Paxton Superchargers 5.7L User Manual

Owner’s Installation Guide for the

Paxton Automotive

Novi 1200 Supercharger

for the

Dodge Hemi

Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033

(805 604-1336 . FAX [phone]

DP/N: 4809650 - v1.0 11/09/04

FOREWORD

roper installation of this supercharger kit requires general
automotive mechanic knowledge and experience. Please

P

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 call Paxton Automotive
for installers in your area.

All rights reserved. No part of this publication may be reproduced, transmitted, transcribed,

or translated into another language in any form, by any means without written permission

P/N: 4809650
©2004 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
11NOV04 v1.0 03DodgeHemi(4809650v1.0)

© 2005 PAXTON AUTOMOTIVE

of Paxton Automotive.

ii

TABLE OF CONTENTS

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

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

RECOMMENDED TOOLS FOR INSTALLATION ................................iv

PARTS LIST ..........................................................v

1. COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. OIL FEED ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3. OIL DRAIN ASSEMBLY .................................................3-1

4. HEATER HOSE RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5. COOLANT RESERVOIR RELOCATION ....................................5-1

6. SUPERCHARGER MOUNTING BRACKET .................................6-1

7. AIR INTAKE ASSEMBLY ................................................7-1

8. FUEL SYSTEM ASSEMBLY ..............................................8-1

9. ENGINE CONTROL UNIT INSTALLATION ................................. 9-1

10. CHARGE COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

11. HEAT EXCHANGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

12. SURGE AND RESERVOIR TANK INSTALLATION ..........................12-1

13. WATER HOSE ROUTING ................................................13-1

14. WATER PUMP WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

15. FINAL ASSEMBLY AND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

iii

All Rights Reserved, Intl. Copr. Secured

11NOV04 v1.0 03DodgeHemi(4809650v1.0)

©2004 Paxton Automotive

P/N: 4809650

RECOMMENDED TOOLS FOR INSTALLATION

2002 Dodge Hemi

efore beginning this installation, please read
through this entire instruction booklet and
the Street Supercharger System Owner's

B

Manual which includes the Automotive Limited
Warranties Program and the Warranty Registration
form.

Paxton supercharger systems are performance
improving devices. In most cases, increases in
torque of 30-35% 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 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 original 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 spark plugs at
least every 15,000 miles and spark plug
wires at least every 50,000 miles.

RECOMMENDED TOOLS

FOR INSTALLATION:

1. Factory Repair Manual

2. 3/8" Socket and Drive Set: SAE & Metric

3. 1/2" Socket and Drive Set: SAE & Metric

4. 3/8" NPT Tap and Handle

5. Adjustable Wrench

6. Open End Wrenches: Metric and Standard

7. Center Punch and a 5/8" Tapered Punch

8. Springlock 3/8" and 5/8”Fuel Fitting
Disconnect Tool

9. 5 Quarts SH/CF Rated Quality Engine Oil

10. Oil Filter and Wrench

11. Flat #2 Screwdriver

12. Phillips #2 Screwdriver

13. Heavy Grease

14. Silicone Sealer

15. Drill Motor

16. 1/8", 3/16", 27/64" Drill Bits

17. Wire Strippers and Crimpers

18. Utility Knife

19. Power Steering Pulley/Puller & Installer

20. Pliers

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

21. Spark Plug Socket

22. NEW Spark Plugs

P/N: 4809650
©2004 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
11NOV04 v1.0 03DodgeHemi(4809650v1.0)

iv

2003 Dodge Hemi

Part No. 1201220

PARTS LIST

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or

damaged parts immediately.

