SUPERCHARGER INSTALLATION GUIDE FOR VW MKIV R32 STAGE 2 (VFK11
Contents
1. LJ PAGE 16 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 MkIV R32 Stage 2 US MODELS www vf engineering com 14 Relocate the smog pump to the lower right hand side of the vehicle just above the aux radiator See picture below for further instruction 79 Sh S i Hien Smog pump 1 is relocated to drivers side US chassis rail and secured with the bracket 2 supplied on factory drilled holes 3 Note how smog pump filter 4 has been re configured to allow it to fit The horns has been adjusted for clearance The wiring harness 5 to the smog pump has been extended and the flexi duct with an extension from the engine is fitted 6 to the pump hidden behind the wiring harness smog pump reloc jp g HEPA bi Win Ps This flexi hose 1 originally ran to the smog pump at the front of the engine After relocating the smog pump the bracket that holds this flexi hose must be removed completely and the hose run as shown with a rubber hose extension fitted to its end enabling it to reach the pump Ensure the hose is routed to prevent chaffing and interference with gear selector and sharp edges smog pump hose jpg PAGE 17 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 W ww vf engineering com MkIV R32 Stage 2 US MODELS 15 Mount the intercooler just below the bumper rebar us2. www vf engineering com MkIV R32 Stage 2 US MODELS VF ENGINEERING ECU DME RETURN FORM This form must be sent along with your vehicles ECU DME when sent to VF Engineering for Flashing Customer Name Address Phone number E mail Ship to Shop Name Address VF Invoice number if purchased direct Purchased from Vehicle Make Vehicle Model Year VIN Transmission Type Manual Automatic SMG DSG Supercharger Serial Number Stage Race Gas option Pre purchased Yes or No Is your ECU DME stock Yes or No Date ECU last updated by dealership PAGE 4 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS DEALER SERVICE RETURN TO STOCK At some point you may take your supercharged car to your VW dealership for a service It is routine for them to update the ECU software from time to time and they may not advise you of this beforehand Therefore it is imperative that you advise them not to update the ECU or else they may overwrite the supercharger software installed by VF or authorized dealer NOTE If your car is flashed back to stock and you drive the supercharged car with stock software engine damage will most likely occur due to inappropriate fuel and ignition mapping lf you wish to return your car back to stock VF advises that the ECU be returned to VF or your local GIAC dealer for a flash to stock This is important be
3. 23 of 38 P N VFM1 1 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS 27 Install the back idler assembly as shown using the replacement alternator bolts supplied Be sure to follow the proper torque specs as shown in your service manual E 4 s M 28 Loosely install the supercharge assembly onto the supercharger mounting bracket using the two bolts provided in the kit 12v motor sown in the picture PAGE 24 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 W ww vf engineering com MkIV R32 Stage 2 US MODELS 29 Replace the power steering pump pulley with the unit supplied then install the replacement serpentine belt included in the kit following the path shown below Be sure the belt is aligned on each pulley and is not offset or de railed THANI OUr VAn ze SC Pulley compressor EN power Mur ule steering crnkshaft pulley PT 30 Tighten the supercharger mounting bolts slightly then tension the serpentine belt by inserting a crow bar as shown below A twist of 30 degrees between the longest run of the belt is also an adequate way to check tension Be careful not to over tension the belt Tighten the supercharger bolts to approx 35 ft Ib 12v motor shown in picture PAGE 25 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 w
4. 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 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering MkIV R32 Stage 2 US MODELS VF ENGI NEERI NG SUPERCHARGER KI T OWNERS MANUAL The following information and recommendations are designed to promote years of trouble free service for your supercharger Care recommendations have also been outlined for your vehicle and maintenance of your supercharger kit MAI NTENANCE INSTRUCTI ONS FOR THE SUPERCHARGER KI T and SUPERCHARGER UNIT Caring for your kit mandatory procedures l After fitting the new supercharger kit
5. any spillage and top off the PSR Note This extension hose is out of reach after the supercharger unit is fitted and it is important to ensure you achieve a good clean fit with minimal rub against other sharp edges or parts ed INS DER MM r EU m arr ud bo 1 4 age ERO n Aa rt LN a me EE T i p 1 Remove power steering hose and cut 6 off length Fit hose provided as an extension and connect to reservoir Ensure good clean joints and angulate before clamping down To avoid mess you may tilt the reservoir back to prevent fluid spill ps hose extend jpg PAGE 13 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS 10 Relocate the PSR slightly using the relocation bracket supplied in the kit 1 Note positioning of crankcase vent 1 Power steering oil reservoir bottle is T re positioned with the bracket 2 supplied ad shown The bolt 3 going into the cast mount E may need to be secured witha nut as the m threads in the mount are easily stripped We chose to route the vacuum line for the bypass valve as shown in position 4 ps reservoir reloc jpg m qa d yit E t ri m oe JU ee a rm a die a r Me n C 11 Replace the OEM fuel regulator
