Product Name:  
Hyper-Gate45  
Product Description:  
Product Number:  
45mm External Wastegate  
TS-0506-1XXX  
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IMPORTANT NOTES ON YOUR EXTERNAL WASTEGATE  
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Fitting your Hyper-Gate45 may require fabrication or modification to your exhaust manifold. Turbosmart recommends that your  
wastegate is fitted by an appropriately qualified technician.  
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The Hyper-Gate45 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.  
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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  
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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 HYPER-GATE45 45MM EXTERNAL WASTEGATE  
Use the diagram to help identify the “top” and “bottom” ports, and inlet/outlet ports of your wastegate.  
Top” Port  
Bottom” Port  
Outlet  
Inlet  
When pressure is applied to the “bottom” port of a wastegate, i.e. underneath the  
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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 Hyper-Gate45 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  
1
Description  
Hyper-Gate45 45 mm External  
Wastegate  
45mm external wastegate with pre-fitted spring (check the  
label on the box for rating)  
Inlet weld flange  
1
1
1
1
1
1
2
2
Stainless steel inlet weld flange  
Valve seat  
Stainless steel valve seat  
Outlet weld flange  
Stainless steel outlet weld flange  
Inlet V-Band clamp assembly  
Outlet V-Band clamp assembly  
Tightening collar  
Inlet V-Band clamp assembly  
Outlet V-band clamp assembly  
Collar tightening tool  
1/16 NPT Blanking plugs  
Blanking off unused pressure ports  
Connecting pressure to the actuator  
5mm 1/16 NPT Vacuum Nipples  
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RECOMMENDATIONS FOR MOUNTING YOUR HYPER-GATE45  
The mounting position of your Hyper-Gate45 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 Hyper-Gate45.  
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The weld flanges should be welded to your exhaust system. The weld  
flanges are compatible with Stainless Steel and Mild steel welding rod  
material.  
Outlet Weld  
flange  
For best results an attempt should be made, if space allows, to mount  
the Hyper-Gate45 at an angle to the exhaust flow to allow for better flow  
than a 90 degree mounting. See the schematic diagrams below for  
examples of mounting positions.  
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The inlet and outlet of the Hyper-Gate45 is compatible  
with turbo systems manufactured for use with other  
manufacturers 44mm wastegates. If your exhaust  
manifold uses another manfacturers 44mm wastegate  
flanges, you can mount the Hyper-Gate45 directly on  
using the included valve seat and V-band clamps.  
Valve seat  
(Remember to install)  
Outlet V-Band  
Secure the Hyper-Gate45 to the weld flanges with the supplied V-Band  
clamps. Do not forget to put the valve seat into the body before mounting the  
unit on the exhaust manifold. Tighten the supplied ¼” screws to a torque  
value of 14 Nm (10 ft/lbs)  
Outlet V-Band  
Inlet Weld flange  
PORTBLANKING PLUGS AND PRESSURE NIPPLES  
The Hyper-Gate40 is supplied with 2 X 1/16NPT nipples and 2 X 1/16 NPT plugs. These are installed in the lower and upper diaphragm  
housings depending on the boost control hook up to create an air tight volume above or below the diaphragm so that air pressure can  
control valve movement. Single port hook ups require a nipple and plug to be installed only on the lower diaphragm housing while two  
port hook ups require a nipple and a plug to be installed in both lower and upper diaphragm housings. Use thread sealant on the  
threads of the nipples and plugs to prevent leaks.  
Upper diaphragm housing  
with nipples installed  
Upper diaphragm housing  
with plugs installed  
Lower diaphragm housing  
with nipples installed  
Lower diaphragm housing  
with plugs installed  
VALVE SEAT  
The valve seat must be installed in the wastegate before mounting it onto the exhaust manifold. Failure to install the valve seat will  
result in very limited boost produced by the turbocharger as the exhaust gases flow between the void where the valve seat normally sits  
and the valve instead of flowing through the turbine.  
