Installation Instructions
Contents
1. 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 I mportant product information Garrett Vehicle Specific Turbos are professional aftermarket products only designed for certain racing vehicles driven on particular racing tracks and shall only be used on racing vehicles that will never be driven on public roads or highways Garrett Vehicle Specific Turbos are not legal for the use in vehicles on public roads or other road to which public road law applies Any vehicle modifications using Garrett Vehicle Specific Turbos are AT YOUR OWN RESPONSIBILITY and AT YOUR OWN RISK Only use Garrett Vehicle Specific Turbos in compliance with all applicable laws regulations and ordinances including but not limited to emission noise operating license performance safety and type approval aspects A vehicle modification using Garrett Vehicle Specific Turbos may particularly affect or void a vehicle s warranty operating license or type approval You should particularly consult the owner s manual and service manual of your vehicle You should also contact your vehicle s manufacturer to determine what effects modifications may have on important asp2. Garrett by Honeywell VW SKODA SEAT Audi TDI Euro4 Upgrade Turbocharger BILL OF MATERIALS amp PRECAUTIONS 2 0L TDI 14 103kKW 140PS with BKD BKP AZV code engine Part Number 838946 5001S x L 2003 10 2009 07 Golf V Mk5 A5 PQ35 typ 1K see Note on Page 5 2005 08 2011 05 Jetta A5 PQ35 typ 1K 2003 08 2010 05 Touran typ 1T AZV for 136 HP 2005 09 2010 05 Passat B6 typ 1T BKP 2004 02 2010 05 Skoda Octavia Mk2 typ 1Z 2 gen AZV for 136HP 2009 01 2010 03 Skoda Superb B6 typ 3T BKD EA188 2005 07 2011 09 Seat Leon Mk2 typ 1P 2004 04 2009 05 Seat Toledo 3 2004 03 2011 09 Seat Altea 2003 08 2007 05 Audi A3 Typ 8P Soil LIST TOOLS NEEDED GTA1749MV Turbocharger Factory Service Manual Installation Instructions For installation use tools recommended in factory service manual NOTE Bolta d fastener izes A Ard be di rerent aen one mo ear to the epen PLEASE INSURE THAT THE PART NUMBER THAT HAS BEEN P specification Different fools t an tho al ORDERED WAS THE INTENDED PART NUMBER BEFORE liste ove may be requir BEGINNING INSTALLATION See Honeywell Turbo Technologies return policy if the incorrect Recommended Other l tems turbo kit has been ordered e Safety glasses e Anti seize compound e Oil filter Oil quantity per service manual IMPORTANT I NFORMATION PLEASE READ CAREFULLY We recommend that this turbocharg
3. c roads or other road to which public road law applies Any vehicle modifications using Garrett Vehicle Specific Turbos are AT YOUR OWN RESPONSIBILITY and AT YOUR OWN RISK Only use Garrett Vehicle Specific Turbos in compliance with all applicable laws regulations and ordinances including but not limited to emission noise operating license performance safety and type approval aspects A vehicle modification using Garrett Vehicle Specific Turbos may particularly affect or void a vehicle s warranty operating license or type approval You should particularly consult the owner s manual and service manual of your vehicle You should also contact your vehicle s manufacturer to determine what effects modifications may have on important aspects such as safety warranty performance etc Rev A www TurboByGarrett com Garrett 2 VW 2 0L TDI Upgrade Turbocharger Part Number 838946 5001S IMPORTANT I NFORMATION 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 mi
4. 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 has to be connected with the turbocharger via existing OEM EGR tube see fig 2 3 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 4 Change engine oil and filter before starting engine Regular oil changes with a high quality diesel specific oil are recommended as clean oil is vital to turbocharger performance and durability 5 Start engine and check for oil leaks Once the system is confirmed to be leak free you are ready to enjoy your new Garrett GTA1749MV turbocharger NOTE After handling the exhaust components it is not uncommon for the components to smoke as the engine heats up Once the initial oil film is burned off there should be no more smoke Honeywell Turbo Technologies Garrett Independent Aftermarket Honeywell International Inc j 2525 W 190 Street a rre HTT U4 Garrett Garage Torrance CA 90504 by Honeywell www TurboByGarrett com Rev A www TurboByGarrett com Garrett 5 by Honeypai
5. ects such as safety warranty performance etc 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 Rev A www TurboByGarrett com Garrett 3 VW 2 0L TDI Upgrade Turbocharger Part Number 838946 5001S IMPORTANT I NFORMATION PLEASE READ CAREFULLY 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 is your responsibility to comply with federal state and local laws prior to driving your vehicle on public roads OTHER PRECAUTIONS Observe all safety precautions a
6. er 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 turbocharger 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 RevA www TurboByGarrett com 1 VW 2 0L TDI Upgrade Turbocharger Part Number 838946 5001S IMPORTANT I NFORMATION 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 s
7. ginal 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 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 I mportant product information Garrett Vehicle Specific Turbos are professional aftermarket products only designed for certain racing vehicles driven on particular racing tracks and shall only be used on racing vehicles that will never be driven on public roads or highways Garrett Vehicle Specific Turbos are not legal for the use in vehicles on publi
8. hip 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 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 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 ori
9. nd 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 I NFORMATION Garrett Vehicle Specific Turbos are professional aftermarket products only designed for certain racing vehicles driven on particular racing tracks and shall only be used on racing vehicles that will never be driven on public roads or highways Garrett Vehicle Specific Turbos are not legal for the use in vehicles on public roads or other road to which public road law applies Any vehicle modifications using Garrett Vehicle Specific Turbos are AT YOUR OWN RESPONSIBILITY and AT YOUR OWN RISK Only use Garrett Vehicle Specific Turbos in compliance with all applicable laws regulations and ordinances including but not limited to emission noise operating license performance safety and type approval aspects A vehicle modification using Garrett Vehicle Specific Turbos may particularly affect or void a vehicle s warranty operating license or type approval You should particularly consult the owner s manual and service manual of your vehicle You should also contact your vehicle s manufacturer to determine what effects modifications may have on important aspects such as safety warranty performance etc Unless
10. shandling 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
11. you have fully read and understood the important product information above and unless you fully agree with the terms and conditions set forth therein do not modify or use a vehicle with a Garrett Vehicle Specific System Contact I nformation 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 Garrett Independent Aftermarket Honeywell International Inc Ga r r eil 2525 W 190 Street HTT U4 Garrett Garage by Honeywell Torrance CA 90504 www TurboByGarrett com Rev A www TurboByGarrett com Garrett 4 VW 2 0L TDI Upgrade Turbocharger Part Number 838946 5001S INSTALLATION INSTRUCTIONS NOTE This turbocharger is intended as an performance upgrade Plug and Play P amp P for vehicles equipped with the 2 0L TDI Euro4 engine code BKD BKP AZV It is recommended as performance replacement for VW SKODA SEAT AUDI OE part number 03G 253 010 J and 03G 253 010 J V100 Garrett OE part number 724930 5009S 5010S and 5011S 5012S model GTA1749MV l Installation of this turbocharger is straightforward and the procedure is almost identical to replacing a stock unit Follow the turbocharger replacement procedure in the Volkswagen factory service manual Anti seize
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