Owner’s Installation Guide for the Paxton Automotive Novi 1000 Supercharger for the 2001-2003 4.6L SOHC Mustang GT Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033 805 604-1336 . FAX (805) 604-1337 DP/N: 4809628 - V2.
FOREWORD Before you start the installation of your supercharger Paxton supercharger kit, you will have to find the Paxton Computer Chip Voucher located in your information packet. The 2001-2003 Mustang GT Supercharger Kit requires a computer chip upgrade. You will need to fill out the chip voucher and send it and your computer to Paxton Automotive to receive your chip upgrade. Please refer to section 7 of this manual for the procedure for removing your engine control module.
TABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv 1.1 INITIAL PREPARATION AND REMOVAL . . . . . . . . . . . . .
IMPORTANT NOTES ongratulations! You have purchased the finest street supercharger available for the Mustang GT. The centerpiece of this kit is the High Efficiency PAXTON Supercharger, a mechanically driven centrifugal blower. C mail from Helm Publications at (800) 782-4356. Become familiar with the details of your car’s system. If it is not operating within normal parameters, we do not recommend the installation or use of the supercharger.
Y tions, you can avoid many potential dangers. The following list is not meant to be a comprehensive list, but rather it is meant to make you aware of some of the risks, and encourage you to take a safety minded approach to your work area. ou are undoubtedly eager to get started, but please take a little more time to insure that your safety is not in jeopardy. A moment’s lack of attention may cause a serious injury to you, or to someone else who happens to be standing around.
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Section 1 INITIAL PREPARATION AND REMOVAL 1.1 INITIAL PREPARATION AND REMOVAL A. Begin the initial preparation and disassembly process by first disconnecting the negative side of the battery, and draining one gallon of coolant from the coolant reservoir. To do this, open the valve at the bottom of the radiator and allow to drain into a suitable container. DO NOT allow coolant to drain onto floor, and be sure to mop up any coolant splatter immediately.
E. C. Using a flat-head screwdriver, loosen the hose clamps at the mass air flow sensor and the throttle body, and remove the air intake hose (see Fig 1-b). Remove the air temperature sensor from the air intake hose and place it aside—it will be re-installed in a later step. NOTE: done. Once the assembly is out of the car, use a 10mm socket to remove the mass air flow sensor and screen from the air filter housing (see Fig 1-d). Place the mass air flow sensor aside to be re-installed in a later step.
Section 2 SUPERCHARGER MOUNTING BRACKET ATTACHMENT 2.1 SUPERCHARGER MOUNTING BRACKET ATTACHMENT A. Loosen (but do not remove) the four 10 mm head bolts securing the water pump pulley. Next, remove the accessory drive belt using a 3/8-inch drive ratchet or breaker bar into the square at the end of the tensioner, and rotate the tensioner clockwise. This will relieve the tension on the belt so it can be removed. It will not be re-used. (See Fig. 2-a.) IDLER PULLEY Fig. 2-b C.
D. Remove both nuts using a 10mm and 13mm socket. Then remove both studs using a 13mm and 18mm socket. Enlarge the hole in the tab that held the wiring harness to the outermost stud. Using a round file, enlarge the hole so that it will slip over the large diameter of the stud. This tab will get sandwiched between the cylinder head and a spacer in a later step.(See Fig 2-d.) Note that on some of the 2001-2003 GTs this step will not be required and a .065 shim will go in its place.
G. Install the supercharger rear support bracket as shown in Fig 2-h. Temporarily install the long 10mm bolt to line up the bracket. Leave the bolts finger tight, as it will be necessary to move the bracket when you install the main supercharger bracket. (This photo is for illustration only. You will have to install the supercharger and accessory belt before installing the bracket. There won’t be clearance after the bracket is installed.) I.
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Section 3 FAN RESISTOR RELOCATION 3.1 FAN RESISTOR RELOCATION A. Disconnect the wiring harness from the fan resistor. (See Fig. 3-a.) Remove clips holding the fan resistor to the fan shroud. Attach the fan resistor to the supplied bracket using the supplied hardware. Fig. 3-c C. Re-attach the fan resistor to the wiring harness to ensure adequate wire length. (See Fig. 3-d.) Position the fan bracket on the passenger side of the lower fan shroud.
