Installation Instructions 2.0T TSI Short Ram Intake System Golf5 / Jetta5 / EOS Part# VFA-2.0TSCAIK

Transcription

1 Installation Instructions 2.0T TSI Short Ram Intake System Golf5 / Jetta5 / EOS Part# VFA-2.0TSCAIK IMPORTANT NOTICE : This product is NOT CARB legal and legal for use on public roads in the US States with CARB laws. This product may void certain aspects of your manufacturer warranty. VF-Engineering is not responsible for consequential damage, losses, or injury resulting from the use of this product. VF ENGINEERING M-F 9:00AM 5:30PM (PST) 1365 N. Dynamics St. #E, Anaheim CA Phone: (714) Fax: (714) PAGE 1 of 19

2 Contents: 1) K&N Air filter, K&N Part # RU ) VF Mandrel Bent one-piece short ram pipe 3) Hardware fitted on item (2) heat shielded ¾ oil resistant hose with clamps 2x M4 cross head screw with split lock washer M6 bolt with split lock washer and flat washer L-shaped bracket with nylon spacer with M6 nut and bolt 4) 2.75 to 2.50 silicon reducer with 2x hose clamps 5) Air filter heat shield 6) Hardware on item (5) plastic liner for through hole K&N # smog pump filter Billet quick-connect adapter M6x40 bolt M6x16 bolt Black-blank off cap PAGE 2 of 19

3 Currently there are 2 versions of the 2.0T (TSI) in the USA : CCTA and CBFA. CBFA is the SULEV emissions model (predominantly sold in CA) as shown below. The CCTA is of similar appearance and is the ULEV emissions model. This intake fits both motors. If you engine is the does not appear as below and is the older version of 2.0T (TFSI) then you need to refer back to your vendor. Remove engine cover by prying it upwards off it grommets. PAGE 3 of 19

4 Remove cover off the ram air box by depressing clips at either end of it. Remove lower section of ram air box by depressing on clips on either side. PAGE 4 of 19

5 Unplug MAF connector. Unclip quick-connect fitting from air box (CBFA models only). Using spring clamp tool, slide grey clamp upwards. Remove 1x airbox mounting screw PAGE 5 of 19

6 Remove the air box and inlet duct by separating them and pulling upwards. The inlet duct does not necessarily have to be separated. The airbox has a drain tube and will look like this when removed. PAGE 6 of 19

7 Unclip coil pack connectors. Remove coil pack from cylinder #2 Disconnect crankcase vent hose. (It is easier when you use a thick glove on a hot engine) PAGE 7 of 19

8 Remove screw retaining the intake tube to exhaust shield bracket. Slide spring clamp around turbo inlet coupler and intake pipe. PAGE 8 of 19

9 Loosen spring clamp on turbo inlet coupler and remove coupler completely. Remove battery and plastic surround PAGE 9 of 19

10 This is how the wiring should appear Remove wiring clip from side of brake reservoir cylinder. PAGE 10 of 19

11 Using great care, use a blade to remove 1-2 of the loom covering. Do this at your own responsibility in ensuring not to cut into the wiring within. If you are unsure, seek advise or assistance from an experienced technician. VF-Engineering is not responsible for damage caused. Note how the wiring harness has been moved across to the left clip (arrow on right). Note how the wiring has been carefully brought around the left of the brake fluid reservoir. All wiring must be slack and the installer should not pull on the wiring else damage can occur to the connector and / or connection within the electrical plugs. PAGE 11 of 19

12 INSTALLATION. Re-install battery with all trims. Remove bolt shown below (behind driver side headlight). Install heat shield as shown below and secure both bolts supplied. CCTA models - the smog pump snorkel shown below is not applicable use the blank off cap to cover the exposed hole in the heat shield. PAGE 12 of 19

13 CBFA models use a heat gun to heat the collar where the snorkel overlaps on top of the 90deg fitting. You may need to use gloves to rotate it 180degrees. TAKE CARE not to overheat and melt the snorkel or to force it and break it when twisting the fitting. Push fit the quick connect onto the adapter under the filter. It should CLICK and the snorkel must not be tort. PAGE 13 of 19

14 Install the VF reducer coupler smaller diameter 2.5 side onto the turbo inlet and clamp down with hose clamp supplied. Install intake tube into position by feeding it through the heat shield first. PAGE 14 of 19

15 With care, guide the stiff oil resistant hose and slide it onto the crank case spout on the valve cover. Use the hose clamp provided. Tighten the clamp once the intake is in its final position. Re-install coil pack in cylinder #2 and re-connect all 4 coil pack electrical connectors. Remove Mass Air Flow (MAF) sensor element from original air box and install into VF intake pipe. Ensure that the split lock washers provided are positioned between the screw head and the MAF. PAGE 15 of 19 Install the L-shape support bracket from the boss on the intake as shown.

