Owner’s Installation Guide for the Paxton Automotive Novi 1200 Supercharger for the 2005 Mustang GT Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033 805 604-1336 . FAX • 805 604-1337 DP/N: 4809654 v2.
FOREWORD P roper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a professional installer/technician. Please call Paxton Automotive for installers in your area. © 2005 PAXTON AUTOMOTIVE All rights reserved.
TABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv RECOMMENDED TOOLS FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2005 Mustang GT IMPORTANT NOTES T his product is protected by state common law, copyright and/or patent. All legal rights therein are reserved. The design, layout, dimensions, geometry and engineering features shown in this product are the exclusive property of Paxton Automotive.
2005 Ford Mustang GT inum spark plugs unless they are original equipment. Change spark plugs at least every 25,000 miles. B efore beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Automotive Limited Warranties Program and the Warranty Registration form. Paxton supercharger systems are performance improving devices.
2005 Mustang GT, Standard Part No. 1001851 PARTS LIST S U P E R C H A R G E R S IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. PART NO.
2005 Mustang GT, H.O. Part No. 1001850 PARTS LIST S U P E R C H A R G E R S IMPORTANT: PART NO. Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged p arts immediately. DESCRIPTION 1016135 S/C ASY, NOVI 2200 05 MUST SAT, 3.
2005 Mustang GT, H.O. Part No. 1001850 PARTS LIST S U P E R C H A R G E R S IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts immediately. PART NO.
Section 1 PREPARATION/REMOVAL 1. PREPARATION/REMOVAL MAF CONNECTOR A. Loosen the hose clamp at the throttle body. Disconnect the plastic 3/8" tube assembly attached to the passenger’s side valve cover. Remove the plastic 3/8" x 90° connector from the plastic tube that was connected at the passenger’s side valve cover. Set this connector aside to be re-used in a later step. Discard the remainder of the hose assembly, as it will not be re-used. (See Fig. 1-a.) RETAIN THIS END RETAIN THIS END Fig. 1-c C.
1. PREPARATION/REMOVAL, cont’d J. Locate the coolant drain plug on the passenger side of the radiator. Next drain the coolant into a clean container. This coolant will be reused in a later step. F. Remove the two 8mm headed bolts securing the coolant overflow reservoir to the plastic fan shroud. (See Fig. 1-f.) G. Disconnect the small overflow hose (running across the top of the radiator) from the overflow reservoir. (See Fig. 1-f.) E.
1. PREPARATION/REMOVAL, cont’d MODIFY STUD STUD BOLT 8mm HEADED SCREWS REMOVE 13mm HEADED BOLT REMOVE STUD BOLT Fig. 1-i Fig. 1-j Q. There is a small tab that secures the wiring harness in place on the valve cover that will need to be removed to gain clearance for the supercharger belt. This tab is best removed with a small air saw but a grinder will work. After removal, smooth the area to prevent damage to the belt. (See Figs. 1-k, 1-l.
1. PREPARATION/REMOVAL, cont’d TAB REMOVED Fig. 1-l MODIFIED STUD BOLT Fig. 1-m R. Using a 15mm socket or wrench, remove the nut that secures the capacitor resistor and coolant hose support bracket to the stud bolt. Using an 18mm socket or wrench, remove the stud bolt. As seen in Fig. 1-j, the upper bolt is removed from the timing chain cover. This bolt will have to be modified by cutting off the threaded end where the resistor attaches. Modify and reinstall the bolt. (See Fig. 1-m.) S.
Section 2 OIL FEED INSTALLATION 2. OIL FEED INSTALLATION A. Locate the factory oil sensor on the driver’s side of the vehicle near the oil filter. B. Remove the sending unit and set aside. C. Locate the supplied 1/4"NPT street TEE fitting. Install the TEE in the same location as the factory sending unit with the 1/4" x –4 x 90° installed in the TEE at the location noted. (See Fig. 2-a.) D. Attach the stainless steel –4 hose to the –4 fitting installed in the street TEE. (See Fig. 2-a.) E.
