Paxton Superchargers 5.9 Dodge Ram User Manual

DP/N: 4809621 - Ram 1500 v1.0 09/18/03

Owner’s Installation Guide for the

Paxton Automotive

Novi 2000 Supercharger

for the

2002 Dodge 5.9L Ram 1500

Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033

888 9-PAXTON . FAX (805) 604-1337

Kit # 1201219

FOREWORD

his manual provides information on the installation, maintenance and service of the Paxton supercharger kit expressly designed for the 2002 5.9L Dodge Ram 1500. Contact Paxton Automotive Corporation for any additional information regarding

this kit and any of these modifications at (805) 604-1336 7:00am-3:30pm PST.

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

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

This is a typical underhood shot after installaton. Your engine compartment may appear different.

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iii

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

Appendix 1201219 Kit, 2002 5.9 Dodge Ram Kit . . . . . . . . . . . . . . . . . . . .A-2

Appendix 1 1016418 Asy, S/C 2002 Dodge N2K CRV . . . . . . . . . . . . . . . . . .A-3

Appendix 2 1020220 Asy, Washer Botl Ram . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Appendix 3 1016624 Asy, S/C Mtg Brkt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Appendix 4 1015938 Asy, Air Intake 02 5.9 Ram . . . . . . . . . . . . . . . . . . . . . .A-6

Appendix 5 1020119 Asy, Air Discharge 02, 5.9 Ram . . . . . . . . . . . . . . . . . .A-7

Appendix 6 1019345 Asy, S/C Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

Appendix 7 1016070 Asy, S/C Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9

Appendix 8 1017417 Asy, Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10

Appendix 9 1019717 Asy, Crank Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-11

Appendix 10 1020215 Asy, Coil Reloc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12

Appendix 11 1015510 Asy, Compressor Bypass . . . . . . . . . . . . . . . . . . . . . . .A-13

Appendix 12 1017737 Asy, Fuel Sys 02, 5.9 Ram . . . . . . . . . . . . . . . . . . . . . .A-14

Appendix 13 1017733 Asy, Fuel Enrichment 02, 5.9 Ram . . . . . . . . . . . . . . . .A-15

Appendix 14 5A001-080 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-16

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

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

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

1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

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

3.1 RELOCATION AND MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

4.1 SUPERCHARGER INSTALLATION AND ASSEMBLY . . . . . . . . . . . . . . . . .4-1

5.1 AIR INTAKE AND DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1

6.1 FINAL CHECK OUT AND START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

RECOMMENDED TOOLS

FOR INSTALLATION:

1. Metric and Standard sockets sets

2. Metric and Standard combination wrenches

3. Phillips and common screw drivers

4. 12" crescent wrench or 36mm

open end wrenches

5. Pliers

6. Wire cutters and wire crimping Tool

7. Hose cutters

8. 1/8" and 37/64" drill bit and hand

drill

9. 12 mm allen wrench

10. Small heat source

11. 3/8 Tap NPT

12. Ruler

13. Air compressor

14. Air hammer

1-1

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Section 1

INTRODUCTION

ongratulations! You have purchased the finest street Supercharger available for

the 2002 5.9L Dodge Ram 1500. The centerpiece of this kit is the highly efficient and reliable Paxton Automotive Corp. NOVI2000 supercharger. A mechanically driven (by belt) centrifugal blower (supercharger).

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

Installation requires a selection of tools which is listed on page iv.

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

For best results follow the instructions closely and in sequence. The average installation time for this kit is 8-10 hours. Your actual installation time will depend on skill level and working conditions. The estimate does not include time for initial vehicle inspection, cleaning, fine tuning or troubleshooting. Before even picking up a wrench, read this entire manual. We are available for technical assistance at (805) 604-1336, 8am-4:30pm pacific time.

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

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

***WARNING***

DO NOT attempt installation if any part(s) are missing from this kit. Failure to contact Paxton prior to beginning installation will result in a charge for any missing parts.

