PERFORMANCE ENGINEERED SYSTEMS - VAG Links

PERFORMANCE ENGINEERED SYSTEMSG2INSTALLATION MANUALFOR RACING OR OFF ROAD USE1

INTRODUCTIONPLEASE PURCHASE AUDIONLY POWER STEERINGFLUID (PENTOSIN CHF 11S)Please note this an older version,and doesn’t include the updatefor the new idler pulley whichreplaces the alternator pulley.The new manuals contain thatprocedure and it isstraightforward. Thank you for purchasing the PESG2 supercharger system. We havegone to great length to engineer thissystem to be a true bolt-on affair.Please read the entire instructionmanual thoroughly beforeproceeding. If there is any part ofthe installation procedure that youare not comfortable with, pleasehave a professional mechanicinstall the system.minimize any residual fuelpressure. This will reduce thefuel leakage that occurs whileremoving the fuel injectors.Remove the negative batterycable from the batteryterminal before and during theinstallation procedure.Please save all parts andfasteners you remove fromthe car during installation. Thesystem has been engineeredso that the car may bereturned to its stockconfiguration if so desired.INSTALLATION1) Disconnect the negative batteryterminal.2) Remove all plastic engine covers.3) Remove ECU and send it to PESfor chip conversion. (See picture1-3)PLEASE NOTE: The photos used in thismanual were taken during theinstallation on a 2000 A4.There will be a special“NOTE” listed when there is avariation in the installationprocedure. New PES supplied parts willbe underlined in this manual.PRE-INSTALLATION STEPSPicture 1Prior to installing the PES G2supercharger system there are a fewsteps that are recommended tomake the installation as safe andeasy as possible. Make sure that the engine iscompletely cool. The car should not have beenstarted for at least 2 hours to2

Picture 2Picture 55) Disconnect PCV tube frompassenger side valve cover. (Seepicture THIS HOSE ISEXTREMELY FRAGILE, BECAREFUL WITH IT NOT TOBREAK IT.NOTE: On early 1998 models thecrossover tube looks slightly different,and connects at the top front cornerof each valve cover. Remove and setaside for now.Picture 34) Remove air box intake ducts.(See picture 4-5)Picture 6Picture 46) Disconnect 6 spark plug wiresfrom the coil pack. (See picture 7)3

10) Disconnect 2 vacuum lines fromthe right side solenoid. (Seepicture 10)11) Remove the 2 screws that holdthe solenoid to the plastic mount,and move to the side.Picture 77) Remove (4) bolts that hold coilpack in place. (See picture 8)8) Leave main electrical connectorattached and move coil pack tothe side.Picture 1012) Disconnect the intake air temp.sensor electrical connector. (Seepicture ) REATTACH THISCONNECTOR WHEN FINISHEDWITH INSTALL.Picture 89) Remove flexible air intake duct.(See picture 9)Picture 1113) Disconnect the left side solenoidelectrical connector. (See picture12)14) Remove the 2 screws that holdthe solenoid to the plastic mount.Picture 94

Picture 1215) Remove the 3 bolts that hold theplastic mount in place. (Seepicture 13)Picture 1417) Disconnect green hose from the“Y” connector. (See picture 15)Picture 1316) Slide the plenum control hose outof position. (See picture 14)Picture 1518) Disconnect black hose from the“T” connector on the manifold.(See picture 16)5

Picture 22Picture 2425) Unplug the PCV tube from theintake tube. (See picture 23)NOTE: On early 98 models thisconnector does not exist as pictured.You will need to disconnect a 5/16”hose as well as a smaller 1/8” hoseat the bottom of the intake tube. The1/8” hose barb on the intake tube willbe capped.27) Remove the intake tube andgasket from the throttle body.(See picture 25)NOTE: On early 1998 models whenremoving the intake tube, you willalso be unplugging the PCV tube.This plastic tube is plugged into theintake tube and retained with a clip.First, remove the o-ring from theexposed end. Next, remove theretaining clip from the intake tubeand pull out the plastic tuberevealing another o-ring. Put this oring onto the PCV adapter and installit back into the intake tube with theretaining clip. The other o-ring will beused in a later step.(See picture24A).Picture 2326) Remove the screw holding theintake tube onto the throttle bodywith a hex wrench. Use a 10mmopen-end wrench to prevent thecenter section from rotating.ALTERNATIVELY YOU CANUSE A HEX HEAD SOCKET(7mm I believe) which waseasier for me. (See picture 24)Picture 24A7

Picture 27Picture 2528) Unbolt the (4) bolts holding thethrottle body onto the manifold.See pic 25 for hole locations(Seepicture 26)Picture 2830) Disconnect throttle cable Movethe cable housing to full openthrottle to allow slack in the cableto remove it.Picture 2629) Disconnect (2) rubber hoses fromthe rear of the intake manifold.One hose is low on the driversside rear of the manifold (Seepicture 27). The brake boosterhose is on the top rear of themanifold (See picture 28)31) Remove the (2) 10 mm screwsthat hold the cruise control pot inposition and move it aside.32) Remove the intake manifold byremoving the (12) screws thathold it in place, and lift it straightup. BE CAREFUL NOT TOSNAP OFF THE PLASTICALIGNMENT PINS WHENLIFTING STRAIGHT UP ORYOU WILL HAVE TO USE ADRILL AT LOW SPEED TO GETTHEM OUT.(See picture 29)NOTE: Pre 2000 cars will only havethe (top) brake booster hose. (Seepicture 28)8

