VW Jetta, Golf, New Beetle 1.9L TDi Unichip PnP Installation Instructions

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1 VW Jetta, Golf, New Beetle 1.9L TDi Unichip PnP Installation Instructions and Warranty Information Tools Required 10mm combination wrench, 13mm Socket (Jetta/Golf only), 3/8-inch or ¼-Inch drive ratchet, Medium Phillips-head Screwdriver (Jetta/Golf only), Small Flashlight, Small pick (Jetta/Golf only), Small Common Screwdriver, T20 Torx (Beetle only) Notes: (1) Although the PnP kits and ECU s are identical, the New Beetle s EC s location is different than the Jetta/Golf; therefore these instructions are split the first section describes Golf/Jetta installation and the second section describes Beetle installation. (2) The ECU connectors lock and unlock by pulling the T-handle located at the connector s edge. Look at the locking handles on the PnP harness and familiarize yourself with the mechanism before trying to remove the OEM plugs. (3) When trying to remove the from the ECU, getting your fingers into the T-handles can be difficult. You can gently pry the T- handles back using a screw driver. (4) The Golf/Jetta OEM ECU bracket will not reinstall with the Unichip PnP harness in place without modification. You can easily modify your bracket as outlined below or can by a modified bracket from UNA (UNA Part # ). Installation Procedures - Golf/Jetta 1. Using the 10mm wrench, disconnect the car s battery at the negative terminal in the engine compartment behind the driver s side headlight. 2. (Photo 1) Remove the Windshield Wiper Arms Note: Installing the wiper arms in the incorrect position may result in damage when they are actuated. a. Using the pick, pry off the windshield wiper drive spindle covers. b. Record the arm position on the drive spindle with a marking pen to assist correct reinstallation. c. Using the 13mm socket, remove the nut securing each wiper arm blade, and remove the arms. 3. (Photo 2) Remove the plastic Rain Tray Cover a. Remove the rubber seal along the top of the firewall b. Slip your fingers between the windshield and the tray at the mid-span point and gently work towards one side unplugging the securing tabs. DO NOT USE ANY TOOLS as they may damage the tray, tray tabs, or windshield. Repeat towards the opposite side and remove the tray. Photo 1 Photo 2 Rain tray cover Drive Spindles Drive Spindles c. Remove the cover; the cover extends underneath the cowl on the passanger s side. Remove it by pulling it forward into the engine compartment.

2 4. Remove the OEM ECU Bracket a. Remove the OEM harness plugs. Slide the T-handle locks back to release the plugs. b. Locate the bracket tab on the passenger s side of the ECU which locks the ECU to the bracket. Use the common screwdriver to slightly bend the tab to release the ECU. c. Slide the ECU forward and remove it from the vehicle. d. Locate the horn on the driver s side of the ECU bracket and disconnect its power wire. e. (Photo 3) Locate and remove the two 10mm nuts on the face of the bracket securing it to the vehicle. Slide the bracket towards the passenger s side and remove it from the vehicle. 5. Modify the OEM ECU Bracket a. (Photo 4) Remove the passenger side support foot from the bracket. Notes: (1) A modified bracket is available from UNA if desired. If you use the UNA bracket, remove the horn from the OEM bracket and attach it to the UNA bracket. 6. Reinstall the ECU Bracket 7. Install the PnP harness and ECU a. Hold the PnP harness with main connectors facing the front of the car and the Molex connector loom on the driver s side. b. Slide the PnP harness into place underneath the ECU Bracket c. (Photo 5) Route the and wire loom underneath the PnP Plugs and loom; insert the into the PnP connectors and close the T-handle locks. d. Install the OEM ECU and ensure the bracket s locking tabs secure it in place. e. (Photo 6) Insert the into the PnP harness connectors and close the T-handle locks. f. Route the Molex Plug loom beside the OEM loom in the rain tray on the driver s side. Photo 3 Photo 4 Photo 5 PnP Plugs Remove Foot PnP Plugs Photo 6

3 8. Install the Unichip computer f. (Photo 7) Locate the ABS plastic cover immediately behind the driver s side strut tower. g. Clean the cover and install one side of the kit supplied Velcro strip as shown. h. Install the other side of the Velcro strip to the back side of the Unichip just below the lip closest to the Molex connector. i. (Photo 8) Press the Unichip computer into place on top of the cover and install the PnP harness Molex connector into the Unichip s large. 9. Test start the engine to ensure all connections are correct. Shut off the engine to reassemble the car. Note: Ensure there are no parts or tools laying on the engine or which might get caught or fall when the engine starts. 10. Replace the plastic rain tray cover. 11. Replace the windshield wiper arms; remember to align the pen marks to ensure proper operation. 12. Reconnect the battery. Installation Procedures New Beetle 1. Using the 10mm wrench, disconnect the car s battery at the negative terminal in the engine compartment behind the driver s side headlight. 2. Expose the ECU a. (Photo 1) Working inside the driver s compartment, press down the center section of the dash cover with both hands, push it forward to release it, and remove it. Photo 7 Photo 8 Center Section Cover Photo 1 b. (Photo 2) Remove the center and left T20 fasteners near the forward end of the opening exposed when you removed the panel. Photo 2 T20 Fasteners c. Using your fingers, gently lift up on the left side of the dash cover to release it from the clips securing it in place and remove the cover.

