Paxton Superchargers 4.6L User Manual

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DP/N: 4809655 - v1.0 08/16/07

Owners Installation Manual for the

PAXTON NOVI Supercharger

for the

1996-2003 4.6L SOHC

MUSTANG GT

Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033

805 604-1336 . FAX (805) 604-1337

FOREWORD

Take note of the following before proceeding:

1. Proper 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 contact your dealer or

Paxton Automotive for possible installers in your area.

2. This product was designed for use on stock (

un-modified, OEM

) vehicles. The PCM (com-

puter), engine, transmission, drive axle ratios and tire O.D. must be stock. If the vehicle or engine has been modified in any way, check with Paxton prior to installation and use of this product.

3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).

4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use (no boost)

until the problem is resolved.

5. Paxton is not responsible for any clutch, transmission, drive-line or engine damage. Exclusions from Paxton warranty coverage considerations include, but not limited to:

1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.

2. Continued operation with an impaired vehicle or sub-system.

3. The combined use of Paxton components with other modifications such as, but not limited to,

exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes.

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

his manual provides information on the installation, maintenance and service of the Paxton supercharger kit expressly designed for this vehicle. All information, illustrations and specifi-

cations contained herein are based on the latest product information available at the time of this publication. Changes to the manual may be made at any time without notice. Contact Paxton Automotive for any additional information regarding this kit and any of these modifications at (805) 888-PAXTON 8:00am-4:30pm PST.

STOP

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TABLE OF CONTENTS

FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

iii

CONGRATULATIONS ON YOUR PURCHASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY FIRST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOOL & SUPPLY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.0 ECM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 AIR INLET REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 COOLANT RESERVOIR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 FACTORY TENSIONER AND RELATED PARTS REMOVAL . . . . . . . . . . . . . . . 1-4

1.4 FAN RESISTOR RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2. SUPERCHARGER MOUNTING BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . 2-1

2.0 SUPERCHARGER MOUNTING BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . 2-1

2.1 SUPERCHARGER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3. OIL FEED AND DRAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.0 SUPERCHARGER OIL FEED AND DRAIN (1996-2003 Models) . . . . . . . . . . . . 3-1

3.1 SUPERCHARGER OIL DRAIN INSTALLATION (1996-2003 Models) . . . . . . . . 3-1

4. AIR INLET/DISCHARGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.0 FUEL INJECTOR REPLACEMENT (1999-2003 Models Only) . . . . . . . . . . . . . . 4-1

4.1 AIR DISCHARGE DUCT INSTALLATION (1996-2003 Models). . . . . . . . . . . . . 4-1

4.2 AIR INLET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

5. IN-TANK FUEL PUMP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.0 FORD 4.6L IN-TANK FUEL PUMP INSTALLATION (1999-2003 Models). . . . . 5-1

5.1 FUEL MANAGEMENT UNIT (1996-1998 Models Only). . . . . . . . . . . . . . . . . . . 5-3

5.2 FORD 4.6L FUEL PUMP INSTALLATION (1999-2003 Models) . . . . . . . . . . . . . 5-5

6. CHECK OUT PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.0 CHECK-OUT PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 COMPLETED INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

A. 1001818 KIT, PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

B. 1011822 ASY, S/C NOVI, REVERSE ROTATION . . . . . . . . . . . . . . . . . . . . . . A-3

C. 1016606 ASY, S/C MTG BRKT (1996-1998 Models Only) . . . . . . . . . . . . . . . A-4

D. 1016609 ASY, S/C MTG BRKT (2000 Models Only) . . . . . . . . . . . . . . . . . . . . A-5

E. 1016616 ASY, S/C MTG BRKT (1999 Models) . . . . . . . . . . . . . . . . . . . . . . . . A-6

F. 1016630 ASY, S/C MTG BRKT (2001-2003 Models). . . . . . . . . . . . . . . . . . . . A-7

G. 1015933 ASY, AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

H. 1017017 ASY, AIR DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

I. 1019336 ASY, OIL SUPPLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

J. 1019328 ASY, OIL RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

K. 1015506 ASY, COMPRESSOR BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12

L. 1015309 ASY, RADIATOR HOSE MODIFICATION. . . . . . . . . . . . . . . . . . . . A-13

M. 1017700 ASY, FUEL CONTROL (1996-1998 Models Only) . . . . . . . . . . . . . . A-14

N. 1016029 ASY, FUEL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15

O. 1017734 ASY, FUEL PUMP / IN-TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16

P. ----- BELT ROUTING DIAGRAM (2000-2003 Models). . . . . . . . . . . . . . A-17

Q. ----- BELT ROUTING DIAGRAM (1996-1999 Models). . . . . . . . . . . . . . A-18

After reading the manual, verify that all major assembly groups are present in the main kit box. As you remove a box or bag, note the identification label and compare it to the parts list.

PAXTON AUTOMOTIVE makes every effort to insure that all parts are included in the

box. If you discover that you are missing

any part, or that a part was damaged in

shipping, call PAXTON immediately. DO

NOT begin installation if a part is missing.

Failure to contact PAXTON prior to begin-

ning installation will result in a charge for

the missing part.

We suggest that the engine compartment be cleaned before the installation. You can clean the engine with the pressure washer found at self-serve car washes. Use a safefor-aluminum cleaner/degreaser, and cover the distributor and any electronics with a plastic bag to prevent water from entering.

You 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 serious injury to you, or to someone else who happens to be standing nearby. By following some simple safety precautions, 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.

ongratulations! You have purchased the finest street supercharger avail-

able for the Mustang GT. The centerpiece of this kit is the High-Efficiency PAXTON Supercharger, a mechanically driven centrifugal blower.

This kit comes with all the parts you will need to install the supercharger. The instruction manual has been written in order of sequence, and photographs and drawings have been included to illustrate the text. This will allow you quick parts identification and orientation.

The installation will require metric and SAE sockets and wrenches, a hand drill and bits, an Air Hammer (and compressor), a 3/8" x 18 NPT tap, screwdrivers, and a supply of buckets for the storing of coolant and oils.

We suggest that you obtain a copy of a Mustang shop manual for your model of car. This may be obtained from your dealer, or may be ordered by 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.

For the quickest installation time, we suggest that you read this manual thoroughly before beginning. Make sure that you understand the process, have identified the areas of the car that you will be working on, and have the tools that you will need on hand. The average installation time is 8 to 10 hours, but your time will depend on your working conditions, experience installing superchargers, personal skill level, and preparedness for the job. This estimate does not include time for the initial vehicle inspection, cleaning, fine tuning, or troubleshooting. Once again, we recommend reading the manual before beginning the process. We are available for tech support at (805) 487-3796, Monday through Friday, 8AM - 4:30 PM PST.

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Never rely solely on a floor jack when working underneath a vehicle. Always

use jack stands that are rated for the

weight of your vehicle, place them at the

recommended lift points, and place your

vehicle in “PARK” or “FIRST” gear with the

parking brake set.

Always use eye protection when using power

tools, such as drills, saws, and grinders, or

when working underneath a vehicle.

Never smoke, use an open flame, or have spark

producing items around gasoline or flammable

objects. Always have a fire extinguisher that

is rated for chemical and electrical fires handy

when working on motor vehicles. Also, make sure

that the extinguisher is fully charged.

Operate engines only in a well ventilated area. Carbon

Monoxide, gasoline, and solvent vapors

are colorless and sometimes odorless, and

may asphyxiate and explode without

warning.

Always disconnect the battery from

your engine before doing work on the electrical

or fuel systems, or doing underdash work.

The chemicals used in the vehicle systems,

such as oils and coolants, are poisonous. Clean

up any spills immediately, and dispose of

waste materials properly.

PAXTON Automotive thanks you for your purchase. We welcome your comments and suggestions to help us improve our product.

SAFETY FIRST

Before 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 for m. Paxton supercharger systems are performance improving devices. In most cases, increases in torque of 3035% and horsepower of 35-45% can be expected with the boost levels specified by Paxton Automotive. This product is intended for use on healthy, well maintained engines.Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger.Paxton Automotive is

not responsible for engine damage.

Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in procedures are followed.

For best performance and continued durability, please take note of the following key points:

1. Use only premium grade fuel 91 octane or higher (R+M/2).

2. The engine must have stock compression ratio.

3. If the engine has been modified in any way, check with Paxton prior to using this product.

4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until the problem

is resolved.

5. Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter every 3,000 miles or less.Never attempt to extend the oil change interval beyond 3,000

miles, regardless of oil manufacturer's claims as potential damage to the supercharger may result.

6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with origi-

nal heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spar k plugs at least every 15,000 miles and spark plug wires at least every 50,000 miles.

TOOL & SUPPLY REQUIREMENTS:

• Factory Repair Manual

• 3/8" Socket and Drive Set:SAE & Metric

• 1/2" Socket and Drive Set:SAE & Metric

• 3/8"NPT Tap and Handle

• Adjustable Wrench

• Open End Wrenches: 3/8", 7/16", 1/2", 9/16"

• Center Punch and a 5/8" Tapered Punch

• Ford Springlock 3/8" Fuel Fitting Disconnect Tool

• 5 Quarts SH/CF Rated Quality Engine Oil

• Oil Filter and Wrench

• Flat #2 Screwdriver

• Phillips #2 Screwdriver

• Heavy Grease

• Silicone Sealer

• Drill Motor

• 1/8", 3/16", 27/64" Drill Bits

• 1/2" Tube Bender

• 3/16" Allen Wrench

• Wire Strippers and Crimpers

• Utility Knife

If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need:

• Spark Plug Socket

• NEW Spark Plugs

1996-2003

FORD 4.6L SOHC MUSTANG

Installation Instructions

50 State Smog Legal, as per CARB EO #D-195-20

Congratulations on selecting the best performing and best backed

automotive supercharger available today!