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Section 4 PREPARING TO MOUNT THE SUPERCHARGER 4.1 PREPARING TO MOUNT THE SUPERCHARGER A. Mount the main supercharger bracket, installing the two 3/8 bolts and spacers in the upper portion of the bracket. Install the long 6mm bolt and spacer in the lower middle portion of the bracket, sandwiching the A/C support between the spacer and rear mounting bracket.
D. Remove the drive belt from the alternator pulley. Install the supercharger into the main bracket, while looping the drive belt around the supercharger pulley. (See Fig. 4-d.) Fig. 4-d E. Tighten the supercharger mounting bolts. Once the supercharger is installed, release the belt tensioner and loop the belt back around the alternator pulley. (See Appendix K for a diagram of the drive belt routing.
Section 5 OIL FEED AND DRAIN LINES 5.1 OIL FEED AND DRAIN LINES A. Your Paxton Automotive NOVI 1000 supercharger uses pressurized engine oil for lubrication. Use an oil sending unit socket (SnapOn tools; part number 6152 or equivalent) to remove the oil sending unit on the underside of the oil filter housing (see Fig 5-a). Install the supplied brass junction fitting using a small amount of Teflon paste. DO NOT USE TEFLON TAPE.
D. Next, apply a small amount of anti-seize lubricant to the tip of the punch, and insert it into the pilot hole. Hit the punch with an air hammer carefully using small bursts, until the punch is inserted up to its shoulder. The hole should measure 9/16". (See Fig 5-d.) G. Install the supercharger drain-back hose fitting so that the elbow is oriented toward the passenger side, away from the harmonic balancer/crank pulley.(See Fig 5-f.) NO DEEPER THAN THIS Fig. 5-f Fig.
Section 6 INTAKE TRACT MODIFICATIONS 6.1 INTAKE TRACT MODIFICATIONS A. Install the discharge tube assembly as shown, using the supplied rubber sleeves and stainless steel clamps. (See Fig. 6-a.) Fig. 6-c D. The supercharger bypass valve requires a vacuum source. Remove the existing plastic coupler in the vacuum hose that runs along the firewall on the passenger side. Replace with the supplied vacuum ‘T’.( See Fig 6-d.
E. H. Attach the supplied K & N air filter, 3-1/2” sleeve, 90° 3-1/2” elbow and #56 hose clamps to the MAF and secure. I. Insert the factory air temperature sensor into the rubber grommet located on the side of the supplied 3-1/2" x 90° elbow. Lubricate for easier fit. Remove the screen from the MAF, which was removed in step 4.(See Fig. 6-e.) ***NOTE*** 2002-2003 models do not have a separate IAT sensor. Use the supplied elbow without a hole or grommet for 2002-2003 models only.
L. Place the MAF/air filter bracket over the existing studs, then secure with the original nuts. (See Fig. 6-h.) Fig. 6-j P. Fig. 6-h M. Carefully open the main wiring harness (runs from the passenger side inner fender into the engine compartment) with a razor blade, making an incision that is approximately 6-inches long. Pull the MAF wiring upwards, until the wires are long enough to be routed back through the opening in the inner fender, and down to the MAF. (See Fig. 6-i.
Q. Join the supercharger inlet duct to the previously installed MAF hose with the supplied #52 hose clamp. R. Connect the opposite ends of each hose to the crankcase breather fitting on the driver’s side valve cover (5/8” hose) and the idle air control resonator (3/x4” hose). Trim hose length if required. S. Install the 5/8” hose union into the crankcase breather line. It may be necessary to trim this line to ensure a proper fit. (See Fig. 6-l.) Fig. 6-l T.
Section 7 ENGINE CONTROL COMPUTER REMOVAL AND MODIFICATION 7.1 ENGINE CONTROL COMPUTER REMOVAL AND MODIFICATION A. Remove the passenger side door sill plate, followed by the passenger side kick panel. This will reveal the engine control computer and its harnesses. The harnesses are secured using clips, which are attached to a small metal bracket. Pull the harnesses off the bracket, then remove the two 7/32-inch bolts that secure the bracket itself. Remove the bracket.(See Fig. 7-a.) Fig. 7-b Fig.
