Product Name:  
Hyper-Gate45  
Product Description:  
Product Number:  
45mm External Wastegate  
TS-0504-1XXX  
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IMPORTANT NOTES ON YOUR EXTERNAL WASTEGATE  
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Fitting your Hyper-Gate may require fabrication or modification to your exhaust manifold. Turbosmart recommends that your  
Hyper-Gate is fitted by an appropriately qualified technician.  
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The Hyper-Gate 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-GATE 45MM EXTERNAL WASTEGATE  
Use the diagram to help identify the “top” and “bottom” ports, and inlet/outlet ports of your wastegate.  
Top” Port  
Outlet  
Bottom” Port  
Inlet  
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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 Hyper-Gate 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-gate 45 mm wastegate  
45mm external wastegate with pre-fitted spring (check the  
label on the box for rating)  
Inlet weld flange  
1
1
1
1
1
Hyper-Gate Stainless steel inlet weld flange  
Valve seat  
Hyper-Gate Stainless steel valve seat  
Outlet weld flange  
Hyper-Gate Stainless steel outlet weld flange  
Hyper-Gate inlet V-Band clamp assembly  
Hyper-Gate outlet V-Band clamp assembly  
Inlet V-Band clamp assembly  
Outlet V-band clamp assembly  
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RECOMMENDATIONS FOR MOUNTING YOUR HYPER-GATE  
The mounting position of your Hyper-Gate 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-Gate.  
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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.  
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The Hyper-Gate45 valve seat is compatible with the Tial  
44 weld flange. If you have an existing Tial 44 weld flange  
on your manifold, you can mount the Hyper-Gate45  
directly onto the flange using the V-Band clamp supplied  
with the Hyper-gate45.  
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Secure the Hyper-Gate 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 M6 screws to a  
torque value of 14 Nm (10 ft/lbs)  
For best results an attempt should be made if space  
allows to mount the Hyper-Gate 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.  
Best Flow – Symmetric Mounting  
Good Flow – Angled Mounting  
Symmetric mounting allows an excellent flow of exhaust to the  
Hyper-Gate.  
Angled mounting allows a good flow of exhaust to the Hyper-Gate.  
Wastegate  
Wastegate  
Exhaust gas  
to exhaust  
pipe  
Exhaust Gas  
Exhaust gas  
from manifold  
to exhaust  
pipe  
Exhaust Gas  
from manifold  
Turbocharger Turbine  
Turbocharger Turbine  
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Poor Flow – 90 Degree Mounting  
0 degree mounting gives poor exhaust flow to the Hyper-Gate  
Not recommended – Less than 90 Degree Mounting  
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An angled mounting as shown is not recommended and gives  
extremely poor exhaust flow to the Hyper-Gate.  
and in some circumstances may contribute to over boosting.  
Wastegate  
Wastegate  
Exhaust gas  
Exhaust gas  
to exhaust  
pipe  
to exhaust  
pipe  
Exhaust Gas  
from manifold  
Exhaust Gas  
from manifold  
Turbocharger Turbine  
Turbocharger Turbine  
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-Gate in conjunction with  
a Turbosmart e-Boost controller.  
IMPORTANTNOTES ON SETTING THE WASTEGATE SPRING PRESSURE  
A stiffer spring should only be used when necessary. The Hyper-Gate allows for different combinations of spring pressures. All springs  
that are adaptable with the Hyper-Gate 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-Gate’s spring pressure. The springs chosen should be rated to the lowest boost level desired.  
Pressure rating  
Part number  
Colour  
5 PSI Inner  
TS-0501-2003  
GRN/GRY  
7 PSI Inner  
TS-0501-2004  
GRN/WHT  
7 PSI Middle  
TS-0501-2005  
GRN/PUR  
10 PSI Middle  
TS-0501-2006  
GRN/BLU  
14 PSI Middle  
TS-0501-2007  
GRN/RED  
7 PSI Outer  
TS-0501-2008  
GRN/PNK  
3
6.5mm OD,  
36.5mm OD,  
93mm length  
49mm OD,  
118mm length  
49mm OD,  
71mm length  
49mm OD,  
86mm length  
59mm OD,  
63mm length  
Dimensions  
55mm length  
Desired Boost  
Pressure  
KPa  
BAR  
0.345  
0.483  
0.69  
PSI  
34.47  
48.26  
68.95  
82.74  
96.53  
103.4  
117.2  
5
7
10  
12  
14  
15  
17  
19  
21  
22  
24  
26  
28  
0.827  
0.965  
1.03  
1.172  
1.31  
131  
144.8  
151.7  
165.5  
179.3  
193.1  
1.448  
1.517  
1.655  
1.793  
1.931  
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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.  
1
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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. Using a 5mm Allen Key, remove the M6 Socket head cap screws that secure the upper  
wastegate cap. WARNING! The cap is under spring tension, wear safety glasses and remove with care! Slowly back off the  
vice or press and remove the cap.  
3)  
4)  
5)  
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.  
Ensure that the diaphragm is inside the diaphragm groove. The six holes on the outer ring of the wastegate diaphragm should  
be in line with the 6 holes in the lower wastegate cap.  
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 re-using 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. Tighten the M6 Socket head cap screws using a 5mm Allen Key and torque to 8 N-m (5.9 lb-ft)  
Diaphragm removal and lower diaphragm housing rotation  
1)  
2)  
3)  
Follow steps 1 and 2 of the spring change instructions.  
Using a pair of circlip pliers, remove the retaining circlip on the diaphragm support.  
Back off the 3 securing grub screws in the top of the diaphragm support, DO NOT REMOVE COMPLETELY FROM  
DIAPHAGM SUPPORT.  
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Remove diaphragm assembly and valve.  
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Remove the 3 M6 counter sunk cap screws and remove lower diaphragm housing. Check that the sealing O-Ring is in good  
condition. Replace if necessary (TS-0501-3004).  
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Refit the lower diaphragm housing in the desire orientation and replace M6 Countersunk screws.  
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Slide the valve back through the guide and place the diaphragm assembly on top of the valve. Apply a small drop of Loctite  
onto the threads of the grub screw and tighten. Make sure that the valve is hard up against the diaphragm assembly.  
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1
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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.  
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Ensure that the diaphragm is inside the diaphragm groove. The six holes on the outer ring of the wastegate diaphragm should  
be in line with the 6 holes in the lower wastegate cap.  
0) 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 re-  
using 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. Tighten the M6 Socket head cap screws using a 5mm Allen Key and torque to 8 N-m  
(5.9 lb-ft)  
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-Gate “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-gate 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-Gate “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-Gate 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  
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port solenoid (sold separately – TS-0301-2003) might be needed.  
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  
Pressure only to Port  
3 of solenoid  
External wastegate  
Turbocharger  
Bottom port of  
wastegate to port 2  
of solenoid  
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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  
Port 3 of solenoid vent to atmosphere  
Solenoid  
Port 1 of solenoid to pressure  
only source  
Port 2 of solenoid to top  
port of wastegate  
Tee Piece  
Wastegate  
Pressure only source  
Bottom port of wastegate  
To pressure only source  
Turbocharger  
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  
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. 5 40 PSI, note that this method of boost control  
may not provide a smooth boost curve)  
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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  
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Port solenoid  
EX Port of solenoid vent  
to atmosphere  
Port A of solenoid to top port of  
wastegate  
IN Port of solenoid to  
pressure only source  
Wastegate  
Turbocharger  
Port B of solenoid to  
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:  
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.  
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Happy motoring!  
The Turbosmart Team.  
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