User's Manual

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DP/N: 4809632 - V1.0 09/25/02

Owner’s Installation Guide for the

Paxton Automotive

Novi 1000 Supercharger

for the

2000/2001 Dodge Durango

Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033

888 9-PAXTON . FAX (805) 604-1337

Summary of content (34 pages)

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Owner’s Installation Guide for the Paxton Automotive Novi 1000 Supercharger for the 2000/2001 Dodge Durango Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033 888 9-PAXTON . FAX (805) 604-1337 DP/N: 4809632 - V1.
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FOREWORD T his manual provides information on the installation, maintenance and service of the Paxton supercharger kit expressly designed for the 2000-2001 4.7L Dodge Durango. Contact Paxton Automotive Corporation for any additional information regarding this kit and any of these modifications at (805) 604-1336 7:00am-3:30pm PST.
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TABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv RECOMMENDED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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RECOMMENDED TOOLS FOR INSTALLATION: 1. Metric and Standard sockets sets 2. Metric and Standard combination wrenches 3. Phillips and common screw drivers 4. 12” crescent wrench or 36mm open end wrenches 5. Pliers 6. Wire cutters and wire crimping Tool 7. Hose cutters 8. 1/8” drill bit and hand drill 9. Allen wrenches 10. Small heat source 11. 3/8 Tap NPT P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.
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Section 1 INTRODUCTION installation will result in a charge for any missing parts. Before starting the installation, we suggest your engine compartment be clean. You can clean the engine and compartment with a pressure washer (such as those used at self serve car washes) and a safe-for-aluminum cleaner/degreaser. Cover the distributor with a plastic bag to prevent water from entering. C ongratulations! You have purchased the finest street Supercharger available for the 2000-2001 4.7L Dodge Durango.
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• Never rely solely on a jack when working under a vehicle. Always use an approved set of jackstands to support the vehicle and place them under the recommended lift points. • When jacking a vehicle, make sure it is on a level surface, preferably concrete or asphalt. The transmission should be in “PARK” or “FIRST”, the parking brake engaged and the wheels blocked. • Never start the car without first verifying that the transmission is in neutral and the parking brake is set.
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Section 2 INITIAL PREPARATION AND DISASSEMBLY d. B egin the initial preparation and disassembly process by disconnecting the battery cables. 2.1 FAN AND FAN SHROUD REMOVAL a. b. Remove the fan using a 36mm or a large crescent wrench. Hitting the wrench with a brass hammer will break it loose. The fan unscrews counter-clockwise as viewed from the front of the engine. (See Fig. 2-3.) Remove the plastic panel under the front of the vehicle by prying out the seven plastic clips. Drain the radiator.
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i. Attach the supplied coolant hoses being careful to get the orientation correct. If necessary, hold the original metal lines in place to see which hose goes with what fitting. Re-use the factory spring type clamps removed from both ends of the original metal lines at the splice point. (See Fig. 2-8.) Fig. 2-5 f. g. h. Remove both metal coolant lines and their mounts that run across the top of the engine.
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Fig. 2-12 Fig. 2-10 p. Detach the cruise control cable at the throttle body. (See Fig. 2-13.) Using a 10mm socket, unbolt the cruise control actuator and seperate it from its mounting bracket. m. Remove the three bolts securing the A/C compressor using a 13mm and 15mm socket. Lift compressor up and let it rest on top of the valve cover. n. Using a 1-1/8” wrench or socket, remove the large bolt on the front of the cylinder head. (See Fig. 2-11.) Fig. 2-13 q.
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r. Re-route the cruise control cable behind the A/C lines at the firewall. Unbolt the computer from the inner fender panel using an 8mm socket and route the cruise control cable behind it. (See Fig. 2-15.) Fig. 2-17 v. Bolt the oil filler neck to the plate using the supplied hardware. (See Fig. 2-18.) Reattach the PCV hose. Fig. 2-15 s. Re-assemble the actuator onto the new bracket. (See Fig. 2-16.) Fig. 2-18 w. Bolt the A/C Compressor back in place using the original hardware.