6. be angled towards the discharge pipe 1 to avoid it from chaffing the inner edge of the bumper 2 the bypass valve willtake some adjustment to get it to fit neatly The trick is to align all the pipes and tighten all together Leave small gap here to prevent chaffe against body 3 bypass valve jpg 38 Route the thin vacuum line on the bypass valve along the inner fender to the empty vacuum nipple you created on the back of the intake manifold see step 4 and connect Secure the line as necessary ensuring it does not come into contact with any moving parts P N VFM1 1 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 PAGE 31 of 38 www vf engineering com MkIV R32 Stage 2 US MODELS 39 Cut the crankcase heater element out from the intake flexi duct that connected the MAF to the throttle body Connect one end of the heater element to the crankcase vent hose and use the heater element adaptor to connect the other end to the port on the side of the supercharger intake tube Use the extension harness supplied to extend the heater element plug from the driver s to the passenger side lt crankcase heater adapter jpg gt ae Try f T m tre nnd S A eb mi dcs Pn EUST LETTE Note how crankcase vent 1 has been re positioned at connection to valve cover The vent is flexed to reach the intake pipe where a section 2 of 3 4 sleeve is u
7. front and rear washer jets and extend using the two lengths of washer fluid rubber line provided Use the two brackets provided to mount the bottle onto factory mounting points as shown in the picture below See the next step for routing instructions cwasher bottle jpg gt The windshield washer reservoir bottle is relocated onto factory mounting points using the brackets and hardware supplied Note Ehe arrows pointing to Ehe mounting brackets Arrow 1 shows where Ehe wiring harness is routed and arrow 2 is the MAF extension wiring harness For vehicles with headlamp washers a smaller replacement reservoir bottle as shown below is supplied The headlamp washer motor is mot attached to the reservoir bottle and is mounted remotely on the chassis rail Feed nozzle 3 is pre drilled into the side of the reservoir and extension water hose is provided to link the headlamp washer pump to the reservoir E c i TCR a mp2 8 11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 PAGE 11 of 38 www vf engineering com MkIV R32 Stage 2 US MODELS 8 This step outlines how the MAF and washer bottle extensions are routed towards the opposite side of the vehicle The extensions are first routed between the battery and inner fender then behind the headlight and under the two panel which must be removed along the top of the radiator support One of the panels must be trimmed to allow routing of all extensi
8. should be allowed to bed in for a run in period of 300 miles during which the engine should not be driven over 4500 rpm 2 The supercharger kit should be routinely inspected and maintained as below i Air filters Use the air filter system provided in your VF Engineering system ii Air Intake Air Discharge Must be in good condition and properly secured If equipped with flex hose this must be Free of damage leaks v Belt Tension Excessive belt tension can lead to supercharger or crankshaft bearing failure Do not use a non slipping or cog type belt on a supercharger designed to be driven with a serpentine belt Replacement belts for your application are available from VF Engineering V Air Assist The air assist system on certain Vortech superchargers must be kept free from kinks and leaks Spare parts are available from VF Engineering 3 Computer Chips Use the computer chip or serial flash provided by VF Engineering for this supercharger system The use of an aftermarket chip is not recommended as they would not be calibrated for use with a supercharger and can cause detonation VF Engineering supplies a computer chip or serial flash with each kit that is specifically developed and calibrated to maximize performance 4 Crankcase Ventilation System You must use the system provided in your VF Engineering kit to prevent excessive crank case pressures and possible engine damage We recommend you clean or replace this every 6000 mil
9. with the unit provided the kit Remove the spring clip and gently pry the stock FPR upwards Caution Wear goggles and keep a large clean dry cloth around the FPR when removing as fuel will leak out Fit the new FPR and push down gently until it snaps into place then refit the spring retainer clip Remember to re fit the vacuum line fitted to the FPR Reinstall the intake manifold PAGE 14 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS 12 Remove the headlights and front bumper drain the coolant from the vehicle coolant can be reused if stored in a clean container and relocate the auxiliary radiator Begin by removing both clamps and hoses leading to the aux radiator PAGE 15 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS 13 Replace the aux radiator hoses with the new units supplied in the kit and remount the aux radiator using the relocation brackets provided Make a cut out in the splash guard to allow passage of the new hoses to the aux radiator Be sure ample space is given while routing hoses and making the cut out as these hoses will expand and move during hard driving The horns will also need to be relocated not shown in picture in front of the aux radiator using the Y bracket included in the kit T be T iue m URE
10. AS BELOW xvi Mounting brackets and hardware xvii Supercharger drive pullies and components xviii Idler pullies xix Air inlet and discharge systems Xx Air valves XXi GIAC software 5 NINETY DAY LI MI TED WARRANTY ON VF ENGI NEERI SUPERCHARGER CONSUMABLES AS BELOW xxii Air filters xxiii Oil feed and oil drain components xxiv Serpentine belts xxv Injectors regulators and fuel components WARRANTY COVERAGE FOR THE SUPERCHARGER KIT 15 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 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 xxvi Any disassembly or attempted disassembly of any VF Engineering assembled parts xxvi
