Turbo Speed Sensor Kit
Contents
1. Honeywell Turbo Technologies Contact Information Please contact Honeywell Turbo Technologies at garrett iamcs honeywell com for any questions regarding this Shipping Returns Cancellation Policy for notifications to Honeywell Turbo Technologies and for instructions on processing damaged shipments and authorized returns Honeywell Turbo Technologies Garrett Independent Aftermarket i Honeywell International Inc Garrett 3201 W Lomita Blvd by Honeywell Torrance CA 90505 www TurboByGarrett com Doc 737639 34 Rev www TurboByGarrett com Garrett 4 Gy Hornell Turbo Speed Sensor Kit Part Number 781328 0001 or 0002 Installation I nstructions 1 Remove the compressor housing from your turbocharger This may necessitate removing the turbo from the vehicle if it is already installed Typically the compressor housing Is attached to the turbo using a v band clamp or bolted clamps Remove all bolts clamps and the wastegate actuator whatever is necessary to separate the compressor housing from the turbo see fig 1 Do not loosen the wastegate rod end or lock nut and do not adjust the actuator simply unbolt its bracket from the compressor housing 1 Refer to the enclosed layout drawing 776243 and Fig 1 find your particular Garrett turbo on sheet 2 Check the turbo nameplate for part number Otherwise cross reference www TurboByGarrett com or your lt eraseon rors60 0005 4s2s7 0028 0 60 Garrett catalo2. line based on turbo speed observed from the test From this point draw a vertical line down to the airflow axis and you will have your flow estimate continued on next page Doc 737639 34 Rev www TurboByGarrett com 12 Turbo Speed Sensor Kit Part Number 781328 0001 or 0002 Installation I nstructions cont d For a more accurate estimate of airflow you will need to correct the turbo speed for the compressor inlet temperature since flow on a compressor map is corrected for standard atmospheric conditions Using a thermocouple or equivalent temperature sensor installed as close as possible to the compressor inlet use the following equation to correct the turbo speed RP M measured corrected I T 460 545 Where T is the measured compressor inlet air temperature in degrees Fahrenheit After calculating the corrected speed for each point plot corrected speed vs pressure ratio on the map and find the corrected airflow on the horizontal axis In this way a boost gauge and the Garrett Turbo Speed Sensor Kit can be used to gauge the effectiveness of performance upgrades such as free flowing air filters or head porting by comparing airflow before and after the upgrade This method will also help to validate your turbo selection and guide decisions to upgrade your turbo by showing where you are on the compressor map more accurately than otherwise possible RPM If you are interested in the actua airflow i
3. the connector Connect the red wire to a fused 12V DC power source Connect the black wire to a chassis ground point Crimp on or soldered connectors are recommended 2 Set the gauge for your particular compressor wheel There are 4 dip switches on the back of the gauge Set the switches to the correct number of compressor blades based on figure 11 below If Fig 10 you desire to use the sensor to pick up a single 12 Blade Setting magnet or machined flat on a shaft choose 1 blade or 2 blades if there are 2 magnets or flats etc See figure 10 for example setting for 12 blades Disregard the 8 6 4 above the dip switches co CH co a Ce pan Ww CH Am AD TT gD gt m AD AnD A AmO s cH m h A ah N a oh a i N a a N am alec NICH N E N A Am AT AT ay N pom om g yoa po goa o ama O un so a 2 D af N a ob gJ Fig 11 Compressor Wheel Blade Setting Diagram Black dot represents switch Example for 12 blades switches are down down up up Doc 737639 34 Rev www TurboByGarrett com Ga rrett 9 by Honeyaell Turbo Speed Sensor Kit Part Number 781328 0001 or 0002 Installation I nstructions 3 The orange and green wires on the pigtail are not needed unless you plan on data logging the speed Signal see Section C below Cover the ends with electrical tape or heat shrink tubing and secure the wires To install th
4. 781328 0001 or 0002 Installation I nstructions Sensor Signal the speed sensor will output a square wave signal at 1 8 the input frequency The input frequency is simply one pulse per blade as the blades pass by the sensor The sensor therefore measures the following input frequency in Hz x f A Equation 1 where N is the number of blades and RPM is the turbo speed The internal sensor electronics then divide this signal by 8 making the sensor output frequency in Hz N RPM Jou l To Equation 2 Solving for turbo speed RPM 480 fou a Equation 3 Therefore your data logger needs to convert the speed sensor signal based on equation 3 For example with a 12 bladed wheel RPM 480 Jou y fy 40 Example So the logger would need to multiply the sensor signal by 40 in order to record true turbo RPM for a 12 bladed wheel Section C STREET KIT WITH GAUGE AND DATA LOGGER data logger not included For data logging with the Street Kit gauge installed follow all instructions in sections A and B above EXCEPT DO NOT connect the orange wire to 5V DC The orange wire will not be used Vehicle 12V DC power is connected to the red wire as in section A and the green wire is connected to the data logger as in section B The black wire is connected to ground Cover the end of the orange wire with electrical tape or heat shrink and secure it out of the way Doc 737639 34 Rev www TurboByGarrett com Garrett 11