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x. Bolt the front plate to the rear plate using a 9/16”, 3/4” and a 17mm socket (See Fig. 2-20.) Check the tightness of the small idler attached to the plate with a 9/16” socket. z. Fig. 2-20 y. Install the new Accessory drive belt. (See Fig. 2-21.) Re-install the fan. (See Fig. 2-22.) From under the vehicle mark and drill the oil pan in preparation for the oil drain. (See Fig. 2-23.) On the front of the pan, measure and mark the center. Now find the centerpoint between the pan rail.
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Section 3 SUPERCHARGER INSTALLATION AND ASSEMBLY 3.1 d. SUPERCHARGER INSTALLATION: a. b. Test fit the supercharger in the mounting bracket. You may need to bend the A/C lines for a perfect fit. Measure and cut the supplied oil drain hose to 22-1/2” long. Secure hose to drain fitting on supercharger using supplied clamp. (See Fig. 3-1.) Fasten supercharger with 6 bolts and attach drain hose to fitting on pan. (See Figs. 3-3, 3-4.) Fig. 3-3 Fig. 3-1 c.
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e. Bolt the belt tensioner assembly to the front of the supercharger using a 7/32” allen wrench or socket (See Fig. 3-5.) Fig. 3-7 h. Fig. 3-5 f. Install the supercharger drive belt and tension by turning the leadscrew clockwise using a 10mm socket. The belt should be very tight as it will stretch after being run and loosen up. (See Fig. 3-6) Fig. 3-8 Fig. 3-6 g. i. Tighten the nut on the tensioner pulley using a 3/4” wrench.
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Fig. 3-11 Fig. 3-9 k. n. Attach the oil line, again supporting the oil jet at the top. (See Fig. 3-10.) Attach the discharge tube so the injectors are situated under the throttle linkage. (See Fig. 3-12.) Fig. 3-12 Fig. 3-10 o. Re-install the plastic undertray reusing the seven plastic fasteners. m. Locate the fuel pressure test port directly under the dipstick on the passenger side fuel rail. (See Fig. 3-11.) Remove the plastic cap and place a rag over the port.
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q. Route the red and black wires along with the small four wire harness back and along the firewall, but do not secure. The relay will be mounted to the stud just above and to the side of the brake booster. (See Figure 3-14.) Fig. 3-16 *****DURANGO ONLY***** Engine Management installation, please refer to assembly drawing #1017718. This shows the pin locations and correct connector on the factory ECM. Mount Paxton’s Engine Control Unit to the cover of the power distribution box in the engine compartment.
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Section 4 FINAL CHECK OUT AND START UP T his section covers pre-start checks and inspections, as well as initial start-up. 4.1 INSPECT THE FOLLOWING: a. b. c. d. e. 4.2 Wires, harnesses and electrical connections. Are all items properly dressed, connected and secured? If any electrical connections have been dis-connected, re-connect them before you start your vehicle. Hoses, lines and fittings. Are all items properly dressed, connected and secured? Fasteners, brackets, and clamps.
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APPENDIX INDEX APPENDIX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) Pg. A-3 A-4 A-5 A-6 A-7 A-8 A-9 A-10 A-11 A-12 A-13 A-14 A-15 PART NO.
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A-3 P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) 1016416 1016623 1015934 1017416 1019342 1019343 1020116 1020217 1212616 1020216 1017718 1020218 4809632 4813001 4813002 4821700 1 1 1 1 1 1 1 1 1 1 1 1 1 1 20 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PART NO. 1 QTY. 1 ITEM NO. Appendix 1 WRAP, NYLON TIE 5.
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P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) A-4 7 6 5 4 HUB TOWARD BLOWER 2 3 1 Appendix 2 FINISH NONE WEIGHT APPR. 21.4 LBS S/C ROTATION SCALE: SIZE D 1:1 1016416 DO NOT SCALE DRAWING DWG. ASY, S/C NOVI 1000 FW ROTATION REV. NC SHEET 1 OF 1 1300 BEACON PLACE OXNARD, CA 93033 TEL: (805) 604-1336 FAX: (805) 604-1337 DESCRIPTION BLWR, NOVI 1000 REAR DISCH. PULLEY, S/C 6 GRV 3.5 KEY, 1.
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A-5 P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) 34 33 10 31 ? x 6 TO SUPERCHARGER 38 37 30 ? 36 30 ? 32 26 x 6 Appendix 3 41 ? TO WATER PUMP 35 28 39 42 43 x 4 TO ENGINE BLOCK FINISH NONE WEIGHT APPR. 23 G. COMPTON 2/12/01 SIZE 12.1 LBS SCALE: 1:1 D ITEM NO. QTY. PART NO.
