Dodge durango 2002, durango 2000, durango 2001 Owner's Installation Manual

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

FOREWORD

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. An understanding of the information contained herein will help novices, as well as experienced technicians, to correctly install and receive the greatest possible benefit from their Paxton supercharger. When reference is made in this manual to a brand name, number, specific tool or technique, an equivalent product may be used in place of the item mentioned. All information, illustrations and specifications contained herein are based on the latest product information available at the time of this publication. All rights reserved to make changes at any time without notice.

All rights recerved. No parts of this publication may be reproduced, transmitted, transcrived, or translated into

another language in any form, by any means without written permission of Paxton Automotive.

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iii

TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

RECOMMENDED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

2.0 INITIAL PREPARATION AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

3.0 SUPERCHARGER INSTALLATION AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .3-1

4.0 FINAL CHECK-OUT AND START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

APPENDIX:

#1201216 KIT, PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

#1016416 ASY, S/C NOVI 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

#1016623 ASY, S/C MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

#1015934 ASY, AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

#1017416 ASY, BELT TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

#1019342 ASY, OIL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

#1019343 ASY, OIL DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

#1020116 KIT, AIR DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

#1020217 KIT, HEATER HOSE RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9

#1015511 ASY, COMPRESSOR BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10

#1020216 ASY, CRUISE CONTROL RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . .A-11

#1017718 ASY, FUEL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12

#1020218 ASY, WASHER HOSE MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . .A-13

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

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Section 1

INTRODUCTION

ongratulations! You have purchased the finest street Supercharger available for

the 2000-2001 4.7L Dodge Durango. The centerpiece of this kit is the highly efficient and reliable Paxton Automotive Corp. NOVI-1000 supercharger. A mechanically driven (by belt) centrifugal blower (supercharger).

This kit comes with all of the parts you’ll need for a successful installation. The operations required have been grouped in order of sequence. Photos and drawings accompany the text, allowing quick orientation and parts identification.

Installation requires a selection of tools which are listed in a table at the end of this section.

We also suggest that you obtain a Dodge shop manual and become familiar with the details of your cars systems. Manuals may be obtained from your local Dodge dealer or you can order one from Helm publications at (800) 782-4356.

For best results follow the instructions closely and in sequence. The average installation time for this kit is 8-10 hours. Your actual installation time will depend on skill level and working conditions. The estimate does not include time for initial vehicle inspection, cleaning, fine tuning or troubleshooting. Before even picking up a wrench, read this entire manual. We are available for technical assistance at (805) 604-1336, 7am-3:30pm pacific time.

After reading the manual, verify that all major assembly groups are present in the main kit box. You should have ample space to layout the components. As you remove a box or bag from the main kit, note the identification label and compare it with the parts list. Please check the box for small parts.

Paxton makes every effort to insure that all parts are included in the box. However, if you discover any missing or mislabeled parts, please contact Paxton by phone for service.

*****WARNING*****

DO NOT attempt installation if any part(s) are missing from this kit. Failure to contact Paxton prior to beginning

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.

*****CAUTION*****

We do not recommend proceeding with the kit installation unless your vehicle is within normal operating parameters.

You are undoubtedly enthusiastic about getting started on your project, but take just a little more time to insure that your safety is not jeopardized. A moment’s lack of attention can result in an accident, as can failure to observe certain simple safety precautions. The possibility of an accident will always exist, and the following points should not be considered a comprehensive list of all dangers. Rather, they are intended to make you aware of the risk and to encourage a safety conscious approach to all work you do on your vehicle.

We look forward to hearing from you, particularly if you have any comments or suggestions regarding this manual at (805) 604-1336

Paxton Automotive Corporation 1300 Beacon Place Oxnard, CA 93033 E-mail Address info@paxtonauto.com.

***** NOTE *****

Throughout these procedures the word “discard” is used periodically in relationship to items that will no longer be utilized in conjunction with the supercharger installation. It is recommended that these items be saved for future use should it become necessary.

1-2

• 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.

• Never remove the radiator cap while the engine is hot.

• Always wear eye protection when using power tools such as drills, saws, grinders, etc., or when working under a vehicle.

• Never smoke, use an open flame, or have spark-producing items around gasoline or flammable solvents. Always have a fire extinguisher rated for chemical and electrical fires handy when working on motor vehicles.

• Run engines only in well ventilated areas. Carbon monoxide, gasoline, and solvent vapors are colorless and sometimes odorless. These can asphyxiate or explode without warning.

• Always disconnect at least the negative (-) or ground terminal of the battery when doing any electrical, fuel system, or underdash work.

We look forward to hearing from you, particularly if you have any comments or suggestions regarding this manual.