11. F Engineering provides the following warranties to the original purchaser of certain VF ere i Engineering products For reference purposes you and your mean only the original purchaser engineering of the warranted VF Engineering product YOU MUST ALSO READ OWNERS MANUAL n The supercharger unit refers to the Vortech Supercharger V Series unit manufactured by Vortech Engineering Inc 2 f you complete and return the Warranty Registration Form along with a copy of Your original receipt within thirty days of Your purchase of a VF Engineering supercharger kit VF Engineering warrants to you that the V 1 V 2 V 5 and V 9 supercharger in the kit will be free from defects in materials and or workmanship in accordance with the Vortech Engineering Inc Warranties Program effective March 1 2000 The balance of the kit will be free from defects in materials and or workmanship for one year 90 days as specified in sections 4 5 from the date of your purchase of the kit If you do not return the Warranty Registration Form and proof of purchase within thirty days then VF Engineering warrants that the supercharger in the kit will be free from defects in materials and or workmanship for a maximum of one year from the date of purchase of your kit 3 REQUIREMENTS AND EXCLUSI ONS i You must be the original purchaser ii The supercharger must NOT be modified disassembled tampered in any way iii The supercharger drive pulley must not be c
12. IN DAMAGE TO YOUR VEHICLE AND MAY LEAD TO INJURY AND POSSIBLE DEATH THE USER AND INSTALLER ASSUME ALL RISKS ARISING FROM THE USE OF THIS PRODUCT VF ENGINEERING OR ITS EMPLOYEES ARE NOT RESPONSIBLE FOR ANY CONSEQUENTIAL LOSSES THIS SUPERCHARGER SYSTEM IS INTENDED FOR USE ON HEALTY WELL MAINTAINED ENGINES INSTALLATION ON WORN OUT OR DAMGAGED ENGINES IS NOT RECOMMENEDED AND MAY RESULT IN DAMAGE TO THE ENGINE AND SUPERCHARGER VF ENGINEERING IS NOT RESPONSIBLE FOR ENGINE DAMAGE 2 PRIOR TO INSTALLATION ENSURE YOU HAVE BEEN SUPPLIED WITH THE CORRECT REPLACEMENT ENGINE ECU CHIP FOR YOUR VEHICLE YOUR VF ENGINEERING DEALER CAN ADVISE YOU OF THE PROPER APPLICATION 3 BE SURE TO READ INSTUCTIONS COMPLETELY INCLUDING ALL WARNINGS NOTES TROUBLESHOOTING AND MAINTAINENCE PRIOR TO INSTALLATION 4 PLEASE SEE ADDITIONAL PRE INSTALLATION NOTES ON NEXT PAGE PAGE 2 of 38 P N VFM1 1 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS ECU MODIFICATION REQUIRED Please print out the ECU return form see next page and include in the package along with your ECU This kit requires ECU modification known as flashing which is electronic overwriting of the original engine management software with new software designed to work in conjunction with your system and has been included in the price of your supercharger upgrade This requires the ECU to be shipped directly to VF Engine
13. ally supplied with your supercharger kit and tap the hole from the outside MAKE SURE YOU NOT TAP PAST 1 3 OF THE LENGTH OF THE THREADED SECTION OF THE TAP PAGE 20 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 W ww vf engineering com MkIV R32 Stage 2 US MODELS 21 Screw the oil drain fitting tight into the block 22 Screw the new oil drain connection to the fitting positioning it as shown in the picture below and connect the oil drain line between it and the oil drain of the supercharger Make sure the oil drain line follows a direct path to the oil pan as it relies on gravity to drain the oil A 5 strip of edge protector is included in the kit to prevent any damage to oil drain line from rubbing against the frame rail see picture on next page teh 60 0500 60000000500000806000 TTP opas pm 525298554 bsshaaa T ILI 1 Seer eelerh eee beoeedeoer MM AS ELALIILIIYOPS oe tti 5565959999 292822255 be 892 dh E PAGE 21 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS s a d Te D PAM p 23 Clean mating surfaces of oil pan and the bottom of the block as per procedure in the workshop manual Ensure that no dirt or debris is left in the oil pan Refit oil pan using the correct pan sealant paste available from afte
14. ase select one 1 YEAR WARRANTY 3 YEAR WARRANTY 150 extra at time of purchase Complete and mail form to VF ENGI NEERI NG 1365 N DYNAMICS STREET SUITE E ANAHEIM CA 92806 USA www vf engineering com SUPERCHARGER SERIAL see blue tag on supercharger unit PRODUCT PURCHASE DATE also warranty start date CUSTOMER NAME CUSTOMER ADDRESS CUSTOMER TEL Name of dealer outlet where you purchased your VF Eng product Did you install the supercharger system yourself Yes No VEHICLE KIT FITTED TO MAKE MODEL YEAR MILEAGE OF VEHICLE CUSTOMER COMMENTS VF Engineering 1365 North Dynamics Street Suite E Anaheim CA 92806 USA Tel 714 585 0066 Fax 714 528 0067 Website www vf engineering com Hours M F 9AM 5PM PST O Zurich Engineering Inc Terms may change without notice PAGE 38 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Hev 1 10 25 06
15. aulty ignition coil distributor Ask VF Engineering for diagnostic info specific to your vehicle v Cooling system not functioning properly Check for a faulty thermostat faulty or improper calibration of the thermostatic fan switch water pump belt slippage a plugged radiator or bad fan clutch vi Dirty air filter cleaner 13 Ensure the spark plug gap is correct for a supercharged application 14 We recommend using manufacturer recommended service components or taking the advice from our dealers specializing in the different makes of cars 15 Spark Plugs need to be changed at intervals of 8 10 000 miles or sooner 16 Spark plug leads wires must be checked for condition When reaching the end of their life they become hard and must be replaced as a complete set Check the condition of your coil pack and test for resistance according to OE spec Check the condition of the distributor cap where applicable and replace if worn or heavily corroded Replace rotor every 15 000 miles and cap every 50 000 or as condition warrant 17 Engine oil should be changed every 3 5 000 miles We recommend OE oil Do not mix different grades of oil qualities PAGE 37 of 38 P N VFM1 1 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS PRODUCT REGISTRATION FOR WARRANTY THIS DOCUMENT MUST BE RETURNED COMPLETED TO VALI DATE WARRANTY Please retain a copy for your records Ple