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY

4PCH110-044 S/C MNTG BRKT ASSY '03 HEMI 1

4PCH 010-044 SUPERCHARGER MTG PLT 1
4PCH010-010 SUPPORT S/C MOUNTING PLT 1
4PCH010-020 SUPPORT S/C MTG PLT 1
4PCH010-030 ALTERNATOR BRACE 1
4PCH017-011 COLLAR, IDLER PULLEY 1
7A312-125 5/16" x 18 x 1.25" HXHD GR5 BOLT 2
7K312-001 WASHER AN 6
7A312-100 5/16" x 18 x 1.00" HXHD GR5 BOLT 4
7C080-120 8mm x 120mm x 1.25" 1
7C010-130 10mm x 130 x 1.5" BOLT 1
7J010-002 10mm WASHER 1
7J012-092 12mm WASHER 2
7C012-100 12mm x 1.00" x 1.75" BOLT 1
7G010-175 12mm x 1.75" NUT 1
4FR016-150 SMOOTH IDLER PULLEY 1
7A437-325 7/16" x 3.25" x 14 BOLT 1
7K437-001 WASHER AN 2
7J438-072 7/16" WASHER .94"OD x .109" THICK 1"
7F437-000 7/16" x 14 NYLOC NUT 1

4PCH130-026 OIL FEED ASSY '03 HEMI

7P125-108 1/8"NPT NIPPLE 1" 1
7P125-104 1/8"NPT FEMALE TEE 1
7P125-004 1/8"NPT TO -4 x 90° JIC FITTING 1
7U250-090-240 OIL FEED HOSE -4 x 26" LONG 1
7P125-005 1/4" x -4 JIC FITTING 1

4PCH130-036 OIL DRAIN ASSY '03 HEMI

7P375-053 3/8"NPT x -8 FTG 1
7P500-500 - 8 x 90° ALUM FITTING 1
7U030-036 1/2" OIL DRAIN HOSE 48"
7R004-002 STEPLESS CLAMP 17.0-70 2
7R001-006 #6 STNL HOSE CLAMP, NARROW 2
7R004-687 CLAMP, 13/16" ONE EAR 2
7P375-055 3/8"NPT x 1/2" HOSE BARB 1

4PCH112-020 DISCHARGE ASSY '03 HEMI

4PCH012-020 DISCHARGE DUCT, '03 DODGE HEMI 1
7P156-082 5/32" TEE 2
7PS350-275 SLEEVE REDUCER 3.5"-2.75" 1
7R002-016 #16 HOSE CLAMP 5
7R002-056 #56 HOSE CLAMPS 1
7U030-046 5/32" VAC HOSE 3'
7U034-016 1" GS HOSE 2'
8D001-001 STANDARD COMPRESSOR BYPASS 1
7P100-103 1" WELD ON BUNG 1
7PS275-200 SLEEVE 2.75" x 2" 2
7R002-044 #44 HOSE CLAMP 4

4PCH212-010 AIR INTAKE ASSY

4PCH013-010 AIR BOX, WELDED, ROTO 1
4HS110-010 FLANGE ASSY, AIR BOX 1
8H040-050 AIR FILTER 3.5" FLG x 7"L 1
7R002-056 # 56 HOSE CLAMPS 4
7R002-060 #60 HOSE CLAMP 2
8H040-050 FILTER 3.50" x 7.0" LONG 1
7U035-001 FLEX HOSE 3.5" x 12" 1'
4PCH112-010 INLET DUCT, ASSY 1
7P100-103 BUNG WELD ON,
7P500-112 BUNG WELD ON, 1/2"NPT 1
7P100-578 AIR TEMP SENSOR BUNG 1
7PS275-200 SLEEVE, 2.75" x 2.00" 2
7PS350-200 SLEEVE,3.5" x 2.00" 1
7P500-026 1/2"NPT x 3/4" HOSE BARB 1
7U038-012 3/4" x 90° HOSE 4" x 12" LONG 2
7P375-075 3/4" HOSE MENDER 1
7A250-126 1/4" x 20 x 1" HXHD BOLT 4
7F250-021 1/4" NYLOC 4
7K250-001 1/4"AN WASHERS 8

4PCH101-001 FUEL PUMP ASSY '03 HEMI

7U031-018 5/16" EFI FUEL HOSE 24"
7U031018 5/16" EFI FUEL HOSE 9"
7U031018 5/16" EFI FUEL HOSE 1.8"
7U031018 5/16" EFI FUEL HOSE 1.8"
7U031018 5/16" EFI FUEL HOSE 6.5"
7U033-010 FUEL/PWR STEERING HOSE 5/8" 2.0"
7P312-017 FUEL PUMP FITTING 1
7P312-020 FUEL LINE FITTING 90° 1
7P312-016 5/16" x 5/16" FORD FITTING 1
8F001-500 FUEL PUMP PURBURG 1
7R003-028 ADEL CLAMP 2-3/8" .26" HOLE 2
7P312-082 TEE HOSE BARB 2
7R004-003 14.5 STEPLESS CLAMP 14
7E010-075 SHEET METAL SCREW 2
7A250-101 1/4" x 20 x 1.0" BOLT 2
7F250-021 NYLOC NUT 2
7J006-094 6mm SS WASHER 4
7F010-024 NYLOC NUT 2
7C010-075 BOLT 2
7J010-001 # 10 WASHER 4
4PCH010-070 FUEL PUMP/FMU MTG BRKT 1

