Turbosmart BLOW OFF VALVES - Type 1 – Universal - Manual

BLOW-OFF VALVE TYPE I (BOV I) INSTRUCTIONS
Head Office: Turbosmart Pty Limited, PO Box 264 Croydon, NSW, 2132 Australia Ph: +61(2) 9798 2866 Fax: +61 (2) 9798 2826 Email: [email protected]
USA Office: Turbosmart USA, 1185 Park Center Drive, Suite Q, Vista CA 92081 USA Ph: (760) 727 7610 Fax: (760) 727 7963 Email: [email protected]
PART NUMBER
FG-BOV-001
IMPORTANT NOTES ON FITTING YOUR BOV I
Do you need an adapter? Check with your local dealer or visit the Turbosmart web-site turbosmart.com.au. We have a large range of Multi-Fit Adapters which make fitting your BOV I very
simple. Using a Turbosmart Multi-Fit Adapter could save you hours of expensive fabrication – remember to check if you can utilise a Multi-Fit Adapter. Turbosmart recommends that your
BOV I is fitted by an appropriately qualified technician. If you are using a Multi-Fit Adapter, refer to the adapter instructions (included with your Multi-Fit Adapter) for specific detail on
fitting your BOV I. To fit a BOV I with a weld on adapter refer to the following:
-
Identify a suitable location along the cross over pipe for the BOV I – this will need to be between the outlet of the turbo and the throttle body
- Ensure the mounting location is a minimum of 200mm away from any source of heat i.e. turbine housing, exhaust manifold. If the BOV I can not be mounted clear of a heat source, then
ensure that it is adequately shielded
- Ensure that the mounting position will not be effected by the engine moving when under load
- The BOV I must be mounted in a position so that it is sheltered from any contamination, i.e. away from where it could be splashed or the direct path of any air borne debris
- Weld the adapter into the cross over pipe – the adapter included is suitable for TIG welding into Mild Steel or Stainless Steel. For aluminium use the aluminium weld on adapter, p/n
FG-ADA2-WA38
- Ensure that the surface of the adapter is not damaged or distorted in the welding process – remember the Base O-ring must seal on this surface
- Ensure that any slag, burrs or debris is removed from the welded region prior to fitting the BOV I – failure to observe this will damage the BOV I and may also cause damage to the
engine
- Lubricate the base O-ring and slide the BOV I fully over the adapter, tighten the grub screws and the lock nuts in the base of the BOV I – do not over tighten, 5NM maximum tightening
torque
- Identify a good vacuum / pressure source and connect with vacuum hose to the nipple in the cap of the BOV I – a shared or poor vacuum source will result in poor function of the BOV I
- Ensure the vacuum hose has a minimum 5mm inside diameter and is clean and free of debris – smaller hose will result in poor function of the BOV I
- Use good quality vacuum hose when fitting the BOV I – other hoses will be effected by heat and will eventually crack, split or collapse. This will cause the BOV I to leak and may cause
poor fuel economy and may lead to serious engine damage
- Ensure that all hose connections are secured with hose clamps
- Minimise the length of the vacuum hose where possible – the longer the hose the slower the BOV I will respond, this may have a dramatic effect on the performance of the BOV I
IMPORTANT NOTES ON SETTING THE SPRING TENSION
-
Adjustment to the BOV I is made by installing the packing shims included (see figure 1)
- With the engine at idle the exhaust ports should be closed off by the piston – the piston should be hard against the seat and not floating or moving
- Free rev the engine and back off quickly, the engine should return to normal idle speed – if the engine drops below idle or stalls install one packing shim
- Repeat this process until the engine free revs and returns to normal idle speed
- Test drive the car and ensure that when decelerating or changing gears that the engine does not backfire or stall. If backfiring or stalling is noticed then check all connections made
during the installation, otherwise fit another packing shim
- Turbosmart recommends that your BOV I is adjusted by an appropriately qualified technician
- Turbosmart recommends that a boost gauge be permanently fitted to the vehicle
MAINTAINANING YOUR BOV I
Turbosmart recommends that the following maintenance procedure is carried out at six monthly intervals. Regular maintenance will ensure that your BOV I is operating at its peak and will
extend the working life of the product.
-
Remove the cap of the BOV I by rotating in an anti-clockwise direction (see figure 1) – CAUTION The cap is under spring tension, wear safety glasses and remove with care!
- Remove the spring and measure the free length or the overall length of the spring (should be no less than 67mm) – replace if below
- Remove the piston, thoroughly clean the piston and the bore of the BOV I
- Inspect the surface of the piston and the bore of the BOV I for scoring or excessive wear, silver coloured marks are an indication of excessive wear
- Check the Base O-ring and the Cap O-ring for any damage – replace if necessary
- Lubricate the bore and the piston with Uni-Glide™, hydraulic oil or sewing machine oil (see figure 1) – DO NOT use grease or viscous oils
- Re-assemble the BOV I in the reverse order
TROUBLE SHOOTING
The following points should be checked if you find that your engine is dipping below normal idle, stalling or if the BOV I is functioning poorly. Please note, the following checks will cure
99% of problems experienced with a BOV I.
-
Check the vacuum hose for splits, cracks, loose connection, kinking or any obstruction – old or fatigued hose may collapse under vacuum causing an obstruction
- With the engine running remove the vacuum / pressure hose from the nipple in the cap of the BOV I, there should a loud hissing sound. The engine should idle poorly, double check by
covering the end of the hose with your finger – otherwise the hose is blocked
- Check to see if the BOV I is blocked or contaminated with dirt or debris, if the valve appears to be contaminated follow the maintenance directions above
- Ensure that the vacuum / pressure source is not shared and that the vacuum source is directly from the inlet manifold
- Check the seal between the adapter and the BOV I – ensure the BOV I is pushed fully onto the adapter
- Check the join between the adapter and the cross over pipe for leaking
Piston
Weld on adapter
Body
Spring
Cap
Grub screws
Lock nuts
Cap O-ring
Lubricate
Free Length
Install packing shims here
Figure 1 Exploded View of the BOV I
Base O-ring inside
Exhaust ports