16. cause VF reprograms the entire ECU and not just the software file For full performance and continued reliability please heed the following recommendations PAGE 5 of 38 Use only premium grade fuel rated at 91 octane or higher R M 2 The compression ratio of the vehicle must be unaltered prior to the installation of this kit If your engine has been modified in any way please contact VF Engineering prior to the installation of this product Always listen for detonation pinging and discontinue hard use full throttle until problem is resolved Perform an oil and filter change upon completion of this installation and prior to the initial test drive All subsequent oil changes should be performed in 3 000 mile intervals using high quality synthetic motor oil FAILURE TO MAINTAIN 3 000 MILE INTERVALS CAN LEAD TO PREMATURE SUPERCHARGER WEAR AND OR FAILURE Before beginning installation replace all spark plugs that are older than 1 year or 10 000 miles with original heat range plugs as specified by the manufacturer and make sure stock timing settings are set DO NOT USE PLATINUM SPARK PLUGS UNLESS THEY ARE ORIGINAL EQUIPMENT ON YOUR VEHICLE CHANGE SPARK PLUGS EVERY 15 000 MILES AND SPARK PLUG WIRES AT LEAST EVERY 50 000 MILES The supercharger unit must never be opened or serviced by anyone other than VF Engineering or Vortech P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 S
17. e ECU from beneath the windshield cowl and send it to VF Engineering for re 2 programming Be sure to package the ECU safely and securely gt ee a ei X2323373330O fe The ECU on the Golf 4 Bora i is gon as iine The plugs are removed by sliding the locks out sideways and gently prying the plugs outwards The ECU is held in 4 by spring clamps and jsut slides out with effort P golf ecu location jog q it 5 1 PAGE 7 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS 3 Disconnect the MAF plug and carefully pry off the vacuum line connected to the back of the intake flexi duct Unclip the large spring clamps around the flexi duct that secure it to the throttle body and the MAF Disconnect the smog pump hose connected to air box Remove the MAF and the airbox completely The MAF sensor will be used later on in these instructions 4 Unhook the crankcase vent 1 from the intake duct as shown in the picture below Remove the small vacuum line connecting points 2 amp 3 below and use the small rubber cap provided in the kit to cover the nipple on the plastic hose The nipple on the manifold is left vacant for the bypass valve vacuum line will be covered later Pivot the crankcase hose 180 degrees counterclockwise at its connection and leave fo
18. ering or you can visit your local GIAC dealer for a serial flash of the VF supercharger software If you choose to ship the ECU to VF the ECU modification can usually be turned around in 2 3 working days in most cases Please not that any delay does not constitute grounds for product return If you have a performance flash already in your ECU you must inform VF Engineering prior to sending the ECU Engineering is not responsible for engine ECU damage due to an improperly installed or shipped ECU DEALER SERVICE RETURN TO STOCK At some point you may take your supercharged car to your VW dealership for a service It is routine for them to update the ECU software from time to time and they may not advise you of this beforehand Therefore it is imperative that you advise them not to update the ECU or else they may overwrite the supercharger software installed by VF or authorized dealer NOTE If your car is flashed back to stock and you drive the supercharged car with stock software engine damage will most likely occur due to inappropriate fuel and ignition mapping If you wish to return your car back to stock VF advises that the ECU be returned to VF or your local GIAC dealer for a flash to stock This is important because VF reprograms the entire ECU and not just the software file In effect the ECU is restored to its original form PAGE 3 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06
19. es 5 Pullies If your supercharger drive belt comes off it may be due to misalignment of the supercharger pulley cause by installation issues or movement of the mounting plate Misalignment can also be caused by over tightening and failure of the supercharger belt For years of trouble free operation when used for street applications we recommend the drive ratios not be changed from the standard specification 6 In case of recurring miss firing or detonation pinging you should contact your vendor By following these procedures you will ensure long term durability and reliability from your conversion 7 Clean the supercharger oil inlet fitting every 3 6000 miles When the vehicle is cold remove the oil inlet fitting at the supercharger and clean it thoroughly utilizing high pressure air to blow the orifice clean before reinstallation Do not attempt to remove the screen filter inside the oil feed fitting This oil inlet fitting is designed with a very small orifice which provides a mist of oil directly onto the gears Never use Teflon tape or other sealants on any oil feed line fitting Do not over tighten fittings 8 Do not use engine oil additives as they may contain solid particulates which can clog the supercharger feed line MAI NTENANCE OF YOUR SUPERCHARGED VEHI CLE 9 Before supercharging your vehicle we recommend you service and inspect your vehicle Ideally the fault codes should be reset This would highlight any existing condition
