Turbonetics Evolution Wastegate 10780 Service manual

INSTALLATION INSTRUCTIONS – Evolution Wastegate
IMPORTANT: Read instructions completely before proceeding. Engine or turbocharger damage may occur
if any wastegate is improperly applied or installed. Consult a knowledgeable turbo installer or Turbonetics
tech support specialist with any questions about correct wastegate application or installation.
SUMMARY: Turbonetics’ Evolution Wastegate has been specifically designed to advance the “state of the art”
in modern wastegate design. Properly applied and installed, it can reliably control turbocharger boost pressure in
high-performance applications up to 400 horsepower per turbo (800 HP for twin turbo). Design features include:
Investment cast stainless steel housing
“Floating” valve seat, which also serves as the inlet seal
1.38” (35mm) diameter valve, made from a special “corrosion & galling resistant” stainless steel
Fabric-reinforced “rolling” diaphragm
Set-screw spring preload adjustment
Polished & painted actuator cover
The Evolution Wastegate has also been specifically designed to directly replace the Deltagate wastegate,
offering the benefits of reduced size, lighter weight, increased flow and better control.
OPERATION: The Evolution Wastegate controls turbocharger boost by bypassing the turbine inlet gas flow in
response to the actuator spring load and/or boost level control signal. The actuator section is fitted with sensing
ports on both sides of the diaphragm, allowing precise control of valve motion, and use of any optional external
variable boost controller, manual or electronic. A choice of actuator springs is included, to suit specific application
requirements.
Fi
gure1 Figure2

INSTALLATION: Remove the wastegate from its carton and inspect for any obvious physical damage. All
wastegates are thoroughly inspected prior to shipment from the factory. If any shipping damage is evident,
contact your supplier and request that they process a claim with the shipper involved.
1. The Evolution Wastegate may be located anywhere between the engine exhaust and the turbine inlet of the
turbocharger (refer to Figure 1), preferably near the header collector, just before the turbine housing. The
wastegate may be mounted in any orientation that is convenient, either directly on a cast exhaust manifold
(with integral mounting flange), or on a flange that has been welded to a fabricated manifold. In the case of a
welded flange, a minimum flange thickness of 3/8” is recommended to minimize flange warpage. When
choosing the location of the wastegate, careful consideration should be taken to insure that the actuator
section (top half of wastegate) is NOT exposed to extreme heat. If selected location places the actuator
section close to a severe heat source, the use of a heat shield is recommended.
2. Once a suitable mounting location has been selected, determine the routing of the wastegate exhaust. It may
exit either away to the side or rear of the vehicle via a dedicated line, or reconnect to the vehicle exhaust
system after the turbine housing. NOTE: Federal and state laws require that all vehicle exhaust must exit
away from the passenger compartment. The exhaust must be connected to the vehicle exhaust system or
routed to the outside of the vehicle away from passenger compartment. The Evolution Wastegate has
designed to be used with 1-1/2” (14-16gauge) tubing, for both inlet and discharge. Be sure to avoid routing
any exhaust piping near any fuel or brake lines, or any other heat sensitive components.
3. The Evolution Wastegate features the same flange-mount inlet and discharge connections as the Deltagate
wastegate (refer to Figure 2). A discharge gasket is supplied with the wastegate kit, and no inlet gasket is
required, as the floating valve seat acts as the inlet seal. Be sure all mating surfaces are flat and free of
irregularities. Once all mounting and discharge routing provisions have been determined and fabricated,
install and secure the wastegate with 5/16” diameter fasteners (grade 5 or better recommended) and
mechanical locknuts (conventional split lockwashers loose their holding power when exposed to high temps).
NOTE: A variety of mating flanges, fittings and other accessories are available from your nearest Turbonetics
distributor (see common accessories list on last page).
4. Refer to the sensing line schematic shown in Figure 1. A minimum sensing line size of 1/8” ID is
recommended for proper response. The wastegate actuator ports are 1/8” NPT pipe thread. Use sealant
tape or liquid on all fitting threads. Sensing line material should be suitable for automotive under-hood
environment, and compatible with gasoline vapor. Care should be taken in routing sensing lines to avoid
damage from any sharp edges or excessive temperatures.
Stand-alone Installation: If Evolution Wastegate is to be installed as a conventional wastegate, the
boost sensing line (bottom actuator port) may be connected to any convenient manifold pressure source,
such as compressor discharge or intake manifold plenum (plenum runner locations not recommended, as
they may cause pulsing which may affect control stability). The top actuator port may be fitted with a filter
fitting or connected to the air intake system after the filter. CAUTION: Do not plug the hole, the top
actuator section needs to “breath” during operation.
Variable boost control installation: If Evolution Wastegate is to be used in conjunction with a variable
boost control device, follow the manufacturer’s instructions relative to connections and routing. As in the
conventional wastegate installation, it is strongly recommended that the boost sensing line be connected
directly to the pressure signal source (do NOT tee into this line for other functions).
5. The Evolution Wastegate has been factory calibrated to control boost within plus or minus 1psi of the
installed spring rating. A choice of actuator springs is included in the kit, to suit a variety of application
requirements. Using a suitable manifold pressure (boost) gauge, road test the vehicle to ascertain proper
operation. If boost levels exceed specified limits during road testing, recheck all sensing line connections for
proper location and leaks. Re-test to verify. CAUTION: If detonation occurs, discontinue testing until source
of detonation has been located and resolved. DO NOT operate vehicle in detonation, as severe engine
damage may result. Any damage incurred as a result of improper installation or usage is a customer
responsibility.