S U P E R C H A R G E R S

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Fig. 1.1-a

C. Contact the Paxton Service Department for a

Return Authorization Number. Send both the ECM and supplied credit tag to Paxton using the enclosed shipping box.

1.1 AIR INLET REMOVAL

A. Before the air intake assembly can be removed,

you must first disconnect the plastic crankcase breather hose (A) and air idle bypass hose (B). Unplug the air temperature sensor

1996-2001

Models Only:

(D). (See Fig. 1.1-a.)

Begin the initial preparation and disassembly process by first disconnecting the negative side of the battery if not already done.

1.0 ECM REMOVAL

A. Remove the passenger’s side front kick-panel

from the interior of the vehicle. Remove the sound deadening material (if any) that is covering the ECM. Remove the plastic ECM hold-down bracket.

B. Using a 10mm socket or wrench, remove the

harness and plug from the ECM (as you

loosen the bolt, the connector will slowly release). Remove the ECM from the vehicle.

*** NOTE ***

Before removing the ECM, disconnect the positive cable from the battery.

1-2

Fig. 1.1-b

Fig. 1.1-c

Fig. 1.1-d

Fig. 1.1-e (1996-1998 Models)

E. Once the assembly is out of the car, use a

10mm socket to remove the mass air flow sensor from the air filter housing. (See Fig.

1.1-d.) Place the mass air flow sensor aside to be re-installed in a later step.

1996-1998 Models Only

F. Unplug the coil pack on the passenger’s side

of the engine. (See Fig. 1.1-e.)

C. Remove the air temperature sensor from the

air inlet duct and set it aside. The sensor will be re-installed in a later step.

D. Use an 8mm socket to remove the single air

filter housing retaining bolt. The air filter and mass air sensor can then be removed as an assembly. (See Fig. 1.1-c.)

*** NOTE ***

This manual covers model years 1996-2003. Some of the photographs and illustrations may be different but the removal and installation of components are similar.

*** NOTE ***

2002-2003 models do not have a separate IAT sensor. (The IAT sensor is integrated with the factory MAF.)

B. Using a flat-head screwdriver or 5/16" nut

driver, loosen the hose clamps at the mass air flow sensor and the throttle body, and remove the air inlet hose. (See Fig. 1.1-b.)

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G. Use a 7mm socket to remove the four coil

pack bolts and move the coil pack toward the passenger’s side and out of your way.

H. Remove the 13mm bolt, nut and stud bolt

securing the coil bracket to the cylinder head. (See Fig. 1.1-f.)

Fig. 1.1-f

REMOVE THREE

RETAINING NUTS

Fig. 1.2-a

1.2 COOLANT RESERVOIR REMOVAL

A. Drain approximately one gallon of coolant

from the radiator into an appropriate container.

B. Remove the large hose from the coolant reser-

voir and drain the contents of the reservoir into a container.

C. The coolant reservoir is secured by three nuts.

(See Fig. 1.2-a.) Use a 10mm socket, remove the reservoir by removing these nuts and place the reservoir aside.

D. Remove the upper radiator hose and set aside

to be modified in a later step.

1-4

1.3 FACTORY TENSIONER AND RELATED PARTS REMOVAL

A. Using a 13mm socket, remove the two nuts

securing the tensioner limiting bracket. Set the bracket and hardware aside as they will not be reused. (See Fig. 1.3-a.)

*** NOTE ***

Some models and some model years may not have this bracket. (See Fig. 1.3-a.)

Fig. 1.3-a

REMOVE 13mm

NUTS

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B. Loosen (but do not remove) the four 10mm

bolts on the water pump pulley. (See Fig. 1.3-b.)

C. Remove the accessory drive belt. Insert a 1/2"

drive ratchet or breaker bar into the square at the end of the tensioner, and rotate the tensioner. This will relieve the tension on the belt so it can be removed. It will not be re-used.

D. Using a 13mm wrench, remove the stud bolt

and set it aside. It will not be reused. (See Figs. 1.3-c, 1.3-d.)

E. Finish removing the four 10mm bolts securing

the water pump pulley and place the pulley along with its fasteners aside to be reinstalled in a later step of the installation.

Fig. 1.3-b

F. Use a 13mm socket to remove the idler pulley

located above the belt tensioner. (See Fig.

1.3-d.)

Fig. 1.3-d

Fig. 1.3-c

REMOVE

IDLER PULLEY

13mm

STUD BOLT

13mm

STUD BOLT

Fig. 1.3-e

G. Place the pulley aside to be reused in a later

step.

H. Remove three bolts at the front of the engine

(passenger’s side), (see Fig. 1.3-e), a 10mm alternator mounting bolt (arrow “A”), and two 13mm timing cover bolts (arrows “B” and “C”).

1-6

I. Using a 13mm socket, remove the two nuts

and stud bolts located at the top of the passenger’s side cylinder head. (See Fig. 1.3-i.)

Fig. 1.4-a

Fig. 1.4-b

Fig. 1.3-f

Fig. 1.3-g

STUD BOLT TO

BE REMOVED

J. Remove the electrical connector mount. Set

the mount aside to be relocated in a later step. (See Fig. 1.3-f.)

K. Remove the 13mm nut located to the left of

the belt tensioner (passenger’s side). (See Fig. 1.3-g.) Push the bracket to the left to gain access to the stud bolt located at the top of the passenger’s side cylinder head. Remove the stud bolt and set aside - it will not be reused.

REMOVE

CONNECTOR

MOUNT

B. Trim the fan resistor mounting tabs on the

fan shroud to provide clearance for the air intake assembly. (See Fig. 1.4-b.) The fan shroud should look like this after trimming. (See Fig. 1.4-c.)

1.4 FAN RESISTOR RELOCATION 2001-2003 Models Only

A. Disconnect the wiring harness from the fan

resistor. (See Fig. 1.4-a.) Remove the clips holding the fan resistor to the fan shroud. Attach the fan resistor to the supplied bracket using the supplied hardware.

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Fig. 1.4-c

Fig. 1.4-d

C. Re-attach the fan resistor to the wiring har-

ness to ensure adequate wire length. (See Fig. 14-d.) Position the supplied fan bracket and hardware on the passenger’s side of the lower fan shroud. Mark two mounting points along the fan shroud and drill the holes. Attach the mounting bracket with the supplied hardware.

1-8

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Fig. 2.0-a

C. Replace the bolt stud at the upper right corner

of the timing chain cover (removed during step

1.3-i) (see Fig. 2.0-d) with the supplied fastener. (See Fig. 2.0-e, 1996-1999 Models only.)

B. Re-install the factory idler pulley using the

factory hardware (see Fig. 2.0-b), followed by the supplied supercharger idler pulley (See Fig. 2.0-c.)

Fig. 2.0-c

Fig. 2.0-b

Fig 2.0-d

Fig. 2.0-e

1996-1999

MODELS ONLY

BOLT STUD

2.0 SUPERCHARGER MOUNTING BRACKET ASSEMBLY

*** NOTE ***

See Appendix for the model year’s supercharger bracket assembly procedure.

A. Install the supercharger idler pulley bracket

using the supplied hardware. Install the provided spacer between bracket and alternator. (See Fig. 2.0-a.) This operation will be per- formed on all model years.

*** NOTE ***

This photo is for illustration purposes. It will be easier for you to install this bolt/spacer first, then install the other two mounting bolts. (See Fig. 2.0-a.)

2-2

Fig. 2.0-h (1996-1999 Models)

Fig 2.0-f

Fig 2.0-g / 2000-2003 Models

*** NOTE ***

Before installing the outer supercharger mounting plate, the supplied accessory’s supercharger drive belt must be installed.

*** NOTE ***

2001-2003 models must have the accessory drive belt installed BEFORE the support bracket is installed.

*** NOTE ***

If possible, use a proper tubing bender for this step. If one is not available, the line can be bent by hand, but extreme care must be taken as the refrigerant within the line is under very high pressure. In any case, use a pair of heavy gloves and eye protection to prevent injury in the event of a ruptured line.

D. Before installing the main supercharger brack-

et, the A/C refrigerant refilling port must be bent from its upright position downward so that the cap is facing the driver’s side fender. (See Fig. 2.0-f.) Note that this operation will

be performed on all model years

except

model

year 2000. This hose assembly will be

replaced with the provided A/C hose assembly.

Fig. 2.0-i / 1996-1999 Models

F. Mount the main supercharger bracket using

the two 3/8-16 x 2.75" bolts and spacers in the upper portion of the bracket. Install the 8mm bolt and spacer in the lower middle portion of the bracket. (See Appendix “C” for 1999

Models, Appendix “D” for 2000 Models, Appendix “F” for 2001-2003 Models, Appendix “E” for 1996-1998 Models.) Install

the lower bolt and two spacers. One between the support and main brackets, the other between the support bracket and the cylinder head. (See Fig. 2.0-i.)

*** NOTE ***

1996-1998 Models Only - The A/C line bracket

should be placed between the spacer and the cylinder head. (See Fig. 2.0-l.)