20. f the connector is ever mis fitted and lead to intermittent connection and cylinder misfire Loose crankcase vent tube is considered a vacuum leak and will cause poor fuel trimming Loose crankcase vent tube to oil separator is a common cause of vacuum leak Vacuum leak at hoses around silicon couplers may not be visible but is a simple mistake Weak OEM crankcase vent tube Melts with age will cause vacuum leak Clean crankcase vent tube and inside of supercharger intake duct every 20K miles and inspect for leaks and kinks and possibly replace udis AND POSSIBLE CAUSES Belt squealing at high RPM Check belt tension e Hunting idle major vacuum leak check silicon couplers especially on throttle body and idle stabilizer e Oil leak check oil feed banjo check redundant oil drain plugs on supercharger check oil drain line e Very erratic idle verify Mass Air Flow sensor may be fitted oriented in incorrect direction e MAF signal CEL check wiring harness extension and electrical continuity in extension harness Please read VF product warranty and maintenance terms of use documents before using this product PAGE 34 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS VF ENGI NEERI NG SUPERCHARGER KIT LI MI TED WARRANTY Subject to all the terms conditions and exclusions set forth in this document Zurich Engineering Inc V
21. g All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS 42 Reconnect the battery clear any all DTC s engine codes and start the car Check for any oil or vacuum leaks See the trouble shooting tips on the next page if necessary Check for any interference issues with all belts and hoses Replace the bumper and headlights when you are satisfied with your installation It may be necessary to slightly trim the back of the bumper upon reinstallation to allow clearance for the new intercooler and pipes PREVENTITIVE MEASURES e Check serpentine belt tension after 500 miles Re tension if necessary e Change spark plugs to 1 range cooler for extreme driving and hot climates e Clean or replace oil feed nozzle contains metal mesh screen with solvent every 6 12 000 miles e Change engine coolant temp senor whilst installing the supercharger kit often a cause of fuelling issues on cars of any age e A gravity oil drain path for the supercharger drain line is critical for the life of the supercharger e DONOT use Teflon paste or tape as it blocks the SC oil feed nozzle and voids warranty e When disconnecting OEM electrical connectors label them to avoid potential confusion when re assembling SHOOTING amp MAINTENANCE TIPS AFTER INSTALLING SUPERCHARGER KITS Injector wiring on older cars can be brittle check for proper connection Contact pins inside injector electrical connectors can bend back i
22. hanged and the original pulley seal must remain intact iv The original Vortech serial number tag must not be removed altered or replaced v You must change the engine oil and oil filter at least every 3000 miles using a SH rated oil or synthetic lubricant regardless of the vehicle filter or oil manufacturers recommendations of oil change intervals vi You must remove inspect and clean the oil inlet fitting oil feed nozzle to the supercharger every 3000 miles vii The conversion must be allowed to break in for a period of 300 miles and inspected as per maintenance instructions viii The main serpentine belt must not be excessively tensioned see belt tensioning instructions ix The Supercharger Kit must be maintained according to the minimum service requirements as listed under the maintenance schedule X Acts of God normal wear and tear rust damage damage to vehicle or engine caused by backfire engine failure accident or collision xi Improper installation not following installation instructions provided or installation by an unskilled person xii Over speeding the supercharger by any method including under drive accessory pulleys or larger crank pulley xiii Damage resulting from entry of foreign particles xiv If the supercharged car is driven after an uncorrected fault has been detected xv Any faults irregularities are not advised to your vendor 4 ONE YEAR LI MI TED WARRANTY ON VF ENGI NEERI NG SUPERCHARGER KI T ANCI LLARI ES
23. i Any disassembly or attempted disassembly of the supercharger volute gearcase or other components xxviii Damage resulting from ingestion of debris by the supercharger xxix Improper supercharger installation xxx Improper drive pulley belt combination on supercharger XXXi Excess belt tension on the supercharger belt drive xxxii Over speeding the supercharger by any method including under drive accessory pulleys or larger crank pulley xxxiii Restricted or blocked supercharger air intake resulting in excessive negative pressure at the air inlet xxxiv Free revving of the engine with the drive belt driving the supercharger in place xxxv Incomplete fitment of all the parts supplied in the VF Engineering kit xxxvi Restricted or lack of oil supply to the supercharger xxxvii Improper installation of or blocked or restricted oil drain line xxxviii Excessive engine crankcase pressures xxxix Dirty or contaminated engine oil xl Removing or defacing the original Vortech serial number tag xli Improper installation not following installation instructions provided or installation by an unskilled person xlii If the supercharged car is driven after an uncorrected fault has been detected or PAGE 35 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Hev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS xliii Any faults irregular noises are not advised to your vendor Xliv xlv xlvi xlvii xlviii xli