BOOST ADJUSTMENT: The Evolution Wastegate is designed with a set screw spring adjustment system. To
adjust the preload of the installed spring (and therefore the boost control pressure of the wastegate), simply “dial
in or out” the preload set screw on top of the wastegate.
To adjust the spring preload (boost pressure) up or down by more than 2psi, you must remove & replace the
coil spring inside the wastegate. To do this, carefully remove the wastegate actuator cover by removing the 6
cap screws (be careful, as the cover is spring loaded), then remove the installed coil spring and replace it with
an appropriate spring needed for your desired boost setting, re-assemble and road test to verify new setting.
To increase spring preload (boost pressure) by a small amount, loosen the set screw nut, and then “dial in”
the preload set screw by 2 or 3 rotations (refer to Figure 3). CAUTION: When increasing boost, adjust in
small enough increments to avoid excessive boost and possible detonation (for reference, 2 or 3 inward
rotations of the preload set screw = approximately 1psi increase in boost).
To decrease spring preload (boost pressure) by a small amount, loosen the set screw nut, and then “dial out”
the preload set screw by 2 or 3 rotations (refer to Figure 3).
Figure 3:
6. Under normal use, the Evolution Wastegate requires no maintenance. As a preventative maintenance
measure, it is suggested that the vehicle be “exercised” (operated at controlled boost levels) as often as
possible to avoid any sticking concerns generated by build-up of carbon deposits on the valve or shaft. It is
also a good idea to periodically check all hose connections for leaks or damage.
KIT CONTENTS (part number in bold):
The following items are included in the Evolution Wastegate kit - 10780:
(1) Main wastegate assembly (one of the springs will be installed) - 10781
(1) 5 PSI spring (blue) – 30778-5
(1) 7 PSI spring (white) – 30778-7
(1) 9 PSI spring (red) – 30778-9
(1) Discharge gasket – 20142
(2) Hose fittings, straight, 1/8 NPT x 5/32 – 30306
(2) Hose fittings, elbow, 1/8 NPT x 5/32 – 30307
(6ft) Silicone hose (sensing line), 5/32 – 30542-BK
(1) Instruction sheet – 60117
The following items are common accessories used with the Evolution Wastegate:
Mating flange, drilled, steel – 20260
Mating flange, drilled, stainless – 20260S
Mating flange, tapped, steel – 20261
Mating flange, tapped, stainless – 20261S
Hose fitting, 3-way tee, 5/32 – 30308