Product Name:  
Pro Port  
Product Description:  
Product Number:  
Document Version:  
BOV Pro Port  
TS-0208-XXXX  
V1.00 Rev A  
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IMPORTANT NOTES ON YOUR GENV PRO PORT  
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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.  
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The Pro Port is designed for use with a turbocharger that do not have inbuilt BOV’s or when a larger flow rate is required.  
Use only high-quality fittings ensuring maximum sealing reliability.  
RECOMMENDATIONS  
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Allow for adequate cool airflow around the top diaphragm housing.  
DO NOT Mount the Pro Port so that the top diaphragm housing is less than 100mm from a heat source.  
Fitting your Pro Port may require fabrication or modification to your turbocharger piping. Turbosmart recommends that your Pro  
Port is fitted by an appropriately qualified technician.  
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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 Pro Port kit.  
Part  
1
Description  
Turbosmart Pro Port  
V-Band Clamp  
Weld Flange  
Use  
Quantity  
Main unit  
1
1
1
1
1
1
2
V-Band Clamp  
3
Aluminium Weld Flange  
Inlet Flange O-Ring seal  
4
O-Ring  
5
Fitting Kit  
1x 1/8” NPT nipple, 1x 1/8” NPT blanking plugs **(1x pre-installed) **  
6
Turbosmart Sticker  
Turbosmart sticker  
5
1
2
4
3
1
CONTENTS  
KIT CONTENTS.............................................................................................................................................................. 1  
TOOLS REQUIRED........................................................................................................................................................ 2  
SUGGESTED SEALANTS ............................................................................................................................................. 2  
PRO PORT OVERVIEW................................................................................................................................................. 3  
FITTING YOUR PRO PORT........................................................................................................................................... 4  
HOW TO CHANGE YOUR PRO PORT SPRING........................................................................................................... 5  
TUNING YOUR VACUUM LEVEL.................................................................................................................................. 7  
HOW TO CHANGE YOUR PRO PORT DIAPHRAGM................................................................................................... 7  
HOW TO CONFIGURE SENSOR CAP VERSION ......................................................................................................... 9  
TROUBLESHOOTING.................................................................................................................................................. 12  
TOOLS REQUIRED  
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Non-marking spanners to tighten fittings  
4mm hex key  
3/16” hex key  
Collar tool (TS-0550-3014)  
Flat Blade screwdriver  
SUGGESTED SEALANTS  
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Loctite 243 Thread locker  
Loctite 271 Thread locker  
Loctite 567 Thread Sealant  
2
PRO PORT OVERVIEW  
“Top” Port  
1/8” NPT  
Master Collar  
Inlet V-Band  
Inlet Weld Flange  
Figure 2 – Pro Port Overview  
3
FITTING YOUR
Mounting your New Turbosmart Pro Port  
1
The Pro Port is a second option fit for Powerport sized Flanges,  
further expanding the Range of BOV’s available from  
Turbosmart.  
For best results, an attempt should be made, if space allows, to  
mount the Pro Port as close to the throttle as possible. The Pro  
Port should be mounted such that it is not on the inside radius of  
any bend.  
CAUTION!  
Do not place the actuator cap near a significant heat source  
as this could shorten the life of the diaphragm.  
Fitting the Pro Port  
2
Prior to mounting the Pro Port, place v-band over weld on flange  
by unscrewing the bolt on the v-band as far out as possible and  
then squeezing the bolt in a syringe motion to expand the v-band  
(squeeze the dots together below). Once the v-band is in its fully  
expanded position, slide the v-band over the flange to allow for  
the Pro Port to be installed.  
Do not forget to put the O-Ring seal into the flange before  
mounting the unit on the charge pipe. Using the 4mm hex bit  
socket and a torque wrench, Tighten the V-Band to 4N.m (3  
ft/lbs). Ensure the Pro Port is home correctly while torquing the  
bolt to not have a false torque as this will likely contribute to leaks.  
Fit Actuator Port Fittings  
3
Fit top chamber port fittings prior to mounting the Pro Port, install  
/8” NPT blank with 3/16” hex key and signal nipple into ports in  
1
the cap. Port order or orientation is not important, select which  
suits your packaging requirements. Apply thread lubricant and  
screw in clockwise until finger tight, then tighten further 1-2 turns  
for seal.  