4 d. (Photo 3) Locate and remove the 6 T20 fasteners securing the lower plastic cover and remove the cover. Note: The panel is shown removed for clarity T20 Fasteners 3. Install the PnP harness a. (Photo 4) Disconnect the from the ECU. Release the plugs by sliding the T-handle locks back. Photo 3 Photo 4 b. Remove the plastic from one side of the long Velcro tape provided with the kit and firmly press the tape in place on the flat side of the PnP case. c. Remove the remaining piece of protective tape from the PnP case Velcro strip and position the case on the OEM ECU with the PnP connectors directly above the ECU connectors. Firmly press the PnP harness into place. 4. (Photo 5) Install the Unichip computer a. Clean the ABS plastic cover just to the left of the ECU. b. Remove the protective plastic strip from the remaining kit supplied Velcro strip and attach it to the back of the Unichip computer. c. Mount the Unichip computer on the plastic cover to the left of the ECU with the connectors facing forward. d. Connect the PnP s 18-pin Molex connector into the Unichip computer. Note: If desired, at this point you can reconnect the battery and test start the vehicle to ensure all connections are correct. 5. Reconnect the battery negative terminal. 6. Test start the engine to ensure all connections are correct. Shut off the engine to reassemble the car. Note: Ensure there are no parts or tools laying on the engine or which might get caught or fall when the engine starts. 7. Replace the plastic tray and 6 T20 Torx fasteners 8. Replace the left side dash cover and 2 T20 Torx fasteners. 9. Replace the center dash cover. Photo 5

5 Unichip Warranty Information For 90 days following the original owner s purchase of a Unichip, Unichip of North America (UNA) warrants no other ECU product generates more power from a specific gasoline engine than a properly functioning, custom tuned Unichip in the specific vehicle for which it is tuned. If another ECU product generates more power from that engine within 90 days of the original owner s purchase of the Unichip, then UNA will refund original owner the cost of all UNA parts, UNA installation, and UNA tuning. Shipping, testing, dynamometer costs and the cost of removing any UNA parts are specifically not covered by this warranty and will not be refunded to the owner. To claim a refund, owners must provide dynamometer proof another ECU product produced more power when installed on the specific vehicle and that vehicle and all of its parts were in an identical condition other than the ECU enhancement. Three dynamometer tests must be performed using the Unichip and three tests using the other ECU product. The average of the three tests performed on each product shall constitute that product s score for determining power. The same technician, using the same dynamometer in an identical condition with the same settings, must perform all test runs. All environmental conditions including temperature and pressure altitude and the vehicle s cooling system temperatures and drive train temperatures must also be identical for all six runs. The vehicle must also use the same fuel for all six tests. UNA reserves the rights to, at UNA s exclusive discretion, re-tune the Unichip involved in a performance warranty claim at no cost to the customer making the claim or to provide a warranty refund; if after a retune, the Unichip still makes less power than another product, UNA will provide a refund IAW this warranty statement. All UNA parts, including Unichip piggyback computers, driver modules, and harnesses also carry a limited warranty against manufacturer s defect. This warranty is valid for the original owner only, for two years from the date of purchase regardless of the installation date. UNA only warrants Unichip products sold directly from UNA or from an authorized UNA reseller. If a UNA product is found defective, UNA will provide a replacement component at no cost to the owner. Shipping to UNA, testing, dynamometer costs and the cost of removing any UNA parts are specifically not covered by this warranty and will not be refunded to the owner. The above warranties are expressly made in lieu of any and all other warranties, express or implied, including any warranty on the engineering or design of the goods as well as the implied warranties of merchantability and fitness for a particular purpose. Any and all warranties on the Unichip are void if: 1) the installation or custom tuning of the Unichip was performed by anyone other than a UNA qualified dealer or tuner, 2) anyone other than a qualified UNA tuner or dealer alters or modifies or attempts to alter or modify any of the electronic data within the Unichip or 3) the UNA product is used for anything other than its intended purpose or is physically or electrically damaged. For all warranty claims, the product return shipping date stamp must be within the appropriate time limitation from the time of purchase. Additionally, proof of purchase in the form of either a properly completed warranty card or a sales receipt indicating both the date of sale and owners name is required and is the owner s responsibility. Customers with hard-wire installations are responsible for providing proof of when and where the installation was performed. UNA will deny any warranty claim if the customer cannot provide proof of purchase. UNA is not liable for incidental, consequential or punitive damages attributable directly or indirectly to the Unichip or UNA s actions or inactions with respect to the Unichip. UNA is also specifically not responsible or liable for damage of any kind: 1) to a vehicle into which UNA products are installed or 2) resulting from the use of a vehicle equipped with any UNA products. UNA believes high performance driving should be confined to appropriate venues such as racetracks or organized closed course events such as Autocross competitions, and does not sanction or participate in any street racing or other illicit driving activity.

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