Paxton Superchargers 4.6L User Manual

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

P/N: 4809655

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

iii

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.

P/N: 4809655

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

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

P/N: 4809655

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

1-1

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.)

P/N: 4809655

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

1-3

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

P/N: 4809655

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

1-5

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.

P/N: 4809655

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

1-7

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

This Page Left Intentionally Blank

P/N: 4809655

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

2-1

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)

+ 36 hidden pages

Paxton Superchargers 4.6L User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual