to its minimum setting and measuring the new minimum boost pressure  
achieved by the new spring, before increasing your boost pressure again  
Rod guide  
Lower Housing  
Diaphragm  
HP springs  
Locking collar  
Clevis locking nut  
Spring ring  
Lower spring  
support  
Clevis  
Pressure nipple  
Top Cap  
IMPORTANT: A press or clamping device must be used when removing or installing the collar as clamping the cap down removes the  
load off the collar from the diaphragm and allows the collar to be removed.  
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5.  
6.  
If the engine has been running, allow it to cool down before removing the actuator from its bracket.  
Use a press or a vice to clamp down the cap to the body and remove collar.  
Remove the actuator from the clamping device carefully as the cap is under spring load.  
Remove cap, diaphragm and upper spring support with rod.  
Change the springs making sure that they sit in the right grooves in the lower spring support  
Reassemble in reverse order. Ensure that the diaphragm is installed in the centre of the upper spring support and when  
installing the cap, make sure that the cap and diaphragm are centred and that the locating notches on the cap match the  
cutouts in the lower housing. When installing the clevis, make sure that there is 2mm worth of preload.  
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NOTES ON BOOST CONTROL HOOKUP  
WARNING! Changing your connection method can cause a higher than expected increase in boost pressure. Turbosmart recommends  
adjusting your boost controller back to its minimum setting and measuring the new minimum boost pressure achieved by the new setup  
before increasing your boost again.  
Basic setup  
If no boost controller is being used connect the BOOST PRESSURE ONLY SOURCE to the wastegate actuator pressure nipple as  
shown.  
Boost Tee setup  
When using your wastegate actuator in conjunction with a Turbosmart Boost Tee, fit the controller between the boost pressure source  
and pressure nipple as shown. Ensure the arrow on the Boost Tee is pointing in the direction illustrated.  
Refer to the instructions supplied with your Boost Tee for further detail if necessary.  
E-Boost connection methods  
Turbosmart recommends using the wastegate actuator in conjunction with the Turbosmart E-Boost.  
E-Boost connection Method  
Port 1 of solenoid vent to atmosphere  
Port 2 of solenoid to pressure nipple of wastegate actuator  
Port 3 of solenoid to pressure only source  
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TURBOSMART  
ONE YEAR LIMITED WARRANTY  
Turbosmart is a company built on Customer Satisfaction and Service. That is why all of our products go through regimented test procedures before they are packaged and shipped. Turbosmart stands  
behind its products for one full year after purchase. Terms of Warranty, Service and Returns are as follows:  
Limited Warranty: Turbosmart warrants its products to be free from defects in material and workmanship under normal use and if properly installed for a period of one year from date of purchase. If found to  
be defective, it will be replaced or repaired if returned prepaid along with proof of date of purchase. This shall constitute the sole remedy of the purchaser and the sole liability of Turbosmart to the extent  
permitted by law, the foregoing is exclusive and in lieu of all other warranties or representations whether expressed or implied, including any implied warranty of merchantability or fitness. In no event shall  
Turbosmart be liable for special or consequential damages. This warranty is only valid on products purchased from Turbosmart Authorized Dealers.  
Service: After the warranty period has expired, repair service is charged based on a minimum and maximum charge rate. (Contact Customer Service for current rate).  
Returns: When returning a Turbosmart product for repair, it must be accompanied by a completed Customer Warranty Form and RMA number. To access this form please go to our website  
www.turbosmartonline.com and you will find it on the Downloads page.  
THE TURBOSMART PLEDGE  
DO NOT USE ANY TURBOSMART PRODUCT UNTIL YOU HAVE CAREFULLY READ AND UNDERSTOOD THE FOLLOWING AGREEMENT.  
Please call if you have any questions or do not understand this agreement. Refer to our brochure, website or catalogue for terms and conditions and further information regarding your product. Turbosmart  
appreciates your business and pride ourselves on our customer service. We are always happy to offer you advice and will provide you with help in any way we can. The purpose of this agreement is to  
avoid any problems or hard feelings.  
We sometimes make mistakes, as do our dealers, distributors and suppliers. Even customers can sometimes order the wrong parts. Do not use, modify, install, trial assemble, nick, drop, scratch or adjust  
any part until you first check for any damage. Damage must be reported immediately. NO EXCEPTIONS. If there are any components missing please contact your authorized reseller immediately upon  
receipt of your shipment. Missing components must be reported within five (5) business days of receipt. Parts returned for any reason MUST BE IN RESALABLE CONDITION. It is YOUR responsibility,  
“THE CUSTOMER” to carefully package any returns to avoid shipping damage. Insurance is highly recommended. Credit cannot be issued for damaged goods.  
Turbosmart warranties the quality of the products it designs and manufactures to be free of defects in material and workmanship. This limited warranty is extended only to the original purchaser and may not  
be transferred or assigned. This limited warranty applies to any product, which after careful inspection by Turbosmart, after receipt of the product from our authorized reseller, is found to have a defect in  
either material or workmanship. Any modifications to the product will void any and all warranties and will not be exchanged. Before installation, check new car warranty. Turbosmart is not responsible for  
voiding any original manufactures warranty.  
All warranty claims must be returned to the nearest Turbosmart Office, you must return the product and sales receipt, at your own expense, accompanied by the Customer Warranty Form stating the reason  
for the claim. Proof of purchase must be provided with any warranty claim and will be verified with the authorized reseller from which the product was purchased.  
If all the above procedures are followed, and the product is found to be defective in either workmanship or material, Turbosmart shall either repair or replace the product, at its sole discretion, and sole cost.  
This limited warranty does not cover or apply to any personal injury, labor charges or any other incidental costs or damages caused by the defective product. The individual purchaser acknowledges and  
agrees that the disclaimer of any liability for personal injury is a material term for this agreement and the individual purchaser agrees to indemnify Turbosmart and to hold Turbosmart harmless for any claim  
related to the item of the equipment purchased. Under no circumstances will Turbosmart be liable for any damages or expenses by reason of use or sale of any such equipment.  
THIS LIMITED WARRANTY IS THE ONLY EXPRESS WARRANTY, WHICH APPLIES TO TURBOSMART PRODUCT AS EXPRESSLY GIVEN IN LIEU OF ANY OTHER WARRANTY EXPRESSED OR  
IMPLIED, INCLUDING THAT OF MERCHANTABILITY. ANY IMPLIED WARRANTY INCLUDING THAT OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICCULAR PURPOSE IS HEREBY  
LIMITED BY THE SAME TERMS AND TIME LIMITATIONS SET FORTH IN THIS LIMITED EXPRESS WARRANTY AND OTHERWISE EXCLUDED. EXCEPT FOR THOSE OBLIGATIONS ASSUMED  
HEREIN, TURBOSMART ASSUMES NO OTHER OBLIGATIONS IN CONNECTION WITH THE SALE OF ITS PRODUCTS.  
IN THE EVENT THAT THE INDIVIUDAL PURCHASER DOES NOT AGREE WITH THIS AGREEMENT THE BUYER MAY PROMPTLY RETURN THIS PRODUCT, IN A NEW AND UN-USED CONDITION,  
WITH A DATED PROOF OF PURCHASE, TO THE PLACE OF PURCHASE WITHIN SEVEN (7) DAYS FROM THE DATE OF PURCHASE FOR A FULL REFUND. THE INSTALLATION OF THIS  
PRODUCT INDICATES THAT THE INDIVIDUAL PURCHASER HAS READ AND UNDERSTOOD THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS.  
Happy motoring!  
The Turbosmart Team.  
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