E. Install the supercharger rear support bracket

with the supplied 8mm bolt, leaving it fingertight. It will be necessary to move this bolt when the main supercharger bracket is mounted. (See Figs. 2.0-g 2000-2003, 2.0-h. 1996-

1999)

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Fig. 2.0-k

Fig. 2.0-j

G. Reinstall the water pump pulley removed in

an earlier step. (See Fig. 2.0-j.)

*** NOTE ***

The belt must be routed BEFORE this bolt and spacer are installed.

Route the supercharger and accessory drive belt.

*** NOTE ***

On 2000-2003 models the drive belt needs to be routed before the rear S/C mounting plate is installed.

Fig. 2.0-m

Fig. 2.0-l

Completed Supercharger Mounting Bracket

2-4

*** NOTE ***

The hose clamp screw head should be parallel to the supercharger mounting base.

B. Locate the 1/8" x -4 x 90° oil feed fitting.

(See assembly

1019327

.) Install the fitting

into the supercharger oil feed.

*** NOTE ***

Use only clean oil to seal this fitting. Teflon paste or Teflon tape may become dislodged and plug the supercharger oil feed.

A. Install the supercharger oil return line (see

assembly

1019328

) to the supercharger drain fitting and secure with the hose clamp provided.. (See Fig. 2

.1-a.)

Fig 2.1-a

C. Remove the drive belt from the alternator pul-

ley.

D. Install the supercharger into the main bracket,

while looping the drive belt around the supercharger pulley. (See Fig. 2

.1-b.)

E. Install the six 3/8-16 x 1.25" bolts and wash-

ers. Tighten the supercharger mounting bolts. Once the supercharger is installed, release the belt tensioner and loop the belt back around the alternator pulley.

*** NOTE ***

1996-1998 model year cars will require a coil bracket and a different spacer. One of the 3/8-16 x 1.25" bolts must be replaced by a 3/8-16 x 1.0" bolt to clear the coil bracket.

Fig. 2.1-b

Fig. 2.1-c

2.1 SUPERCHARGER INSTALLATION

OIL FEED

FITTING

H. Install the spacer and coil mounting bracket

after installing the supercharger.

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

3-1

A. Your Paxton Automotive NOVI supercharger

uses pressurized engine oil for lubrication. Use an oil sending unit socket (Snap-On tools; part number 6152 or equivalent) to remove the oil sending unit on the underside of the oil filter housing. (See Fig. 3.0-a.)

Fig. 3.0-a

B. Install the supplied 1/4"NPT x 1/4"NPT

STRT-T fitting. DO NOT USE TEFLON

TAPE or paste. The sealant may become dislodged and clog the supercharger oil feed orifice and cause damage to the supercharger.

C. Once installed, the junction fitting should be

oriented so that the opening faces toward the front of the car. (See Fig. 3.0-b.)

D. Install the oil sending unit onto the end of the

brass junction. Install the 1/4" x -4 x 90° fitting into the side of the brass junction, and orient this fitting to face towards the driver’s side frame rail. Attach the supplied length of braided stainless steel feed line, and route upwards to the 90° fitting on the supercharger.

*** NOTE ***

Be sure to stay clear of any moving parts or coolant hoses (engine vibration can cause the stainless line to chafe the rubber coolant hose, creating a leak over time).

E. Install the line, and tighten moderately - no

sealant is required. (See Fig. 3.0-b.)

A. Mark the front of the oil pan 1-1/8" below the

pan rail and between the the two pan rail bolts, directly in the center of the small “hump”. (See Appendix “G”.) Drill a pilot hole with a 3/16" drill bit. (See Fig. 3.1-a.)

Fig 3.1-a

B. Smear the drill bit with heavy grease first to

prevent small metal particles from falling into the pan.

C. Once the hole has been drilled, insert a

straight length of welding rod or heavy wire (such as a coat hanger) into the hole approxi- mately three inches to make sure no interference is encountered. If the path is blocked, turn the engine over until the pathway is clear.

Fig. 3.0-b

3.1 SUPERCHARGER OIL DRAIN INSTALLATION (1996-2003 Models)

3.0 SUPERCHARGER OIL FEED AND DRAIN (1996-2003 Models)

3-2

NO DEEPER THAN THIS LINE

Fig. 3.1-b

Fig. 3.1-c

Fig. 3.1-d

D. Next, apply a small amount of anti-seize

lubricant to the tip of the punch, and insert it into the pilot hole. Using the appropriate tool, (an air hammer works the best), use small bursts until the punch is inserted up to its shoulder. The finished hole size should be 9/16". (See Fig. 3.1-b.)

*** NOTE ***

Do not use hand tools. Using an ordinary hammer will dent the pan. Use extreme caution not to make the hole to big, or the drain fitting will not fit fter tapping the pan.

E. Apply a liberal amount of heavy grease to a

3/8-18 NPT tap (not included), and gradually thread into the hole. Clean the threads using a clean rag and an approved solvent, such as carburetor cleaner.

F. Apply an ample amount of silicone RTV to

the threads of the supplied 3/8"NPT x -8 fitting and insert into the hole. Be careful not to over-tighten. (See Fig. 3.1-c.)

G. Install the supplied drain-back hose fitting so

that the elbow is oriented toward the passenger’s side, away from the harmonic balancer/ crank pulley. Attach the supercharger drain hose and fitting installed on the supercharger during an earlier step. (See Fig. 3.1-d.)

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

4-1

4.0 FUEL INJECTOR REPLACEMENT 19992003 Models Only

B. Install the supplied length of rubber hose to

the end of the hard crank case ventilation line that runs from the driver’s side valve cover across the engine, (See Fig. 4.1-b.)

Fig. 4.1-b

Route the hose over the passenger’s side valve cover and towards the front of the engine. This hose will be attached to the 3/8"NPT x 3/8" x 90° barbed fitting installed in the air inlet duct. (See Appendix “G” for fitting and hose location.) Please note that this hose will

be attached in a later step of the installation.

C. Install the idle air control valve to the throttle

body housing with the original hose, and to the discharge tube with the supplied length of rubber hose and hose clamps. (See Fig. 4.1-c.)

A. Disconnect the eight fuel injector wiring clips

and retainers from the fuel injectors. Release any residual fuel pressure from the rail by opening the schrader valve on the rail.

B. Remove the four 8mm headed bolts holding

the factory fuel rail onto the intake manifold. Lift up on the rails evenly, removing all eight injectors.

C. Using a small amount of clean motor oil,

lightly lubricate the O-rings on both ends of the supplied fuel injectors.

D. Install the new injectors into the fuel rails

with the terminals facing outward.

E. Carefully lower the fuel rail/injector assembly

down onto the intake manifold. Check to see that each injector has been seated properly into the manifold.

F. Tighten down the fuel rail assembly with the

original bolts and attach the injector plugs to the injector terminals.

*** NOTE ***

Make sure injector retainers are secure and properly installed. Recheck after cycling the fuel system.

Fig. 4.1-c

4.1 AIR DISCHARGE DUCT INSTALLATION (1996-2003 Models)

A. Install the discharge tube assembly as shown,

using the supplied rubber sleeves and stainless steel clamps. (See Fig. 4.1-a.)

Fig. 4.1-a

4-2

Fig. 4.2-a

*** NOTE ***

The MAF mounting bracket you receive may be different than what is shown but the assembly is the same.

A. Assemble the MAF, mounting bracket,

MAF/air filter adapter and air filter. (See Fig.

4.2-a & Appendix “G”.)

B. Using the supplied 1/4-20 hardware, mount

the MAF meter to the MAF bracket and secure. (See Fig. 4.2-a.)

** NOTE ***

Remove the factory MAF screen before attaching the meter to the new bracket.

4.2 AIR INLET INSTALLATION

VIEW FROM INSIDE ENGINE

COMPARTMENT

(Steel inner fender not shown for

ease of description)

FACTORY AIR

TEMPERATURE SENSOR

(NOT ON 2002+ MODELS)

3-1/2" ELBOW

SLEEVE

#56 CLAMPS

FACTORY STUDS & NUTS

INSIDE RIGHT FRONT PASSENGER FENDERWELL

FRONT

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

4-3

C. Attach the supplied K & N air filter, 3-1/2"

sleeve, 90° x 3-1/2" elbow and #56 hose clamps to the MAF and secure.

*** NOTE ***

1996-2001 models use the 90° x 3-1/2" plastic inlet elbow with the hole and grommet in the side. 2002+ models use the 90° x 3-1/2" plastic elbow without a hole in the side. Both elbows have been supplied.

D. (1996-2001 Models only.) Insert the factory

air temperature sensor into the rubber grommet located on the side of the 90° elbow. Lubricate for easier fit. (See Fig. 4.2-a.)

*** NOTE ***

2002-2003 models do not have a separate IAT sensor.

E. From beneath the vehicle, remove the two

factory nuts and washers from the passenger’s side lower fender valence. Mount the MAF/bracket assembly onto the existing studs using the same washers and nuts originally removed.

F. Using a #52 hose clamp, connect the piece of

3-1/2" flex hose to the elbow attached to the MAF meter and route it through the opening in the right side inner fender toward the supercharger. Make sure the 3-1/2" flex hose does not contact or rub on the edge of the inner fender opening. (Eventual hose failure will result if the hose is not properly routed.)

G. Route the factory temperature sensor and

MAF sensor connectors out through the inner fender opening. Reattach the connectors to the relocated sensors.

H. Install the bypass valve assembly on the

underside of the secondary intake tube. (See

Fig. 4.2-c.) (See Appendix “J” for bypass assembly procedure.)

