MkIII Golf Jetta 2.0L, OBD I & II BBM Supercharger Installation Instructions

Please read in full prior to installation

CAUTION: This screw compressor like all precision superchargers is sensitive to dirt and foreign particle ingestion. Please keep the protective wrap on the intake and discharge pipes installed until you are ready to hook up the intake and discharge tubes. Be careful to keep the intake tract clean at all times. Replace check and service your air filter element at required intervals or at every engine oil change service. Clean the main oil jet to the supercharger at every oil / filter change or every 3k miles.

(Preparation) After you drain and drop your oil pan for the oil return fitting. Be sure to replace your engine oil and filter using a non-synthetic based oil and German brand oil filter. After three thousand miles change your oil with a full synthetic oil and German brand oil filter.

1. Disconnect the negative battery terminal

2. Remove stock air box and air intake boot. The vacuum line that hooks to the air box will later be hooked up to the diverter valve on the supercharger.

3. Disconnect the carbon canister hose from the throttle body. This hose will later attach to the brass fitting on the intake plate of the supercharger.

4. Remove the throttle cable and the throttle plug from the throttle body. Then remove the throttle body.

5. Remove the throttle cable bracket off of the back side of the intake manifold.

6. OBD I cars only Remove the idle stabilizer valve complete with attached hoses.

7. Remove the brake booster hose from the intake manifold.

8. Carefully cut the plastic hose off of the barbed fitting on the end of the booster hose. Be sure to keep the 2 piece of hose and booster hose for reinstallation later.

9. Remove the intake manifold. Be sure not to forget to remove the two rear tail bracket bolts.

10. Separate the throttle switch harness from the injector harness.

11. OBD I cars only Extend air intake temperature plug harness. Be sure to do quality work with good connections and cover your wires with electrical tape when done.

12. Remove the fuel rail from the cylinder head with the injectors still connected.

13. Remove each injector from the rail. Be sure to cover the injector with a rag and wear eye protection as the fuel system could still be pressurized.

14. Reinstall new larger injectors into the fuel rail.

15. Swap out the spark plugs with the supplied plugs.

16. Reinstall the fuel rail.

17. Reinstall the intake manifold.

18. OBD I cars only Press the billet ISV hole plug into the back side of the intake manifold. Be sure to coat it with a thin layer of red loc tight.

19. Remove upper timing belt cover.

20. Remove fuel rail protection bracket.

21. Remove upper radiator hose bracket.

22. Install ½ rubber vacuum plug onto the intake manifold.

23. Install K&N valve cover breather.

24. Install AC line stand off bolt and stand off. AC cars only. This is to get the AC line out of the way of the alternator when you rock it forward making room for the supercharger assembly. Be sure to double check this AC line clearance and tweak the line for clearance after the charger is installed.

25. Remove the serpentine belt by compressing the belt tensioner.

26. Remove the inboard alternator bolt and rock the alternator forward. The supercharger will nest between the alternator and the inboard alternator mount.

27. Install idler pulley bracket.

28. Get the main supercharger assembly, bolts and tools in hand and place the supercharger into position.

29. Install the main inboard supercharger bolt through the mount and where the rear of the alternator used to attach.

30. Install the socket head bolt through the front supercharger mount and alternator.

31. Install the idler pulley onto the idler bracket.

32. Install the oil feed line onto the top of the oil filter housing. Be sure to remove the top plug first.

33. Install the upper manifold to boost tube adaptor, upper boost tube, hose and clamps onto the intake manifold and supercharger.

34. Install the throttle cable bracket onto the supercharger intake tube.

35. Install coal canister vent line to the barbed fitting on the intake plate of the supercharger.

36. Install the bypass valve, hoses and clamps to the supercharger. Hook the vacuum line that was attached to the air box to the diverter valve.

37. Remove the radiator top plastic guard.

38. Install the throttle body onto the intake of the compressor assembly.

39. Install the brake boost hose with the barbed fitting to the throttle body.

40. Lengthen and wrap the throttle switch plug wires and connect.

41. Remove the MAF sensor from the air box.

42. Assemble the MAF housing, hose, clamps and adaptor. Attach to the throttle body.

43. Lengthen and wrap the MAF harness wires. Connect the plug to the MAF housing.

44. Drain the oil pan and remove it.

45. Drill 9/16 hole in the oil pan 7-3/4 from the left side and 1-5/8

from the top. Be sure not to drill this oversize or the O-ring on the bulk head fitting will leak. Be sure to also file de-bur this hole. Do not even attempt to do this with the pan installed or your engine and supercharger will be severely damaged.

46. Install the longer throttle cable.

47. Install the serpentine belt

48. Install the oil return line. Be sure to route a nice path for the line so it is not kinked and can drain properly. Be sure that they also do not interfere with any other engine parts.

49. Loosen and slide the battery back as for as it will go. You may need to adjust or route your battery cables to make the most room for the air filter.

50. Install the intake bracket filter and duct.

51. Refill your car with new oil and install a new oil filter. Be sure not to ever overfill your oil.

52. Install the custom BBM chip in the ecu OBD II Cars only . OBD I cars must send there ecu to BBM for soldered in chip programming. Do not ever run any other software or stock software. Severe engine damage could occur. Performance chips that are not mapped for boost will have aggressive timing and not enough fuel. This could detonate your engine thus blowing it up.

53. Only run premium fuel 92+ octane or better.

Some reference pics

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