16 The lower end of the L-shape bracket is to be mounted as shown. In some cases, the plastic spacer may not be used to allow for improved positioning of the intake tube (due to variation in the production of these engines). Install large K&N air filter at open end of intake pipe and manipulate intake to allow clean install. Ensure intake tube is not resting on the cap of the brake fluid reservoir and tighten all clamps and mounting points (turbo inlet, crankcase vent and L-shape bracket). PAGE 16 of 19

17 Final step: remove 90deg plastic shield on MAF electrical connector and rotate it 180degress and lock back onto the connector. Fit engine cover and then connect MAF electrical connector. PAGE 17 of 19

18 VF-ENGINEERING ACCESSORIES LIMITED WARRANTY Subject to all the terms, conditions and exclusions set forth in this document, Zurich Engineering, Inc. ( VF-Engineering ) provides the following warranties to the original purchaser of certain VF- Engineering products. For reference purposes, you and your mean only the original purchaser of the warranted VF-Engineering product. 1. In the cases where 3 rd party products are supplied in conjunction with VF-Engineering parts, the 3 rd party warranty terms and conditions apply. 2. Installation issues must be queried with your vendor/dealer before calling VF-Engineering. i. Use of VF-Engineering accessories in combination with any other accessories may render the performance gain for the VF accessory useless or dangerous, for example air intake systems and may cause lean conditions with certain 3 rd party ECU software or turbo downpipes. ii. VF-does not guarantee compatibility with any other accessories and has not conducted air/fuel ratio testing with commonly used combinations of accessories. It is the users/installers responsibility to ensure that a safe combination of accessories is used / verified prior to installation. 3. REQUIREMENTS AND EXCLUSIONS: i. You must be the original purchaser. ii. The product must NOT be modified, disassembled, tampered in any way. iii. The original spec parts must be replaced with like for like parts in the case of air filters with matching part#s. iv. The accessory must be allowed to break in for a period of 300 miles and inspected / for loose parts. v. The main serpentine belt must not be excessively tensioned see belt tensioning instructions. vi. Improper installation, not following installation instructions provided, or installation by an unskilled person is excluded. vii. Damage resulting from entry of foreign particles is excluded. viii. If the car is driven after an uncorrected fault has been detected cover is excluded. ix. Any faults/irregularities are not advised to your vendor. 4. ONE YEAR LIMITED WARRANTY ON VF-ENGINEERING ACCESSORIES AS BELOW: i. Mounting brackets and hardware ii. Idler pullies. iii. Air inlet and discharge systems. iv. Air valves. 5. NINETY DAY LIMITED WARRANTY ON VF-ENGINEERING SUPERCHARGER KIT CONSUMABLES AS BELOW: i. Air filters. ii. Oil feed and oil drain components. iii. Serpentine belts. iv. Injectors, regulators and fuel components WARRANTY COVER FOR THE PRODUCT IS EXCLUDED BUT NOT LIMITED TO THE FOLLOWING CONDITIONS. 6. VF-Engineering does not provide any warranty to You for damages to and/or failure of any non-vf-engineering component or equipment on a vehicle, including but not limited to the engine, electrical systems, transmission and differentials; 7. The warranties do not protect You from Acts of God, normal wear and tear, or damage to a vehicle or engine caused by backfire, collision and or engine failure; 8. These warranties do not cover any costs incurred for towing or downtime of the vehicle, any labor costs to diagnose problems, to remove or replace the VF-Engineering products, or any damage caused by the use of another company's fittings or pullies.; 9. The following non-vf-engineering occurrences, uses and modifications are considered misuse of the VF-Engineering product and invalidate all Your VF-Engineering Warranties, including but not limited to: i. Any disassembly or attempted disassembly of any VF-Engineering assembled parts; ii. Any disassembly or attempted disassembly of sealed units; iii. Damage resulting from ingestion of debris; iv. Improper product installation; v. Over-speeding the engine; vi. Restricted or blocked air intake; vii. Free revving of the engine; viii. Incomplete fitment of all the parts supplied in the VF-Engineering kit. ix. Excessive engine crankcase pressures; x. Dirty or contaminated engine oil; xi. Improper installation, not following installation instructions provided, or installation by an unskilled person; xii. If the car is driven after an uncorrected fault has been detected; or xiii. Any faults/irregular noises are not advised to your vendor; xiv. OEM catalytic converters must be utilized. 10. Power increases plots and data with Zurich Engineering, Inc. accessories are based on unmodified engines and quoted from results obtained from dynamometer tests using the Dynojet 248C & 224XLC and no guarantee is given that every car will achieve the same results as pre-existing conditions may affect results. EXTENT OF WARRANTY- ADDITIONAL EXCLUSIONS AND LIMITATIONS 11. The duration of any and all warranties is limited to the duration of this express warranty. All incidental and consequential damages are hereby excluded. Some US states do not allow limitations on how long an implied warranty lasts, or exclusion or limitations of incidental or PAGE 18 of 19

