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PERFORMANCE ENGINEERED SYSTEMS

G2 INSTALLATION MANUAL

FOR RACING OR OFF ROAD USE

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INTRODUCTIONPLEASE PURCHASE AUDI-ONLY 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.

PLEASE NOTE:• The photos used in this

manual 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 STEPS

Prior 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 to

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.

INSTALLATION

1) Disconnect the negative batteryterminal.

2) Remove all plastic engine covers.3) Remove ECU and send it to PES

for chip conversion. (See picture1-3)

Picture 1

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Picture 2

Picture 3

4) Remove air box intake ducts. (See picture 4-5)

Picture 4

Picture 5

5) 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 6

6) Disconnect 6 spark plug wiresfrom the coil pack. (See picture 7)

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Picture 7

7) Remove (4) bolts that hold coilpack in place. (See picture 8)

8) Leave main electrical connectorattached and move coil pack tothe side.

Picture 8

9) Remove flexible air intake duct.(See picture 9)

Picture 9

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 1012) Disconnect the intake air temp.

sensor electrical connector. (Seepicture ) REATTACH THISCONNECTOR WHEN FINISHEDWITH INSTALL.

Picture 11

13) Disconnect the left side solenoidelectrical connector. (See picture12)

14) Remove the 2 screws that holdthe solenoid to the plastic mount.

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Picture 12

15) Remove the 3 bolts that hold theplastic mount in place. (Seepicture 13)

Picture 13

16) Slide the plenum control hose outof position. (See picture 14)

Picture 14

17) Disconnect green hose from the“Y” connector. (See picture 15)

Picture 15

18) Disconnect black hose from the“T” connector on the manifold.(See picture 16)

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Picture 16

19) Unclip the (6) fuel injectorelectrical connectors. (Seepicture 18)

Picture 18

20) Remove the (4) screws that holdthe fuel rail in place. (See picture19)

Picture 19

21) Pull up on the fuel rail to dis-engage it from the intakemanifold. (See picture 20)

Picture 20

22) Remove the injector-retainingclips as shown, and pull injectorsout of fuel rail. (See picture 21)

Picture 21

23) Move fuel rail aside while stillconnected to fuel lines.

24) Disconnect electrical connectorfrom the throttle body. (Seepicture 22)

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Picture 22

25) 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..

Picture 23

26) 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 24

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 o-ring 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 24A

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Picture 25

28) Unbolt the (4) bolts holding thethrottle body onto the manifold.See pic 25 for hole locations(Seepicture 26)

Picture 2629) Disconnect (2) rubber hoses from

the 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)

NOTE: Pre 2000 cars will only havethe (top) brake booster hose. (Seepicture 28)

Picture 27

Picture 28

30) Disconnect throttle cable Movethe cable housing to full openthrottle to allow slack in the cableto remove it.

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)

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Picture 29

At 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 manifold

alignment pins. (See picture 30)

Picture 30

34) Remove the (2) rubber seals fromthe bottom of the intake manifoldand set aside for later use. (Seepicture 31)

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 high-pressure line. Call PES for moreinformation.

35) A. Loosen 3 power steeringpulley bolts (See picture 32)

B. Remove serpentine belt.C. Remove power steering pumppulley (3 bolts).

Picture 32

36) Remove and replace the rubberpower steering hose with thesupplied part. (See picture 33)

BE CAREFUL NOT TO HAVE THISHOSE KINKED OR FLUID WILLNOT FLOW.

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NOTE: Only early 1998 models WILLNOT need to have the hose replaced.

Picture 33

37) Remove (6) bolts that hold thepower steering pump/bracket tothe engine block. (See picture 34)

Picture 34

38) Remove the bolt that secures thepower steering high-pressure lineto the valve cover. (See picture35)

Picture 3539) Remove the screw holding the

power steering pump bracket tothe solid airline. (See picture USEA TIE WRAP TO SECURE THESOLID AIRLINE

Picture 36

40) 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)

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Picture 37

42) 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 38

Picture 39

43) The P/S high-pressure hose willneed to be bent back into positionand bolted back onto the valvecover. (See picture 40)

Picture 40

44) Bolt the pulley back onto the P/Spump.

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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 41

NOTE: 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 42

48) 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 4350) Attach brake booster hose onto

the brass hose barb. (See picture44)

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Picture 44

51) Re-install throttle cable byfeeding the cable through thehole in the cruise control mountbracket. (See picture 44A)

Picture 44A

Have 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)

52) Attach the cruise control pot ontothe new cruise control mountbracket. (See picture 44B)

Picture 44B

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 44C

Picture 45

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54) Lubricate the o-rings of the (6)new fuel injectors usingpetroleum jelly. (See picture 46)

Picture 46

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 with

the 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 o-ring to be pinched and cut. Afuel leak will result. Push downon the fuel rail until it is fully

engaged with the injectors. (Seepicture 48)

Picture 48

57) 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.

