Product Name: PSG50V Vacuum Pneumatic Straight Gate  
Product Description:  
PSG50V Vacuum Pneumatic Straight Gate  
TS-0565-1212  
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V1.00 Rev A  
Product Number:  
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Document Version:  
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IMPORTANT NOTES ON YOUR EXTERNAL WASTEGATE  
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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 Straight external Wastegate 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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Use only high-quality fittings ensuring maximum sealing reliability.  
Correctly setting up a sensible boost control strategy to ensure engine safety is highly recommended.  
RECOMMENDATIONS  
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Allow for adequate cool airflow around actuator.  
DO NOT Mount the wastegate so that the actuator is less than 100mm from a heat source.  
DO NOT wrap the body of the wastegate with exhaust wrap.  
Fitting your Straight Wastegate 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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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.  
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.  
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KIT CONTENTS  
Please check that the following items have been provided in your Straight Wastegate kit.  
Part  
1
Description  
Turbosmart Straight Wastegate  
Inlet V-Band clamp  
Use  
QTY  
Main unit  
1
1
1
1
1
1
2
Inlet V-band clamp  
Inlet V-band weld flange  
Outlet V-band clamp  
Outlet V-band weld flange  
Turbosmart sticker  
3
Inlet Weld flange  
4
Outlet V-Band clamp  
Outlet weld flange  
5
6
Turbosmart Sticker  
2
1
3
4
5
Figure 1 - Kit Contents  
1
CONTENTS  
KIT CONTENTS................................................................................................................................................................ 1  
TOOLS REQUIRED .......................................................................................................................................................... 2  
PART NUMBERS.............................................................................................................................................................. 2  
STRAIGHT PNEUMATIC WASTEGATE OVERVIEW..................................................................................................... 2  
FITTING YOUR PNEUMATIC STRAIGHT GATE............................................................................................................ 3  
Mounting your new Pneumatic Straight Wastegate ..........................................................................................................3  
Applying Actuator Preload / Ensuring Wastegate Flap is Closed .............................. Error! Bookmark not defined.  
Clocking Actuator Housing ....................................................................................................................................................4  
HOW TO CHANGE YOUR GEN V WASTEGATE SPRING ............................................Error! Bookmark not defined.  
ACHIEVING YOUR TARGET BOOST PRESSURE ........................................................Error! Bookmark not defined.  
TROUBLESHOOTING...................................................................................................................................................... 6  
TOOLS REQUIRED  
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3/8” square drive deep socket  
Square drive ratchet wrench  
Torque wrench (3/8” drive)  
Metric Allen Key set  
PART NUMBERS  
TS-0565-1212 – PSG50v Vacuum Pneumatic Straight Gate 6psi Black  
TS-0565-1762 – PSG50 Pneumatic Straight Gate 6psi Black  
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STRAIGHT PNEUMATIC WASTEGATE OVERVIEW  
Vacuum Feed IN  
3
x Housing locating  
screws  
Outlet V-Band  
Inlet V-Band  
Inlet Weld Flange  
Outlet Weld flange  
Figure 1 - Pneumatic Straight Gate Overview  
2
FITTING YOUR PNEUMATIC STRAIGHT GATE  
Angle mounting allows a good flow of exhaust flow to the  
Straight Gate.  
Mounting your new Pneumatic Straight  
Wastegate  
1
The weld flanges should be welded to your exhaust system.  
The weld flanges are compatible with Stainless Steel and Mild  
steel welding rod material.  
The Straight Gate utilises WG60 Outlet Flanges to connect the  
Pneumatic straight gate to exhaust manifolds.  
For best results, an attempt should be made, if space allows,  
to mount the Straight 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.  
NOTE!  
The Straight Gate can be used in both directions. Both  
directions will regulate the same. It is advisable however  
to place the Butterfly Valve pins exhaust side up.  
Figure 6 - 90 Degree mounting  
90 Degree mounting gives poor exhaust flow to the Straight  
Gate and in some circumstances may contribute to over  
boosting.  
Straight Gate  
Figure 4 - Best flow - Symmetric mounting  
Symmetric mounting allows an excellent flow of exhaust to the  
Straight Gate.  