19 consequential damages, so the above limitations or exclusions may not apply to You. This warranty gives You specific legal rights, and You may have other rights that vary from state to state (USA) only. 12. No warranties of merchantability of fitness for particular purpose, or affirmation of fact, of the warranty, expressed or implied, other than any available manufacturer s warranties are extended or granted by VF-Engineering. DISCLAIMER 13. Motor racing is extremely hazardous, and death may occur. VF-Engineering products have no warranty or representations made with ability to protect against injury or death. Motor racing, aggressive driving, including driving for any period of time at full throttle, and car modifications of any kind that facilitate aggressive driving may reduce the useful life of the car and or any of its wearable parts. Improving the performance of an engine by altering the engine s computer software may cause the engine to work harder and could result in damage to the car. The user assumes these risks. REMEDIES 14. Your sole remedy for the above warranties is the repair or replacement of the defective product only, at VF-Engineering s discretion. 15. WARRANTY CLAIM PROCEDURE i. If a VF-Engineering product is within the warranty period and You wish to make a claim, please follow the procedure as follows: ii. Contact VF-Engineering on (+1) asking for the service department and have the following information available: iii. Supercharger serial number iv. Copy of original invoice on which the product was purchased (must be dated and show retail store name); v. Year, make, model, vehicle mileage, and engine specifications of the vehicle; vi. Number of miles on the VF-Engineering product; and vii. Perceived problem viii. 16. VF-Engineering will then offer suggestions to help you in troubleshooting or will issue a return authorization (R.A.) number to return the product for warranty evaluation; 17. If you have been issued an R.A. number, you must safety package each product, which means You must place the product(s) within a shipping box strong enough to hold the weight of the product(s) and to maintain its shape during shipping with adequate packing material so that the product(s) will not hit other product(s), component(s), or the side of the box during shipping. You want to use a professional company. Clearly mark the R.A. number in large (approximately 2 ) alphanumeric characters in two locations on the outside of the box with a bold marker. Returned items in transit remain the responsibility until signed for by a member of VF-Engineering shipping dept. 18. INCLUDE IN THE SHIPPING BOX THE FOLLOWING ITEMS: i. Serial number if applicable; ii. Copy of original invoice on which the product was purchased (must be dated and show retail store name); iii. Year, make, model, vehicle mileage, and engine specifications of the vehicle; iv. Number of miles on the VF-Engineering product; and v. Perceived problem vi. A copy of the original Three Year Warranty Registration, if applicable; vii. Return authorization number; and viii. Address to which the product is to be shipped after inspection. 19. Ship the properly safety packaged and marked box via UPS or other carrier, prepaid and insured for the retail value of the product being returned to: VF-Engineering Service department 1365 North Dynamics Street, Suite E. Anaheim, CA USA R.A. number 20. If a VF-Engineering warranty applies, Your product will be repaired or replaced at VF-Engineering s option and returned to you, freight prepaid excluding any international shipping, taxes, tariffs, customs and/or duties, etc which must be paid by You), via UPS/Fedex/DHL ground service. If a VF-Engineering Limited Warranty does not apply, we will advise you of the specific reason for denial and explain to You the costs involved in repair or replacement of your product. After relaying this information we will, at your option, either proceed with the repairs as quoted or return Your products(s) to you in the condition it/they are in at the time of inspection of the warranty evaluation by VF-Engineering. Timing is not of the essence in delivery or turn around. If the warranty does not apply and you do not want VF-Engineering to repair or replace your product, You will be charged the disassembly and inspection charges for the product and return shipping with insurance by means of UPS COD. 21. This warranty cannot be amended orally or in writing by any VF-Engineering employee, representative or agent, and any promises inconsistent with this warranty are void and unenforceable against VF-Engineering. PAGE 19 of 19