Product Name:

BOV Kompact EM F150

TS-0225-1X02

Product Description:

Product Number:

Document Version:

V1.00 Rev A

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IMPORTANT NOTES ON YOUR BOV

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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.

The EM series BOV is designed for use as a factory replacement for a turbocharger that utilises an electronic diverter valve, this valve can be

used on other applications as long as there is a control signal to actuate the BOV.

Ensure the engine is cold prior to installation.

RECOMMENDATIONS

- Turbosmart recommends that your Blow off valve (BOV) is fitted by an appropriately qualified technician

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KIT CONTENTS

Please check that the following items have been provided in your EM Series BOV packaging

Part

Description

Turbosmart EM Series BOV

Mounting Brackets

Use

1

4

Main unit

Mounting BOV to intercooler x 2 Model dependent

Block off OEM plumb back hose

Turbosmart sticker

Plumb back block off

Turbosmart Sticker

Figure 1 - Kit Contents

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ABOUT YOUR EM SERIES BOV

Turbosmart has developed a unique “plug and play” diverter valve (or bypass valve) upgrade for your vehicle that is currently equipped

with an electronic diverter valve. While we have developed this unit to be as simple as possible for you to install, we have not

compromised on performance. This unit will not leak under elevated boost pressures and will still provide you with rapid response

ensuring that all the OEM calibration strategies are not interfered with, providing you with maximum boost performance while the

advanced strategies of the OEM’s are retained.

The EM series BOV is available in two configurations, Dual Port and Plumb Back. The functionality of the BOV is still the same, there

is no performance difference between the two units, it is a personal preference if the user wishes to utilise a classic vent to atmosphere

sound or revert all bypass gasses back into the inlet tract of the turbocharger.

As the valve is completely controlled by the factory engine control unit, the factory diverter valve is almost silent, due to our

construction, it is possible that your EM series will be much more audible. By being able to hear the unit actuate, occasionally the

valve may be opening for a few seconds under the following events such as traction control, cruise control management, rapid

gearchanges and varying throttle position changes, these are all coded as part of the torque management software in the OEM engine

control unit, there is no adjustment available over these functions via our product. By hearing these events, it is not abnormal, it is

completely normal for the EM series BOV to be considered “very active” as it is protecting your turbocharger from surge events or

bypassing air for torque management purposes.

Electronic Actuator

Control Signal Plug

Connect to BOV Control

circuit

Controls when the valve opens,

and closes based on OEM

signal.

Vent to Atmosphere Port

Only on “Dual Port” Models)

(

Vents excess air to

atmosphere.

Inlet Port

Boost pressure from the Intercooler

enters BOV from this port.

Mounts

Two mounts are supplied for both

options for intercooler.

Blanking Plate

Blanking plate used if vent to

atmosphere is not required.

Figure 2 - EM Series BOV Overview

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FITTING YOUR EM SERIES BOV

Removing Circulation Hose from OE Valve.

Identify Diverter Valve Location

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3

The recirculation hose below needs the grey collar to be

rotated in the direction of the arrow. Once rotated the tabs

will move up and the part can be separated by pulling apart.

On the 13^t^h Generation Ford F Series Truck (P552) the

diverter valve is located on the intercooler on the twin turbo

model. This is located at the front of the car in the lower grill

portion. It is accessible from the bottom of the car.

Removing the Undertray

2

Remove the under-tray of the vehicle by removing all the

plastic clips holding the tray in place. Once the under-tray is

removed, the intercooler assembly can be accessed.

Remove Intercooler Piping

Undo the bolts securing the intercooler cross member to

remove the intercooler from the vehicle. The Intercooler

undertray is held on with 2 x 15mm bolts.

4

The intercooler piping is held on with a quick release

clip. As well as a 7mm hose clamp, once these are

removed the pipe can be wiggled free.

3

The Turbo feed charge pipe also need to be removed.

These are also held on with 7mm hose clamps.

Remove Diverter Valve Chamber

6

The chamber is held on at the top of the intercooler

with 1 x 8mm self-taping screw. Once removed the

chamber is free to be removed.

