Product Name:  
IWG75  
Product Description:  
Internal wastegate actuator  
range with a clevis  
TS-06XX-XXXX  
Product Number:  
V4  
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IMPORTANT NOTES ON YOUR IWG75 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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-
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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 INTERNAL WASTEGATE ACTUATOR  
IWG75 with ø8.2mm clevis  
IWG75 with ø6.3mm clevis  
MOUNTING YOUR IWG75  
Depending on the kit purchased, the IWG75 might not be provided with a bracket. You will need to either modify the existing bracket of  
the standard internal wastegate actuator or fabricate a bracket. The spacing for the mounting 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 to the bracket.  
The Rod in the Universal IWG75 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 onto the wastegate valve arm, make sure that there is 2mm of preload. Then use  
compressed air (do not apply air pressure supply higher than 3 bar (40 psi) gauge). This is required to pressurise the IWG75 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  
arm  
Rod Nut  
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ACHIEVING YOUR TARGET BOOST PRESSURE  
There are various factors involved in achieving your target boost pressure including:  
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-
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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.  
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 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 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  
3 PSI Inner  
TS-0505-2001  
BRN/BLK  
5 PSI Inner  
TS-0505-2002  
BRN/GRY  
7 PSI Middle  
TS-0505-2003  
BRN/PUR  
11 PSI Middle  
TS-0505-2004  
BRN/RED  
10 PSI Outer  
TS-0505-2005  
BRN/BLU  
7 PSI Outer  
TS-0505-2006  
BRN/PNK  
Dimensions  
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2mm Length  
9mm OD,  
29mm OD,  
36mm Length  
36.5 OD, 43mm  
Length  
36.5 OD,  
52mm Length  
44mm OD, 68mm  
Length  
44mm OD,  
57mm Length  
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Desired Boost  
Pressure  
PSI  
BAR  
KPa  
3
5
7
0.207 20.68  
0.345 34.47  
0.483 48.26  
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
0
0.69  
0.76  
68.95  
75.84  
1
2
3
4
5
6
7
9
0
1
2
3
4
6
0.827 82.74  
0.89 89.6  
0.965 96.53  
1.03  
1.1  
103.4  
110  
1.172 117.2  
1.31  
1.38  
1.45  
131  
138  
145  
1.517 151.7  
1.59 159  
1.655 165.5  
1.793 179.3  
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Changing the springs  
WARNING! Fitting a wastegate actuator with a higher spring pressure 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  
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.  
1.  
2.  
3.  
4.  
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 cut-outs 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.  
Changing Nipple  
The Wastegate actuator will come prebuilt with the straight nipple pre-installed this may be swapped out for the swivel nipple. The  
swivel nipple will require a small dab of blue Loctite on the threads. This is to be torqued to 4 N.m (2.95ft-lb). If swapping back to the  
straight nipple a small amount of Loctite is required and a torque setting of 8 N.m (5.90ft-lb) will be required to ensure a tight fit.  
Basic setup  
If no boost controller is being used connect the BOOST PRESSURE ONLY SOURCE to the wastegate actuator pressure nipple as shown.  
Note: Some vehicles are fitted with a “tee” type inlet port on the for the internal waste gate actuator. In such applications, when  
upgrading to a Turbosmart IWG75, use a hose tee-piece to supply a pressure signal to both the internal wastegate actuator and the  
factory 2 port boost solenoid.  
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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  
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