24. ing the preexisting anchor points and bolts from the power steering cooler Steel pipes shown installed for photography purposes only It may be necessary to trim the plastic radiator ducting behind the intercooler to allow it to sit flush 16 Remove the oil pan 17 With a pencil or marker make a mark on the front of the engine block that is 0 750 above the oil pan mating surface of the engine block 0 850 to the left of the leftmost side of the bolt highlighted below PAGE 18 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS NOTE It is important that your hole is not marked directly behind the rib of the cast block as shown from the inside view below 18 Use a center punch to mark the hole then make a pilot hole with your drill parallel to the ground using your 1 8 drill bit note the block sits tipped back at an angle in the engine bay and you will be drilling parallel to the ground to ensure that the oil drain fitting allows oil to drain into the engine by gravity and does not see an upward path P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 PAGE 19 of 38 www vf engineering com MkIV R32 Stage 2 US MODELS 19 Using a 9 16 drill bit open the pilot hole by drilling through Use an abrasive to clean any burrs 20 Using the 3 8 NPT thread tap origin
25. irbox and install the silicon coupler as shown PAGE 29 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS 36 Mount with clamp provided the air filter with pre filter and cylindrical airbox over the silicon coupler and onto the correct side of the MAF Make sure the arrow on the MAF sensor indicating the direction of airflow will be pointing away from the air filter side em 1 PAGE 30 of 38 P N VFM1 1 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS 37 Install the supercharger intake pipe with the MAF sensor air filter and pre filter installed on the pipe Connect the bypass valve between the supercharger intake and discharge pipes as shown Note for 1999 and 2000 the MAF should be rotated as shown in the picture below For 2001 2003 models the MAF should be rotated in a position such that the flat face of the circuit box on it is vertical Connect the MAF plug to the MAF Use a piece of the edge protector supplied in the kit to prevent the filter from being damaged against the sharp front panel edge Pierce a small 10 mm hole through the end cap of the pre filter and filter Press fit the air temp sensor through the hole ensuring a tight fit Cable tie the MAF harness and air temp sensor harness to ensure they do not interfere with the fan blade Note filter must
26. l the supercharger discharge pipe between the supercharger outlet and the intercooler inlet It may be necessary to trim the plastic core support just behind the passenger side U S headlight to allow fitment of the pipe MY i P N VFM11 02 2006 VF Engineering PAGE 27 of 38 All rights reserved Rev 1 10 25 06 W ww vf engineering com MkIV R32 Stage 2 US MODELS Discharge pipe 1 is connected to throttle body as shown Note bracket i not visible under pipe at position 2 which holds smog pump hose has been removed Emm FP ox PINO UN cll Note crankcase vent heater has been elminated and electrical plug 3 is now redundant i da iiec ace ete UT SSH a CMe ree p throttlebody pipe jpg PAGE 28 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS The long pipe to the throttle body fits as shown Adjust all pipes to clear other parts before tightening silicon joiners Water hose 1 may need 1 2 cut from its end to prevent is chaffing the pipe MAL Binh LC FM x u 4 tbpipe routing jpg uae P X M 4 d r fy j XN ELLE S x n i 35 Remove the MAF sensor from your original a
27. ons harnesses and hoses see picture below Tuck the wires and hoses up to the underside of the front panels and cable tie them were required keeping in mind that the wires hoses may sag in hot conditions causing them to fall onto the radiator fan blades The extensions continue to run across to the side of the engine compartment where the windshield washer reservoir was previously located her bottle and the pair of water und er the front panel Note how make room for the pxtronsiin the panel Iso be run along the Sextensions routing jpg _ PAGE 12 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS 9 The power steering return line is extended and re routed using a custom hose provided in the kit Unscrew the power steering reservoir PSR from the side engine mount The PSR bottle will be re secured to the side mount later in the instructions Tilt the PSR back and remove the clamp securing the hose to the PSR drain spout Remove the hose and empty fluid into a clean container taking caution not to spill any fluid Cut 6 inches off of the end of the power steering hose that was connected to the PSR bottle Run the remaining hose under the chassis leg and up through a factory hole in the leg Fit the extension hose provided in the kit in and secure all clamps after the hose has been positioned so it is not stressed or chaffing other parts Clean up
28. r later instruction Note Take caution as this hose is very brittle and can crack easily if it is flexed excessively m L Li OCE I m eis i E E a POEM Jh Jh ds atm vr eed a kn mL Du E ET av K is 41 n Fos i LLU PAGE 8 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 MkIV R32 Stage 2 US MODELS www vf engineering com 5 Remove the other crankcase vent hose from its connection on the back of the manifold and cap the nipple on the manifold with the large rubber vacuum cap and clamp supplied The hose can be left there or removed as it is serves no purpose from the factory RA m AST 27 PAGE 9 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS 6 Use the MAF extension harness supplied in the kit to extend the MAF wiring Cut the harness about inches from the MAF plug Strip all exposed wires and use the butt connectors provided to connect the extension harness between the stock MAF wiring and MAF plug MAF harness routing is covered later in these instructions The extension harness provided may contain more wires or different colored wires than your factory MAF harness Ensure you make consistent color to color wire connections a
