Installation Instructions
Contents
1. 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 Honeywell 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 pa2. to smoke as the engine heats up Once the initial oil film is burned off there should be no more smoke Honeywell Turbo Technologies pae Garrett Independent Aftermarket Honeywell International Inc 2525 W 190 Street Tea by Honeywell Torrance CA 90504 www TurboByGarrett com Doc 737639 35 Rev C www TurboByGarrett com 6
3. EGR tube kit will need to be used in conjunction with the turbocharger Part number is shown below Kit includes unique EGR tube and 2 gaskets Contact your distributor for availability See Fig 3 Garrett EGR tube kit 795496 0001 2 3 If the port is blocked off a simple plate with a gasket or suitable seal will suffice This plate is also a convenient location for an EGT thermocouple or probe Blocking off this port necessitates removing the EGR cooler assembly and blocking its outlet port as well Note vehicles with altered emissions equipment may not be highway legal in your state Consult local laws Doc 737639 35 Rev C www TurboByGarrett com rrett 5 by Hongyatll VW TDI Golf Jetta New Beetle Upgrade Turbocharger Part Number 778445 5002S Installation Instructions cont d 4 In order to realize the performance upgrade potential of this turbocharger upgrades to the fuel injectors and engine tuning are recommended Consult with a TDI specialist for guidance and recommendations 5 Change engine oil and filter before starting engine Regular oil changes with a high quality diesel specific oll are recommended as clean oil is vital to turbocharger performance and durability 6 Start engine and check for oil leaks Once the system is confirmed to be leak free you are ready to enjoy your new Garrett GT1749V turbocharger NOTE After handling the exhaust components it is not uncommon for the components
4. Garrett by Honeywell VW TDI Golf Jetta New Beetle Upgrade Turbocharger Bill of Materials amp Precautions 1 9L TDI with BEW code engine 2003 5 2006 A4 New Beetle TDI 2003 5 2006 0 A4 Golf 2003 5 2005 0 A4 J etta Parts List Tools Needed GT1749V Turbocharger e Factory Service Manual Installation Instructions Sold Separately EGR Tube Kit e For installation use tools recommended in 795496 0001 factory service manual Part Number 778445 5002S e NOTE Sor and fastener sizes ma be different from one model year to the next depending on P ifferent tools than those listed above may be required PLEASE INSURE THAT THE PART NUMBER THAT HAS BEEN ORDERED WAS THE INTENDED PART NUMBER BEFORE Recommended Other l tems BEGINNING INSTALLATION e Safety glasses e Anti seize compound e Oil filter See Honeywell Turbo Technologies return policy if the incorrect turbo kit has been ordered e Oil quantity per service manual IMPORTANT INFORMATION PLEASE READ CAREFULLY We recommend that this turbocharger be installed by a qualified automotive technician If you have any doubts as to your ability to install this turbocharger 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 turbo
5. charger from for clarification Prior to the Garrett turbocharger 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 NOTE It is recommended that the oil and oil filter are changed prior to running the Garrett turbocharger This will provide clean oil to the new turbocharger To ensure optimal performance always follow oil and filter change intervals per the Factory Service Manual Doc 737639 35 Rev C www TurboByGarrett com 1 VW TDI Golf Jetta New Beetle Upgrade Turbocharger Part Number 778445 5002S 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 80 days from original ship date from Honeywell All accepted returns are subject to a 20 restocking charge NO EXCEPTIONS Damaged Shipments The customer must file a claim with the shipping company if goods arrive in a damaged condition The customer must also notify the distributor from which the goods were purchased with pertinent information Refused Shipments Sending a ship
6. 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 Consumers are required to work through Honeywell s distributors in order to process any warranty claims 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 35 Rev C www TurboByGarrett com Garrett 2 VW TDI Golf jetta New Beetle Upgrade Turbocharger Part Number 778445 5002S 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 inspection 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
7. ment back to The Garrett Garage or Honeywell does not automatically give rise toa 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 to the distributor from which the goods were purchased The Honeywell distributor will determine the best solution 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 Honeywell 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
8. public roads or highways Contact Information for Questions Please contact the Honeywell distributor from which the equipment was purchased 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 e Garrett Independent Aftermarket Honeywell International Inc Ga rrett 2525 W 190 Street HTT_UA by Honeywell Torrance CA 90504 www lurboByGarrett com Doc 737639 35 Rev C www TurboByGarrett com Garrett 4 VW TDI Golf Jetta New Beetle Upgrade Turbocharger Part Number 778445 5002S Installation nstructions NOTE This turbocharger is intended as an upgrade for vehicles equipped with the BEW code 1 9L TDI engine It replaces Volkswagen OE part numbers 0382530195 amp 038253014E model KP39 BorgWarner 3K l Installation of this turbocharger is straightforward and the procedure is almost identical to replacing a stock unit The only exception concerns the EGR cooler port on the exhaust manifold see Fig 2 Follow the turbocharger replacement procedure in the Volkswagen factory service manual Anti seize compound is recommended on exhaust studs for ease of removal if necessary Be sure to connect the VNT actuator vacuum line and electrical connector 2 The EGR cooler port will either need to be blocked off and the cooler removed or the Garrett
9. rticular 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 authorities 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 i
10. s your responsibility to comply with federal state and local laws prior to driving your vehicle on public roads Doc 737639 35 Rev C www TurboByGarrett com Garrett 3 VW TDI Golf Jetta New Beetle Upgrade Turbocharger Part Number 778445 5002S 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 This product is an aftermarket part that is not legal for street use in California and New York Use on public roads may also be prohibited in other states adopting California emissions standards under section 177 of the Clean Air Act If you do not live in California or New York you should check with your state authorities to find out whether this product is legal for street use in your state Federal and state laws also prohibit the tampering with parts or vehicle design elements affecting emissions on vehicles intended for use on public roads You are responsible for ensuring that the use of this product complies with all applicable federal state or local laws regulations and ordinances This product may be used on racing vehicles that will never be driven on
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