4PCH238-068 FMU ASSY '03 HEMI

6PZ001-001 DECAL PAXTON FMU 1
6Z010-101 FMU HOUSING (BLUE ANODIZED) 1
6Z010-111 FMU VALVE COVER 1
6Z010-132 COVER FMU w/SPRING NO LZR, 1
6Z020-130 SML DIAPHRAM 1
6Z020-140 LRG DIAPHRAM 1
6Z030-150 BRACKET FMU 1
6Z040-160 PISTON, FMU 1
6Z050-161 FMU WASHER, 6:1/30LB PLATED 1
6Z060-181 SHIM, FMU 1
6Z070-010 FMU RING SPCER 6:1 1
6Z080-011 RETAINER,FMU SPRING 4.3 GM 2
6Z090-010 SPRING FMU 1
7C010-050 10-24 x .50" SHCS GR8 PLT 6
7C010-075 10-24 x 3/4" SHCS GR5 ZINC 4
7C024-025 10-24 x 1/4" PHIL HEAD 3
7P125-025 1/8"NPT x 5/32" HOSE 90° 1
7P125-031 1/8"NPT x 90° 5/16" HOSE BARB 1
7P125-032 1/8"NPT x 5/16" STR HOSE BARB 1
7u030-218 7/32" VAC HOSE 12"
7P157-219 5/32" x 7/32" UNION 1
7P156-082 5/32" TEE 1
7U030-046 5/32" VACUUM HOSE 10'
7U100-030 O-RING, FMU 1

8PN101-180 POWER CHARGE COOLER ASSY '03 HEMI

8N003-070 COOLER DUC T,LT1,GROUND

8N101-001 WELDED CORE, ASSY W/ENDS ONLY

8N003-011 INLET DUCT, MACH

8PN105-010 WATER TANK MTG ASSY '03 HEMI

8N055-030 RESERVOIR 1
4PCH010-110 BRKT RESERVOIR 1
7A250-050 1/4-20 SHD 1/2" LONG 3
7A250-074 1/4-20 HHD, 3/4" LONG PLTD 3
7J006-093 1/4" WASHER 8
7U038-000 3/4" HEATER HOSE CUT TO FIT 14"
7U038-012 3/4" 90° HOSE 4" x 12" 5
7U030-065 3/4" HOSE (TANK-PUMP) 1
7R007-001 NYLON CLAMP 1-1/8" 16
7P500-026 1/2" TO 3/4" 90° HOSE BARB 2
7U038-150 3/4" x 150° HOSE 2
7P375-075 3/4" HOSE MENDER 1
7F250-021 1/4" NYLOCK NUTS 3
7J250-150 1/4" FENDER WASHERS 3

v

All Rights Reserved, Intl. Copr. Secured

11NOV04 v1.0 03DodgeHemi(4809650v1.0)

©2004 Paxton Automotive

P/N: 4809650

2003 Dodge Hemi

Part No. 1201220-P

PARTS LIST

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or

damaged parts immediately.