Fig. 4.2-b

Fig. 4.2-c

ATTACH TO

DISCHARGE DUCT

I. Place the secondary intake tube/bypass valve

assembly on the supercharger inlet and attach it to the flex hose. Attach the other end of the bypass valve to the discharge tube. Connect the hose that was previously installed on the hard plastic crank case ventilation line to the brass fitting on the intake tube. Tighten the clamps. The finished installation appears as shown. (See Fig 4.2-d.)

Fig. 4.2-d

BRASS FITTING TO

VALVE COVER VENT

4-4

J. Remove the 2" bolts securing the lower reser-

voir bracket. Reinstall the support bracket using one of the existing holes and factory fasteners and the self-tapping screw provided.

K. Re-install the stock coolant reservoir. (See

Fig. 4.2-f.)

*** NOTE ***

The Novi 2000 application will have spacers provided to move the coolant reservoir to gain clearance for the supercharger.

Fig. 4.2-f

Fig. 4.2-e

COOLANT RESERVOIR

RELOCATION BRACKETS

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

5-1

5.0 FORD 4.6L IN-TANK FUEL PUMP

INSTALLATION (1999-2003 Models)

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. Slowly lower the fuel tank, allowing it to lean

over with the filler side up until the electrical connections leading to the center mounted fuel pump are revealed. Disconnect these two electrical connections.

F. Remove the six bolts securing the fuel pump

access cover (on top of the fuel tank) with an 8mm wrench. Depress the two clips securing the plastic fuel pump enclosure and slide it out of the tank. The fuel sender float is attached to the fuel pump enclosure and must be handled with care. Ensure that the tank has been lowered enough to remove the fuel pump enclosure.

G. Remove the two screws securing the plastic

fuel pump outlet manifold to the enclosure cap. Pull the manifold up and away from the fuel pump.

H. Remove the three screws securing the fuel

pump enclosure cover using a 3/16" nut driver and remove the cover.

I. Remove the stock fuel pump from its enclo-

sure. Separate the rubber pump support from beneath the filter and install it on the supplied pump. Secure the support with the new filter provided.

J. Using the supplied fuel pump, reassemble the

fuel pump assembly and canister with cap.

K. Reinstall the canister assembly into the fuel

tank. Reattach the electrical connections.

L. Reinstall the fuel tank, reconnect the fuel fil-

ter inlet line, reattach the fuel filler neck, and reinstall the fuel pump.

M. Turn the ignition key on and check the fuel

pump for leaks.

5-2

This Page Left Intentionally Blank

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

5-3

Fig. 5.1-a

A. Position the fuel management unit (FMU)

against the inner fender ahead of the right side shock tower about an inch from the top. Mark and drill two holes in the inner fender to mount the FMU. Secure with the sheet metal screws provided. (See Figs. 5.1-a, 5.1-b,

5.1-c.)

5.1 FUEL MANAGEMENT/UNIT (1996-1998

Models Only)

FUEL

MANAGEMENT

UNIT (FMU)

VACUUM LINE

OUTLET

INLET

FACTORY QUICKDISCONNECT FITTING

FUEL RETURN LINE

FACTORY

SPRINGLOCK

CONNECTOR

FILTER

T-REX

FUEL TANK

FACTORY REGULATOR

ENGINE

FUEL FEED LINE

5-4

B. Disconnect and discard the factory rubber

fuel return line running from the fuel rail (the

return line DOES NOT have a pressure test fitting on it) to the steel return line (the smaller of the two) located behind the right side

shock tower using a spring lock disconnect tool.

C. Connect the FMU inlet hose (the hose that

goes to the 90° fitting on the side of the FMU) to the return side of the factory fuel

regulator on the fuel rail.

D. Connect the FMU outlet hose (attaches to the

center fitting on the bottom of the unit) to the

steel return line running to the tank. Make sure the hose end is securely “snapped” onto factory fuel return line.

E. Secure the fuel lines away from abrasion and

exhaust heat with the tie-wraps provided.

F. Attach the supplied length of 5/32" vacuum

hose to the fitting on top of the FMU. Connect the opposite end of the hose to the factory fuel regulator vacuum connection using the 5/32" TEE provided.

Fig. 5.1-b

Fig. 5.1-c

PASSENGER’S SIDE

ENGINE COMPARTMENT

STRUT

SHOCK TOWER

FMU

TOP VIEW

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

5-5

B. Connect the power wire from the relay

(Terminal #30) to the battery positive (+) terminal. (See Fig. 5.2-d.)

Fig. 5.2-d

C. Locate the wiring harness connection from the

battery. Connect the gray trigger wire from the relay (Terminal #86) with the supplied quick connector to the solid red wire coming from the wiring harness connection. (See Fig.

5.2-e.)

D. Route the red wire from the relay (Terminal

#87) through the provided split loom along

the back of the firewall, across to the passenger’s side, and along the other components to the fuel tank where it will be connected to the additional fuel pump.

Fig. 5.2-e

POWER FROM

RELAY TO

TERMINAL

QUICK

CONNECTOR

POWER WIRE TO

TRIGGER RELAY

5.2 FORD 4.6L FUEL PUMP INSTALLA-

TION (1996-1998 Models Only)

5-6

E. Disconnect the factory fuel line at the fuel fil-

ter using the supplied tool. Connect the male fitting from the fuel pump to the line that you removed from the fuel filter. Connect the female end from the fuel pump to the fuel filter.

F. The in-line auxiliary fuel pump is installed

next. Remove the spare tire from the well in the trunk. Mount the pump/bracket assembly by drilling two 1/4" holes in the spare tire well using the bracket as a template.

1. Placement should be as close as possible to

the fuel tank while still providing access to the mounting bolts with a socket.

G. From inside the trunk (not underneath), use a

grinder or a piece of course sandpaper to remove the paint from around one of the holes you just drilled. This will ensure a good ground point that is not exposed to the elements.

H. From underneath the car, connect the pump

ground wire to this hole as you secure the pump to the spare tire well using the supplied fastening bolts. (See Fig. 5.2-f.)

I. Connect the wire from the relay to the pump

power terminal.

Fig. 5.2-f

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

6-1

A. Inspect all wiring harnesses and electrical connections. Make sure

that all items are properly routed, connected and secured.

B. Check all hoses, lines, and fittings for properly secured connec-

tions.

C. Make certain all fasteners, brackets, and clamps are installed and

properly tightened.

D. Check the serpentine accessory belt and supercharger drive belts

for proper tension and alignment.

E. Cycle ignition key from “off” to the “on” position. F. Check the entire fuel system for possible leaks. G. Start the engine and verify that the oil pressure is within normal

range.

H. Allow the engine to come up to normal operating temperature. I. Check the coolant level in the coolant recovery bottle and top off

as needed.

J. Check for the following:

• Fluid Leaks

• Fluid Levels

• Belt Slippage

• Throttle Response

6.0 CHECK-OUT PROCEDURES

We know that you are anxious to get out and drive your new vehicle, but please take a little bit more time to perform these simple check-out steps.

Now that the work is done, it’s time to enjoy the results of your efforts.

PAXTON Automotive

wants to thank you for choosing our product, and wants to remind you that the performance and response of your vehicle will now be different from that to which you have been accustomed. Please drive cautiously until you feel comfortable with the handling of your vehicle.

Please see the service manual included in your kit for information on the service and maintenance of your

PAXTON Supercharger

. Belt tightening, troubleshooting, special tuning requirements, and warranty information is also included in the Service Manual.

6-2

Fig. 6.1-a

6.1 COMPLETED INSTALLATION

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

A-1

Please realize that PAXTON Automotive is constantly improving the performance

and look of the NOVI 1000/2000 superchargers. Parts in your kit may appear differ-

ently 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 components will remain the same.

List of Appendices

App. No. DWG No DWG Title Pg. No.

A. 1001818 KIT, PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

B. 1011817 ASY, S/C NOVI, REVERSE ROTATION . . . . . . . . . . .A-3

C. 1016606 ASY, S/C MTG BRKT (1996-1998 Models) . . . . . . . . .A-4

D. 1016609 ASY, S/C MTG BRKT (2000 Models) . . . . . . . . . . . . .A-5

E. 1016616 ASY, S/C MOUNTING BRKT (1999 Models) . . . . . . .A-6

F. 1016630 ASY, S/C MOUNTING BRKT (2001-2003 Models) . . .A-7

G. 1015933 ASY, AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

H. 1017017 ASY, AIR DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . .A-9

I. 1019336 ASY, OIL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10

J. 1019328 ASY, OIL RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-11

K. 1015506 ASY, COMPRESSOR BYPASS . . . . . . . . . . . . . . . . . . .A-12

L. 1015309 ASY, RADIATOR HOSE MODIFICATION . . . . . . . . . .A-13

M. 1017700 ASY, FUEL CONTROL (1996-1998 Models Only) . . . .A-14

N. 1016029 ASY, FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-15

O. 1017734 ASY, FUEL PUMP / IN-TANK . . . . . . . . . . . . . . . . . . .A-16

P. BELT ROUTING DIAGRAM, (2000-2003 Models) . . .A-17 Q. BELT ROUTING DIAGRAM, (1996-1999 Models) . . .A-18

APPENDIX

A-2

A 1001818 Kit, Parts List

REV.

SHEET 1 OF 1

1001818

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

MUSTANG GT, SATIN

KIT, 1996-2003 4.6L SOHC

DO NOT SCALE DRAWING

1:1

SCALE:

SIZE DWG. NO.