Paxton Automotive makes every effort to insure that all parts are

included in the box, but mistakes do occur. If you discover that you are

missing any part, or that a part is damaged in transit, please call Paxton Automotive for service. DO NOT attempt installation if any part(s) are missing from this kit. Failure to contact Paxton prior to beginning installation will result in a charge for any missing parts.

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Section 2

INITIAL PREPARATION AND DISASSEMBLY

egin the initial preparation and disassembly process by disconnecting the battery cables.

2.1 FAN AND FAN SHROUD REMOVAL

a. Remove the plastic panel under the front of

the vehicle by prying out the seven plastic clips. Drain the radiator.

b. Remove the upper fan shroud/reservoir by

first disconnecting the three elctrical plugs and two small hoses on the passenger side. (See Fig 2.1.)

Fig. 2-1

c. Disconnect the coolant overflow hose at the

filler cap.

(See Fig. 2-2.) Make sure to

clamp or plug this hose to avoid coollant loss. Remove the two bolts securing the shroud using a 10mm socket. Lift up and remove shroud.

Fig. 2-2

d. 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.)

Fig. 2-3

2.2 AIR FILTER REMOVAL

Fig. 2-4

e. Remove the air filter assembly (See Fig. 2-

4). by first loosening the clamp at the throt-

tle body, then disconnect the “S” shaped pcv hose. (See Fig. 2-5.) Remove the nut securing rear of air box using a 10mm socket. Lift assembly up and off the rubber mounts.

2-2

f. Remove both metal coolant lines and their

mounts that run across the top of the engine.

g. On the passenger side of the engine, remove

the uppermost hose fitting that was connected to the coolant hose using a 3/4” wrench.

h. Using Teflon sealant, install the supplied 45

deg. brass fitting so it points back and up slightly. Thread the straight hose fitting into this using Teflon sealant. (See Figs. 2-6, 2-7.)

Fig. 2-5

Fig. 2-6

Fig. 2-7

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. 2-8

j. Detach wiring harness from the front of the

engine. (See Fig. 2-9.)

Fig. 2-9

k. Remove the fan belt by rotating the tension-

er using a 15mm wrench or socket.

l. Remove the four bolts securing the oil filler

neck using a 10mm deep socket. (See Fig. 2-10.)

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Fig. 2-10

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. 2-11

o. Trim the plastic hose that connects to the oil

filler by cutting it off just before the second barb (approx 3/4”). Do not remove the second barb as this keeps the hose from coming off under boost. (See Fig. 2-12.) Install the supplied longer hose.

Fig. 2-12

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.

Fig. 2-13

Fig. 2-14

q. Once you have removed the two 10mm nuts

securing the cable to the actuator, pull out the small pin using a pair of pliers. (See Fig. 2-14.)

2-4

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. 2-15

s. Re-assemble the actuator onto the new bracket.

(See Fig. 2-16.)

Fig. 2-16

t. Bolt the bracket to the fender panel using

the two existing holes next to the large opening. The plug portion should point straight down. Re-attach the cable at the throttle body. Re-attach the computer.

u. Attach the rear support plate to the cylinder

head using the supplied large bolt.

(See Figure

2-17)

Use at least two of the supplied 6mm

bolts to align the bracket with the other mounting holes before tightening. Make sure the supplied O-ring is in place on the rear of the plate.

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. 2-18

w. Bolt the A/C Compressor back in place

using the original hardware. You may need to bend the A/C line slightly to fit in corner of plate. (See Fig. 2-19.)

Fig. 2-19

A/C COMPRESSOR

A/C LINE

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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.

Fig. 2-20

y. Install the new Accessory drive belt. (See

Fig. 2-21.) Re-install the fan. (See Fig. 2-22.)

Fig. 2-21

Fig. 2-22

z. 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. Coat a 3/16” drill bit with grease and drill the hole. Coat the supplied punch with anti-seize or heavy grease and drive it in only halfway using an air chisel with a blunt tip. Do not use a hammer. Do not go in all the way or you will damage internal engine components. Now you must cut off the front portion of the hardened steel punch with either a grinder or a cut off wheel. Continue driving the punch in, and expand the hole until it measures Ø9/16". Go slow with this. It will affect your tapped hole if you go too far. Now tap the hole using a greased 3/8 NPT tap. Go slowly and make sure the tap goes in straight. Stop periodically to clean and regrease the tap. Run the tap in only 2/3 of the way and check to see that the fitting will screw in leaving at least three threads exposed. Clean threads thoroughly, coat fitting with Teflon sealant and install.

Fig. 2-23

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Dodge durango 2002, durango 2000, durango 2001 Owner's Installation Manual

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