29. rmarket parts store of OEM parts counter Re fill engine oil to correct level 24 On some cars it may be necessary to trim the fuel line support bracket as show to allow installation of the supercharger bracket in the next step Cut a section off the fuel line support bracket to provide clearance with the supercharger bracket Remove support bracket to cut it fuel support bkt jpg PAGE 22 of 38 P N VFM1 1 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS 25 Use the fuel line relocation bracket supplied in your kit to slightly reposition the fuel lines to allow fitment of the supercharger efual line bkt jpa v TAS 7 26 Remove the tensioner assembly from the cylinder head by removing the three bolts and replace the tensioner with the supercharger head bracket supplied reusing the OEM bolts Torque the bolts to 18 ft 165 Be sure to place the large upper bolt with washer through the upper bolt hole empty hole in picture below in the bracket as it will not be possible to pass the bolt through from behind once installed ANA WES S ES C Secure the head bracket in the same place the original belt tensioner as mounted reuse original bolts Note one of the 2 1 2 18 bolts with a washer must be passed through from behind the head bracket before you secure the bracket note 12v engine shown head bracket jpg PAGE
30. 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 FOLLOWI NG I TEMS i Serial number if applicable lii liii liv lv Ivi lvii lviii Copy of original invoice on which the product was purchased must be dated and show retail store name Year make model vehicle mileage and engine specifications of the vehicle Number of miles on the VF Engineering product and Perceived problem A copy of the original Three Year Warranty Registration if applicable Return authorization number and 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 92806 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
31. s that may need attention The condition of consumables such as oil filters spark plugs HT plug wires leads ignition coil and air mass sensor should be inspected and replaced where needed 10 Never operate your engine at full throttle when the engine is cold When starting the engine each day always allow plenty of time for the oil to reach full operating temperature before running above 2500 RPM Full operating temperature is generally achieved only after the engine water temperature has reached the normal indicated operating range for 2 3 minutes 11 Always utilize the highest octane super premium unleaded fuel available in your area Where possible try to use the same brand of fuel Where possible do not use fuels sold at low cost service stations and preferably use national brands whenever possible 12 After filling up with fuel from a source other than the one you use regularly carefully listen for engine detonation If any detonation is audible you may have a fuel problem Cease utilizing heavy throttle and drive with greater care until the fuel is consumed If detonation is still evident inspect for other causes such as i Faulty fuel pump s Check fuel pressure when detonation is occurring ii Dirty injector s clogged fuel filter or pinched fuel line iii Faulty spark plug s or spark plug wires with too much resistance Consult your factory vehicle service manual Most wires should not exceed 10 Ohms of resistance iv F
32. sed to join the two crank vent route jpg PAGE 32 of 38 P N VFM1 1 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 W ww vf engineering com MkIV R32 Stage 2 US MODELS 40 Install the first of three plastic check valves by first locating the vacuum line originating from the driver s side U S of the intake manifold and follow this hose to the Manifold Air Pressure MAP sensor mounted on the body of the car by the passenger side strut tower Cut the hose and fit the check valve in line Make sure the arrow or black side of the check valve faces the manifold SA Fe SS E En HPected to Throttle 70g ENS Silicon fine and special clamp x Y once situated with adequate clei EN obstructing parts i Ew 41 Install the second and third check valves as shown below The blue arrows indicate which direction the black side of the check valves should be facing Y S a T FE 5 d J c E E x in p as 1 EA E E 4 E UU E n Fit check valves 2 mH 3 in positions shown in the directions indicated by the blue arrows NE TA i 5 M o 2 E E ue To fit the valves cut the hard plastic lines and push fit the silicon sleeves at least 1 2 onto each end of the plastic lines and secure by crimping the clamps down check valve2and3 jpg PAGE 33 of 38 P N VFM1 1 02 2006 VF Engineerin
33. t each end of the extension harness NOTE Make sure the wire in your MAF extension harness containing an inline resistor capsule is used inline with the BLACK wire of your MAF wiring ENGINE DAMAGE MAY OCCUR IF THIS IS NOT FOLLOWED NOTE Use a heat gun or other non open flame heat source to shrink the ends of the butt connectors which contain a self sealing glue to form a water tight seal Wiring harness extensions Cut slit loom upto butt 2 connectors and cover expose section securely with ele tape PY ue Fe j Ti Cut and extend harness to MAF plug winshield g washer bottle level sensor and motor Butt connectors are heat shrinkable use a heat source to seal ends extend harness jpg P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 PAGE 10 of 38 www vf engineering com MkIV R32 Stage 2 US MODELS 7 Vehicles fitted with factory installed HID lights are usually fitted with a large windshield washer bottle This bottle is replaced with a different shaped bottle as supplied with the kit for non US models only The windshield washer bottle is relocated to the area vacated by the air box Remove the reservoir from its current location by removing the two retaining nuts Disconnect the water level sensor and electrical motor s electrical plugs Extend these two plugs using the single harness Disconnect both of the water connections for