PART NO. DESCRIPTION QTY

8PN104-010 ASSY SURGE TANK '03 HEMI

8N056-060 SURGE TANK 1
7E010-075 #12 SHEET METAL SCREWS 2
7P500-078 1/2" x 3/4" STR HOSE BARB 2
8N055-050 PLASTIC CAP, SURGE TANK 1
7J006-093 6mm WASHER, PLATED 4
7C060-016 M6 x 1.00" x 16 HXHD 2
7U100-055 6" TIE-WRAP 10
7P500-078 1/2" x 3/4" STR HOSE BARB 3
7P500-026 1/2" x 3/4" 90° HOSE BARB 1
7U100-044 4" TIE-WRAP 5
7A250-050 1/4-20 SHCS 1/2" LONG 2
8N010-130 MTG TAB 1

8PN107-010 WATER PUMP MTG ASSY, '03 HEMI

8F001-402 PUMP, HELLA WATER 1
7R003-027 ADEL CLAMP 1
5W001-009 16-14GA MALE SLIDE INSULATED 2
5W001-010 16-14GA FEMALE INSULATED 2
5W001-019 10-12GA BUTT CON INSUL 1
5W001-042 12-10GA x 3/16" RING TERMINAL 1
5W001-017 3/8" RING TERMINAL 12GA 1
5W001-030 14GA STRD WIRE BLACK 3'
5W001-014 FUSE HOLDER 10GA WIRE 1
5W001-011 16-14GA EYELET .25" HOLE 2
5W001-015 FUSE, BLADE TYPE 20AMP 1
5WOO1-009 16-14GA MALE SLIDE INSULATED 1
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 1
7J006-093 6mm WASHER, PLTD 1
5W001-022 T-TAP CONN 14-16AWG 1
8F101-510 H

8PN106-010 WATER CLR MTG ASSY, '03 HEMI

8N006-010 WATER COOLER 1
7P500-026 1/2"NPT TO 3/4" HOSE BARB 90° 2
7A250-074 1/4-20 HHD 3/4" LONG 8
7F250-021 1/4-20 NYLOCK NUT 8
7J250-001 1/4" FLAT WASHER 16

1016419 SUPERCHARGER ASSY

2A047-119 ACCESSORY DRIVE BELT

4PCH114-018 COOLANT RESV ASSY

7R002-016 # 16 HOSE CLAMPS 3
2A017-876-01 .875" x .328" x .952" LONG SPACERS 3
7C060-050 6mm x 1.0" x 50mm LONG BOLTS 3
7J006-093 6mm LARGE OD FLAT WASHERS 3
4PCH014-010 FORMED COOLANT TUBE 1
7U038-012 3/4" x 90° HOSE 4" x 12" 1
7P375-045 45° STREET ELBOW 2
7R002-012 #12 HOSE CLAMP 2

7U133-065 “J” SHAPED HOSE

7P500-001 1/2" HOSE UNION 1

5A001-110 ENGINE CONTROL UNIT

5A001-111 PROGRAMMED ENGINE CONTROL UNIT

2O PUMP WIRING ASSY 1

P/N: 4809650
©2004 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
11NOV04 v1.0 03DodgeHemi(4809650v1.0)

vi

2003 Dodge Hemi

Part No. 1201220-P

PARTS LIST

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or

damaged parts immediately.

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY

4PCH110-044 S/C MNTG BRKT ASSY '03 HEMI 1

4PCH 010-044 SUPERCHARGER MTG PLT 1
4PCH010-010 SUPPORT S/C MOUNTING PLT 1
4PCH010-020 SUPPORT S/C MTG PLT 1
4PCH010-030 ALTERNATOR BRACE 1
4PCH017-011 COLLAR, IDLER PULLEY 1
7A312-125 5/16" x 18 x 1.25" HXHD GR5 BOLT 2
7K312-001 WASHER AN 6
7A312-100 5/16" x 18 x 1.00" HXHD GR5 BOLT 4
7C080-120 8mm x 120mm x 1.25" 1
7C010-130 10mm x 130mm x 1.5" BOLT 1
7J010-002 10mm WASHER 1
7J012-092 12mm WASHER 2
7C012-100 12mm x 100 x 1.75" BOLT 1
7G010-175 12mm x 1.75" NUT 1
4FR016-150 SMOOTH IDLER PULLEY 1
7A437-325 7/16" x 3.25" x 14 BOLT 1
7K437-001 WASHER AN 2
7J438-072 7/16" WASHER .94"OD x .109" THICK 1
7F437-000 7/16" x 14 NYLOC NUT 1

4PCH130-026 OIL FEED ASSY '03 HEMI

7P125-108 1/8"NPT NIPPLE 1" 1
7P125-104 1/8"NPT FEMALE TEE 1
7P125-004 1/8"NPT TO -4 x 90° JIC FITTING 1
7U250-090-240 OIL FEED HOSE -4 x 26" LONG 1
7P125-005 1/4" x -4 JIC FITTING 1