DATE

12/11/00

0.0 LBS

L. KECK

A. PROCTOR

G. COMPTON

APPROVALS

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

DRAWN

ENGINEERING

R&D

WEIGHT

APPR.

DESCRIPTION

ASY, S/C NOVI 1000 REVERSE ROTATION

ASY, S/C MTG BRKT

ASY, AIR INTAKE

ASY, AIR DISCHARGE

ASY, S/C OIL SUPPLY HOSE

ASY, S/C OIL RETURN HOSE

ASY, RADIATOR HOSE MODIFICATION

ASY, COMPRESSOR BYPASS

See App

1011817

1015933

1017017

1019336

1019328

1015309

PART NO.

11111111181

QTY.

1015506

123456789

ITEM NO.

ASY, FUEL PUMP, INTANK

FUEL INJECTOR, '99-'03 Models only

VOUCHER, COMPUTER CHIP

BOOKLET, 4.6L SOHC MUSTANG GT

WRAP, NYLON-TIE 5.50"

1017734

4809633

8F060-030

4809605-1

101112

7U100-055 20

.XXX±.005

±1/2•

.XX± .01

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

ANGLES: ±1/16

SEE PARTS LIST

MATERIAL

NONE

FINISH

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

A-3

B 1011822 ASY, S/C NOVI 1000, REVERSE ROTATION

REV.

NUT CORNER IN

LINE WITH EDGE

1011822

ASY, S/C NOVI - REVERSE ROTATION

SIZE DWG. NO.

-----

12/4/01

-----

G. COMPTON

R&D

APPR.

SEE PARTS LIST

MATERIAL

FINISH

SHEET 1 OF 1

DO NOT SCALE DRAWING

3:4

SCALE:

20.8 LBS

WEIGHT

NONE

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

4.6L V2, 1996-2003

DATE

12/4/01

28 29

272

AS REQD.

4 232

31 32

AS REQD.

26 302

16 6-REQD.17

A. PROCTOR

APPROVALS

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

DRAWN

ENGINEERING

±1/2•

.XXX±.005

.XX± .01

ANGLES: ±1/16

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

S/C ROTATION

SAME ROTATION AS 1011810

FTG, NIPPLE, 3/8"NPT x 1/2" HOSE, MODIFIED

ASY, GEARCASE, NOVI 1000, CCW

FTG, PLUG, 3/8"NPT WITH MAGNET

WASHER, COPPER CRUSH, 3/8"

OIL JET, LG.

SCREW, SCHD, 3/8-16UNC-2A x 1.00"LG.

CAP, SHIPPING, T2

KEY, 1/8"SQ x 1.25"LG.

PULLEY, S/C 6-GRV 3.25"

RET, CUP BLWR PULLEY

RET, PULLEY, S/C, 3/8"

CAP, TAMPER PROOF

SCREW, HXHD, 3/8-24UNF-2A x 1.00"LG.

VOLUTE, NOVI 1000, CCW, STR DISCHARGE

CLAMP, VOLUTE

SCREW, HXHD, 1/4-20UNC-2A x .50"LG.

SCREW, SET, 1/4-20UNC-2A x .50"LG.

CAP, SHIPPING, 3"

CAP, SHIPPING, 4"

NAMEPLATE, NOVI 1000

SCREW, DRIVE, #4 x .187"LG.

IMPELLER, NOVI 1000, CCW, BALANCED

7PP375-017

7P375-104

7PP375-090

2H229-000

112211221111116621114111100100000

1234567

ITEM NO. QTY. PART NO. DESCRIPTION

008704

7J375-024

7P375-016

008718

7U100-075

7B375-110

2H036-325

2H040-021

2H040-011

10111213141516171819202122232425262627272829303133

7A250-051

2H019-021

2H100-040

008706

008719

7A250-052

2H100-030

7U100-021

2H021-201

224 REQD

WASHER, ANTI-ROTATION

NUT, 3/8-24UNF-2B, FLG LOCK

MATING RING, .090"THK

SHIM, IMP, .003"THK.

SHIM, IMP, .005"THK.

2H017-021

7G010-155

2H060-030

2H100-003

2H100-005

SHIM, IMP, .010"THK.

2H100-010

MATING RING, .099"THK

MATING RING, .103"THK

MATING RING, .112"THK

2H060-031

2H060-040

2H017-125

2H060-041

SHORT HUB TOWARDS S/C

NOTES: UNLESS OTHERWISE SPECIFIED

1. ALL PARTS TO BE SUITABLY PROTECTED AT ALL TIMES TO PREVENT DAMAGE.

2. SHIM IMPELLER TO .017 WORKING HEIGHT USING ITEMS 26, 27, 28, 29, 30, 31 AND 32

(FLOOR STOCK) AS REQUIRED.

3. TORQUE TO 36 FT-LBS.

4. HEAT TO 200°F TO EASE ASSEMBLY.

A-4

PLATE, FRONT S/C MTG BRKT

C 1016606 ASY, S/C MTG BRKT

BRKT, MTG COIL

PLATE, MTG IDLER

PLATE, REAR S/C MTG BRKT

SPACER, .875"OD x 3.123"L x .404"ID

SPACER, .750"OD x 1.690"L x .328"ID

SPACER, .875"OD x 1.315"L x .404"ID

SPACER, .875" x 1.25"L

COLLAR, STEP IDLER (SMOOTH)

PULLEY IDLER SMOOTH 3"

PULLEY RETAINER S/C

WASHER, 5/16" FLAT SAE GR5

SCREW, M8-1.25 x 66mm HXHD CL 10.9

SCREW, M8-1.25 x 55mm HXHD CL 10.9

WASHER, 3/8"SAE PLTD

SCREW, 3/8-16 x 1.65" HXHD MOD. GR8

SCREW, M8-1.25 x 30mm HXHD CL 10.9

SCREW, M8-1.25 x 80mm HXHD CL 10.9

SCREW, M8-1.25 x 90mm HXHD CL 10.9

SCREW, M8-1.25 x 160mm HXHD CL 10.9

SCREW, 3/8-16 x 2.75" HXHD GR5

SCREW, 3/8-16 x 4.25" HXHD GR5

SPACER, .875"OD x .952"L x .328"ID

3/8-16 x 1-1/4" HXHD

3/8-16 x 1" HXHD

SCREW, M8-1.25 x 60mm HXHD CL10.9

SCREW, M8-1.25 x 65mm HXHD CL 10.9

WASHER, 5/16" AN, PLATED

SCREW, M8-1.25 x 70mm HXHD CL 10.9

BRKT, MTG THERMACTOR VALVE

BELT, 6-GRV GATORBACK, 113"L x 21mm THK

WASHER, 1/4"SAE, PLATED

HOSE, 1/2" SILCONE

CLAMP, HOSE, #6

SCREW, 1/4-20 x .50" HXHD, PLA TED

1/2" SILICONE HOSE, HIGH TEMP

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

1996-1998 4.6L MUSTANG

#6 SS HOSE CLAMP

REV.

SHEET 1 OF 1

1016606

ASY, S/C MTG BRKT

DO NOT SCALE DRAWING

3:4

SEE NOTE 3

TO ENGINE BLOCK

REPLACE STOCK STUD

ON TIMING COVER

UPPER PASSENGER

(R.H.) SIDE

2616

7J312-000

7J375-044

7C080-066

7C080-056

7A375-165

7C080-030

7C080-081

7C080-090

7C080-160

7A375-276

7A375-425

7A375-124

7A375-100

7C010-060

7C010-065

7K312-001

7C080-070

ON WATER PUMP

2A046-113

4PFK010-010

2H040-011

4PFK010-021

4PFH010-034

4PFH010-041

4PFH010-044

2A017-753-02

2A017-875-03

11111111211181110121112115111111111211

123456789

ITEM NO. QTY PART NO. DESCRIPTION

TO MTG LOCATION

ON WATER PUMP

1413

TO S/C

25 16

4FR016-150

4PFK017-011

2A017-750-01

2A017-875-01

2A017-876-02

1011121314151617181920212223242526272829303234343536353637

TO STOCK

ALTERNATOR

2516

TO ENGINE

2A017-876-01

REPLACE STOCK

FLANGE-HEAD BOLT

23 16

TO ENGINE

7J250-001

7U040-000

17 16

7A250-051

7R002-006

7U040-000

SEE NOTE 2

7R002-006

DATE

4/15/09

APPROVALS

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

DRAWN

.XXX±.005

±1/2•

.XX± .01

ANGLES: ±1/16

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

SIZE: DWG. NO.:

-----

ENGINEERING

R&D

APPR.

SEE PARTS LIST

MATERIAL

FINISH

SCALE:

8.0 LBS

WEIGHT

NONE

(IF VEHICLE IS NOT EQUIPPED WITH

COIL PACK, THIS ITEM IS NOT USED)

MOUNT COIL PACK w/ STOCK HARDWARE.

2216

2113

TO ENGINE

STOCK

SCREW

EXISTING

314

2013 TO ENGINE

33324

TO VACUUM

TO EXHAUST

MANIFOLD

SOURCE

TO SMOG PUMP

1. PARTS TO BE SHIPPED LOOSE.

2. IMPORTANT: CUT ITEM 17 SO THAT IT DOES NOT PROTRUDE PAST MACHINED SURFACE OF ITEM 3.

DO NOT USE A 1-1/2" BOLT.