Select a suitable manifold pressure source, use the shortest  
possible hose length to the Pro Port.  
CAUTION!  
Do not share manifold pressure source with fuel pressure  
regulator or any other critical instrument.  
.
Start Engine and Check for Leaks  
5
Congratulations, your Pro Port is installed and ready for use.  
Double check all fittings, lines and mountings then proceed to  
start engine and check for leaks.  
4
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HOW TO CHANGE YOUR PRO PORT SPRING  
The Pro Port has a variety of springs to suit different Vacuum levels and applications. Turbosmart provides the Pro Port pre-installed  
with 18InHg spring. Different spring combinations may be required to suit different application requirements and tuning.  
Remove Pro Port BOV From Charge Pipe  
1
Remove Top Cap (cont.)  
2
Remove manifold pressure source hose from the BOV. Unscrew  
V-band bolt in an anti-clockwise direction to the very end of the  
thread, squeeze the bolt against the V-band in a syringe like  
motion to expand the V-band over the flange. Remove Pro Port  
being careful not to drop or lose the sealing O-Ring.  
CAUTION!  
Allow engine to cool down before removing your Pro Port  
Remove Top Cap  
2
Prior to removing the Pro Port cap, remove all fittings from the  
1
/8”NPT ports. Press down with light to medium load on the cap  
in a press or vice. Unscrew locking collar with a collar tool (TS-  
550-3014) in an anti-clockwise direction until completely  
0
disengaged and gently 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 Pro Port with preferred spring combination.  
CAUTION!  
Maintain downward pressure on cap while removing collar  
or non-repairable thread damage will occur.  
Replace springs  
3
A new configuration of springs can now be selected.  
There are two sets of types of springs. An inner and  
outer. It is not possible to run two of the same. It must be  
an inner and outer.  
5
Press Cap onto Body  
5
Familiarise Yourself with Cap and Body  
Notches  
4
Using a press or vice, compress the cap onto the body ensuring  
the notches are remaining aligned. Once the cap has seated  
home onto the body, screw the collar down by hand in a  
clockwise direction. While still in the press or vice, Tighten the  
collar further with the collar tool until the collar will not turn.  
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!  
CAUTION!  
Maintain downward pressure on cap while tightening collar  
or non-repairable thread damage will occur.  
Ensure notches are aligned and seated home correctly prior  
to exerting force to tighten collar, permanent damage will  
Reinstall fittings to the cap of the Pro Port using fresh Loctite  
567 thread sealant.  
Reinstall Pro Port  
6
Place V-band over weld on flange by unscrewing the bolt on the  
V-band as far out as possible and then squeezing the bolt in a  
syringe motion to expand the V-band. Once the V-band is in its  
fully expanded position, slide the v-band over the flange to allow  
for the Pro Port to be installed.  
Do not forget to put the O-ring into the flange before mounting  
the unit on the Charge pipe. Using the 4mm hex bit socket and a  
torque wrench tighten the V-Band to 4N.m (3 ft/lbs).  
6
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TUNING YOUR VACUUM LEVEL  
The Pro Port has a variety of springs to suit different vacuum levels. Different tuning levels and engine configurations produce  
different levels of idle vacuum. The Pro Port is fitted with a standard spring which will remain closed until the engine produces more  
than 18 in/Hg. Turbosmart has a range of springs to suit different vacuum levels to ensure high levels of response from the Pro  
Port.  
IMPORTANT NOTES ON SETTING THE PRO PORT PRING  
PRESSURE  
A stiffer spring should only be used when necessary. The Pro  
Port allows for different combinations of spring pressures. All  
springs that are adaptable with the Pro Port are shown in the  
table below. The tuner can use combinations of up to 3 springs  
to achieve the following Manifold vacuum pressures. To aid in  
the identification of these springs they are supplied colour coded.  
Please see the following detailed instructions on setting your Pro  
Port’s spring pressure. The springs chosen should be rated to  
the lowest boost level desired.  