5. ByGarrett com Garrett 6 by Honeywell Fig 6 Turbo Speed Sensor Kit Part Number 781328 0001 or 0002 Installation I nstructions 6 Setting the sensor depth if the turbocharger is still in the vehicle ensure that there is enough space to adjust the sensor by turning it in and out Also ensure there is sufficient Space to turn the compressor wheel by hand If not remove the turbocharger from the vehicle Slowly turn the sensor clockwise while simultaneously spinning the wheel very Slowly Turn the sensor inwards just until the tip contacts the edge of a compressor wheel blade see figure 7 Be extremely careful not to jam the wheel into the sensor the blades or sensor could be damaged You should be able to feel a SLIGHT resistance and noise while gently turning the wheel as it contacts the sensor Then turn the sensor back counterclockwise approximately 1 6 full turns This sets the sensor depth correctly The nominal distance from the blade edge is 0 8mm The sensor thread pitch is 0 5mm thread 0 5mm thread x 1 6 threads 0 8mm NOTE f the Garrett Turbo Speed Sensor Kit is being used with an older Garrett T Series turbo or with a non Garrett unit refer to figure 7 below for general placement of the sensor It should always be installed at 0 8mm clearance from the wheel The sensor hole should be drilled at an angle placing the sensor near the base of the wheel below the level of the splitter blades in order to accurately
6. Garrett by Honeywell Turbo Speed Sensor Kit Bill of Materials amp Precautions Application Part Numbers 781328 0001 Street Kit All Catalog Garrett GT Turbos 781328 0002 Pro Kit Parts List Tools Needed l e 10mm open end wrench Speed sensor 769366 0001 e Wire cutters crimpers Spacer block e Threadlocking compound _ e Heat shrink or electrical tape Layout machining drawing 776243 e 20 gauge connectors for 12V power and ground Installation Instructions e Zip ties to secure wiring harness M4 x 0 70 x 18mm screw e 6mm wrench or socket for gauge bracket M4 x 0 70 x 20mm screw Wrench es to remove compressor housing and turbo if M4 x 0 70 x 22mm screw necessary Main Wiring Harness 778178 0001 e NOTE Bolt and fastener sizes may be different from one Power Logger Pigtail 778178 0002 model year to the next depending on OE specifications Gauge Different tools than those listed above may be required Gauge Extension Harness 778178 0003 Recommended Other j tems Table of Contents e Safety glasses e Anti seize compound General Installation Instructions Section A STREET KIT WITH GAUGE ONLY Section B PRO KIT WITH DATA LOGGING NO GAUGE a PLEASE INSURE THAT THE PART NUMBER THAT HAS BEEN section C STREET KIT WITH GAUGE AND DATA RECEIVED WAS THE INTENDED PART NUMBER BEFORE LOGGER BEGINNING INSTALLATION Section D MAXIMUM SPEED RECALL FUNCTION Section E MAPPING has been ordered See Honeywell Turbo Techn
7. by Horneyaell Turbo Speed Sensor Kit Part Number 781328 0001 or 0002 Installation I nstructions cont d Section D MAXIMUM SPEED RECALL FUNCTION 1 Push the recall button once to display the last maximum speed 2 Push the recall button again and release it immediately to go back to normal operation mode The speed gauge will return to normal operation mode after 5 seconds if the button is not pressed again TO RESET 1 Push and hold the recall button for at least 2 seconds to reset the recorded maximum speed 2 Push the recall button again to verify that the previous max speed has been cleared Section E Mapping If you are familiar with turbocharger operational theory as explained in the Turbo Tech sections on www TurboByGarrett com you can use the turbo speed data to plot operating points on your compressor map which can enable you to make a close estimate of airflow through the engine For example during a full throttle acceleration test up to redline you can observe maximum boost and maximum turbo speed which will be near redline and use this information to estimate flow at redline From the boost gauge pressure you can estimate Pressure Ratio across the compressor by accounting for atmospheric pressure and losses in the intake plumbing as in Turbo 103 on the Garrett website Draw a horizontal line on the map at this estimated PR value The compressor s operating point is where it intersects the estimated speed