Figure 7 - Not Recommended - Less than 90 Degree Mounting.  
An angle mounting as shown in not recommended and gives  
extremely poor exhaust flow to the Straight Gate which can  
contribute to poor boost control and over boosting.  
CAUTION!  
Do not place the Straight Gate near a significant heat  
source as this could shorten the life of the internal  
actuator.  
Exhaust flow  
from engine  
Figure 5 - Good Flow - Angle mounting  
3
Fitting the Pneumatic Straight Gate  
Clocking Actuator Housing  
2
3
Even though possible to mount the Straight gate in both  
directions, it is suggested that the Butterfly valve pins (Figure  
The actuator can be removed and rotated through 3 different  
orientations; these are every 120 degrees. The actuator 3 x  
M5 Allen bolts that lock the body to the actuator. It may be  
required to remove the snap ring ensuring not to lose it. And  
one Spindle Bolt that locate the linkage to the shaft. Once  
these are removed the actuator can be rotated to two other  
po
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) are facing towards the exhaust exit.  
Valve Pins  
Figure 8 – Butterfly Valve Pins  
Prior to mounting the Straight Gate, place v-band (Figure 10)  
over weld on flange by unscrewing the nut 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 wastegate to be  
installed.  
Connecting Your Wastegate  
4
Using the 3/8” deep socket and a torque wrench Tighten the  
V-Band to 7N.m (5 ft/lbs). Ensure the wastegate is home  
correctly while torquing the nut to not have a false torque as  
this will likely contribute to exhaust leaks.  
The Vacuum Wastegate is plumbed up utilising the top swivel  
nipple. This source is connected to an adjustable vacuum  
pressure source used to control the boost. The standard hook-  
Figure 10 – V Band Clamp  
Figure 11 – Exploded drawing of assembly of Pneumatic  
Straight Gate.  
4
Flow Characteristics  
5
Top Port  
6
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Port 1 - Vent  
Port 2 - Vacuum Pressure In  
Port 3 – Top Port  
Due to the nature of the butterfly valve design, the flow  
characteristics are nonlinear. In some cases, it may be  
advantages to correlate the linear sensor output to match the  
flow of the valve. The following plot compares butterfly valve  
rd  
position with valve flow. A 3 order polynomial is provided to  
relate valve position to flow.  
y = -2.1519x3 + 3.0586x2 + 0.0582x + 0.0326  
2
R = 0.999  
1
20%  
00%  
1
IF REQUIRED Bottom Port  
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Port 1B - Vent  
Port 2B - Boost Pressure IN  
Port 3B – Bottom Port  
80%  
60%  
40%  
20%  
0%  
0%  
50%  
100%  
Butterfly Position  
Butterfly Position  
Flow Percentage  
3.3%  
3.7%  
0
3
%
%
Ensure all connections are high quality and away from  
any heat source.  
6%  
4.7%  
6.7%  
1
0%  
0%  
0%  
0%  
0%  
0%  
0%  
0%  
0%  
2
3
4
5
6
7
8
9
14.9%  
26.7%  
40.8%  
55.7%  
70.4%  
83.4%  
93.5%  
99.4%  
100.0%  
1
00%  
5
Checking/Adjusting Preload  
47  
NOTE!  
Turbosmart sets preload from factory and should only  
need to be set after changing springs.  
To correctly preload the wastegate, ensure wastegate valve is  
in the full closed position by applying vacuum to the valve to  
set preload.  
To apply 1mm/0.039” preload, simply turn the adjuster nut 1  
CAUTION!  
This step is important  
To lock the actuator in this position, turn the locking nut by  
hand until finger tight, then proceed to tighten nut firmly to  
secure actuator in place. (6.5Nm / 4.8 ft lb)  
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TROUBLESHOOTING  
Wastegate not actuating - Confirm signal hose is plumbed to a pressure only source, confirm preload during installation  
Poor wastegate actuation - Ensure signal hose is not shared and is sourced as close to the compressor as possible, check seal  
on fittings  
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Poor wastegate actuation – Confirm no obstructions in actuator rod path  
Boost creeping at high rpm - Wastegate flow path is poor, wastegate is too small for the application, ensure linkage joints are  
not seized  
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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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