4PCH130-036 OIL DRAIN ASSY '03 HEMI

7P375-053 3/8"NPT x -8 FTG 1
7P500-500 -8 x 90° ALUM FITTING 1
7U030-036 1/2" OIL DRAIN HOSE 48"
7R004-002 STEPLESS CLAMP 17.0-70 2
7R001-006 #6 STNL HOSE CLAMP, NARROW 2
7R004-687 CLAMP, 13/16" ONE EAR 2
7P375-055 3/8"NPT x 1/2" HOSE BARB 1

4PCH112-028 DISCHARGE ASSY '03 HEMI

4PCH012-020 DISCHARGE DUCT, '03 DODGE HEMI 1
7P156-082 5/32" TEE 2
7PS350-275 SLEEVE REDUCER 3.5" - 2.75" 1
7R002-016 #16 HOSE CLAMP 5
7R002-056 #56 HOSE CLAMPS 1
7U030-046 5/32" VAC HOSE 3'
7U034-016 1" GS HOSE 2'
8D001-001 STANDARD COMPRESSOR BYPASS 1
7P100-103 1" WELD ON BUNG 1
7PS275-200 SLEEVE 2.75" x 2" 2
7R002-044 #44 HOSE CLAMP 4

4PCH212-010 AIR INTAKE ASSY

4PCH013-010 AIR BOX, WELDED, ROTO 1
4HS110-010 FLANGE ASSY, AIR BOX 1
8H040-050 AIR FILTER 3.5" FLG x 7L 1
7R002-056 # 56 HOSE CLAMPS 4
7R002-060 #60 HOSE CLAMP 2
8H040-050 FILTER 3.50" x 7.0" LONG 1
7U035-001 FLEX HOSE 3.5" x 12" 1'
4PCH112-010 INLET DUCT, ASSY 1
7P100-103 BUNG WELD ON,
7P500-112 BUNG WELD ON, 1/2"NPT 1
7P100-578 AIR TEMP SENSOR BUNG 1
7PS275-200 SLEEVE, 2.75" x 2.00" 2
7PS350-200 SLEEVE,3.5" x 2.00" 1
7P500-026 1/2"NPT x 3/4" HOSE BARB 1
7U038-012 3/4" x 90° HOSE 4" x 12" LONG 2
7P375-075 3/4" HOSE MENDER 1
7A250-126 1/4" x 20 x 1" HXHD BOLT 4
7F250-021 1/4" NYLOC 4
7K250-001 1/4"AN WASHERS 8

4PCH101-001 FUEL PUMP ASSY '03 HEMI

7U031-018 5/16" EFI Fuel hose 24"
7U031-018 5/16" EFI Fuel hose 9"
7U031-018 5/16" EFI Fuel hose 1.8"
7U031-018 5/16" EFI Fuel hose 1.8"
7U031-018 5/16" EFI Fuel hose 6.5"
7U033-010 FUEL/PWR STEERING HOSE 5/8" 2.0"
7P312-017 FUEL PUMP FITTING 1
7P312-020 FUEL LINE FITTING 90° 1
7P312-016 5/16" x 5/16" FORD FITTING 1
8F001-500 FUEL PUMP PURBURG 1
7R003-028 ADEL CLAMP 2-3/8", .26" HOLE 2
7P312-082 TEE, HOSE BARB 2
7R004-003 14.5 STEPLESS CLAMP 14
7E010-075 SHEET METAL SCREW 2
7A250-101 1/4" x 20 x 1.0" BOLT 2
7F250-021 NYLOC NUT 2
7J006-094 6mm SS WASHER 4
7F010-024 NYLOC NUT 2
7C010-075 BOLT 2
7J010-001 #10 WASHER 4
4PCH010-070 FUEL PUMP/ FMU MTG BRKT 1