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Section 3 OIL DRAIN ASSEMBLY INSTALLATION 3. OIL DRAIN ASSEMBLY INSTALLATION Thoroughly clean the threaded area. Apply a small amount of silicone sealer or teflon paste to the new threads. Apply more sealer to the 3/8"NPT hose fitting and secure in the hole. Make sure a seal is formed all around the fitting. (See Fig. 3-b.) G. Drain the engine oil and change the filter. F. A.
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Section 4 POWER STEERING RELOCATION 4. POWER STEERING RELOCATION D. Attach the 3/4" and the 3/8" hose barb unions to the factory hoses using the factory clamps. E. Attach the reservoir to the passenger’s side radiator core support using one of the factory ground strap retaining bolts. (See Fig. 4-c.) A. Locate the power steering assembly 4FU110010. B. Attach the P/S relocation bracket 4FU010-010 using the hardware provided to the P/S reservoir removed in an earlier section. (See Fig. 4-a.) Fig.
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Section 5 COOLANT TUBE RELOCATION 5. COOLANT TUBE RELOCATION A. Locate assembly 4FU214-021. B. Remove the hose connected to the back lower portion of the engine coolant cross-over tube. (See Fig. 5-a.) HOSE CONNECTION BLEED PLUG Fig. 5-c E. Fig. 5-a F. C. Remove the nylon clip retaining the wire harness to the alternator brace and the four 10mm headed bolts securing the alternator brace. Set the brace aside to be reinstalled. (See Fig. 5-b.
5. COOLANT TUBE RELOCATION G. Locate the supplied 1-1/4" expansion plug (7P125-002.) H. Coat the expansion plug with sealant. Using a tube or socket that matches the recessed diameter of the plug, install the plug flush with the machined surface sealing the outlet of the cross-over tube. (See Figs. 5-e, 5-f.) Fig. 5-g J. Install the fitting in the location of the factory coolant bleed plug. (See Fig. 5-h.) Screw the jam nut all the way onto the fitting. Tighten the fitting in the position shown.
5. COOLANT TUBE RELOCATION Y. N. Tighten the cross-over tube retaining bolts, and remove the two manifold retaining bolts. O. Reconnect the coolant cross-over tube hose at the lower rear portion of the coolant cross-over tube. Remove any coolant that may have spilled into the engine valley. P. Reinstall the alternator support bracket and the four 10mm headed retaining bolts removed earlier. Attach the capacitor resistor removed from the stud bolt on the front cover to one of the 10mm bracket retainers.
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Section 6 THERMOSTAT HOUSING RELOCATION 6. THERMOSTAT HOUSING RELOCATION *** NOTE *** Because of manufacturing tolerances, it is best to leave this hose long and trim to fit. A. It will be necessary to relocate the thermostat housing to gain clearance for the supercharger mounting bracket. B. Locate hose 7U133-050. The hose will be modified and will replace the factory lower radiator hose removed in a previous step. (See Fig. 6-a.) E. F.
6. THERMOSTAT HOUSING RELOCATION J. G. Locate hose 7U133-185 “S” shaped hose. (See Fig. 6-c.) Attach the 2-3/4" piece of hose (removed from the long end of the “S” shaped hose,) to the supplied outlet of the cross-over tube. (See Fig. 6-d.) SECTION TO BE TRIMMED 2.75" TO THERMOSTAT HOUSING Fig. 6-d Fig. 6-c K. Install the supplied formed coolant tube to the 2-3/4" long section of hose installed in the last step. Secure the “S” shaped hose in place with the #20 clamps provided. (See Fig. 6-e, 6-f.
Section 7 SUPERCHARGING MOUNTING PLATE INSTALLATION 7. SUPERCHARGER MOUNTING PLATE INSTALLATION C. It is necessary to install the supercharger accessory drive belt and loosely route it following Fig. 7-e, as not all pulleys are currently in place. D. Locate the supercharger mounging plate 4FU010-044 from the supercharger mounting plate assembly. (See Fig. 7-c.) E. Locate the two 8mm x 140mm long bolts and washers from the mounting bracket assembly and install in the locations noted. (See Fig. 7-c.) A.