8. e gauge connect the gauge extension harness to the shortest end of the main wiring harness 7 9 in 200mm Run the extension into the vehicle interior and connect the gauge after determining a suitable mounting location The gauge itself is a standard 2 1 16 diameter and should mount in any properly sized gauge pod using the included bracket and nuts The gauge extension harness can be left out if the main harness is long enough without tt Fig 12 4 Gauge lighting refer to a wiring diagram for your vehicle and connect the white gauge wire to the output of the dash light dimmer knob or directly to the headlight switch if desired see figure 12 Section B PRO KIT WITH DATA LOGGING NO GAUGE data logger not included 1 For data logging connect the orange wire on the pigtail to a 5V DC 0 5V source This Supplies sensor power Your data logging device may have a 5V DC source available The sensor output signal is carried by the green wire Connect the green wire to the data logging device on a channel selected for turbo speed signal Connect the black wire to data logger ground The red wire is not used cover the end with electrical tape or heat shrink CAUTION DO NOT CONNECT THE ORANGE WIRE IF SENSOR IS USED WITH A DATA LOGGER IN ADDITION TO THE SPEED GAUGE see section C below continued on next page Doc 737639 34 Rev www TurboByGarrett com Garrett 10 by Horeryperell Turbo Speed Sensor Kit Part Number
9. eywell Turbo Technologies for any of its turbochargers and related parts and or services and is in lieu of and excludes all other warranties expressed or implied including warranties of merchantability or fitness for a particular purpose Honeywell Turbo Technologies hereby disclaims all other warranties not expressly set forth Some jurisdictions do not allow for the exclusion of implied warranties so the above exclusions may not apply to you however if implied warranties do apply they are limited to the original purchaser and for a period of one 1 year from the date of shipment Diagnosing Your Vehicle Do not rely on diagnostic software without seeking the advice of an ASE certified mechanic Diagnostic software should only be used as a general guideline to help you facilitate the repair of your car If you experience or suspect any malfunction of vital safety equipment such as your brakes exhaust motor transmission fuel delivery system your car s structural integrity or any other potentially life threatening malfunction cease driving your vehicle immediately and seek professional help Always consult your owner s manual Vehicle Modification Notice Any modifications to your car are AT YOUR OWN RISK You should consult the owner s manual and service manual You should also contact your car s manufacturer to determine what effects modifications may have on your safety warranty performance etc Please also contact your local author
10. g to confirm your turbo part number Grose ee or call a distributor if you are unsure Once you TE Beet paree have identified the part number highlight the naa correct row in the table for future reference The _ Grassors 467937 0015 ac dimensions in this table refer to the views on sheet 1 of this drawing these are instructions for the machinist to modify your housing For example if you have a Disco Potato turbo GT2860RS part number 739548 1 or 5 or 11 highlight row 18 You will only need the dimensions listed in this row see figure 2 wie 2 Take your compressor housing and the highlighted layout 776243 all sheets to a qualified machine shop Make sure the machinist is capable of meeting the tolerances on the drawing and knows which row of dimensions to use before agreeing to pay for the work You may want to Supply the machine shop with the spacer screw and speed sensor so they can test fit the parts in the housing see figure 3 NOTE On the machining Layout 776243 sheet 1 datum A is always the main compressor housing mating surface which is a machined surface around the perimeter of the housing and is usually inset by several millimeters Doc 737639 34 Rev www TurboByGarrett com Garrett 5 by Honeyaell Turbo Speed Sensor Kit Part Number 781328 0001 or 0002 Installation I nstructions 4 Once the housing is machined install the spacer with the supplied M4 screw There are differe
11. ities to determine whether your intended modifications will make your car illegal to drive on public roads A vehicle modified by the use of competition parts may not meet the legal requirement for use on public roads It is your responsibility to comply with federal state and local laws prior to driving your vehicle on public roads Doc 737639 34 Rev www TurboByGarrett com Garrett 3 Gy Hornell Turbo Speed Sensor Kit Part Number 781328 O0001 or 0002 IMPORTANT INFORMATION PLEASE READ CAREFULLY OTHER PRECAUTIONS Observe all safety precautions and warnings contained in the installation instructions Wear eye and ear protection and appropriate protective clothing When working under or around the vehicle support it securely with jack stands Use only the proper tools Exercise extreme caution when working with flammable corrosive and hazardous liquids and materials LEGAL INFORMATION The Garrett turbo kits are for use off the public roadways Federal law restricts the removal or modification of any part of a federally required emission control system on motor vehicles Also many states have enacted laws which prohibit tampering with or modifying emission or noise control systems Vehicles which are not operated on public roadways may be exempt from certain regulations however the buyer is strongly urged to check all applicable local and state laws and is ultimately responsible for compliance with the applicable laws and regulations