4PCH238-068 FMU ASSY '03 HEMI

6PZ001-001 DECAL PAXTON FMU 1
6Z010-101 FMU HOUSING (BLUE ANODIZED) 1
6Z010-111 FMU VALVE COVER 1
6Z010-132 COVER FMU w/SPRING NO LZR, 1
6Z020-130 SML DIAPHRAM 1
6Z020-140 LRG DIAPHRAM 1
6Z030-150 BRACKET FMU 1
6Z040-160 PISTON, FMU 1
6Z050-161 FMU WASHER,6:1/30LB PLATED 1
6Z060-181 SHIM, FMU 1
6Z070-010 FMU RING SPACER 6:1 1
6Z080-011 RETAINER,FMU SPRING 4.3 GM 2
6Z090-010 SPRING FMU 1
7C010-050 10-24 x .50" SHCS GR8 PLT 6
7C010-075 10-24 x 3/4" SHCS GR5 ZINC 4
7C024-025 10-24 x 1/4" PHIL HEAD 3
7P125-025 1/8"NPT x 5/32" HOSE 90° 1
7P125-031 1/8"NPT x 90° 5/16" HOSE BARB 1
7P125-032 1/8"NPT x 5/16" STR HOSE BARB 1
7u030-218 7/32" VAC HOSE 12"
7P157-219 5/32" x 7/32" UNION 1
7P156-082 5/32" TEE 1
7U030-046 5/32" VAC HOSE 10'
7U100-030 O-RING, FMU 1

8PN101-188 POWER CHARGE COOLER ASSY '03 HEMI

8N003-078 COOLER DUCT,LT1,GROUND

8N101-001 WELDED CORE, ASSY W/ENDS ONLY

8N003-018 INLET DUCT, MACH

8PN105-010 WATER TANK MTG ASSY '03 HEMI

8N055-030 RESERVOIR 1
4PCH010-110 BRKT RESERVOIR 1
7A250-050 1/4-20 SHD 1/2" LONG 3
7A250-074 1/4-20 HHD,3/4" LONG PLTD 3
7J006-093 1/4" WASHER 8
7U038-000 3/4" HEATER HOSE CUT TO FIT 14"
7U038-012 3/4" 90° HOSE 4" x 12" 5
7U030-065 3/4" HOSE (TANK-PUMP) 1
7R007-001 NYLON CLAMP 1-1/8" 16
7P500-026 1/2" TO 3/4" 90° HOSE BARB 2
7U038-150 3/4" x 150° HOSE 2
7P375-075 3/4" HOSE MENDER 1
7F250-021 1/4" NYLOCK NUTS 3
7J250-150 1/4" FENDER WASHERS 3

vii

All Rights Reserved, Intl. Copr. Secured

11NOV04 v1.0 03DodgeHemi(4809650v1.0)

©2004 Paxton Automotive

P/N: 4809650

2003 Dodge Hemi

Part No. 1201220

PARTS LIST

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or

damaged parts immediately.

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY

8PN104-010 ASSY SURGE TANK '03 HEMI

8N056-060 SURGE TANK 1
7E010-075 #12 SHEET METAL SCREWS 2
7P500-078 1/2" x 3/4" STR HOSE BARB 2
8N055-050 PLASTIC CAP, SURGE TANK 1
7J006-093 6mm WASHER, PLATED 4
7C060-016 M6 x 1.00" x 16 HXHD 2
7U100-055 6" TIE-WRAP 10
7P500-078 1/2" x 3/4" STR HOSE BARB 3
7P500-026 1/2" x 3/4" 90° HOSE BARB 1
7U100-044 4" TIE-WRAP 5
7A250-050 1/4-20 SHCS 1/2" LONG 2
8N010-130 MTG TAB 1

8PN107-010 WATER PUMP MTG ASSY, '03 HEMI

8F001-402 PUMP, HELLA WATER 1
7R003-027 ADEL CLAMP 1
5W001-009 16-14GA MALE SLIDE INSULATED 2
5W001-010 16-14GA FEMALE INSULATED 2
5W001-019 10-12GA BUTT CON INSUL 1
5W001-042 12-10GA x 3/16" RING TERMINAL 1
5W001-017 3/8" RING TERMINAL 12GA 1
5W001-030 14GA STRD WIRE BLACK 3'
5W001-014 FUSE HOLDER 10GA WIRE 1
5W001-011 16-14GA EYELET .25" HOLE 2
5W001-015 FUSE, BLADE TYPE 20AMP 1
5WOO1-009 16-14GA MALE SLIDE INSULATED 1
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 1
7J006-093 6mm WASHER, PLTD 1
5W001-022 T-TAP CONN 14-16AWG 1
8F101-510 H

