GFB EX44 Handleiding

GFB Niet gecategoriseerd EX44

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GFB EX44

External wastegate

instruction manual

Part no. 7002

Ph: +61 (0)2 9534 0099

Fax: +61 (0)2 9534 3999

Email: sales@gfb.com.au

Web: www.gfb.com.au

INSTAlLation

GFB EX44 Packing list:

Assembled EX44 wastegate

10psi spring and 5psi spring (both

installed for base boost of 15psi)

2 x v-band clamps

2 x 1/8” BSPT hose tails

1 x outlet weld-on flange (part # 7042)

1 x inlet weld-on flange (part # 7052)

1 x valve seat

Exhaust in Smooth flow to

wastegate inlet

Smooth entry of

wastegate gases

Exhaust out

Wastegate exhaust

Install the hose tails onto the wastegate. The thread is 1/8” BSP, which is a commonly available thread should you

wish to use a different type of fitting.

Identify the inlet and outlet weld-on fittings. These are to be welded onto your turbo exhaust manifold and exhaust

system, onto which the EX44 is mounted using the supplied v-band clamps. The inlet and outlet weld-on fittings are

designed to fit the pipe that is most suitable for each purpose.

Please note the EX44 is compatible with TiAl MVR weld-on fittings, so if you already have an exhaust manifold with

a TiAl fitting, the EX44 will bolt straight up using the GFB-supplied clamps.

The inlet fitting, which is welded to the exhaust manifold and supports the weight of the wastegate, is best suited to

2” (50.8mm) O.D. pipe with a wall thickness of at least 0.120” (3mm). It is also possible to use 1.5” nominal bore

Schedule 10 pipe – a commonly available heavy-walled pipe. The outlet fitting is designed to accept 1.75”

(44.5mm) O.D. thin-walled tube, which is commonly used for exhaust systems and screamer pipes. Of course, it is

possible to use different size and wall-thickness pipes than those recommended, provided a suitable weld can be

achieved. Replacement weld-on fittings are available separately from GFB if required.

The inlet fitting should be welded to the exhaust manifold after all the exhaust runners have merged, and in a

position that promotes smooth flow to the wastegate – fast-moving exhaust gas is reluctant to make sharp turns,

which significantly reduces the flow potential through the wastegate. The diagram below shows a suggested

installation location.

On any street-driven car, legally the wastegate outlet MUST be connected to the vehicle's exhaust system (before

any catalytic converters and mufflers), and should be done in a way that allows the gases to merge smoothly. On

race cars where regulations allow, the outlet can be routed out of the engine bay to atmosphere.

Ensure the valve seat is inserted into the bottom of the wastegate before final installation.

Base Boost

Pressure (psi)

5psi Inner

(part #7205)

7psi Middle

(part #7207)

10psi Outer

(part #7210)

Changing the Spring

Use a metric 3mm hex key to remove four of the cap screws, leaving two opposing screws in place. Care must be

taken during the next step, as the spring force can exceed 40kg, depending on the springs used.

Carefully remove the remaining two screws whilst restraining the cap to prevent it popping off. It is a good idea to

have a helper during this step, or better still, use a press or suitably padded vise to restrain the cap and allow you to

remove it slowly.

Change the spring/s as required, and ensure they sit into the corresponding grooves in the cap. Ensure the bead of

the diaphragm is sitting into the groove, then press the cap down and fully screw in two opposing cap screws,

followed by the remaining four. Nip the screws up tight and it is preferable to use a drop of Loctite on the threads.

The EX44 comes fitted with a 5psi and a 10psi

spring (for a base boost pressure of 15psi).

Available separately is a 7psi spring. All 3 springs

can be used individually or installed together to

achieve different boost levels. Use the table

opposite to determine the combination of springs

required for your desired base boost level.

Note that this table is only a guide to help your

selection – the actual boost level achieved

ultimately depends on a large number of variables,

and may differ from the base boost pressure

shown in the table.

spring selection

Use the following guide to help set up your EX44. You should first determine the minimum and maximum boost

pressure that you want to run, and your control method.

Care should be taken when selecting boost pressures, and it is always best initially to err on the conservative side,

until the engine can be run on a dynamometer to ensure safety. Always consult an expert when making boost

changes, and it is recommended that the car be checked on a dyno, as high boost and/or lean air/fuel mixtures can

cause engine damage or worse, total failure.

If you are planning on having variable boost through the use of a boost controller, the range you can achieve

depends on your turbo setup. The lowest boost your car can run is determined by the spring (this is commonly

known as “gate pressure”), and boost can then be increased through the use of a boost controller.

As a rule of thumb, try to select springs so that your maximum boost is no more than double the “gate pressure”.

Whilst it is possible to increase boost beyond this, you may find that boost becomes less stable and harder to control.

This is because the boost controller must bleed most of the control pressure signal to the actuator, so the wastegate

is less able to self-correct for changes in manifold pressure. Using a stronger spring means the controller bleeds off

less of the pressure signal, giving the wastegate greater ability to regulate boost changes.

boost control methods

There are many different ways to connect the wastegate boost ports; three of the more common methods are

shown on the next page. Whilst it is possible to use any number of different methods that are not shown here, you

should always remember the following:

The lowest boost pressure possible is determined by the spring

The lowest possible boost pressure for a given spring combination is achieved when the

full boost pressure is applied to the lower actuator port, and none to the upper port

Boost pressure increases when you do one or both of the following:

Decrease the pressure at the lower port

Increase the pressure at the upper port

Product specificaties

Merk:	GFB
Categorie:	Niet gecategoriseerd
Model:	EX44

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