P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 29JUL05 v2.0 05MusGT(4809654v2.0) 7-2 A/C COMPRESSOR PULLEY FACTORY TENSIONER PULLEY FACTORY IDLER PULLEYS ALTERNATOR PULLEY Fig. 7-e / Belt routing FACTORY POWER STEERING PULLEY SUPERCHARGER PULLEY CRANK SHAFT PULLEY SUPPLIED IDLER PULLEY 4PCS016-160 7.
7. SUPERCHARGER MOUNTING PLATE INSTALLATION, cont’d I. J. L. Locate the 8mm x 150mm bolt and washer. Loosely install the bolt through the mounting plate and remaining 2.712" long spacer into the engine cover using Fig. 7-a for location reference. Locate the supplied idler, 1.776" idler spacer, idler pilot spacer, 3/8-16 x 3.75" long bolt and washer. Install the bolt/washer through the mounting plate, 1.776" spacer, supplied idler, idler pilot spacer and into the triangle-shaped bracket. Use Figs.
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Section 8 CHARGE AIR COOLER INSTALLATION (H.O. Kits Only) 8. CHARGE AIR COOLER INSTALLATION (H.O. KITS ONLY) 4. Remove the five plastic clips retaining the front portion of the fender liner. Both sides need to be removed. (See Fig. 8A-c.) *** NOTE *** For non-cooled kits skip this section and proceed to Section 9. A. BUMPER COVER AND SPLASH PAN 1. Raise the vehicle with a floor jack and set on jack stands. 2. Remove the seven 5.5mm headed screws retaining the lower splash panel. (See Fig. 8A-a.) Fig.
8A. CHARGE AIR COOLER INSTALLATION, cont’d (H.O. KITS ONLY) 6. Disconnect the connectors on the parking and the lower fog lights. (See Fig. 8-e.) 10mm HEADED BOLT LIGHT CONNECTIONS Fig. 8A-g 9. Fig. 8A-e 7. Lift up on the tabs releasing them from the clips. (See Fig. 8A-h.) Remove the six nylon clips retaining the upper radiator core support cover. (See Fig. 8A-f.) NYLON CLIPS DRIVING LIGHT CONNECTOR Fig. 8A-h 10. Pull out on the bumper cover 11.
8A. CHARGE AIR COOLER INSTALLATION, cont’d (H.O. KITS ONLY) 13mm HEADED BOLTS Fig. 8A-k 15. Replace the bolts previously removed with the four 8mm x 1.25" x 35mm long bolts and washers provided. 16. Install the four 2A017-036 spacers (two each side) to the bolts. (See Fig. 8A-l.) Fig. 8A-i 13. Remove four nylon push pins from the styrofoam bumper support and set the support and the pins aside to be reinstalled. (See Fig. 8A-j.) SPACERS PROVIDED NYLON PUSH PINS Fig. 8A-l 17.
8B. CHARGE AIR COOLER INSTALLATION, cont’d (H.O. KITS ONLY) B. CHARGE AIR COOLER ASSEMBLY SHORT ENDS OF 90° ELBOWS PROVIDED *** NOTE *** Use Fig. 8B-a to aid in the next few steps DISCHARGE DUCT CHARGE COOLER TUBE “D” TUBE “C” TUBE “B” Fig. 8B-c 3. TUBE “A” TUBE “E” Fig. 8B-a 1. Using a 3" x 3" bump sleeve and two #48 hose clamps, loosely attach tube “A” to the supercharger discharge. *** NOTE *** The by-pass port should be facing the driver’s side Locate the Charge Air Cooler assembly.
8B. CHARGE AIR COOLER INSTALLATION, cont’d (H.O. KITS ONLY) 5. 6. Attach a 3" x 3" sleeve and #48 hose clamps to the open end of tube “D”. 10. Install the short end of tube “E” into the sleeve attached to tube “D”. Secure the tube support bracket using the previously installed #48 hose clamp. (See Fig. 8B-g.) 9. Install the provided 3" x 3" sleeve and #48 hose clamps onto the open end of tube “B”. Using a 5/16-18 tap, tap the lower hole on the driver’s and passenger’s side core support.