8PN106-010 WATER CLR MTG ASSY, '03 HEMI

8N006-010 WATER COOLER 1
7P500-026 1/2"NPT TO 3/4" HOSE BARB 90° 2
7A250-074 1/4-20 HHD 3/4" LONG 8
7F250-021 1/4-20 NYLOCK NUT 8
7J250-001 1/4" FLAT WASHER 16

1016419-P SUPERCHARGER ASSY

2A047-119 ACCESSORY DRIVE BELT

4PCH114-018 COOLANT RESV ASSY

7R002-016 # 16 HOSE CLAMPS 3
2A017-876-01 .875" x .328" x .952" LONG SPACERS 3
7C060-050 6mm x 1.0" x 50mm LONG BOLTS 3
7J006-093 6mm LARGE OD FLAT WASHERS 3
4PCH014-010 FORMED COOLANT TUBE 1
7U038-012 3/4" 90° HOSE 4" x 12" 1
7P375-045 45° STREET ELBOW 2
7R002-012 #12 HOSE CLAMP 2

7U133-065 “J” SHAPED HOSE

7P500-001 1/2" HOSE UNION 1

5A001-110 ENGINE CONTROL UNIT

5A001-111 PROGRAMMED ENGINE CONTROL UNIT

2O PUMP WIRING ASSY 1

P/N: 4809650
©2004 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
11NOV04 v1.0 03DodgeHemi(4809650v1.0)

viii

1. COMPONENT REMOVAL

Section 1

COMPONENT REMOVAL

1. COMPONENT REMOVAL

A. Using a suitable container drain the engine

coolant. On the driver’s side of the vehicle
at the lower corner of the radiator locate the
drain petcock using a 16mm open-end
wrench rotate the petcock and drain the
coolant.

B. Locate the coolant over flow reservoir locat-

ed on the top of the radiator, loosen the hose
clamp securing the large 1" coolant hose and
remove the hose from the reservoir.
Disconnect the smaller coolant hose from
the over flow reservoir that connects to the
radiator. (See Figs. 1-a, 1-b.)

D. Using a pair of needle nose pliers or a spring

hose clamp tool remove the spring clamps
that retain the two heater hoses that are
located on the passenger side of the front
cover. Remove the hoses.

*** NOTE ***
Set the hoses aside in the engine compartment to
be modified in a later step of the installation)

Fig. 1-a

C. Remove the three 10mm headed screws that

retain the reservoir to the top of the radiator
fan shroud and set the reservoir aside to be
reinstalled at a later stage of the installation.
(See Fig. 1-b.)

COOLANT OVERFLOW HOSE

10mm BOLTS

Fig. 1-b

Fig. 1-c

E. Using a 19mm deep socket or wrench

remove the heater hose barbed fitting at the
front cover. Set the fitting aside to be
installed in a later step of the installation.

F. Locate the hose clamp securing the factory

air ducting attached to the large plastic throt­tle body enclosure to the air filter cover.
Using a 8mm socket or flat blade screw­driver loosen the clamp and remove the duct
from the plastic throttle body enclosure.
(See Fig. 1-d.)

Fig. 1-d

1

All Rights Reserved, Intl. Copr. Secured

11NOV04 v1.0 03DodgeHemi(4809650v1.0)

©2004 Paxton Automotive

P/N: 4809650

G. Unclip the 4 clips that retain the top portion

of the factory air filter housing and set the
housing and rubber duct aside it will not be
reused.

H. Remove the air filter and lift up on the lower

portion of the factory air filter housing and
remove it from the air filter support bracket
set the lower portion of the housing aside it
will not be reused. (See Fig. 1-e.)

Fig. 1-e

I. Locate the intake air temperature sensor on

the passenger side of the large plastic throt­tle body enclosure. Disconnect the wire har­ness plug, remove the sensor using a twist­ing motion and set the sensor aside to be
reinstalled in a later step of the installation.

J. Remove the two 10mm headed bolts secur-

ing the plastic throttle body enclosure.
Remove the rubber hose going to the oil fill
neck and remove the enclosure and set aside
it will not be reused. (See Fig. 1-f.)