D. Remove the 10mm bolt that secures the main harness to the computer, and remove the harness. (See Fig. 7-d.) Fig. 7-d E. Once the computer is removed from the car, you will need to send your computer and the chip voucher to Paxton Automotive. The computer will be cleaned, a computer chip installed and returned to you, ready to be install back into your vehicle. P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.
Section 8 IN-TANK FUEL PUMP INSTALLATION 8.1 IN-TANK FUEL PUMP INSTALLATION (2001-2002 Models Only) A. Raise the rear of the car and support it with jack stands. B. Open the fuel door and remove the fuel cap and the three filler neck screws using a 10mm socket. C. Remove the fuel filter inlet line with a 3/8" spring-lock tool. D. With the weight of the fuel tank supported with a jack, remove the bolts securing the two fuel tank straps. E.
8.1 IN-TANK FUEL PUMP INSTALLATION (2001-2002 Models Only), cont’d. M. Remove the screen from the bottom of the canister assembly being careful not to puncture flapper valve. (See Fig. 8.2-b.) N. Reinstall the fuel tank, reconnect the fuel filter inlet line, reattach the fuel filler neck, and reinstall the fuel pump. O. Turn the ignition key on and check for fuel leaks. The installation is complete. Congratulations! Fig. 8.2-b 8.
Fig. 8-c / Completed Installation 8-3 P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.
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Section 9 FINAL ASSEMBLY AND CHECK 9.1 Now that the work is done, it’s time to enjoy. PAXTON Automotive wants to thank you for choosing our product, and wants to remind you that the performance and response of your vehicle is now different that what you are used to. Please drive cautiously until you have grown accustomed to the feel of your vehicle.
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APPENDIX A-1 P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.
Please realize that PAXTON Automotive is constantly improving the performance and look of the NOVI 1000 supercharger. Parts in your kit may appear differently than what is pictured in this manual. This is due to photographs taken in pre-production, a change in material, costs, or an improvement in performance. Rest assured that you have purchased the best quality kit that PAXTON Automotive manufactures at this time. The installation of the materials will remain the same. List of Appendices Appendix Number.
A-3 P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.1) 13 14 12 11 SHORT HUB AWAY FROM S/C 8 10 9 7 6 4 2 21 AS REQD. 3 2 26 30 31 32 Appendix A 4 REQD 22 AS REQD. 2 27 28 29 2 3 4 1 5 7 24 25 3 19 FINISH WEIGHT APPR. ASY, S/C NOVI 1000 NONE 20.8 LBS G. COMPTON 10/4/01 SCALE: 98-03 4.6L MUSTANG GT REV.
P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.1) A-4 2 TO RADIATOR 2 3 Appendix B 4 MODIFIED 2 1.50" INTERNAL DIAMETER 1015309 FINISH WEIGHT ?.? LBS 1 CUT HERE 1.25" INTERNAL DIAMETER D 1015309 DO NOT SCALE DRAWING DWG. NO. REV. A SHEET 1 OF 1 ASY, RADIATOR HOSE MODIFICATION 99-03 4.6L MUSTANG GT 1300 BEACON PLACE OXNARD, CA 93033 TEL: (805) 604-1336 FAX: (805) 604-1337 ITEM NO. QTY. PART NO.
A-5 P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.1) 18 17 TO ENGINE NOTES: UNLESS OTHERWISE SPECIFIED: 28 22 TO ENGINE 4 2 19 2 TO ENGINE 3 2 TO S/C 1 Appendix C REPLACE STOCK STUD 25 24 1 ON TIMING COVER TO STOCK 6 7 3 2 TO S/C 5 27 2 11 22 14 29 23 22 1 12 26 22 A 1 1 1 1 1 26 22 REPLACE STOCK FLANGE-HEAD 13 10 15 20 ITEM NO. QTY. PART NO.