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MOUNTING  
For the best results, an attempt should be made, if space allows, to mount the Hyper-Gate45 at an angle to the exhaust flow to allow for  
better flow. See the schematic diagrams below for examples of mounting positions.  
Turbine  
Wastegate  
Turbine  
Wastegate  
Exhaust gas flow  
from engine  
Exhaust gas flow  
from engine  
Exhaust gas flow  
to wastegate  
Exhaust gas flow  
to wastegate  
Best flow – shallow  
mount angle  
Good flow – slight  
mount angle  
Turbine  
Turbine  
Exhaust gas flow  
to wastegate  
Exhaust gas flow  
to wastegate  
Exhaust gas flow  
from engine  
Exhaust gas flow  
from engine  
Poor flow – 90  
degree mounting  
Not recommended – less  
than 90 degree mounting  
SPARE PARTS AND ACCESSORIES LIST  
TS-0504-3001: WG45 Inlet weld flange  
TS-0504-3002: WG45 Outlet weld flange  
TS-0504-3003: WG45 Valve seat  
TS-0504-3004: WG45 Inlet V-Band  
TS-0504-3005: WG45 Outlet V-Band  
TS-0505-3006: WG38/40/45 Diaphagm assembly  
TS-0505-3007: 74mm Locking collar  
TS-0505-3008: 74mm Collar tool  
TS-0505-3009: 1/16TH NPT - 6mm barb vacuum fittings  
TS-0505-2007: 1/16TH NPT - 1/8 NPT Female fittings  
TS-0505-2008: 1/16TH NPT - -3AN Flare fittings  
TS-0505-2009: 1/16TH NPT - -4AN Flare fittings  
ACHIEVING YOUR TARGETBOOSTPRESSURE  
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 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 exhaust manifold backpressure in your system.  
Turbosmart recommends the ideal setup for achieving your target boost pressure is to use the Hyper-Gate45 in conjunction  
with a Turbosmart e-Boost controller.  
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IMPORTANTNOTES ON SETTING THE WASTEGATE SPRING PRESSURE  
A stiffer spring should only be used when necessary. The Hyper-Gate45 allows for different combinations of spring pressures. All  
springs that are adaptable with the Hyper-Gate45 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 Hyper-Gate45’s spring pressure. The springs chosen should be rated to the lowest boost level desired.  
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  
2
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
0
1
2
3
4
5
6
7
9
0
1
2
3
4
6
0.69  
0.76  
68.95  
75.84  
1
1
1
1
1
1
1
1
2
2
2
2
2
2
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  
Changing the springs  
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.  
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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 and allows it to be removed. The following are examples of different clamping devices that can be used to remove or  
install the collar:  
Vice  
Vice  
Hydraulic Press  
Hydraulic Press  
Drill Press  
Drill Press  
Arbor press  
Arbor press  
1
)
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Remove the wastegate from the exhaust manifold. Use CAUTION! The wastegate may still be HOT!  
2
Remove any pressure nipples in the top cap. Hold the cap down in a press or vice. Using the provided locking collar tool,  
unscrew the locking collar. Slowly, back off the vice or press and remove the cap.  
3)  
Select and locate the required wastegate spring or combination of inner and outer springs on the upper diaphragm spring  
support. See spring information above for detail on wastegate spring identification and selection.  
4
)
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Ensure that the diaphragm is inside the diaphragm groove.  
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Slowly push the top cap down on the lower diaphragm housing in a vice or press. As the cap reaches the diaphragm, line up  
the notches in the cap (Figure 1) with the cut outs (Figure 2) in the lower diaphragm housing. Carefully push the cap down till  
the cap is home on the lower diaphragm housing. Reinstall the locking collar and tighten with the provided locking tool. Make  
sure that the cap is clamped down while tightening the collar.  
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NOTES ON BOOSTCONTROL 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.  
