Neuspeed 49.10.95 User Manual

SUPERCHARGER INSTALLATION INSTRUCTIONS

PLEASE READ CAREFULLY BEFORE YOU BEGIN!

THIS SUPERCHARGER KIT IS FOR:

2002-UP VOLKSWAGEN GOLF IV AND JETTA IV 2.0L 8V ENGINES WITH A/C

FOR DRIVE-BY-WIRE VEHICLES ONLY

As soon as you receive your NEUSPEED Supercharger Kit, please check the Kit Contents to be sure you have
all parts before starting installation. Notify us immediately if you are missing something. Also, send us your
ECU (along with a copy of your receipt) ASAP (see LOCATION AND REMOVAL OF ECU Page 15 and 16),
so that we can install our custom P-Chip program, which is required before starting engine. SAVE SPECIAL

SUPERCHARGER SHIPPING CONTAINER – SEE WARRANTY.

KIT CONTENTS:

1 – SUPERCHARGER/MANIFOLD ASSEMBLY (EGR plate, by-pass valve to Supercharger vacuum hose installed).
2 – SUPERCHARGER REAR SUPPORT BRACKETS (driver side rod end and jam nut installed).
1 – SUPERCHARGER HEAD STAY BRACKET
1 – SUPERCHARGER BELT
5 – SUPERCHARGER/MANIFOLD MOUNTING BOLTS – 3-25mm, 2-95mm.
5 – STAINLESS STEEL/NEOPRENE BACKED MOUNTING WASHERS
1 – NEUSPEED SPECIAL UNDER-WASHER LUBRICATING GREASE
1 – IDLER PULLEY MOUNT AND BELT ADJUSTER WITH PULLEY (installed).

1

1 –

/2” HOSE CLAMP

1 – AIR FILTER BOX COVER
1 – ALUMINUM HEAT SHIELD
1 – COOLANT HOSE SUPPORT BRACKET
1 – VITON INTAKE MANIFOLD GASKET
1 – THROTTLE BODY GASKET
1 – COMBI-VALVE GASKET
4 – IRIDIUM SPARK PLUGS
1 – 4-BAR FUEL PRESSURE REGULATOR
1 – CHECK VALVE
8 – VARIOUS ASSEMBLY BOLTS
1 – EVAP PURGE HOSE

1 – THROTTLE BODY TO COOLANT TANK HOSE
1 – BRAKE BOOSTER HOSE

5

1 –

/16” STRAIGHT HOSE BARB

5

1 –

/16” ‘T’ HOSE BARB

5

/16” X 28”

3

/8” X 12”

5

/16” X 20”

2 – HOSE CLIPS
1 – LOCTITE 262
1 – NEUSPEED SUPERCHARGER BADGE
1 – CARB EXEMPTION PLATE – 50-STATE LEGAL
2 – PREMIUM FUEL ONLY DECALS – ONE FOR GAS GAUGE, ONE FOR FUEL DOOR
1 – BELT PATH ROUTING DECAL
1 – WARRANTY CARD – FILL OUT IMMEDIATELY WITH SERIAL NUMBER AND RETURN

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TOOLS REQUIRED:

• INCH AND FOOT LBS TORQUE WRENCH, METRIC SOCKET, HEX KEY, TORX, OPEN END
WRENCHES, SCREW DRIVERS – PHILLIPS AND BLADE, PLIERS, HAMMER AND KNIFE, #8
TRIPLE SQUARE (12-POINT).

SPECIAL ITEMS RECOMMENDED:

• PENCIL AND PAPER FOR NOTES.

• MASKING TAPE TO COVER INTAKE PORTS, LABEL PARTS REMOVED AND THEIR

CONNECTIONS.

• A CLEAN WORK BENCH.

• A PARTS TRAY.

• CLEAN RAGS OR SHOP TOWELS.

PREPARATION:

• BEFORE YOU BEGIN: ENGINE SHOULD BE CHECKED WITH A VAG SCAN TOOL OR
EQUIVALENT TO MAKE SURE THERE ARE NO STORED FAULTS. ANY FAULTS SHOULD
BE REPAIRED AND CLEARED, i.e. VW DEALER.