Before starting the installation, we suggest your engine compartment be clean. You can clean the engine and compartment with a pressure washer (such as those used at self serve car washes) and a safe-for-aluminum cleaner/degreaser. Cover the distributor with a plastic bag to prevent water from entering.

***CAUTION***

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

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

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

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

*** NOTE ***

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

1.1 INTRODUCTION

1-2

• Never rely solely on a jack when working under a vehicle. Always use an approved set of jackstands to support the vehicle and place them under the recommended lift points.

• When jacking a vehicle, make sure it is on a level surface, preferably concrete or asphalt. The transmission should be in “PARK” or “FIRST”, the parking brake engaged and the wheels blocked.

• Never start the car without first verifying that the transmission is in neutral and the parking brake is set.

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

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

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

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

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

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

Paxton Automotive makes every effort to insure that all parts are

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

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

beginning installation will result in a charge for any missing parts.

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Section 2

INITIAL PREPARATION AND DISASSEMBLY

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

2.1 AIR INTAKE ASSEMBLY REMOVAL

A. Remove the spring clips that retain the top

cover of the air assembly. And remove the filter.

B. Using an 8mm socket or flat blade screw

driver loosen the clamps from the Rubber flex hose between the air box and the throttle body. Remove the cover and the flex hose and set aside. (See Fig. 2-a.)

Fig. 2-a

Fig. 2-b

E. Reinstall the inner fender liner bolts and

clips.

2.2 FAN AND FAN SHROUD REMOVAL

A. Start by draining coolant in to a suitable

container. Locate the coolant petcock on the drivers side of the truck attach a piece of hose to the petcock and drain coolant.

B. Remove the 10mm bolt that attaches the

coolant over flow bottle to the fan shroud and disconnect the overflow hose from the radiator and set the coolant bottle to the side to be reinstalled in a later stage of the installation.

C. Remove the windshield washer bottle hose

from the washer pump along with the connector. Drain washer fluid if necessary.

D. Remove the fan clutch nut using A factory

tool or a 1 1/16 wrench. Once you have the nut loose allow the fan to rest in the fan shroud.

E. Remove the two 13mm headed bolt that

attach the shroud to the radiator and remove the fan, fan shroud and window washer bottle together. And set aside to be installed in a later stage of the installation. (See Fig. 2-c.)

Fig. 2-c

C. Lift out the lower portion of the air cleaner

box and set aside.

D. Remove the fasteners and clips that retain

the passenger side inner fender liner. This will aid in access to the two fasteners that secure the air filter housing bracket to the inner frame rail. Next remove the two bolts that are located on the side of the frame in the engine compartment and lift the bracket assembly out and set a side. (See Fig 2-b.)

F. Remove the windshield washer bottle from

the fan shroud. From the backside of the shroud you will find a flat tab. You will have to bend this tab to remove the washer bottle from the shroud. Set the washer bottle aside it will not be reused.

2-2

Fig. 2-f

Fig. 2-d

Fig. 2-e

B. Remove the bolt attaching the dipstick to the

alternator bracket and set the bolt aside to be reinstalled in a later step. (See Fig. 2-e.)

C. Remove the nut that attaches the factory ten-

sioner and set the tensioner aside to be reinstalled in a later step. (See Fig. 2-f.)

D. Remove the three bolts and nuts that retain

the tensioner bracket and set aside to be reused in a later step of the installation. (See Fig. 2-g.)

Fig. 2-g

2.3 ACCESSORY BELT, AND BELT TENSIONER REMOVAL

A. Remove the Accessory belt by detensioning

the Factory tensioner rotate the tensioner in a clock wise direction using a 15 mm wrench (See Fig. 2-d.)