12. l Turbo Technologies approval This is purchaser s sole and exclusive remedy and provides the complete financial responsibility of Honeywell Turbo Technologies for a warranty claim To be eligible for reimbursement Customer must a submit all warranty claims to Honeywell Turbo Technologies within 30 days of the discovery of the alleged Turbocharger Product defect and b complete and return a Returned Material Authorization Form This form may be obtained from Honeywell Turbo Technologies at garrett iamcs honeywell com When Honeywell Turbo Technologies requires the examination of a failed part Honeywell Turbo Technologies will promptly notify Customer and will await receipt of the failed part before further processing the warranty claim If Honeywell Turbo Technologies ultimately determines that the failed part is covered under the Limited Warranty Honeywell Turbo Technologies will reimburse Customer for the actual cost of ground shipment for any part found to be defective Doc 737639 34 Rev www TurboByGarrett com Garrett 2 Turbo Speed Sensor Kit Part Number 781328 O0001 or 0002 IMPORTANT INFORMATION PLEASE READ CAREFULLY Limitations on Warranty The Limited Warranty does not apply to any parts a not used in accordance with Honeywell Turbo Technologies written instructions b for which no fault is found c that have been modified in any manner not specifically approved by Honeywell Turbo Technologies d for which an i
13. measure the speed On custom applications the sensor can be used with or without the spacer block a g SS ARAT y fa ah Sos COMPRESSOR LLL WHEEL LOCKNUT SPACER ZZ SENSOR HOUSING Fig 7 Doc 737639 34 Rev www TurboByGarrett com rrett 7 by Honeyaell Turbo Speed Sensor Kit Part Number 781328 0001 or 0002 Installation I nstructions 7 Tighten the speed sensor lock nut firmly with a 10mm wrench If there is not enough clearance to use a wrench use needle nose or similar pliers in conjunction with threadlocking compound to tighten the nut as securely as possible see figures 7 and 8 8 Reinstall your turbocharger if it is not already in the vehicle 9 Unpack the 3 way wiring harness and find the longest end 3 pins approx 35 5 in 900mm long This end connects to the speed sensor Connect the harness to the sensor and lay the harness out in the engine bay to begin determining wiring harness routing See figure 9 below GAUGE CONNECTOR POWER DATA LOGGER CONNECTOR Fig 9 Wiring Harness Diagram Doc 737639 34 Rev www TurboByGarrett com Garrett 8 by Horeryperell Turbo Speed Sensor Kit Part Number 781328 0001 or 0002 Installation I nstructions Section A STREET KIT WITH GAUGE ONLY 1 Locate the second to longest end of the harness approx 23 5 in 600mm Connect the power data logger pigtail which has 4 loose wires extending from
14. n b min through the compressor you will need to uncorrect the flow estimate with the following equation _ WAR 13 95 T 460 545 act Where P is the measured compressor inlet pressure in psi and W is the corrected airflow estimate from the map lb min You can use corrected airflow to make before and after comparisons but calculating the actual airflow will give a more accurate measurement of the true flow through the engine Honeywell Turbo Technologies Garrett Independent Aftermarket Honeywell International Inc a r r e 3201 W Lomita Blvd Torrance CA 90505 by Honeywell www TurboByGarrett com Doc 737639 34 Rev www TurboByGarrett com 13
15. nspection indicates that reasonable and proper installation and or preventative care and maintenance has not occurred e that have been subject to damage attributable to or caused by misuse abuse or vandalism mishandling improper shipping or other transit related damage acts of god or insurrection foreign object entry any part not supplied by Honeywell Turbo Technologies any repair maintenance or service by anyone other than Honeywell Turbo Technologies or any other acts that are beyond Honeywell Turbo Technologies reasonable control or f attributable to parts not supplied by Honeywell Turbo Technologies Honeywell Turbo Technologies expressly disclaims any and all warranties relative to the foregoing circumstances Honeywell Turbo Technologies shall not be liable to Customer under any circumstances for any special incidental or consequential damages including without limitation damage to or loss of property other than for Turbocharger Products damages incurred in installation repair or replacement lost profits revenue or opportunity loss of use losses resulting from or related to downtime of Turbocharger Products the cost of replacement transportation power or compression the cost of substitute products or claims of third parties for such damages howsoever caused and whether based on warranty contract and or tort including negligence strict liability or otherwise The Limited Warranty is the only warranty made by Hon