8C. CHARGE AIR COOLER INSTALLATION, cont’d (H.O. KITS ONLY) C. COMPRESSOR BYPASS VALVE ASSEMBLY INSTALLATION 1. Bypass valve #1: a. Cut a piece of the provided 1" heater hose approximately 3" long and secure it to the by-pass valve inlet (opposite the vacuum port) using the #16 hose clamps provided. b. Locate the 1" molded rubber 90° elbow and cut approximately 6" from the long end and 1" from the short end. Attach the long end to the bypass valve discharge and secure using the #16 hose clamps provided.
8C. CHARGE AIR COOLER INSTALLATION, cont’d (H.O. KITS ONLY) c. C. COMPRESSOR BYPASS VALVE ASSEMBLY INSTALLATION, cont’d 2. Bypass valve #2: a. Cut a piece of the supplied 1" heater hose 4.5" long and a piece 15" long. b. Attach the 4.5" piece of hose to the inlet of the by-pass valve, securing it with a #16 hose clamp. d. Secure the 15" piece to the by-pass valve discharge using a #16 hose clamp. Attach the open end of the 4.
8C. CHARGE AIR COOLER INSTALLATION, cont’d (H.O. KITS ONLY) e. f. g. h. Attach a length of 5/32" vacuum hose to bypass valve #2 and route to the vacuum port of the fuel rail sensor. Cut a section of the factory hose and install the vacuum TEE that is provided. (See Fig. 8C-c.) Attach the vacuum hose from the bypass valve to the TEE. Attach a length of 5/32" vacuum hose to the previously installed bypass valve #1.
BYPASS VALVE 4.5" LENGTH OF HOSE #16 HOSE CLAMPS ON ALL HOSE ENDS PORT ON THROTTLE BODY DUCT TUBE “A” VACUUM TEE AT FUEL REGULATOR 8-9 Fig. 8C-d TO 90° RUBBER HOSE 3" LENGTH OF HOSE F HOSE 15" LENGTH O 7U133-100 MOLDED 90° HOSE APPROX. 5.75" VACUUM TEE BY-PASS VALVE VIEW FROM FRONT OF VEHICLE APPROX. 4" TO STRAIGHT FITTING ON INLET DUCT 8C. CHARGE AIR COOLER INSTALLATION, cont’d (H.O. KITS ONLY) P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 29JUL05 v2.
8D. CHARGE AIR COOLER INSTALLATION, cont’d (H.O. KITS ONLY) 3. D. WIRING HARNESS RELOCATION 1. On the passenger’s side of the engine, attached to the valve cover, is a large wire harness. The harness will have to be relocated to gain clearance for the radiator overflow reservoir. (See Fig. 8D-a.) 4. 5. 6. Remove the small clip retaining the small wiring harness to the shock tower. (See Fig. 8D-b.) Attach the small harness to the large harness with wire ties.
8E. CHARGE AIR COOLER INSTALLATION, (H.O. KITS ONLY) E. ENGINE COOLANT RESERVOIR INSTALLA- BRACKET TION 1. Locate assembly 8N155-080. 2. Attach the rear reservoir mounting bracket 4FU010-051 to the reservoir with the 1/420 x 3/4" long bolts and washers provided. (See Fig. 8E-a.) Fig. 8E-b 4. Locate and install 1/4"NPT x 3/8" barbed fitting in the tapped hole just above the previously installed mounting bracket. This hole may have to be opened using the appropriate drill bit. (See Fig. 8E-c.
8E. CHARGE AIR COOLER INSTALLATION, cont’d (H.O. KITS ONLY) 5. 7. Remove the 10mm headed bolt that secures the back of the ECU and the power distribution box. (See Fig. 8E-d.) Attach the rear mounting bracket to the strut tower with the 6mm x 20mm long screws and washer provided. (See Fig. 8E-f.) *** NOTE *** Reinstall the factory ground wire with one of the 6mm screws and washers. FACTORY GROUND STRAP 10mm HEADED BOLT Fig. 8E-f Fig. 8E-d 6. 8. Install the coolant reservoir.