• FILL GAS TANK WITH PREMIUM FUEL.

• THOROUGHLY CLEAN THE ENGINE AND ENGINE COMPARTMENT.

• ENGINE SHOULD BE COLD BEFORE YOU BEGIN.

• TO MAKE INSTALLATION EASIER, DRAW DIAGRAMS AND LABEL YOUR ENGINE’S

CABLE ROUTING, AND VARIOUS HOSES, ETC. THESE WILL BE REROUTED AND
RECONNECTED IN DIFFERENT PLACES. NOTE: SOME HOSES LOOK ALIKE AND ARE THE
SAME SIZE. IT IS IMPERATIVE THAT THEY BE RECONNECTED CORRECTLY!

• THE NEUSPEED SUPERCHARGER KIT HAS BEEN DESIGNED TO REUSE MANY OF THE
STOCK COMPONENTS. WE HIGHLY SUGGEST THAT AS YOU REMOVE THEM, KEEP THEM
WITH THEIR COMPONENTS AND LABEL THEM.

• READ ALL INSTRUCTIONS BEFORE STARTING INSTALLATION!

1. See section on LOCATION AND REMOVAL of ECU on Page 15 and 16. Send us your ECU as soon as possible.

2. Make note of Supercharger serial number before installation. Bar code label with correct number (consisting of three letters

followed by four numbers) is located on bottom of front drive. NOTE: You will NOT be able to read the serial number once the

Supercharger has been installed! Send Warranty Card in promptly in case we need to notify you of any updates.

3. Disconnect negative battery cable, and remove upper strut tie-bar if equipped.

4. ENGINE COVER/COWL REMOVAL: Remove plastic
engine cover by removing dipstick, lifting up on front corners,
then pull cover forward to slide off rear mount. Replace dip stick.

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5. AIR CLEANER ASSEMBLY REMOVAL: Disconnect air
intake hose from throttle body, electrical connector from PCV
valve, and MAF (mass air flow) sensor, fuel injector vacuum
hose and air pump hose from air cleaner top. Unscrew upper air
cleaner lid from lower housing and remove assembly.

6. THROTTLE BODY REMOVAL: Disconnect electrical
harness from throttle position sensor, vacuum hose from EVAP
canister purge valve, and coolant hoses. Remove four bolts using
#8 triple square driver, and lift off throttle body – move aside.

8. Remove the two rear bolts on back side of intake manifold to
heat-shield/support using a 6mm hex driver, and five bolts
holding upper intake manifold to lower intake runner using a
5mm hex driver. Carefully separate, and remove gasket. Clean
off any remaining gasket material. Immediately cover intake
runner ports with masking tape. Now is a good time to install the
new hi-performance Denso Iridium spark plugs. NOTE: Spark
plugs are pre-gapped. NOTE: Before removing old spark plugs,
use compressed air to blow out around plug recesses so that any
dirt will not fall into cylinder. Put anti-seize on threads!

7. MANIFOLD REMOVAL: Disconnect brake servo vacuum
hose by cutting crimp-clamp, leak detection pump vacuum hose
from white plastic fitting, EVAP purge valve hose, and fuel
pressure regulator vacuum hose.

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9. HEAT-SHIELD REMOVAL/ASSEMBLY: Disconnect hard
plastic air pump hose and secondary metal air pipe flare nut from
combi-valve. Loosen lower flange nut so that you can push pipe
out of fitting and rotate pipe towards driver side of vehicle to
allow removal. Remove three bolts using a 6mm hex driver and
one bolt using a 5mm hex driver – lift heat shield, and remove O
sensor. The heat shield can now be removed. Remove combi­valve assembly using a 5mm hex driver. Remove combi-valve
gasket using a scraper or knife. Use new gasket supplied, and
transfer assembly to the new supplied heat-shield. Torque
combi-valve bolts to 7ft. lbs. Re-install heat shield, hoses, and
metal pipe in reverse of disassembly with factory bolts. Torque
heat-shield bolts to 18ft. lbs. Use Loctite on all bolts.