16. nt PORTED sHROUD V lengths of screws supplied in the kit the layout oe ae drawing shows which screw to use on each turbo ALL AROUND Do not torque the screw at this point If your housing has a ported shroud and the machined Spacer pocket has broken through to the inside coat the outside of the spacer with RTV or similar sealant to prevent an air leak past the spacer see SENSOR lt figure 4 4 Test fit the speed sensor If the lock nut is not accessible by wrench once installed apply a threadlocking compound that will cure slowly enough to allow adjustment and final tightening Install the speed sensor loosely in the housing do not tighten the lock nut yet IMPORTANT Make sure the tip of the sensor is approximately flush with the inside contour of the housing see figure 5 Tighten the M4 spacer screw once the sensor has been installed in the housing 4 Count the number of blades on your compressor wheel including small splitter blades Record this number below you will need it later see figure 3 Number of Compressor Wheel Blades 4 Install the housing on the turbocharger with its bolts and clamps Make sure housing orientation is correct Reinstall the wastegate actuator with bracket Tighten and torque the clamping bolts according to the tabulated columns Comp Housing Clamp Bolt Torque and Clamp Bolt Thread Type on the layout 776243 for your turbocharger Doc 737639 34 Rev www Turbo
17. ologies return policy if the incorrect kit IMPORTANT INFORMATION PLEASE READ CAREFULLY We recommend that this Garrett product be installed by a qualified automotive technician If you have any doubts as to your ability to install this product consult with a local automotive repair company Please be sure to carefully read all of the attached instructions prior to starting the installation process If you have any questions about the enclosed parts or the instructions call the distributor that you purchased the kit from for clarification Prior to the Garrett product installation be sure that the vehicle is parked on a level surface and the engine is cool Engine fluids and components can be extremely hot following normal vehicle operation Avoid direct contact of engine fluids or components with your skin which may cause personal injury Doc 737639 34 Rev www TurboByGarrett com 1 Turbo Speed Sensor Kit Part Number 781328 O0001 or 0002 IMPORTANT INFORMATION PLEASE READ CAREFULLY Return Policy Only unused and complete merchandise will be accepted for return subject to inspection and acceptance by Honeywell Turbo Technologies No goods will be accepted without prior return authorization from Honeywell Turbo Technologies No returns are accepted after thirty 30 days from original ship date from The Garrett Garage All accepted returns are subject to a 20 restocking charge NO EXCEPTIONS Damaged Shipments The cu
18. stomer must file a claim with the shipping company if goods arrive in a damaged condition The customer must also notify Honeywell Turbo Technologies with pertinent information Refused Shipments Sending a shipment back to The Garrett Garage or Honeywell does not automatically give rise to a complete refund or credit Honeywell Turbo Technologies may at its sole discretion require different payment means for any shipment refused and then reshipped It is the customer s responsibility to make all arrangements with Honeywell Turbo Technologies for disposition of refused shipments Shortage or Discrepancy Claim Shortage or Discrepancy claims must be reported within forty eight 48 hours of receipt of goods Honeywell Turbo Technologies will either issue a credit or send a replacement s at no charge Please contact garrett iamcs honeywell com for instructions on how to address shortages or discrepancies Limited Warranty Honeywell Turbo Technologies warrants to the original purchaser of its Turbocharger Products that such Turbocharger Products will for a period of 1 year from date of shipment and subject to the Limitations on Warranty be free from defects in materials and workmanship For approved warranty claims Honeywell Turbo Technologies will at its sole discretion either credit the original purchaser in an amount equal to the original purchase price or replace the applicable Turbocharger Product free of charge within 60 days of Honeywel
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