34. tage 2 US MODELS Preparation for the installation Prior to installation of your VF Engineering supercharger system be sure to have the following maintenance items at hand to replace during the installation Engine oil and oil filter Spark plugs Upper intake manifold gasket Oil pan sealant THIS MANUAL PROVIDES INFORMATION ON THE INSTALLATION MAINTENCE AND SERVICE OF THE VF ENGINEERING SUPERCHARGER KIT SPECIFICALLY DESIGNED FOR THE U S SPECIFICATION GTI R32 THIS DOCUMENT MUST BE GIVEN TO THE END USER BY THE INSTALLER AND THE REGISTRATION FORM LAST PAGE MUST BE COMPLETED PLEASE CONTACT VF ENGINEERING OR YOUR LOCAL AUTORIZED VF ENGINEERING DEALER FOR ANY ADDITIONAL INFORMATION REGARDING THE INSTALLATION OF THIS KIT AN UNDERSTANDING OF THE INFORMATION CONTAINED IN THIS MANUAL WILL HELP NOVICES AS WELL AS EXPERIENCED TECHNICIANS IF YOU BEGIN INSTALLING THIS PRODUCT IT IS ASSUMED THAT YOU HAVE READ THE ACCOMPANYING TERMS AND CONDITIONS OF USE DOCUMENT AND PRODUCT WARRANTY DOCUMENT INFORMATION ILLUSTRATIONS AND SPECIFICATIONS CONTAINED HERIN ARE BASED ON THE LATEST INFORMATION AVAILBALE AT THE TIME OF THIS PUBLICATION ALL RIGHTS RESERVED TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE PAGE 6 of 38 P N VFM1 1 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 MkIV R32 Stage 2 US MODELS www vf engineering com INSTALLATION INSTRUCTIONS 1 Disconnect the ground lead to the battery Remove the engin
35. ul 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 If a VF Engineering product is within the warranty period and You wish to make a claim please follow the procedure as follows Contact VF Engineering on 1 714 528 0066 asking for the service department and have the following information available Supercharger serial number Copy of original invoice on which the product was purchased must be dated and show retail store name Year make model vehicle mileage and engine specifications of the vehicle Number of miles on the VF Engineering product and Perceived problem 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
36. ww vf engineering com MkIV R32 Stage 2 US MODELS 31 Connect the oil drain line running to the open port on the bottom of the supercharger using the hose clamp supplied Be sure the drain line is positioned in such a way that a consistent downward path is made to the oil pan and that it will not contact any moving parts during use If necessary cut the oil drain line to ensure a direct path is made The oil drain line will run very close to the serpentine belt and possibly touch the alternator It is important that the oil drain provide a good gravity feed back to the oil pan oi drain route jpg 32 Remove the oil plug on the front of the oil filter housing and replace it with the supercharger oil supply line with copper crush washer supplied in the kit Oil Feed HT Use spare port on oil filter Fit oil feed for supercharger by removing factory fitted oil block cap on the oil filter housing at point shown by arrow Screw in metric adapter proivded with crush washer and screw braided oil line to the fitting oil feed connection jpg TEM E PAGE 26 of 38 P N VFM1 1 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS Route the oil feed line up to the supercharger oil feed port and connect Make sure the oil feed line will not 33 contact any moving parts during vehicle operation 12v motor shown in picture 34 Instal
37. www vf engineering com MkIV R32 Stage 2 US MODELS SUPERCHARGER INSTALLATION GUIDE FOR VW MKIV R32 STAGE 2 VFK11 02 NOT CARB APPROVED WARNING DO NOT BEGIN INSTALLATION PRIOR TO READING THE PRE INSTALL NOTES ON PAGES 2 4 VF ENGINEERING www vf engineering com M F 9 00AM 5 30PM PST 1365 N Dynamics St E Anaheim CA 92806 e Phone 714 528 0066 e Fax 714 528 0067 PAGE 1 of 38 P N VFM11 02 2006 VF Engineering All rights reserved Rev 1 10 25 06 www vf engineering com MkIV R32 Stage 2 US MODELS IMPORTANT PRE INSTALL NOTES SPECIAL INSTALL NOTES This installation guide serves as an outline of the steps needed to install your supercharger system and is not intended to guide a novice through the installation If you do not have the proper tools knowledge and experience to carry out the installation please seek help from a professional The pictures in this manual are for reference only and may not match the exact appearance of your vehicle or parts provided VF Engineering strongly recommends Bentley Publishers service manual VG05 Golf Jetta for this install 1 INSTALLATION OF THIS KIT GREATLY INCREASES THE POWER OUTPUT OF YOUR STOCK VEHICLE IT IS IMPERATIVE THAT THE CONDITION OF THE RECIPIENT VEHICLE BE THOROUGHLY INSPECTED PRIOR TO INSTALLATION AND THAT BRAKES TIRES CLUTCH ENGINE MOUNTS AND SUSPENSION ARE UPGRADED TO HANDLE THE RATED POWER INCREASE FAILURE TO DO SO MAY RESULT
38. x PAGE 36 of 38 10 Power increases with Zurich Engineering Inc Supercharger Kits are based on unmodified engines and quoted from results obtained from dynamometer tests using the Dynojet 248C amp 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 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 DI SCLAI MER 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 usef
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