P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.1) A-6 1 NOTES: UNLESS OTHERWISE SPECIFIED 3 2 3 6 7 4 8 4 9 10 4 11 16 12 13 5 TO STOCK PVC HOSE 17 1 FINISH WEIGHT ASY, AIR INTAKE NONE APPR. 10.3 LBS G. COMPTON SCALE: 10/30/00 SIZE 1:2 D ITEM NO. QTY. PART NO.
A-7 P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.1) 8 NIPPLE ON P/N 4810127-6 2 3 TO S/C OUTLET Appendix E 4 6 7 1017017 1017018 1017017-P ASY ITEM QT 1 1 3 1 1 1 1 TEST1 5 PART 4PFH012-020 4PFH012-048 4PFH012-028 FINISH NONE WEIGHT APPR. 3.6 LBS G. COMPTON 10/30/00 D SCALE: 1:1.75 SIZE 1017017 DO NOT SCALE DRAWING DWG. NO. ASY, AIR DISCHARGE 99-03 4.6L MUSTANG GT REV.
P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.1) A-8 Appendix F 1 1019336 1 1 1 2 3 4 7P250-082 7P125-004 7P250-034 7U250-000-465 PART NO. HOSE, OIL SS BRAID, AN4 x AN4, 46.5" LG. DESCRIPTION NONE WEIGHT APPR. ASY, OIL SUPPLY FINISH .2 LBS SCALE: SIZE FTG, 90° ELBOW, AN4 x 1/4NPT FTG, 90° ELBOW, AN4 x 1/8NPT FTG, STREET TEE, 1/4NPT OIL FEED HOSE, 46.
A-9 P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.1) 1. SHIP THIS ITEM LOOSE. NOTES: UNLESS OTHERWISE SPECIFIED 4 TO OIL PAN 3 OIL PAN 2 PUNCH HOLE WITH ITEM 6 1.00 Appendix G LOCATION FOR ITEM 5 (FRONT OF OIL PAN) 1.75 1019328 5 QTY. 1 1 1 2 1 1 PART NO. 7P500-063 7P500-052 7P375-053 7R002-010 7T640-011 7U030-036x13 NONE WEIGHT APPR. ASY, OIL RETURN FINISH .
P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.1) A-10 -01 5 4 TO AIR INTAKE ASY 4 4 4 1 Appendix H 5 -02 TO AIR DISCHARGE ASY 3.25±.06 5 5 -02 10 1015506 FINISH WEIGHT APPR. 2.8 LBS ASY, COMPRESSOR BYPASS NONE QTY. 1 4 1 1 1 1 SCALE: SIZE ITEM NO. 1 4 6 10 D 11 12 2.50±.06 UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING, DIMENSIONS ARE IN INCHES DO NOT MANUALLY UPDATE TOLERANCES ARE: .XX± .01 DECIMALS: .XXX±.
A-11 P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.1) 2 REQD 3 2 5 2 REQD Appendix I 1015530 NUT, HEX, 10-24UNC-2B, STEEL WITH NYLOK SCREW, SHCS, 10-24UNC-2A X .75 LG, STEEL GR5 7J010-001 7F010-024 7C010-075 4 2 2 3 4 5 NONE WEIGHT APPR. .2 LBS G. COMPTON ASY, FAN RESISTOR RELOC. FINISH SCALE: 12/11/00 SIZE 2:1 C WASHER, FLAT, #10 7E014-075 2 2 1015530 DO NOT SCALE DRAWING DWG. NO. ASY, FAN RESISTOR RELOCATION REV.
P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.1) A-12 1. ALL ITEMS SHIPPED LOOSE. NOTES: UNLESS OTHERWISE SPECIFIED Appendix J 1017734 NONE ASY, FUEL PUMP FINISH WEIGHT APPR. 2 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 G.
A-13 P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.1) A/C Appendix K CRANK SUPERCHARG 7000170 WATER PUMP NONE APPR. WEIGHT DIAGRAM, BELT ROUTING FINISH SCALE: SIZE POWER STEERING 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.
Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033 805 604-1336 . FAX (805) 604-1337 P/N: 4809628 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 05JUN03 v2.1 MusGT(4809628 v2.