3. IF VEHICLE IS EQUIPED WITH COIL PACK, USE ITEM 8. IF VEHICLE IS NOT EQUIPPED

WITH COIL PACK, USE ITEM 5.

MODIFIED THERMACTOR VALVE

NOTES: UNLESS OTHERWISE SPECIFIED

4. FOR USE IN 96 - 97 MODEL YEARS ONLY.

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

A-5

D 1016609 ASY, S/C MTG BRKT

REPLACE STOCK STUD

ON TIMING COVER

REV.

SHEET 1 OF 1

1016609

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

PLATE, FRONT, S/C MTG

WASHER, 3/8"SAE PLTD

3/8-16 x 1-1/4" HXHD

SCREW, HXHD, 3/8-16 UNC-2A x 2.75"LG.

SPACER, .875" x .404" x .290"LG.

SPACER, .875" x .404" x 1.565"LG.

SPACER, 875" x 1.25"L

SPACER, FLARED, .386"

PLATE, IDLER MTG

SPACER, .750" x .328" x .130"LG.

10mm WASHER PLATED

PLATE, REAR, S/C MTG

WASHER, FLAT, 5/16"

SCREW, HXHD, M8-1.25 x 30mm LG.

STANDOFF, IDLER

ASY, IDLER PULLEY, SMOOTH, 6-RIB

PULLEY RETAINER S/C

SPACER, .875" x .404" x 1.275"LG.

SPACER, .875" x .404" x 1.235"LG.

6mm WASHER PLATED

SCREW, HXHD, M6-1.00 x 80mm LG.

SCREW, HXHD, M10-1.50 x 160mm LG.

3/8-16 x 4.75" HXHD

SCREW, FHSH, M10-1.50 x 110mm LG.

SCREW, HXHD, M8 -1.25 x 65mm LG.

SCREW, HXHD, M10-1.50 x 60mm LG.

WASHER, FLAT, 5/16", AN960

SCREW, HXHD, M8-1.25 x 50mm LG.

SCREW, HXHD, M8-1.25 x 55mm LG.

SCREW, HXHD, 3/8-16 UNC-2A x 1.75"LG.

BELT, 6-GRV 21mm x 108"LG.

1210517

7J375-044

7A375-124

7A375-276

4PFH010-034

2A017-875-08

TO STOCK ALTERNA TOR

11062131111313111111111111211111

123456789

ITEM NO. QTY. PART NO. DESCRIPTION

14 13

2A017-875-02

2611

7J010-002

7J312-000

4PFL017-011

4PFL010-031

2A017-876-02

7C080-030

4PFL010-046

2A017-750-03

101112131415161718192021222324252627282930

4PFH017-021

2H040-011

2A017-875-07

2A017-875-06

2913

7J006-093

7C060-080

7C010-160

2827

7A375-475

7C010-110

7C080-066

REPLACE STOCK BOLT

7C010-060

7K312-001

ON WATER PUMP

7C080-051

7C080-056

7A375-178

2A046-073

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

.XX± .01

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

2000 4.6L MUSTANG GT

DATE

3/26/99

HAL

APPROVALS

DRAWN

ENGINEERING

±1/2•

.XXX±.005

ANGLES: ±1/16

DECIMALS:

FRACTIONS:

ASY, S/C MTG BRKT

SIZE: DWG. NO.:

7.4 LBS

R&D

WEIGHT

APPR.

NONE

SEE PARTS LIST

MATERIAL

FINISH

DO NOT SCALE DRAWING

1:1

SCALE:

2611

TO S/C

325

TO S/C

TO ENGINE

TO S/C

TO ENGINE

2120

23 2

22 11

NOTES: UNLESS OTHERWISE SPECIFIED

1. SHIP THIS ITEM LOOSE.

A-6

E 1016616 ASY, S/C MOUNING BRACKET

REV.

SHEET 1 OF 1

1016616

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

TO STOCK ALTERNATOR

PLATE, FRONT, S/C MTG

PLATE, REAR, S/C MTG

SPACER, .875" x .404" x 1.565"LG.

SPACER, .875" x .328" x 1.565"LG.

SPACER, .875" x .404" x 3.457"LG.

SPACER, .750" x .328" x 2.045"LG.

PLATE, IDLER MTG

SPACER, .750" x .328" x .130"LG.

STANDOFF, IDLER

PULLEY, IDLER, SMOOTH

RET, PULLEY, 3/8"

WASHER, FLAT, 3/8"

SCREW, HXHD, 3/8-16UNC-2A x 1.75"LG.

SCREW, HXHD, 3/8-16UNC-2A x 4.75"LG.

SCREW, HXHD, 3/8-16UNC-2A x 2.75"LG.

WASHER, FLAT, 5/16"

SCREW, HXHD, M8-1.25 x 30mm LG.

SPACER, .875" x .404" x 1.235"LG.

WASHER, FLAT, M10

SCREW, HXHD, M8-1.25 x 90mm LG.

SCREW, HXHD, M8-1.25 x 55mm LG.

SCREW, HXHD, M8-1.25 x 65mm LG.

SCREW, HXHD, 3/8-16UNC-2A x 1.25"LG.

SCREW, HXHD, 3/8-16UNC-2A x 1.00"LG.

NUT, HEX, 3/8-16UNC-2B

SCREW, HXHD, M10-1.50 x 65mm LG.

SCREW, HXHD, M10-1.50 x 160mm LG.

SCREW, HXHD, M10-1.50 x 60mm LG.

SCREW, HXHD, M8-1.25" x 80mm LG.

7C010-065

7C010-160

7C010-060

BELT, 6-GRV, 21mm x 113"LG.

7C080-081

2A046-113

DESCRIPTIONPART NO.QTY.ITEM NO.

7J375-044

7J312-000

7A375-276

7C080-030

7J010-002

7C080-090

2A017-875-06

2A017-875-02

2A017-876-02

2A017-875-04

2A017-750-02

4PFL010-031

4PFH017-021

2A017-750-03

101112131415161718192021222324252627282930

4PFH010-034

4PFH010-044

113111111111011251131115112111

123456789

7A375-178

7A375-475

2H040-011

4FR016-150

7C080-056

7C080-066

7A375-124

7F375-016

7A375-100

1999, MUSTANG GT

ASY, S/C MOUNTING BRACKET

-----

DATE

6/18/99

DO NOT SCALE DRAWING

1:1

SCALE:

SIZE DWG. NO.

-----

REPLACE STOCK BOLT

ON TIMING COVER

17 16

188

21 16

ON WATER PUMP

2614

REPLACE STOCK BOLT

JFC

-----

7.5 LBS

APPROVALS

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

DRAWN

ENGINEERING

R&D

WEIGHT

APPR.

±1/2•

.XXX±.005

.XX± .01

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

ANGLES: ±1/16

SEE PARTS LIST

MATERIAL

NONE

FINISH

198

188

TO S/C

158

TO ENGINE

TO S/C

2916

TO ENGINE

2016

27 14

108

NOTES: UNLESS OTHERWISE SPECIFIED

1. SHIP THIS ITEM LOOSE.

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

A-7

F 1016630 ASY, S/C MOUNING BRACKET

REV.

SHEET 1 OF 1

1016630

1300 BEACON PLACE OXNARD, CA 93033

TO STOCK

ALTERNATOR

TO ENGINE

2622

21 22

1122

SCREW, HXHD, 3/8-16UNC-2A x 1.25"LG.

SCREW, HXHD, 3/8-16UNC-2A x 2.75"LG.

SPACER, .875" x .404" x 1.565"LG.

SPACER, .875" x .328" x 1.565"LG.

SPACER, FLARED, 3/8"

PLATE, IDLER MTG

SPACER, .750" x .328" x .130"LG.

PLATE, REAR, S/C MTG BRKT

SCREW, HXHD, M8-1.25 x 30mm

COLLAR, IDLER

PULLEY, IDLER

RET, PULLEY, 3/8"

SPACER, .875" HEX x 1.275"LG.

SPACER, .875" x .404" x 1.235"LG.

WASHER, FLAT, 6mm

SCREW, SCHD, M6-1.00 x 80mm

SCREW, HXHD, 3/8-16UNC-2A x 4.75"LG.

STUD, M8-1.25 x 3.35"LG.

SCREW, HXHD, M8-1.25 x 65mm

WASHER, FLAT, 5/16"

SCREW, HXHD, M8-1.25 x 50mm

WASHER, FLAT, 10mm

SCREW, HXHD, M10-1.50 x 60mm

7J010-002

7K312-001

7C080-051

7C010-060

SCREW, HXHD, M8-1.25 x 55mm

7C080-056

PLATE, FRONT, S/C MTG BRKT

WASHER, FLAT, 3/8"

7J375-044

7A375-124

7A375-276

4PFL010-034

110623111111111111111161112111

123456789

ITEM NO. QTY. PART NO. DESCRIPTION

4PFL010-021

4PFL017-011

2A017-875-02

2A017-876-02

1210517

2H040-011

4PFL017-021

2A017-875-06

7J006-093

7C060-080

7A375-475

FLANGE-HEAD

23 22

REPLACE STOCK

7C080-066

7PC080-335

PUMP

BOLT ON WATER

7C080-030

4PFL010-044

4PFH017-021

2A017-750-03

101112131415161718192021222324252627282930

272

SCREW, HXHD, 3/8-16UNC-2A x 1.75"LG.