8E. CHARGE AIR COOLER INSTALLATION, cont’d (H.O. KITS ONLY) 12. Route the overflow hose across the radiator and under the radiator retaining bracket to the 1/4"NPT x 3/8" hose barb fitting in the coolant reservoir securing with a clamp. (See Fig. 8E-j.) Reinstall the factory passenger’s side upper radiator hose removed in a previous step. (See Fig. 8E-j.) 10. Modify the small hose removed from the factory coolant overflow reservoir. By cutting the “S” bend off the hose end. (See Fig. 8E-h.) 9.
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Section 9 AIR DISCHARGE ASSEMBLY INSTALLATION (Non-cooled Kits Only) 9. H. Connect the supplied length of 5/32" vacuum to the port on the bypass valve. Route the line to the fuel regulator vacuum hose. Using the supplied vacuum TEE, connect the bypass vacuum line. (See Figs. 9-b, 9-c on Page 9-2, for assistance.) AIR DISCHARGE ASSEMBLY (noncooled kits only) A. Attach the 4.5" sleeve to the discharge duct with the #72 clamps provided. B. Install the 3.0" x 2.75" reducer to the inlet of the discharge duct.
9. AIR DISCHARGE ASSEMBLY (Non-cooled Kits Only) 4.25" x Ø1" HOSE (TRIM TO FIT) TO DISCHARGE TUBE BYPASS VALVE 15" x Ø1" HOSE (TRIM TO FIT) TO INLET DUCT #16 HOSE CLAMPS TO MANIFOLD PRESSURE/VACUUM Fig. 9-b FUEL REGULATOR SUPPLIED VACUUM TEE Fig. 9-c P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 29JUL05 v2.0 05MusGT(4809654v2.
Section 10 COOLANT RESERVOIR RE-INSTALLATION (Non-Cooled Kits Only) 10. COOLANT RESERVOIR RE-INSTALLATION (Non-cooled Kits Only) A. Reinstall the factory passenger’s side upper radiator hose removed in a previous step. B. Reinstall the factory coolant reservoir using factory hardware to secure. C. Reattach the large hose at the bottom of the reservoir to the thermostat housing using the factory hose clamp. D. Reconnect the small overflow hose at the top using the factory clamps. E.
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Section 11 CRANK CASE BREATHER AND PCV INSTALLATION 11. CRANK CASE BREATHER AND PCV INSTALLATION 3/8" TO 5/8" REDUCER UNION A. Locate PVC/MAF assembly 4FU139-096. B. Locate the factory 5/8" x 90° hose end connector removed in a previous step. Cut two pieces of the supplied 5/8"ID hose approximately 3" long. Connect one hose to the 90° fitting. C. Install the supplied PCV valve into the 5/8" hose. D. Cut a piece of the supplied 3/8"ID hose 5" long and connect to the previously installed PCV valve. E.
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Section 12 AIR INLET ASSEMBLY 12. AIR INLET ASSEMBLY A. Locate assembly 4FU112-010. B. Remove two of the 3/8-16 x 1" bolts securing the supercharger in place. Install the air inlet support bracket and secure with the 3/8" bolts removed from the supercharger mounting plate. (See Fig. 12-a.) Fig. 12-c Attach the 4.0 x 3.5 reducer sleeve (H.O. kits, 4.0" x 2.0" long sleeve) to the inlet duct. Secure the sleeves with the clamps provided. (See Fig. 12-c.) H.O. Kits only (Non-cooled - skip to Step 12-i.) F.
12. AIR INLET ASSEMBLY, cont’d I. J. Attach the 1" bypass outlet hose to the 90° plastic fitting and secure the hose with a # 16 hose clamp. Attach the 3/8" hose previously connected to the passenger’s side valve cover, to the 1/4"NPT x 3/8" hose x 90° fitting installed in a previous step. *** NOTE *** Trim hoses for best fit. K. Install the duct to the inlet of the supercharger and secure in place with the clamps provided. L. Locate and install a 4.0" x 2.