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Section 3

CRANK PULLEY AND COIL REMOVAL AND INSTALLATION

3.1 CRANK PULLEY REMOVAL AND INSTALLATION

A. Loosen the large crank pulley-retaining bolt. B. Using a three jaw puller slowly remove the

pulley you will have to use the retaining bolt to back up the puller so there will not be damage to the crank threads.

C. Once you have the pulley removed set aside

it will not be reused.

D. With the supplied Crank pulley reinstall the

crank pulley. Using the factory-retaining bolt or a crank pulley installation tool, slowly pull the new pulley in to place take time with this as to not damage the threads.

E. Once the supplied pulley has been installed

remove the factory-retaining bolt. Install the supplied dowel pins and supplied supercharger pulley spacer. Reinstall the factory crank pulley retaining bolt using lock tight and torque to factory specs.

***NOTE***

This spacer fits tight. Take care in installing it so as not to damage it or the new crank pulley.

F. Install the supplied supercharge pulley using

the supplied fasteners and lock tight. (See Fig. 3-a.)

Fig. 3-a

coil from the existing coil bracket. Remove the factory coil bracket from the cylinder head and set aside the coil bracket will be replaced with a supplied coil bracket.

B. Attach the supplied coil bracket to the coil

with the supplied fasteners and install the coil and bracket in its new location using the supplied-retaining bolt. (See Fig. 3-b.)

Fig. 3-b

G. Check factory crank pulley belt for align-

ment with accessories. To assure that the new crank pulley is properly installed and seated.

3.2 COIL REMOVAL AND INSTALLATION.

A. Remove the 10mm nuts and bolt that retain

the coil disconnect the plug. And remove the

C. You may need to extend the wires on the

factory coil plug using the supplied wire and but connectors.

***NOTE***

This may not be necessary on all vehicles check length first and modify if necessary)

3-2

This Page Left Intentionally Blank.

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4.1 SUPERCHARGER MOUNTING BRACKET

A. Remove the pulley from the stock accessory

belt tensioner and the tensioner from the stock bracket for re-installation.

B. This is how the bracket should look prior to

installation. (See Fig. 4-a.) Note the accessory belt tensioner bracket. This spacer will have to be removed before you install the bracket. The dipstick goes between the tensioner and spacer.

***NOTE***

The idler pulley and pulley stand-off have been removed. They will be installed once the supercharger bracket has been installed.

Fig. 4-a

C. Mount the bracket in the holes at the stock

accessory belt tensioner location. Remove the two countersunk allen head bolts and lower this arm to gain access to the dip-stick bolt. (See Fig. 4-b.)

***NOTE***

When installing the spacer, you may have to bend the dipstick. Do not bend it excessively as it will become harder to get in and out.

D. Re-install the countersunk bolts. E. This is how the spacer should look installed.

Short portion toward the engine block. (See Fig. 4-c.)

Fig. 4-b

Fig. 4-c

Section 4

SUPERCHARGER BRACKET ASSEMBLY

REMOVE THIS SPACER BEFORE INSTALLING THE S/C BRACKET

4-2

Fig. 4-d

Fig. 4-h

Fig. 4-g

Fig. 4-f

Fig. 4-e

C. Attach the supercharger to the mounting

bracket using the six 3/8-16 x 1-1/4" bolts and washers provided.

4.3 IDLER PULLEY STAND-OFF

A. Install the idler pulley stand-off. (See Fig.

4-g.)

B. Install the idler pulley on the idler pulley

stand-off and tighten to approximately 35 ft/lbs.

C. Install the oil drain hose to the supercharger

using the hose and hose clamp provided. (See Fig. 4-h.)

4.2 ACCESSORY BELT TENSIONER

A. Install the tensioner using the factory nut

and washer. (See Fig. 4-d.)

B. Reinstall the factory tensioner pulley and

factory accessory belt. (See Figs. 4-e, 4-f.)

+ 28 hidden pages

Paxton Superchargers 5.9 Dodge Ram User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

TABLE OF CONTENTS

1.1 INTRODUCTION