Remove Diverter Valve Plug

5

Removing the plug is done by simply pushing down

waiting for the click and removing the plug by pulling

backwards.

The chamber pictured below can be removed, the

chamber is simply rotated anti clockwise and it will

uncouple from the intercooler.

4

Mounting Turbosmart BOV

Refitting BOV/Intercooler to car

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7

We can install the Turbosmart BOV now the intercooler is

removed from the car. The BOV is supplied with a

recirculation silicone hose. The longer end of the silicone

hose is fitted to the BOV and the recirculation hose

connector is pre fitted to the shorter end. Use the supplied

hose clamps on the silicone hose. It is advised to leave the

clamps loose while installing to ensure everything is correctly

aligned.

With everything fitted back to the intercooler we can fit the

intercooler back into the car. It’s helpful to use the intercooler

bracket to assist with the intercooler to remain in place.

The turbo feed pipes as well as charge pipe to the throttle

body must be refitted, the charge pipe needs an audible click

to sound from the retention clip.

The two 7mm hose clamps must be correctly clamped.

The alignment of the BOV is important. The BOV can screw

in with two directions. The recirculation port must face

towards the intercooler as pictured above.

The mount that holds the valve comes in two options. The

most suitable one needs to be used. The Smaller right

angled one pictured is for the small version intercooler. We

must use a M3 Allen key to attach to the BOV

5

The recirculation pipe must be fitted ensuring the connector

clips and locks into place, at this point we should tighten up

any loose hose clamp to ensure that we have correct

orientation of the recirculation pipe

Refitting Undertray

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Refit Undertray with the 2 x 15mm bolts that were

moved to originally gain access to the Diverter valve

area.

Finalising your Install

10

It is important to check for leaks and correct operation as well

as listening for compressor surge. This noise is the sound of

the boost pressure air running back into the turbo causing

cavitation.

Refitting Electrical Connector

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Now the car can be taken for a test drive in a safe

environment and listen for the correct operation and that no

turbo charger surge occurs

Plug in Connector ensuring that a positive and

audible click is heard with the connector to ensure that it is

locked in place.

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CHANGING THE ELECTRONIC ACTUATOR

Remove Your EM series BOV

1

CAUTION!

Failure to ensure O-rings are seated correctly may lead to

cutting of an O-Ring and unexpected results from the EM

series BOV

Remove the electronic plug from the EM series BOV and

remove the BOV from the vehicles

Slowly insert the new actuator while turning in a clockwise

direction to avoid tearing the O-rings

NOTE!

Cosmetic engine covers may be required to be removed

prior to the assembly being visible.

CAUTION!

The turbocharger assembly may require the vehicle to be

raised on a hoist or jacked up and secured using vehicle

jack stands, ensure your safety is not compromised.

Remove Electronic Actuator from your EM

series BOV

2

Using a 11mm open end wrench in the flat sides of the

solenoid, undo the actuator in an anti-clockwise direction

when viewed from the end. Ensure the wrench is placed on

the metallic portion of the flats and not on the plastic cover.

Tighten the new solenoid into the EM series BOV ensuring the

wrench is on the metallic portion of the solenoid.

NOTE!

Tightening the solenoid on the plastic cover may result in

unrepairable damage to the solenoid.

Mount your EM Series BOV

4

Reinstall the BOV

Once the valve has been mounted, connect the electrical plug

into the OEM factory plug or into BOV controller and secure

the wiring safely away from a heat source.

Ensure the cavity is free from debris using avoiding shifting dirt

into the passages.

Install New Electronic Actuator into your

EM series BOV

Congratulations, your EM Series BOV is installed and ready

for use. Double check all electrical connections and mounting

screws.

3

Ensure the O-rings on your new actuator are correctly seated

in the grooves before installation

O-Rings

7

TROUBLE SHOOTING

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BOV not actuating - Confirm electrical signal plug is connected appropriately, as the plugs are new, some force may be

required to click the plug into place.

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Valve is staying open – Confirm the valve has O-rings as they may have been dropped or lost during installation

Boost pressure loss or lower than before - Confirm the valve has O-rings as they may have been dropped or lost during

installation

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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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