K. Remove the factory orange silicone ring

from the throttle body and set aside. Remove
the accessory drive belt. (See Fig. 1-g.)

Fig. 1-g

L. Using a 8mm socket, remove the eight fac-

tory screws securing the underside of the
passenger side inner fender well cover.
Remove the four 13mm head screws secur­ing the air filter enclosure bracket to the
fender and remove the bracket it will not be
reused. Reinstall the inner fender well cover
using the factory hardware. (See Fig. 1-h.)

10mm HEADED BOLTS

CRANKCASE BREATHER

Fig. 1-f

P/N: 4809650
©2004 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
11NOV04 v1.0 03DodgeHemi(4809650v1.0)

HOSE

Fig. 1-h

2

2. OIL FEED ASSEMBLY

Section 2

OIL FEED ASSEMBLY

2. OIL FEED ASSEMBLY

A. Disconnect the factory oil pressure sending

unit wire harness from the sending unit.
Remove and set aside the factory oil pres­sure sender located on the passenger of the
engine. Using the supplied fitting install the
short 1" nipple into the side of the supplied
TEE fitting.

*** NOTE ***
Do not use Teflon paste or Teflon tape on this fitting
as it may clog the supercharger oil jet and lead to
premature supercharger failure.

B. Install the supplied TEE fitting into the

location were the factory sending unit was
originally located. With the supplied TEE
fitting installed and the outlets facing up and
down install the factory sending unit into
the outlet of the tee that is facing up. Install
the supplied 1/8" NPT x –4 x 90º fitting into
the outlet that is facing down and orientate
the supplied 90º fitting to face to the passen­ger side of the vehicle. (See Fig. 2-a.)

Fig. 2-b

Fig. 2-a

C. Install the straight portion of the supplied

steel braided –4 hose to the 90º fitting. The
90º end will attach to the supercharger oil jet
in a later step.

D. Reattach the oil pressure sending unit wire

harness. (See Fig. 2-b.)

1

All Rights Reserved, Intl. Copr. Secured

11NOV04 v1.0 03DodgeHemi(4809650v1.0)

©2004 Paxton Automotive

P/N: 4809650

This Page Left Intentionally Blank.

P/N: 4809650
©2004 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
11NOV04 v1.0 03DodgeHemi(4809650v1.0)

2

3. OIL DRAIN ASSEMBLY

Section 3

3. OIL DRAIN ASSEMBLY

OIL DRAIN ASSEMBLY

A. On the passenger side of the oil pan locate

the large hump in the oil pan measure
down1-3/4" from the lip of the oil pan and
make a mark. Center the mark between the
two oil pan retaining bolts. (See Fig 3-a.)

*** NOTE ***
It may be necessary to slightly bend the transmis­sion cooler lines to gain access to the oil drain loca­tion.

E. Thoroughly clean the threaded area. Reach

inside the oil pan and retrieve any stray
chips. Apply a small amount of sealer to the
new threads. Apply more sealer to the sup­plied 3/8" x 16 x –8 fitting and secure in the
hole using a 13/16" open end wrench. Make
sure a seal is formed all around the fitting.
(See Fig. 3-b.)

Fig. 3-a

B. Using a 3/16" drill bit drill a pilot hole at the

designated mark, use grease on the drill bit
to catch any metal shavings from falling into
the oil pan. With a small piece of wire con­firm that there is nothing to interfere with
the punch that is provided.

C. Using an air hammer and the supplied punch

start to enlarge the hole to 9/16" of an inch.
It is recommended to use anti seize or grease
on the punch, which will allow the punch to
role the pan correctly.

*** NOTE ***
Using a hammer can damage the oil pan, extra care
is required.)

D. When you have the hole enlarged to 9/16"

pack the flutes of a 3/8" NPT tap (not sup­plied). Tap the hole until the fitting can be
started.

Fig. 3-b

F. Drain the engine oil, install a new oil filter,

and refill the engine with fresh oil.

1

All Rights Reserved, Intl. Copr. Secured

11NOV04 v1.0 03DodgeHemi(4809650v1.0)

©2004 Paxton Automotive

P/N: 4809650