PART NUMBER
FG-BOV-003PB
BLOW-OFF VALVE TYPE III PLUMBACK (BOV III PB) INSTRUCTIONS
IMPORTANT NOTES ON FITTING YOUR BOV III PB
Do you need an adapter? Check with your local dealer or visit the Turbosmart web-site [Link]. We have a large range of Multi-Fit Adapters which make fitting your BOV III PB
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 III PB 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 detail on
fitting your BOV III PB. To fit a BOV III PB with a weld on adapter refer to the following:
- Identify a suitable location along the cross over pipe for the BOV III PB – 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 III PB 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 III PB 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 III PB – failure to observe this will damage the BOV III PB and may also cause damage
to the engine
- Lubricate the base O-ring and slide the BOV III PB fully over the adapter, tighten the grub screws and the lock nuts in the base of the BOV III PB– 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 III PB – a shared or poor vacuum source will result in poor function of the
BOV III PB
- 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 III PB
- Use good quality vacuum hose when fitting the BOV III PB – other hoses will be effected by heat and will eventually crack, split or collapse. This will cause the BOV III PB to leak and
may cause poor fuel economy and may lead to serious engine damage
- Minimise the length of the vacuum hose where possible – the longer the hose the slower the BOV III PB will respond, this may have a dramatic effect on the performance of the BOV III
PB
- Connect the exhaust port of the BOV III PB to the intake system, ideally between the inlet of the turbo and the air flow meter – the exhaust fitting is suitable for 32mm ID hose
- Ensure that all hose connections are secured with hose clamps
IMPORTANT NOTES ON SETTING THE SPRING TENSION
- Adjustment to the BOV III PB is made by rotating the cap (see figure 1), to increase spring tension rotate in the direction of hard, marked on the top of the cap
- Rotate the cap in the direction of soft to decrease the spring tension – CAUTION Do not rotate the cap beyond the indicator groove (see figure 1)
- With the engine at idle the exhaust port 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 increase the spring tension by half a turn
- 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 increase the spring tension
- Turbosmart recommends that your BOV III PB is adjusted by an appropriately qualified technician
- Turbosmart recommends that a boost gauge be permanently fitted to the vehicle
Exhaust port Figure 1 Exploded View of the BOV III PB
Indicator groove
Piston Cap
Base O-ring inside
Spring
Free Length
Weld on adapter
Lubricate
Grub screws &
Lock nuts Body
Cap O-ring
MAINTAINANING YOUR BOV III PB
Turbosmart recommends that the following maintenance procedure is carried out at six monthly intervals. Regular maintenance will ensure that your BOV III PB is operating at its peak and
will extend the working life of the product.
- Remove the cap of the BOV III PB 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 155mm) – replace if below
- Remove the piston, thoroughly clean the piston and the bore of the BOV III PB
- Inspect the surface of the piston and the bore of the BOV III PB 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 III PB 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 III PB is functioning poorly. Please note, the following checks will
cure 99% of problems experienced with a BOV III PB.
- 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 III PB, 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 III PB 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 III PB – ensure the BOV III PB is pushed fully onto the adapter
- Check the join between the adapter and the cross over pipe for leaking
Warranty
Turbosmart warrants its products to be free from faults or defects for the life of the product. *
* Subject to Turbosmart trading terms and conditions
Warning!
Incorrect use of this product may result in damage to your vehicle. Failure to observe any notes or recommendations may result in incorrect use of this product. This product is intended for use in off-road racing only. Turbosmart will accept no responsibility for the
incorrect use of this product.
Disclaimer!
Turbosmart will not be held responsible for any damage caused to property or person, directly or indirectly related to the use of a Turbosmart product.
Turbosmart Pty Limited [Link] 264 Croydon, NSW, 2132 Australia ABN: 69 081 069 794
Ph: +(612) 9798 2866 Fx: +(612) 9798 2826 Email: instructions@[Link]