Location  
Colour  
Inner  
Inner  
Middle  
Purple/White  
TS-0208-9008  
9 InHg  
Middle  
Green/White  
TS-0208-9009  
15 InHg  
Outer  
Blue/White  
TS-0208-9010  
18 InHg  
Pink/White  
Orange/White  
TS-0208-9007  
7 InHg  
Part # TS-0208-9006  
Vacuum  
4 InHg  
0
-4 InHg  
-7 InHg  
●
4
●
7
-10 InHg  
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●
1
1
1
1
1
2
2
0-13 InHg  
3-15 InHg  
5-18 InHg  
8-19 InHg  
9-22 InHg  
2-23 InHg  
3-26 InHg  
●
●
●
●
●
●
●
●
●
●
●
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* Purple TS-0204-2104 only available in the spring kit  
Table 1: Spring Chart  
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HOW TO CHANGE YOUR PRO PORT DIAPHRAGM  
Pro Port replacement diaphragm kit:  
Piston Assembly: TS-0208-9005  
Collar Tool: TS-0550-3014  
CAUTION!  
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Ensure diaphragm is contained within the groove prior to cap re-assembly.  
Pay attention not to rotate diaphragm.  
CAUTION!  
Allow engine to cool down before removing your Pro Port  
motion to expand the V-band over the flange. Remove Pro Port  
being careful not to drop or lose the sealing O-Ring.  
Remove Pro Port BOV From Charge Pipe  
CAUTION!  
Allow engine to cool down before removing your Pro Port  
1
Remove manifold pressure source hose from the BOV. Unscrew  
V-band bolt in an anti-clockwise direction to the very end of the  
thread, squeeze the bolt against the V-band in a syringe like  
Remove Top Cap  
2
7
Prior to removing the Pro Port cap, remove all fittings from the  
/8”NPT ports. Press down with light to medium load on the cap  
in a press or vice. Unscrew locking collar with a collar tool (TS-  
550-3014) in an anti-clockwise direction until completely  
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disengaged and gently 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.  
CAUTION!  
Maintain downward pressure on cap while removing collar  
or non-repairable thread damage will occur.  
Change Piston Guide  
4
The Pro Port Piston replacement kit includes a new guide that is  
to be fitted to the cap.  
This guide is held into the cap with Loctite and will require some  
effort to remove, Hold the cap in a way that does not distort or  
damage the cap in any way, use a friction wrench to undo the  
guide from the cap in and anticlockwise direction (standard Right-  
Hand thread). Clean any debris from the cap and replace with  
the new guide applying a small amount of red 271 thread locker  
to the threads.  
Change Piston Assembly  
3
Lift the piston assembly out of the body of the Pro Port, use a O-  
Ring pick to lift the bead of the diaphragm out of the groove if  
necessary. Clean all components removing all dirt and dust from  
the assembly.  
Inspect for Damage before inserting new piston assembly into  
Pro Port Body. Ensure Diaphragm bead is seated correctly in the  
groove on the body.  
CAUTION!  
Do NOT allow any thread locker to dry on the inside of the  
guide, this will result in the piston seizing.  
Familiarise Yourself with Cap and Body  
Notches  
5
8
Press Cap onto Body  
6
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.  
Using a press or vice, compress the cap onto the body ensuring  
the notches are remaining aligned. Once the cap has seated  
home onto the body, screw the collar down by hand in a  
clockwise direction. While still in the press or vice, Tighten the  
collar further with the collar tool until the collar will not turn.  
CAUTION!  
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.  
Maintain downward pressure on cap while tightening collar  
or non-repairable thread damage will occur.  
HOW TO CONFIGURE SENSOR CAP VERSION  
CAUTION!  
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Applicable to Sensor Cap versions of GenV Pro Port only.  
Cool air flow is required around the actuator to keep the sensor in its operating window.  
CAUTION!  
Allow engine to cool down before removing your Pro Port  
Maintain downward pressure on cap while removing collar  
or non-repairable thread damage will occur.  
Remove Pro Port BOV From Charge Pipe  
1
Remove manifold pressure source hose from the BOV. Unscrew  
V-band bolt in an anti-clockwise direction to the very end of the  
thread, squeeze the bolt against the V-band in a syringe like  
motion to expand the V-band over the flange. Remove Pro Port  
being careful not to drop or lose the sealing O-Ring.  
CAUTION!  