Picture 31NOTE: On the earliest 1998models Audi used the 1997 powersteering pump. This pump isvisually and dimensionallydifferent from the one pictured inthis manual. In this case you willneed to replace the powersteering pump, pulley, and highpressure line. Call PES for moreinformation.Picture 29At this time exercise extremecaution not to let any objects dropinto intake ports! I also used avacuum to suck the intake portsclean as well.33) Remove 2 nylon manifoldalignment pins. (See picture 30)35) A. Loosen 3 power steeringpulley bolts (See picture 32)B. Remove serpentine belt.C. Remove power steering pumppulley (3 bolts).Picture 3034) Remove the (2) rubber seals fromthe bottom of the intake manifoldand set aside for later use. (Seepicture 31)Picture 3236) Remove and replace the rubberpower steering hose with thesupplied part. (See picture 33)BE CAREFUL NOT TO HAVE THISHOSE KINKED OR FLUID WILLNOT FLOW.9

NOTE: Only early 1998 models WILLNOT need to have the hose replaced.Picture 3539) Remove the screw holding thepower steering pump bracket tothe solid airline. (See picture USEA TIE WRAP TO SECURE THESOLID AIRLINEPicture 3337) Remove (6) bolts that hold thepower steering pump/bracket tothe engine block. (See picture 34)Picture 36Picture 3440) The power steering pump bracketcan now be completely removed.(See picture 34)41) Bolt power steering bracket topower steering pump using (2)8x25mm hex bolts & washers.(See picture 37)38) Remove the bolt that secures thepower steering high-pressure lineto the valve cover. (See picture35)10

Picture 37Picture 3842) The power steering pump cannow be bolted into position using(2) 8x80mm hex bolts andwashers and (2) spacers. (Seepicture 38). At the same time, therear support should be bolted intoposition with (3) 8x20mm sockethead cap screws. Be sure totighten ALL FIVE boltssimultaneously. ATTACH THEREAR BRACKET FIRST. THELOWER BOLT SHOULD GO INFIRST AS IT HARD TO REACHONCE BOLTED TO THE CAR.ALSO, A BALL HEAD ALLENWRENCH REALLY HELPSHERE. (See picture 39)Picture 3943) The P/S high-pressure hose willneed to be bent back into positionand bolted back onto the valvecover. (See picture 40)Picture 4044) Bolt the pulley back onto the P/Spump.11

45) NOTE: Step 46 ONLY applies toearly 1998 models. Install theother o-ring retained from step 28onto the crank vent adapter andinsert into crankcase vent hole.Tighten the large nut whileholding the main tube. This willexpand and seal the o-ring in thehole.46) Take the rubber seals that wereremoved from the stock intakemanifold in step 35 and insertthem into the grooves on the newmanifold. NOTE: In order to keepthe seals from falling out duringassy., put a small dab of greasein the grooves. (See picture 41)Picture 4248) Bolt the throttle body in positionusing the factory screws and asmall amount of sealant. Nonewas included in the kit, but Iused small amount of Vaselinejust to hold the gasket in placewhile I bolted the manifolddown.49) On 2000-on (drive by wire)models use the factory spacerbetween the throttle body andmanifold, using sealant on theside without the rubber seal. Donot over tighten. (See picture 43)Picture 41NOTE: Before proceeding to step 48,be sure that the mating surfaces areclean and unobstructed.47) Lower the supercharger/manifoldassembly down onto the engineand secure it with (14) M6X30socket head cap screws andwashers. Tighten evenly in acrisscross pattern. Avoid overtightening. (See picture 42)Picture 4350) Attach brake booster hose ontothe brass hose barb. (See picture44)12

Picture 44Picture 44B51) Re-install throttle cable byfeeding the cable through thehole in the cruise control mountbracket. (See picture 44A)53) Re-attach the intake tube ontothe throttle body. (See picture 45)NOTE: Early 1998 models will installPCV connector hose at this timeusing (2) supplied hose clamps. (Seepicture 44C)Picture 44AHave an assistant hold theaccelerator to the floor and adjustthe length of the throttle cable sothat the throttle body is openedfully without the cable binding orcreating over tension on thethrottle body. Adjust the throttlecable length by moving theretaining clip. (See picture 44A)Picture 44C52) Attach the cruise control pot ontothe new cruise control mountbracket. (See picture 44B)Picture 4513

54) Lubricate the o-rings of the (6)new fuel injectors usingpetroleum jelly. (See picture 46)engaged with the injectors. (Seepicture 48)Picture 48Picture 4657) Position (4) 2” long spacersbetween the fuel rail tabs and thebosses on the manifold. Line upthe coil support brackets with thetop of the fuel rail and securethem into place using (4) M6X70hex head cap screws andwashers. (See picture 49) Thebolts will go through the coilsupport, fuel rail tabs, and thespacer and screw into themanifold.55) Seat all 6 fuel injectors intomanifold. Simply push downwhile twisting until fully engaged.(See picture 47)Picture 4756) Carefully line up the fuel rail withthe tops of the (6) injectors. It isvery important that all (6) cups onthe fuel rail are lined up with theinjectors. Make sure to positionthe electrical connectors onthe injectors for ease ofplugging connectors in.Misalignment can cause the oring to be pinched and cut. Afuel leak will result. Push downon the fuel rail until it is fullyPicture 4958) Plug the (6) injector electricalconnectors back in, as well as thethrottle body electrical connector,intake air temp. sensor, and the14