Basic setup  
If no boost controller is being used connect the boost pressure source to the “bottom” port as shown. Connect the Hyper-Gate45 “top”  
port to the intake side of the turbo, between the air cleaner and the inlet on the front of the turbocharger. Otherwise connect a short  
piece of the silicon hose and face the vent downwards to stop water or debris entering the top port.  
Top port of wastegate  
vent to atmosphere  
Wastegate  
Bottom port of wastegate  
vent to pressure only  
source  
Turbocharger  
Boost Tee setup  
When using your Hyper-Gate45 in conjunction with a Turbosmart Boost Tee, fit the controller between the boost pressure source and  
“bottom” port as shown. Ensure the arrow on the Boost Tee is pointing in the direction illustrated. Connect the Hyper-Gate45 “top” port  
to the intake side of the turbo, between the air cleaner and the inlet on the front of the turbocharger. Otherwise connect a short piece of  
the silicon hose and face the vent downwards to stop water or debris entering the top port.  
Refer to the instructions supplied with your Boost Tee for further detail if necessary.  
Top port of wastegate  
vent to atmosphere  
Pressure only source to  
Boost Tee  
Wastegate  
Bottom port of wastegate  
to Boost Tee  
Turbocharger  
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e-Boost 2 connection methods  
Turbosmart recommends using the Hyper-Gate45 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.  
There are 3 different 2 port connection methods that can be trialled to achieve different results. The 2 port method (1) can be used if  
there is high exhaust manifold back pressure forcing the valve open. The 2 port method (2) allows the user to achieve the maximum  
boost pressure their turbo system is capable of. If a wide range of boost pressures is desired i.e. 5 – 40 PSI, a 2 port connection with a  
4
port solenoid (sold separately – TS-0301-2003) might be needed.  
All unused ports and vents must have the pressure nipple installed and a piece of silicon connected and routed to an area which is  
shielded from dust and water.  
Single port connection Method  
Port 1 of solenoid vent to atmosphere  
Port 2 of solenoid to bottom port of wastegate  
Port 3 of solenoid to Pressure only source  
Top port vent to  
atmosphere  
Port 1 of solenoid  
vent to atmosphere  
External wastegate  
Pressure only to Port  
3
of solenoid  
Turbocharger  
Bottom port of  
wastegate to port 2  
of solenoid  
*
NOTE: An increase in your minimum boost pressure is expected when using any of the 2 port connection methods. Ensure all boost  
set point values and gate pressure values are set to Zero and measure the new minimum boost pressure achieved by this method  
before increasing your Boost Set Point values.  
Two port connection Method (1) (For controlling boost on a turbo system with high back pressure)  
Connect the bottom port of the wastegate and Port 1 of the solenoid to a Pressure only source  
Port 2 of the solenoid to the top port of the wastegate  
Solenoid  
Port 3 of solenoid vent to atmosphere  
Port 1 of solenoid to pressure  
only source  
Port 2 of solenoid to top  
port of wastegate  
Tee Piece  
Pressure only source  
Wastegate  
Turbocharger  
Bottom port of wastegate  
To pressure only source  
Port 3 of solenoid vent  
To atmosphere  
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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  
Turbocharger  
Wastegate  
Port 3 of solenoid to  
bottom port of wastegate  
Two port connection Method (3) (For obtaining a wide range of boost pressures e.g. 5 40 PSI, note that this method of boost control  
may not provide a smooth boost curve)  
Port A of solenoid to Top port of wastegate  
Port B of solenoid to Bottom port of wastegate  
EX port of solenoid vent to atmosphere  
IN port of solenoid to Pressure only source  
4 Port solenoid  
Port A of solenoid to top port of  
wastegate  
EX Port of solenoid vent  
to atmosphere  
Wastegate  
IN Port of solenoid to  
pressure only source  
Port B of solenoid to  
Turbocharger  
bottom port of wastegate  
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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:  
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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.  
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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.  
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Happy motoring!  
The Turbosmart Team.  
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