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10. BELT TENSIONER REMOVAL: Using a 15mm open-end
wrench, rotate tensioner to release tension on belt and remove the
ribbed V-belt. Remove the three 13mm tensioner mounting bolts
and remove tensioner assembly.

11. DRIVER SIDE REAR SUPERCHARGER SUPPORT
BRACE INSTALLATION: We have assembled (mounting
bracket, insulated rod end, jam nut) to its approximate length.
Remove the two rear driver side valve cover nuts (10mm hex)
from area shown. Install bracket on valve cover studs with rod
end leaning forward. Install nuts. Torque to 7ft. lbs.

12. SUPERCHARGER INSTALLATION: First assemble the
supplied new stainless steel/neoprene backed washers on the
supplied new (3) M6X25mm and (2)M6X95mm intake manifold
bolts. Ensure that the steel side of the washers are in contact with
the heads of the bolts, and apply a small amount of NEUSPEED
special grease to the neoprene side. With the Supercharger on the
bench, and the mounting flange vertical, position the intake
manifold gasket on the inlet runner flange and align ports. Be
very careful here because the gasket only fits one-way – double
check alignment of ports and bolt mounting holes! Insert bolts
into proper holes to hold gasket in place. Remove tape covering
lower intake ports, and lower Supercharger onto lower intake
runners. Carefully support backside of Supercharger until

you have run mounting bolts down and torqued to 44inch lbs.
(3.6 ft. lbs.). Now you must check to see if the Driver Side Rear

Support Bracket is in alignment with threaded hole on
Supercharger. Bolt MUST align perfectly with hole. If not,
determine amount of adjustment (up-or-down) to properly
position rod end. You will need to remove Supercharger, make
adjustment, re-torque bolts and try again. NOTE: Supercharger

MUST be torqued to proper setting BEFORE
checking/installing bolt! When you have a perfect fit, apply

Loctite and torque Supercharger Rear Support bolt M8X35mm to
15ft. lbs, and tighten jam nut on rod end if you made an
adjustment. NOTE: This step is very important – you MUST

take time to do it right!

NOTE: The by-pass valve has been pre-installed and adjusted –
DO NOT change adjustment!

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13. PASSENGER SIDE REAR SUPERCHARGER SUPPORT
BRACE INSTALLATION: Insert the supplied new
8X1.25X40mm bolt through lower boss of the support brace –
align with threaded boss on engine block and tighten by hand.
Now check to see that rod end aligns with hole on boss on
Supercharger (you can rotate this support on lower mounting bolt
away from Supercharger to turn rod end) – make adjustment (in­or-out) for perfect alignment. Position Head Stay bracket by
inserting button end into the hole located in the lower right-hand
corner of cylinder head. Insure that the slot on the bracket aligns
with the threaded boss of the Supercharger, then the rod end.
Apply Loctite and insert supplied M8X35 bolt through assembly.
Push and hold the Head Stay firmly against head as you torque
bolt to 18ft. lbs. Now tighten jam nut, and torque lower support
rod to 18ft. lbs. With the Supercharger supports properly in
place and tightened, remove one manifold mounting bolt at a
time – apply Loctite #262 (supplied) to each bolt and re-torque.

14. FUEL PRESSURE REGULATOR REMOVAL: NOTE: Dirt
can accumulate around fuel pressure regulator. Use air pressure
to clean out around regulator so that any dirt will not fall into
fuel rail. Remove vacuum hose from regulator, pull out retaining
clip. Cover regulator with an absorbent twoel or shop rag, and
carefully lift out regulator. Use caution when removing regulator,
as fuel will spray from the pressurized line – NO SMOKING!

15. 4-BAR FUEL PRESSURE REGULATOR
INSTALLATION: Lube O-ring and install supplied new 4-bar
regulator into bore. Push down on regulator and install factory
retaining clip. Connect vacuum hose from regulator to
Supercharger plenum port.

16. BELT TENSIONER MOUNTING PLATE
INSTALLATION: Remove factory engine cover/coolant hose
mounting bracket. Position new mounting plate as shown using
supplied new 6mm hex socket bolts, apply Loctite and torque to
18ft. lbs.

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