Turbosmart WASTEGATES EXTERNAL User Manual

1

Product Name:

Ultra

-

Gate38

Product Description: 38mm External Wastegate
Product Number: TS-0501-1XXX

------------------------------------------------------------------------------------------------------------------------

IMPORTANT NOTES ON YOUR EXTERNAL WASTEGATE

- Fitting your Ultra-Gate38 may require fabrication or modification to your exhaust manifold. Turbosmart recommends that your
Ultra-Gate38 is fitted by an appropriately qualified technician.

- The Ultra-Gate38 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.

- 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

- 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.

------------------------------------------------------------------------------------------------------------------------

BASIC COMPONENTS OF YOUR ULTRA-GATE38 38MM EXTERNAL WASTEGATE

Use the diagram to help identify the “top” and “bottom” ports, and inlet/outlet ports of your wastegate.

- 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 Ultra-Gate38 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 Description

“Top” Port

“Bottom” Port

Outlet

Inlet

Ultragate 38 mm wastegate 1 38mm external wastegate with pre-fitted spring (check the label on the

box for rating)

Stainless steel gasket 2 Stainless steel gaskets for sealing external wastegate to flanges
Valve seat 1 Stainless steel valve seat
M8X25 Socket head cap screw 2 For securing the outlet flange to the wastegate
M8 Nuts 2 For securing the Wastegate to the inlet flange
M8X35 Socket head cap screw 2 For securing the inlet flange to the wastegate

www.TURBOSMARTONLINE.com

2

RECOMMENDATIONS FOR MOUNTING YOUR ULTRA-GATE38

The mounting position of your Ultra-Gate38 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 Ultra-Gate38.

- The optional exhaust weld flanges should be welded to

your exhaust system. The weld flanges are compatible
with Stainless Steel and Mild steel welding rod material.

- When securing your Ultra-Gate38 use the supplied

gaskets between the weld flanges and the inlet/outlet
flanges. Use the M8X25 screws to secure the outlet
flange (Note: The bolts screw into the threaded holes on
the outlet flange). Use the M8 nuts and M8X35 screws if
needed to secure inlet flange to your manifold (Note:
Your manifold may have studs to suit so the screws may
not be necessary). Tighten the screws and nuts to a
torque of 8 Nm & lubricate with Never Seize every time
you re-fit the wastegate.

- For best results an attempt should be made if space

allows to mount the Ultra-Gate38 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

Symmetric mounting allows an excellent flow of exhaust to the
Ultra-Gate38.

Good Flow – Angled Mounting

Angled mounting allows a good flow of exhaust to the Ultra­Gate38.

Exhaust Gas

from manifold

Wastegate

Exhaust gas

to exhaust

pipe

Turbocharger Turbine

Wastegate

Exhaust gas

to exhaust

pipe

Exhaust Gas

from manifold

Turbocharger Turbine

www.TURBOSMARTONLINE.com

3

Poor Flow – 90 Degree Mounting

90 degree mounting gives poor exhaust flow to the Ultra-Gate38
and in some circumstances may contribute to over boosting.

Wastegate

Not recommended – Less than 90 Degree Mounting

An angled mounting as shown is not recommended and gives
extremely poor exhaust flow to the Ultra-Gate38.

Exhaust Gas

from manifold

Exhaust gas

to exhaust

pipe

Turbocharger Turbine

Wastegate

Exhaust Gas

from manifold

Turbocharger Turbine

Exhaust gas

to exhaust

pipe

ACHIEVING YOUR TARGET BOOST PRESSURE

There are various factors involved in achieving your target boost pressure including.

- 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 Ultra-Gate38 in conjunction
with a Turbosmart eBoost controller.

IMPORTANT NOTES ON SETTING THE WASTEGATE SPRING PRESSURE

A stiffer spring should only be used when necessary. The Ultra-Gate38 allows for different combinations of spring pressures. All springs
that are adaptable with the Ultra-Gate38 are shown in the table below. The tuner can use combinations of the 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 Ultra-Gate38’s spring pressure. The springs chosen should be rated to the lowest boost level desired.

Pressure rating 5 PSI Inner 7 PSI Inner 7 PSI Middle 10 PSI Middle 14 PSI Middle 7 PSI Outer

Part number TS-0501-2003 TS-0501-2004 TS-0501-2005 TS-0501-2006 TS-0501-2007 TS-0501-2008

Colour GRN/GRY GRN/WHT GRN/PUR GRN/BLU GRN/RED GRN/PNK

Dimensions

Desired Boost

Pressure

KPa BAR PSI

34.47 0.345 5 ▲

48.26 0.483 7

68.95 0.69 10

82.74 0.827 12 ▲

96.53 0.965 14

103.4 1.03 15 ▲

117.2 1.172 17

131 1.31 19 ▲

144.8 1.448 21

151.7 1.517 22 ▲

165.5 1.655 24

179.3 1.793 26 ▲

193.1 1.931 28

36.5mm OD,

55mm length

Changing the springs

36.5mm OD,

93mm length

▲

▲

▲

▲

49mm OD,

118mm length

▲

▲

49mm OD,

71mm length

▲

▲
▲

▲
▲

49mm OD,

86mm length

▲

▲
▲

▲ ▲
▲ ▲

www.TURBOSMARTONLINE.com

59mm OD,

63mm length

▲
▲