SCREW, HXHD, M8-1.25 x 160mm

SCREW, FHSH, M8-1.25 x 20mm

7A375-178

7C080-160

7C080-023

TEL: (805) 604-1336 FAX: (805) 604-1337

BELT, 6-GRV

2A046-073

2001-2003 MUSTANG

DATE

11/6/00

10/25/00

A. PROCTOR

G. COMPTON

APPROVALS

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

DRAWN

ENGINEERING

±1/2•

.XXX±.005

.XX± .01

ANGLES: ±1/16

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

ASY, S/C MTG BRKT

SIZE: DWG. NO.:

12/11/0

L. KECK 12/11/00

7.3 LBS

G. COMPTON

R&D

WEIGHT

APPR.

NONE

SEE PARTS LIST

MATERIAL

FINISH

DO NOT SCALE DRAWING

1:1.5

SCALE:

TO STOCK

TIMING COVER

2524

ON TIMING COVER

REPLACE STOCK STUD

UPPER PASSENGER (R.H.) SIDE

3 TO S/C2

32TO S/C

1817

28 22

TO ENGINE

19 2

TO ENGINE

NOTES: UNLESS OTHERWISE SPECIFIED:

1. THESE ITEMS SHIP LOOSE.

A-8

TO S/C INLET

G 1015933 ASY, AIR INTAKE

TO STOCK

PCV HOSE

MAF BRACKET

SLEEVE, 3.50"ID x 2.00"L

CLAMP, HOSE, #56

FILTER, AIR w/CLAMP

CLAMP, HOSE, #64

INTAKE ELBOW, 90°

GROMMET, RUBBER 7/16"

SCREW, 1/4-20 x 3/4", ZINC

WASHER, 1/4"SAE

NUT, 1/4-20 w/NYLOCK

CLAMP, HOSE, #52

HOSE, FLEX, 3.50"ID x 9.0"L

TUBE, AIR INTAKE, MODIFIED

7J250-001

7F250-021

8H040-090

7R002-064

4FH012-012

7U100-052

191

7A250-075

7R002-052

7U035-001

4PFK012-011

101112131415161718

7R002-056

7PS350-200

MUSTANG MAF

4FH010-050-BENT

11121311444211111

QTY.ITEM NO. DESCRIPTIONPART NO.

1234567

1300 BEACON PLACE OXNARD, CA 93033

ELBOW, RUBBER, 4"ID x 90°

1/2" OIL DRAIN HOSE

COUPLING, INLINE HOSE, 1/2"

FTG, ELBOW, 90°, 1/2" HOSE BARB x 3/8"NPT

7P375-055

7S400-001

7P500-001

7U030-036 x 4

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

TEL: (805) 604-1336 FAX: (805) 604-1337

ASY, AIR INTAKE

1996-2003, MUSTANG

DATE

10/30/00

10/23/00

10/30/00

L. KECK

A. PROCTOR

G. COMPTON

APPROVALS

DRAWN

ENGINEERING

R&D

REV.

SHEET 1 OF 1

1015933

DO NOT SCALE DRAWING

1:2

SCALE:

SIZE DWG. NO.

10/30/00

10.3 LBS

G. COMPTON

WEIGHT

APPR.

STOCK AIR SENSOR

COMPRESSOR

BYPASS VALVE

12 11

.XXX±.005

±1/2•

.XX± .01

ANGLES: ±1/16

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

SEE PARTS LIST

MATERIAL

NONE

FINISH

NOTES: UNLESS OTHERWISE SPECIFIED

1. USED IN KITS 1001814-1 AND 1001819 ONLY.

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

A-9

BODY

H 1017017 ASY, AIR DISCHARGE

ROTTLE

TO TH

TUBE, DISCHARGE w/NIPPLE

HOSE, TURBO 3.00"I.D. x 2.00"LG

TUBE, DISCHARGE MODIFIED

CLAMP, HOSE #48

CLAMP, HOSE #10

HOSE, HEATER .75"I.D. x 9.00"LG

REV.

SHEET 1 OF 1

1017017

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

ASY, AIR DISCHARGE

1996-2003, MUSTANG

DO NOT SCALE DRAWING

10/30/00

10/20/00

10/23/00

L. KECK

A. PROCTOR

G. COMPTON

ENGINEERING

R&D

SEE PARTS LIST

ANGLES: ±1/16

MATERIAL

1:1.75

SCALE:

SIZE DWG. NO.

10/30/00

----- LBS

G. COMPTON

WEIGHT

APPR.

NONE

FINISH

SEE TABLE

7R002-048

7R002-010

7PS300-200

13162

QTY. PART NO. DESCRIPTION

12345

TO ANTI-REVERSION BAFFLE

TO S/C OUTLET

ITEM NO.

QTITEMASY NUMBER PART NUMBER

7U038-000

.75'

4PFH012-041

4PFH012-020

4PFH012-048

4PFH012-028

111

313

1017017

1017017-P

DATE

APPROVALS

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

DRAWN

.XXX±.005

±1/2•

.XX± .01

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

46x

23x

NIPPLE ON P/N 4810127-6

TO COMPRESSOR BYPASS

A-10

I 1019336 ASY, OIL SUPPLY

REV.

SHEET 1 OF 1

1019336

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

TO S/C ASY

OIL FEED HOSE 46.5 -4 STRT

FTG, STREET TEE, 1/4"NPT

FTG, 90° ELBOW, AN4 x 1/8"NPT

FTG, 90° ELBOW, AN4 x 1/4"NPT

TO STOCK OIL SENDER

STOCK OIL SENDER LOCATION

7P250-034

7U250-000-465

111

123

ITEM NO. QTY. PART NO. DESCRIPTION

7P125-004

7P250-082

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

DATE

APPROVALS

6/14/99

JFC

DRAWN

ASY, S/C OIL SUPPLY

1996-2003, MUSTANG

- - - - -

ENGINEERING

R&D

DO NOT SCALE DRAWING

3:4

SCALE:

SIZE DWG. NO.

- - - - -

0.2 LBS

WEIGHT

APPR.

.XXX±.005

±1/2•

.XX± .01

ANGLES: ±1/16

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

SEE PARTS LIST

MATERIAL

NONE

FINISH

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

A-11

TO S/C ASY

J 1019328 ASY, OIL RETURN

REV.

SHEET 1 OF 1

1019328

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

ASY, OIL RETURN

1996-2003, MUSTANG

DESCRIPTION

HOSE, OIL RETURN, 1/2" x 13"LG.

FTG, HOSE END, AN8 x 1/2" BARB

FTG, 90° SWIVEL, AN8 MALE x AN8 FEM

FTG, STR, AN8 x 3/8"NPT

CLAMP, HOSE, #10

PUNCH, OIL PAN

PART NO.

7P500-063

7U030-036

11121

QTY.

1.083'

12345

ITEM NO.

7P500-052

7P375-053

7T640-011

7R002-010

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

DATE

APPROVALS

5/5/00

JFC

DRAWN

ENGINEERING

-----

R&D

DO NOT SCALE DRAWING

3:4

SCALE:

SIZE DWG. NO.

-----

0.8 LBS

WEIGHT

APPR.

1.00

1.75

OIL PAN

PUNCH HOLE

WITH ITEM 6

(FRONT OF OIL PAN)

LOCATION FOR ITEM 5

.XXX±.005

±1/2•

.XX± .01

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

ANGLES: ±1/16

SEE PARTS LIST

MATERIAL

NONE

FINISH

TO OIL PAN

NOTES: UNLESS OTHERWISE SPECIFIED

1. SHIP THIS ITEM LOOSE.

A-12

TO EXISTING

K 1015506 ASY, COMPRESSOR BYPASS

VACUUM LINE

VALVE, BY-PASS

CLAMP, HOSE #16

VAC, HOSE 5/32" x 36"

1"ID HOSE

HOSE, ELBOW, 1"ID x 90° MOLDED

TEE, 5/32"

REV.

SHEET 1 OF 1

1015506

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

1996-2003, MUSTANG

ASY, COMPRESSOR BY-PASS

DO NOT SCALE DRAWING

5.25" ±.06

DISCARD

- - - - -

4/23/99

JFC

- - - - -

DRAWN

ENGINEERING

ANGLES: ±1/16

MATERIAL

SIZE DWG. NO.

- - - - -

R&D

APPR.

SEE PARTS LIST

- - - - -

NONE

FINISH

3:4

SCALE:

2.8 LBS

WEIGHT

8D001-001

2.50" ±.06

-01

3.25" ±.06

DISCARD

ITEM 5 MODIFICATION DETAIL

7R002-016

14111

ITEM NO. QTY. PART NO DESCRIPTION

7P156-082

7U133-100-02

7U133-100-01

7U030-030 x 30

101112

DATE

APPROVALS

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

±1/2•

.XXX±.005

.XX± .01

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

TO AIR DISCHARGE ASY

5 -02

TO AIR INTAKE ASY

-01

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

A-13

1.25" INTERNAL

L 1015309 ASY, RADIATOR HOSE MODIFICATION

DIAMETER

CUT HERE

(JUST BEFORE

THE BEND)

REV.

SHEET 1 OF 1

1015309

HOSE, RADIATOR

CLAMP, HOSE #24

REDUCER, RADIATOR HOSE

DESCRIPTIONQTY.ITEM NO. PART NO.

7R002-024

4PFH014-020

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

1996-2003, MUSTANG

4PFH014-011

RADIATOR HOSE MODIFICATION

DO NOT SCALE DRAWING

1:1.25

TO MODIFIED STOCK RADIATOR

HOSE AND ENGINE BLOCK

1.50" INTERNAL DIAMETER

CUT HERE

(1" FROM END)

MODIFIED 1

131

123

SCALE:

SIZE DWG. NO.