12. AIR INLET ASSEMBLY, cont’d *** NOTE *** Install the MAF sensor element so the inlet of the sensor faces the air filter. (See Fig. 10-h.) L. Install the MAF sensor and air filter to the 180° duct. (See Fig. 12-h.) AIR INLET SUPPORT BRACKET Fig. 12-i O. MAF (Mass Air Meter) Harness Extension (Non-cooled kits only): 1. Locate the supplied wire and butt connectors in assembly 4FU139-096. *** NOTE *** It is strongly recommended that the wires be soldered.
12. AIR INLET ASSEMBLY, cont’d P. MAF Interface Adapter Installation (H.O. kits only) 1. If in the event you have received a MAF Interface Adapter that is not a “plug in” unit, it will be necessary to modify the adapter as outlined in steps 2 & 3 below. Otherwise, plug the MAF interface adapter between the factory MAF and the MAF harness connector and ignore steps 2 & 3 below. 2. Remove the connector that is attached to the MAF Interface Adapter leave approximately 2-3" of wire measured from the plug end.
Section 13 FUEL PUMP UPGRADE 13. FUEL PUMP UPGRADE *** NOTE *** This section is best performed with the fuel level BELOW half a tank. A. Remove the rear seat by depressing the two release buttons at the front edge of the seat. (See Fig. 13-a.) CROSS-OVER LINE CONNECTION Fig. 13-c Slowly pull the fuel pump assembly up. Locate the cross-over fuel line connection on the fuel pump assembly and disconnect. (See Fig. 13-c.) F.
H. Using the supplied 17.0 stepless clamps and 2.75" length of Ø3/8" rubber hose, connect supplied “Y” fitting to the distribution rail. (See Fig. 13-e.) Y-FITTING #44 HOSE CLAMP PUMP INLET SCREEN Fig. 13-e I. J. Locate the supplied fuel pump and pump inlet screen. Attach the pump inlet screen to the pump and orient exactly as shown. (See Fig. 13-f.) Secure the supplied fuel pump to the side of the factory pump assembly using the #44 hose clamp supplied.
L. Slide the supplied 11.3 stepless clamps onto the two open legs of the Y-fitting. Connect the discharge of both pumps to the previously installed “Y” fitting using the two supplied Ø3/8" corrugated teflon hoses. Secure the remaining hose ends using the supplied 11.3 stepless clamps. (See Fig. 13-h.) O. Reinstall the fuel pump assembly into the fuel tank in the reverse order of removal. Ensure that the fuel hoses do not rub on the sharp edges of the fuel tank. Take care not to damage the assembly.
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Section 14 REFLASH COMPUTER 14. REFLASH COMPUTER IMPORTANT! To ensure trouble-free programming of your vehicle's computer: • Make sure the vehicle's battery is sufficiently charged. • Turn off all accessories and close doors to prevent unnecessary drain on the battery. • Do not attempt to program your vehicle while a battery charger is connected. • Improper battery voltage will result in failure of the programming process. • Do not disconnect the cable or turn off the ignition during programming. A.
13. REFLASH COMPUTER, cont’d H. Turn the ignition on (do not start the vehicle). Set the parking brake and press the ENTER button to continue. I. SELECT TUNE will be displayed at the top of the screen. Use the arrow keys to select the appropriate tune for your vehicle and press the ENTER button. You will have a choice of four to choose from: 1. STD OUTPUT (non charge-cooled) 2. Charge-cooled, air/water - (this option is NOT used in this application.) 3. Charge-cooled, air/air 4. Original Backup J.
Section 15 FINAL CHECK 15. FINAL CHECK *** WARNING *** Do not attempt to operate the vehicle until all components are installed and all operations are completed including the final check. A. If your vehicle has gone over 15,000 miles since its last spark plug change, you will need to change the spark plugs now before test driving the vehicle. B. Check all fittings, nuts, bolts and clamps for tightness.
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