Picture 49

58) Plug the (6) injector electricalconnectors back in, as well as thethrottle body electrical connector,intake air temp. sensor, and the

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left side solenoid electricalconnector.

59) Lubricate the o-rings on the PESfuel pressure regulator withpetroleum jelly. Insert it into thefuel rail and replace the retainingclip.

60) Trim the plastic outer sheatharound the coil pack wires toallow it to move rearward. Becareful not to cut into the wires.(See picture 50)

Picture 50

Picture 51

61) Bolt the coil pack onto thebrackets using the (3) factoryscrews. (See picture 51)

62) Attach the fuel pressure regulatorvacuum hose coming from thesupplied hose on the left side ofthe supercharger.

63) Re-attach the crankcase venttube to passenger side valvecover. On older models re-attachthe crossover tube.

64) Remove #1 spark plug wire andre-label it as #3.

65) Remove #3 spark plug wire andre-label it as #1. This isnecessary for the wires to havethe correct length. All other wiresuse their original numbers.

66) Re-install the wires to theircorresponding number on the coilpack. The numbers are cast intothe coil pack bracket.

67) Replace flexible intake duct.68) Install new belt. The belt

configuration is the same asstock, except it runs over thesupercharger pulley.

69) Re-install the air box intake ducts.70) Tie wrap the left side solenoid to

the fuel rail.71) Replace the plastic engine valve

covers. The center cover willneed extensive trimming to fit.Note, I don’t run any covers andthat is better as it allows heat toescape from the engine easier.

72) Re-install the ECU.73) Re-connect the negative battery

terminal.74) Do a final inspection of all hoses,

fittings, screws, and connectors.75) Be sure all tools have been

removed from the enginecompartment.

STARTING THE CAR• First turn the key to the on

position to verify that the“check engine” light comes on.In the rare instance that thereis no “check engine” lightpresent, do not attempt to

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start the car. Call PES if thisoccurs.

• When starting the car for thefirst time, you should haveanother person looking underthe hood for fuel leaks or anyother unforeseen problems.

• As a precaution, theobserver should have a fireextinguisher nearby.

• Never touch the acceleratorpedal before or duringcranking the engine.

MAINTAINENCE• USE ONLY SUPER

UNLEADED FUEL (Minimumoctane 92)

• Race fuel (100+octane)should be used on track days.

• The Eaton SC is internallylubricated with a specialsynthetic lubricant developedby Eaton. The SC oil levelshould be checked every7000 miles. To check the oillevel, simply remove the oilplug on the front of the SCunit. The oil should be just atthe bottom of the oil fill hole.USE ONLY EATONLUBRICANT WHEN ADDINGOIL. OTHER OILS WILLDAMAGE THE UNIT ANDVOID THE WARRANTY. Ihave posted Eaton part #son my site you can get fromany GM or Ford dealer.

• Change your engine oil every3000 miles.

• Regularly inspect thefasteners for tightness.

• Periodically inspect theserpentine belt for wear.

• Avoid turning and holding thesteering wheel to full lock.This may cause belt slippage.

• PES recommends using aspark plug one(1) heat rangecolder than stock ingeographic areas with veryhigh temperatures, or whenthe car will be driven on thetrack.

CONCLUSION

We hope that you enjoy your newPES supercharger system. If youhave any questions please call ustoll free at 877-697-1688 or 908-806-8426.

We greatly appreciate yourbusiness!

PES LIMITED WARRANTY

THE WARRANTY

The original purchaser of the PES Racing &Off Road supercharger system is warrantedagainst defective materials andworkmanship for one year from date ofpurchase with unlimited mileage.

WHAT VOIDS THE WARRANTY

• Incorrect installation and/ormaintenance: The PESsupercharger system must beinstalled and maintained as per theprescribed routine maintenanceprocedure as outlined in theinstallation guide.

• No proof of purchase: At the time ofa warranty claim, buyer mustprovide proof of purchase (originalreceipt or invoice).

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• Incorrect use: Any damaged,abused, or modified superchargerunits or system parts will not bewarranted.

EXTENT OF WARRANTY

Any defective part properly returned to PESwill be replaced by PES. PES will not beresponsible for any other expenses incurredby the customer under the terms of thiswarranty, nor shall it be responsible for anydamages either consequential, special,contingent, or otherwise; or expenses orinjury from the installation or use of thesupercharger system. Any parts returned toPES shall be sent at the customer'sexpense along with a proof of purchase.PES reserves the right to determine whetherthe terms of the warranty, set out above,have been properly complied with. In theevent that the terms are not complied with,PES shall be under no obligation to honorthis warranty.