Allow engine to cool down before removing your Pro Port  
Remove Top Cap  
2
Prior to removing the Pro Port cap, remove all fittings from the  
1
/8”NPT ports. Press down with light to medium load on the cap  
in a press or vice. Unscrew locking collar with a collar tool (TS-  
550-3014) in an anti-clockwise direction until completely  
0
disengaged and gently 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.  
CAUTION!  
9
Install Magnet  
3
Clean the top of the stem ensuring nothing will impede the  
installation of the magnet. Fit the magnet into the top of the stem  
with the marking facing out of the stem ensuring the magnet is  
placed all the way in.  
Apply 243 thread locker to the locking screw provided and screw  
down with a flat blade screwdriver until firm against the magnet.  
Familiarise Yourself with Cap and Body  
Notches  
4
CAUTION!  
Excessive force may damage the magnet or threads.  
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.  
Locking screw  
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.  
Inspect for Damage before inserting piston assembly into Pro  
Port Body. Ensure Diaphragm bead is seated correctly in the  
groove on the body.  
1
0
Press Cap onto Body  
Temperature exposure above 260ºC (500ºF) can cause  
permanent damage to the sensor.  
5
Calibration*  
7
Using a press or vice, compress the cap onto the body ensuring  
the notches are remaining aligned. Once the cap has seated  
home onto the body, screw the collar down by hand in a  
clockwise direction. While still in the press or vice, Tighten the  
collar further with the collar tool until the collar will not turn.  
Insert the relevant calibration curve into your data logger for the  
product family you have.  
Valve Lift (mm)  
V
OUT  
CAUTION!  
Maintain downward pressure on cap while tightening collar  
or non-repairable thread damage will occur.  
-0.75  
0
1
2
3
4
5
6
7
2.650  
2.731  
2.753  
2.775  
2.805  
2.85  
2.9  
2.95  
3.002  
3.099  
3.199  
3.3  
Wiring  
6
Your new Turbosmart sensor cap required installation of the  
sensor into the cap, apply a small amount of 243 Loctite to the  
threads of the sensor housing and screw into the cap of the Pro  
Port by hand. If and grabbing is felt stop and try again ensuring  
the sensor is properly seated within the housing. The Sensor is  
supplied with unterminated wires for you to fit the connector of  
your choice.  
8
9
1
1
1
1
1
0
1
2
3
4
3.44  
3.67  
3.852  
4
CAUTION!  
Ensure magnet is installed in the correct direction if Vout is  
more than 2.5V If the magnet reads higher, it needs to be  
flipped 180deg.  
NOTE! For best results, each Pro Port should be calibrated to  
your setup.  
4
3
2
1
0
.5  
4
Note  
Rating  
Wire  
Red  
Sensor Supply (Vsup  
)
4.5-5.5 Vdc  
0V  
.5  
3
Black Sensor Ground (V )  
0
White Sensor Output (Vout  
)
0-Vsupply  
.5  
2
Connect the wires to your data logger accordingly. Use a high-  
quality connection to reduce noise and calibration fluctuation.  
.5  
1
Ensure that the wiring is properly shielded from external heat  
sources.  
.5  
0
CAUTION!  
To ensure longevity from the sensor, ensure adequate  
airflow is supplied directly to the sensor to avoid  
overheating or sensor failure.  
0
5
10  
15  
20  
Standardised Lift (mm  
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  
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TROUBLESHOOTING  
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Check the vacuum hose for splits, cracks, loose connection, kinking or any obstruction – old or fatigued hose may collapse under  
vacuum causing an obstruction.  
With the engine running remove the vacuum / pressure hose from the nipple in the cap of the Pro Port, there should a loud  
hissing sound. The engine should idle poorly, double check by covering the end of the hose with your finger. If this does not  
occur, the hose could be blocked or crimped. Check the hose and replace if necessary.  
Ensure that the vacuum / pressure source is not shared and that the vacuum source is directly from the inlet manifold.  
Check the seal between the adapter and the Pro Port – ensure that there is no gap between the Pro Port base and the weld  
flange.  
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Check the join between the adapter and the intercooler pipe for leaking.  
Ensure that the right spring is installed in the Pro Port for your engine’s vacuum level.  
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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