User Manual

ManualsBrandsTurbosmart ManualsCarWASTEGATES – EXTERNAL - Ultra-Gate 38 (no locking ring)

www.TURBOSMARTONLINE.com

------------------------------------------------------------------------------------------------------------------------

IMPORTANT NOTES ON YOUR EXTERNAL WASTEGATE

- Fitting your Ultra-Gate38 may require fabrication or modification to your exhaust manifold. Turbosmart recommends that your

Ultra-Gate38 is fitted by an appropriately qualified technician.

- The Ultra-Gate38 is designed for use with a turbocharger that does not have an internal wastegate.

- Consult your local specialist before setting your desired boost pressure, setting boost beyond your engines capability may result in

engine damage.

- DO NOT wrap the body of the wastegate with exhaust wrap

- DO NOT Mount the wastegate so that the top diaphragm housing is less than 100mm from a heat source

- Allow for adequate cool airflow around the top diaphragm housing

RECOMMENDATIONS

- 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.

------------------------------------------------------------------------------------------------------------------------

BASIC COMPONENTS OF YOUR ULTRA-GATE38 38MM EXTERNAL WASTEGATE

Use the diagram to help identify the “top” and “bottom” ports, and inlet/outlet ports of your wastegate.

- When pressure is applied to the “bottom” port of a wastegate, i.e. underneath the wastegate diaphragm, it acts against the

wastegate spring and the wastegate valve opens.

- When pressure is applied to the “top” port of a wastegate, i.e. above the wastegate diaphragm, its acts with the wastegate

spring and helps to close the wastegate valve.

- The Inlet is connected to the exhaust manifold before the turbine housing of your turbocharger. See recommendations

following for Ultra-Gate38 mounting position.

- Outlet returns exhaust gas back into the exhaust system after the turbocharger. (NOTE if mounted on a dedicated race car

the outlet can be vented directly to atmosphere towards the ground)

CONTENTS

Please make sure that the following parts have been included in the box

Part Quantity Description

Ultragate 38 mm wastegate 1 38mm external wastegate with pre-fitted spring (check the label on the

box for rating)

Stainless steel gasket 2 Stainless steel gaskets for sealing external wastegate to flanges

Valve seat 1 Stainless steel valve seat

M8X25 Socket head cap screw 2 For securing the outlet flange to the wastegate

M8 Nuts 2 For securing the Wastegate to the inlet flange

M8X35 Socket head cap screw 2 For securing the inlet flange to the wastegate

Product Name:

Ultra

Gate38

Product Description: 38mm External Wastegate

Product Number: TS-0501-1XXX

Outlet

“Top” Port

“Bottom” Port

Inlet

Summary of content (9 pages)

PAGE 1
Product Name: Product Description: Product Number: Ultra-Gate38 38mm External Wastegate TS-0501-1XXX -----------------------------------------------------------------------------------------------------------------------IMPORTANT NOTES ON YOUR EXTERNAL WASTEGATE Fitting your Ultra-Gate38 may require fabrication or modification to your exhaust manifold. Turbosmart recommends that your Ultra-Gate38 is fitted by an appropriately qualified technician.
PAGE 2
RECOMMENDATIONS FOR MOUNTING YOUR ULTRA-GATE38 The mounting position of your Ultra-Gate38 will be largely determined by your turbo and manifold setup and may be constrained by space restrictions in your engine bay. The following points should be considered when mounting your Ultra-Gate38. - The optional exhaust weld flanges should be welded to your exhaust system. The weld flanges are compatible with Stainless Steel and Mild steel welding rod material.
PAGE 3
Poor Flow – 90 Degree Mounting Not recommended – Less than 90 Degree Mounting 90 degree mounting gives poor exhaust flow to the Ultra-Gate38 and in some circumstances may contribute to over boosting. An angled mounting as shown is not recommended and gives extremely poor exhaust flow to the Ultra-Gate38.
PAGE 4
WARNING! Fitting a heavier wastegate 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. 1) Remove the wastegate from the exhaust manifold. Use CAUTION! The wastegate may still be HOT! 2) Hold the cap down in a press or vice.
PAGE 5
10) Slowly push the top cap down on the lower diaphragm housing in a vice or press. As the cap reaches the diaphragm, slowly turn the cap left and right as you lower the cap to the lower diaphragm housing. Make sure that the convolution of the diaphragm is not pinched between the top cap and the lower diaphragm housing. Refit the upper wastegate cap reusing the M6 Socket head cap screws. Again you may find it helpful to use a press to hold down the cap with a press or a clamp while tightening these screws.
PAGE 6
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. IMPORTANT! Refer to your boost controller instructions for most suitable connection method to an external wastegate.
PAGE 7
e-Boost 2 connection methods Turbosmart recommends using the wastegate in conjunction with the Turbosmart e-Boost. The first method of installation is a one port connection. If the desired boost level is not achieved i.e. boost level is too low, or not controllable, it is recommended that the wastegate spring be changed to a spring which is closer to the desired boost pressure or to trial a 2 port connection method.
PAGE 8
Two port connection Method (2) (For obtaining maximum boost pressure on your turbo system)  Port 1 of solenoid to Top port of wastegate  Port 2 of solenoid to Pressure only source  Port 3 of solenoid to Bottom port of wastegate Solenoid Port 1 of solenoid to Top port of wastegate Port 2 of solenoid to pressure only source Wastegate Turbocharger Port 3 of solenoid to bottom port of wastegate Two port connection Method (3) (For obtaining a wide range of boost pressures e.g.
PAGE 9
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.