Neuspeed 49.10.95 User Manual download pdf

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 –

” 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

” X 28”

1 – THROTTLE BODY TO COOLANT TANK HOSE

” X 20”

1 – BRAKE BOOSTER HOSE

” X 12”

1 –

” STRAIGHT HOSE BARB

1 –

” ‘T’ HOSE BARB

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

Page 1

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Summary of Contents

Page 1

SUPERCHARGER INSTALLATION INSTRUCTIONS PLEASE READ CAREFULLY BEFORE YOU BEGIN! THIS SUPERCHARGER KIT IS FOR: 2002-UP VOLKSWAGEN GOLF IV AND JETTA

Page 2

28. Reconnect battery. Re-install upper front strut tie-bar. 29. Clean front plastic radiator cover, and apply your NEUSPEED Exemption Plate, and B

Page 3

FUEL PRESSUREREGULATOREVAP CANISTER PURGE VALVE5/16 T-FITTINGLEAK DETECTIONPUMPBYPASSVALVEAIR PUMPFUEL INJECTION AIR ASSISTCHECK

Page 4

GOLF IV & JETTA IV NEUSPEED Supercharger installation shown with optional P-Flo, Upper Strut Tie Bar, and various Billet Engine Dress-up Items.

Page 5

GOLF IV, JETTA IV LOCATION AND REMOVAL OF ECU 1. Open engine hood. ECU is located under plastic cover at base of windshield. 2. Remove four T-20

Page 6 - BELT PATH

SUPERCHARGER FACTS: The NEUSPEED Supercharger has been designed for stock engines in good mechanical condition. Engine recalibration devices that mo

Page 7

Page 15 NEUSPEED® SUPERCHARGER LIMITED WARRANTY Automotive Performance Systems Inc., d.b.a. NEUSPEED and Neumann Distributing, located at 3300 Corte

Page 8

TOOLS REQUIRED: • INCH AND FOOT LBS TORQUE WRENCH, METRIC SOCKET, HEX KEY, TORX, OPEN END WRENCHES, SCREW DRIVERS – PHILLIPS AND BLADE, PLIERS, HAMME

Page 9

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 manif

Page 10

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 1

Page 11 - COOLANT SCHEMATIC

13. PASSENGER SIDE REAR SUPERCHARGER SUPPORT BRACE INSTALLATION: Insert the supplied new 8X1.25X40mm bolt through lower boss of the support brace – al

Page 12 - GOLF IV & JETTA IV

BELT PATH 17. BELT TENSIONER ARM, PULLEY AND BELT INSTALLATION: Pulley has been pre-installed on arm. Install tensioner arm with pulley, and tighten

Page 13 - Page 13

21. In order to obtain peak performance from the Supercharger Kit, the O.E. intake baffle MUST be removed from the Golf IV and Jetta IV. Modify the ai

Page 14 - Page 14

22. MAF AND AIR BOX COVER INSTALLATION: Remove O-ring from factory air box cover, lubricate, and transfer to new air box cover. Install MAF on new ai

Page 15 - LIMITED WARRANTY

24. Using factory clamps, install supplied PCV hose as shown. 25. CHECK VALVE INSTALLATION: Cut fuel injector vacuum line halfway between fuel rail