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P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) A-6 TO S/C ASY 9 7 8 5 4 X3 TO COMPRESSOR BY-PASS ASY Appendix 4 6 10 FINISH NONE APPR. WEIGHT 3.8 LBS SCALE: SIZE D 1:2 1015934 DO NOT SCALE DRAWING DWG. ASY, AIR INTAKE 00/01 4.7L DODGE REV. NC SHEET 1 OF 1 1300 BEACON PLACE OXNARD, CA 93033 TEL: (805) 604-1336 FAX: (805) 604-1337 ITEM NO. QTY. PART NO.
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A-7 P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) 1. THESE PARTS SHIP LOOSE. NOTES: UNLESS OTHERWISE SPECIFIED 8 9 4 10 2 3 4 Appendix 5 7 6 3 1 1 11 12 PART NO. 2A046-305 7PA375-500 4FA016-150 7J500-001 7F500-025 7A250-100 7PB500-200 4PFA010-031 7A375-176 2A017-879-06 4PCE017-061 4PCE010-031 DESCRIPTION BELT, 6 GRV LEADSCREW FINISH NONE WEIGHT APPR. G. COMPTON 2/12/01 SIZE 2.
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P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) A-8 5 6 TO S/C ASY ? TO FACTORY OIL SENDER PORT Appendix 6 8 FACTORY OIL SENDER FINISH NONE WEIGHT APPR. G. COMPTON 2/12/01 SIZE .5 LBS SCALE: UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING, DIMENSIONS ARE IN INCHES DO NOT MANUALLY UPDATE TOLERANCES ARE: .XX± .01 .XXX±.005 DECIMALS: DATE APPROVALS ±1/2• FRACTIONS: DRAWN A. PROCTOR 12/01/00 ANGLES: ±1/16 ENGINEERING G.
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A-9 P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) 3 1. SHIP THESE PARTS LOOSE. NOTES: UNLESS OTHERWISE SPECIFIED TO OIL PAN 2 6 Appendix 7 1 NONE WEIGHT APPR. .6 LBS UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING, DIMENSIONS ARE IN INCHES DO NOT MANUALLY UPDATE TOLERANCES ARE: .XX± .01 DECIMALS: .XXX±.005 DATE APPROVALS ±1/2• FRACTIONS: DRAWN A.
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P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) A-10 TO STOCK THROTTLE BODY 6 7 TO FUEL RAIL 2 REQD 4 5 6 3 TO COMPRESSOR BY-PASS ASY 2 REQD 2 Appendix 8 6 5 1 ITEM NO. QTY. 1 1 2 2 1 3 2 4 2 5 4 6 1 7 PART NO. 4PCE012-031 8F060-042 1016044 7PA250-275 7PS300-200 7R002-048 1018913 FINISH NONE WEIGHT APPR. 1020116 DO NOT SCALE DRAWING DWG. REV. A SHEET 1 OF 1 ASY, AIR DISCHARGE w/FUEL ENRICHMENT 00/01 4.
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A-11 P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) TO UPPERMOST FITTING ON PASSENGER SIDE OF ENGINE 4 3 5 Appendix 9 1 FINISH NONE WEIGHT APPR. 1.8 LBS 2 SCALE: SIZE D 1:1 1020217 DO NOT SCALE DRAWING DWG. ASY, HEATER HOSE RELOCATION REV. NC SHEET 1 OF 1 2000/2001 4.7L DODGE DURANGO 1300 BEACON PLACE OXNARD, CA 93033 TEL: (805) 604-1336 FAX: (805) 604-1337 ITEM NO. QTY. PART NO.
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P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) A-12 4 11 TO AIR DISCHARGE ASY TO AIR INTAKE ASY 4 4 10 1 4 12 9 8 Appendix 10 14 TO VACUUM PORT ON INTAKE MANIFOLD ITEM NO. 1 4 8 9 10 11 12 13 14 FINISH NONE WEIGHT APPR. 4.3 LBS 2 6.00 ±.06 SCALE: SIZE 5:8 D PART NO. 8D001-001 7R002-016 7P156-082 7P157-219 7U133-100-10 7U133-100-09 7U030-046X30-2 7U030-046X36 7U030-046X15 1015511 DO NOT SCALE DRAWING DWG. NO.
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A-13 P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) 1 4 2x Appendix 11 2 2 2 4 2 3 4 SCREW, HXHD, 1/4-20UNC-2A X .75 LG., STEEL GR5 NUT, HXHD, 1/4-20UNC-2B STEEL GR5 WITH NYLOK WASHER, 1/4 FLAT SAE 4PCE010-060 7A250-074 7F250-021 7J250-022 FINISH NONE WEIGHT APPR. 1300 BEACON PLACE OXNARD, CA 93033 TEL: (805) 604-1336 FAX: (805) 604-1337 G. COMPTON 2/12/01 SIZE C .3 LBS SCALE: 1.5:1 1020216 DO NOT SCALE DRAWING DWG.
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PCM CONNECTOR (BLACK) PIN #26 O2 SENSOR PIN #24 O2 SENSOR PIN #18 CAM SENSOR LIGHT GREEN/RED LIGHT GREEN/RED BLACK/GREEN BLACK/GREEN TAN/YELLOW TAN/YELLOW PIN #8 CRANK SENSOR GRAY/BLACK GRAY/BLACK P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.
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A-15 P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0) TO FACTORY HOSE 2 Appendix 13 QTY. 1 1 ITEM NO. 1 2 PART NO. 7P157-219 7U125-010 FINISH NONE WEIGHT APPR. G. COMPTON 2/12/01 SIZE .01 LBS SCALE: B 2:1 1020218 DO NOT SCALE DRAWING DWG. ASY, WASHER HOSE MODIFICATION REV. A SHEET 1 OF 1 1300 BEACON PLACE OXNARD, CA 93033 TEL: (805) 604-1336 FAX: (805) 604-1337 00/01 4.
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1300 Beacon Place, Oxnard CA 93033 • Tel: 888 9-PAXTON • www.paxtonautomotive.com P/N: 4809632 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.