-----

9/18/00

-----

DRAWN

ENGINEERING

ANGLES: ±1/16

MATERIAL

-----

R&D

APPR.

SEE PARTS LIST

-----

----- LBS

WEIGHT

NONE

FINISH

DATE

APPROVALS

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

.XXX±.005

±1/2•

.XX± .01

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

TO RADIATOR

A-14

M 1017700 ASY, FUEL CONTROL

REV.

SHEET 1 OF 1

1017700

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

'96-'98 MUSTANG

KIT, FUEL CONTROL

DO NOT SCALE DRAWING

TO VEHICLE FIREWALL

-----

5/10/95

-----

DRAWN

ENGINEERING

ANGLES: ±1/16

MATERIAL

-----

R&D

SEE PARTS LIST

1:1.5

SCALE:

SIZE: DWG. NO.:

-----

6.3 LBS

WEIGHT

APPR.

NONE

FINISH

SCREW, #10-24 x .75" PANHD SLT SHTMTL, GR5

ASY, FUEL LINE INLET, FEMALE

ASY, FUEL LINE OUTLET, MALE

WRAPS, NYLON TIE 5.50" LG

INSTALLATION INSTRUCTIONS FCU

TOOL, SPRING LOCK CPLR

1018900

1019000

4822100

7U100-055

7T375-001

7T312-001

1211800-TOP

7U030-218 x 81

DATE

APPROVALS

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

±1/2•

.XXX±.005

.XX± .01

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

7E010-048

211211111

2346789

ITEM NO. QTY. PART NO. DESCRIPTION

TO GAS TANK

TO FUEL RAIL

NOTES: UNLESS OTHERWISE SPECIFIED

1. TO BE SHIPPED LOOSE

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

A-15

BLACK 14 Ga WIRE 8" LG

N 1016029 ASY, FUEL PUMP

1/4"SCREW RING

TERMINATOR 14-16 Ga.

#6 SCREW EYELET

#8 SCREW EYELET

SPLICE INTO

FUEL PUMP

TRIGGER WIRE

QUICK

CONNECTOR

GREY 18 Ga

WIRE 36" LG

RED 14 Ga WIRE 216" LG

BLACK 18 Ga

VEHICLE

FRAME

87A85 86

(UNUSED)

WIRE 6" LG

EYELET

#6 SCREW

RED 14 Ga

WIRE

WIRING DIAGRAM

24" LG

TO BATTERY TERMINATOR

3/8 RING TERMINATOR

ITEM QTY PART NO. DESCRIPTION

FTG, 90° FUEL RAIL TO HOSE 8.3mm HOSE x 7.9mm TUBE

FTG, ADAPTER 5/16-5/8 HOSE BARBS

CLAMP, HOSE #4, THIN

FTG, FUEL STRAIGHT 5/16" HOSE '98 F350 V10 w/NOVI

CLAMP, HOSE #4

7P625-312

7P312-016

7P312-020

7R001-004

113

423

COPPER CRUSH

NUT, 1/4-20 HEX w/NYLON INSERT GR5

HOSE, FUEL INJ 5/16"ID x 12"LG

HOSE, FUEL LOCK-ON 1/2"ID x 2" LONG

HOSE, FUEL INJ 5/16"ID x 21"LG

SCREW,1/4-20 x .75" HXHD GR5

WASHER, 1/4" FLAT SAE GR5

7F250-021

7J250-022

7A250-074

7U031-018

7U037-030

7U031-018

.16'

1.75'

689

WASHER

GROUND

TO CHASSIS

WIRE, 14AWG x 8"LG BLK

RELAY, 30AMP 12 VDC

FUEL PUMP, AUX HIGH PERF

WLDMNT, BRKT, FUEL PUMP MTG, 1999 4.6L DOHC MUSTANG

CONNECTOR, RING 14-16 AWG 5/16" HOLE

8F001-500

5W014-030

5W001-016

5W001-046

4PFH010-071

.67'

TO INSIDE OF

FENDERWELL

86 85 30

WIRE, 14 AWG 600V x 24"LG f/RED

WIRE, 18 AWG 600V x 36"LG GRAY

CONNECTOR, WIRE 16-14AWG BLADE FEMALE 1/4"

WIRE, 14 AWG 600V x 216"LG RED

WIRE, 18 AWG x 6"LG BLK

TUBING, SPLIT POLY 1/4"OD x 216"LG

CONNECTOR, 16-14GA QUICK CONNECT

RING TERMINAL, 10GA 3/8" SCREW SOLDERLESS

5W014-010

5W018-030

5W001-044

5W014-010

5W018-020

5W001-032

5W001-001

5W001-017

.5'

18'

20 4x

SCREW, #10 x .50" PAN HEAD SHEET METAL

TERMINAL, RING 16-14GA # 8 SCREW VINYL INSULATED

CLAMP, HOSE #10

7E010-052

7R002-010

5W001-045

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

ASY, FUEL PUMP

'96-'98 SOHC MUSTANG

FTG, BARBED, 9mm

-----

DATE

01/14/99

7P312-017

CAD GENERATED DRAWING,

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

-----

HAL

APPROVALS

DO NOT MANUALLY UPDATE

DRAWN

ENGINEERING

.XXX±.005

±1/2•

.XX± .01

ANGLES: ±1/16

DECIMALS:

FRACTIONS:

TOLERANCES ARE:

MATERIAL

REV.

SIZE: DWG. NO.:

-----

R&D

APPR.

SEE PARTS LIST

SHEET 1 OF 1

1016029

DO NOT SCALE DRAWING

1:1

SCALE:

-----

----- LBS

WEIGHT

NONE

FINISH

TO ENGINE

FACTORY FUEL FILTER

FACTORY

FUEL FITTING

TO BATTERY

POS. (+)

FROM TERM.

#30

FACTORY

FUEL LINE

BLACK 14 Ga

WIRE 8" LG

FROM

TRIGGER

TERM. #86

CHASSIS GND

1. SHIP THIS ITEM LOOSE

NOTES: UNLESS OTHERWISE SPECIFIED

A-16

O 1017734 ASY, FUEL PUMP / IN-TANK

REV.

SHEET 1 OF 1

1017734

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

1999-2003, MUSTANG

ASY, FUEL PUMP, IN-TANK

DO NOT SCALE DRAWING

1:1

SCALE:

SIZE DWG. NO.

DATE

5/3/01

- - - - -

ENGINEERING

R&D

APPR.

2.0 LBS

WEIGHT

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

G. COMPTON

APPROVALS

DRAWN

DESCRIPTION

FUEL PUMP, 255 LPH

PART NO

8F001-260

QTY.

ITEM NO.

±1/2•

.XXX±.005

.XX± .01

ANGLES: ±1/16

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

SEE PARTS LIST

MATERIAL

NONE

FINISH

NOTE: UNLESS OTHERWISE SPECIFIED-

1. ALL ITEMS SHIPPED LOOSE.

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

A-17

POWER/STEERING

P BELT ROUTING DIAGRAM

REV.

SHEET 1 OF 1

2000-2003

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

'00 -'03 MUSTANG

BELT ROUTING DIAGRAM

DO NOT SCALE DRAWING

1:1

SCALE:

SIZE: DWG. NO.:

-----

DATE

07/10/00

ALTERNATOR

SUPERCHARGER

WATER PUMP

CRANK

-----

APPR.

ENGINEERING

R&D

NONE

SEE PARTS LIST

MATERIAL

FINISH

----- LBS

WEIGHT

A. PROCTOR

APPROVALS

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

DRAWN

±1/2•

.XXX±.005

.XX± .01

ANGLES: ±1/16

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

A/C

A-18

WATER PUMP

Q BELT ROUTING DIAGRAM

POWER/STEERING

REV.

SHEET 1 OF 1

1996-1999

1300 BEACON PLACE OXNARD, CA 93033

TEL: (805) 604-1336 FAX: (805) 604-1337

96-99 MUSTANG

BELT ROUTING DIAGRAM

DO NOT SCALE DRAWING

-----

SCALE:

SIZE: DWG. NO.:

-----

DATE

09/03/06

-----

----- LBS

APPROVALS

CAD GENERATED DRAWING,

DO NOT MANUALLY UPDATE

SUPPLIED IDLER PULLEY

SUPERCHARGER PULLEY

ALTERNATOR

CRANK

ENGINEERING

R&D

APPR.

SEE PARTS LIST

MATERIAL

FINISH

WEIGHT

NONE

DRAWN

.XXX±.005

±1/2•

.XX± .01

ANGLES: ±1/16

DECIMALS:

FRACTIONS:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

TOLERANCES ARE:

FACTORY IDLER PULLEY

A/C COMPRESSOR PULLEY

NOTE:

1. APPLICABLE STANDARD/SPECIFICATIONS

ANSI Y14-5-1982, DIMENSIONS AND TOLERANCES

2. REMOVE ALL BURRS AND SHARP EDGES

P/N: 4809655

16AUG07 v1.0 96-03MusGT(4809655v1.0)

A-19

This Page Left Intentionally Blank

DP/N: 4809655 - v1.0 08/16/07

Paxton Automotive • 1300 Beacon Place . Oxnard CA93033

805 604-1336 • FAX (805) 604-1337

Paxton Superchargers 4.6L User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual