Paxton Superchargers Dodge Viper User Manual

DP/N: 4809644 - v2.0 12/13/04

Owner’s Installation Guide for the

Paxton Automotive

Novi 2000 Supercharger

for the

2003-2005 Dodge Viper

Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033

805 604-1336 . FAX • 805 604-1337

KIT # 1201810

FOREWORD

roper 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 call Paxton Automotive for installers in your area.

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

of Paxton Automotive.

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iii

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

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

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

RECOMMENDED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

1. PREPARATION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

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

4. CRANK PULLEY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5. SUPERCHARGER MOUNTING BRACKET INSTALLATION. . . . . . . . . . . . . . . . . . . . . 5-1

6. SUPERCHARGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7. TIMING CONTROLLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8. CHARGE AIR COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9. AUXILIARY FUEL PUMP ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 9-1

10. AIR INLET DUCT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

11. FINAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

his product is protected by state common law, copyright and/or patent. All legal rights therein are reserved. The design, layout, dimensions, geome-

try and engineering features shown in this product are the exclusive property of Paxton Automotive. This product may not be copied or duplicated in whole or part, abstractly or fundamentally, intentionally or fortuitously, nor shall any design, dimension, or other information be incorporated into any product or apparatus without prior written consent of Paxton Automotive.

This supercharger kit is designed to work on stock vehicles. Vehicles with modifications may not be compatible with this kit as delivered and should be tested with a wide band oxygen sensor and fuel pressure gauge to determine if the air/fuel ratio is safe. Detonation will quickly damage an engine.

Dodge Viper

IMPORTANT NOTES

When driving the vehicle on non-public roads (off-road applications such as racing/high rpm) it it recommended that the spark plugs be gapped down to .032".

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efore beginning this installation, please read through this entire instruction book-

let and the Street Supercharger System Owner's 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 com-

pletion 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 (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. Combination Wrench: SAE and Metric

7. Center Punch

8. Springlock 3/8" and 5/16" Fuel Fitting

Disconnect Tool

9. 10 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 / Pneumatic Right Angle

16. 1/4" Drill Bits

17. Stepless Clamp Pliers

18. 3/16" Allen Wrench

19. Wire Strippers and Crimpers

20. Utility Knife

21. Ø1-1/8" Hole Saw

22. Pliers

23. Threadlocker (Blue)

24. Thread Sealant

25. Fuel Pressure Gauge

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

26. Spark Plug Socket

27. NEW Spark Plugs

Dodge Viper

1011840 VIPER SUPERCHARGER ASSY 1

2A038-495 BELT K080495 1 4PCW038-375 S/C PLY, 8-GRV 3.75" MOD 1

4PCW118-011 CRANK PULLEY ASSY, VIPER 1

4PCCW016-011 PULLEY, ACC, '03 VIPER 1 4PCW018-011 PULLEY, S/C CRANK, '03 VIPER 1 4PCV110-010 FIXTURE w/GUIDE, DWL PIN INST. V 1 7A312-100 5/16-18 x 1" HDCS GR5 P 12 7K312-001 5/16"AN WASHER 12 7T100-120 DRILL BIT, #31, Ø.120" HSS 1 7T110-125 REAMER, Ø.1247" HSS 1 7U250-023 DOWEL PIN, 1/8" x 1.25" 2

4PCW111-033 MTG PLATE ASSY, VIPER 1

2A017-497 SPACER, 4.975"L, '03 VIPER, MTG BRKT 1 2A017-103-110 SPACER, COG TENSIONER IDLER 35 4 2A017-462 SPACER, IDLER, SMOOTH 6-RIB 1 2A017-875-05 SPACER, .875"ID, .404"ID x 3.489" LONG 1 4PCW010-033 PLATE, MTG PRIMARY 1 4PCW010-044 PLATE, S/C MOUNTING 1 4PCW016-021 PULLEY, ALTERNATOR, '03 VIPER 1 4PCW016-031 IDLER PULLEY, 8-RIB GROOVED, MO 1 4PCW017-011 SPACER, BLOCK UPPER SRT10 1 4PCW017-168 SPACER, FACTORY IDLER SRT10 1 7A312-875 5/16-18 x 8.75" STUD GR8 ZNC 1 7A375-126 3/8-16 x 1.25" HXHD GR8 PLT 7 7A375-224 3/8-16 x 2.25" GR5 HX 1 7A375-276 3/8-16 x 2-3/4" HXHD ZINC 1 7A375-300 3/8-16 x 3" HXCS G5P 1 7A375-425 3/8-16 x 4-1/4" 1 7A375-562 3/8-16 x 5-5/8" ALL THREAD 1 7A375-950 3/8-16 x 9.5" ALL THREAD 1 7F312-018 5/16-18 NUT USS PLTD 1 7F375-016 3/8-16 HX NUT 4 7J312-000 5/16" FLAT WASHER, SAE 1 7J375-044 3/8" SAE WASHER, PLTD 19

4PCW111-052 SPRING TENS, ASSY, '03 VIPER 8-RIB 1

4PCW010-100 BLOCK, TENS. RECEIVER 1 4PCW010-110 BLOCK, TENS. THRUST 1 4PCW011-052 SPRING TENSIONER, WITH IDLER BO 1 4PCW016-171 IDLER PULLEY, 8-RIB SMOOTH, MOD 1 7A375-275 3/8-16 x 2-3/4" HXCS G8P 2 7A375-602 3/8-16 x 6 HHCS FLY THRD w/GROOVE 1 7C008-050 #8-32 x 1/2" SOC HD BOLT 1 7C010-067 M10-1.5 x 65 HXCS G8P FULLY THREADED 17 7F375-016 3/8-16 HEX NUT 1 7J010-002 10mm WASHER, PLATED 1

4PCW130-026 OIL FEED LINE ASSY. VIPER 1

7P125-004 1/8"NPT 90°x -4 JIC FTG 2 7P125-005 1/8"NPT x -4 JIC FTG 1 7P125-034 1/8"NPT x 1/8"NPT STRT T 1 7U100-055 TIE-WRAP, 6" NYLON 2 7U250-220 OIL FEED HOSE, 22" -4 STRT 1

4PCW130-036 OIL DRAIN LINE ASSY. VIPER 1

7P375-055 3/8"NPT 90° x 1/2" HOSE BARB 1 7R001-008 #8 STNLS HOSE CLAMP 2 7T560-001 CUTTER, 9/16" ROTABROACH 1 7T560-002 ARBOR, ROTABROACH 1 7U030-036 1/2" OIL DRAIN HOSE 1.5' 7U100-066 TIE-WRAP, 11" NYLON 2

2003-2005 Dodge Viper

Part No. 1201840

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

ages or damaged parts immediately.

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY

PARTS LIST

4PCW112-010 AIR INTAKE ASSY. '03 VIPER 1

4PCW012-010 INLET DUCT, '03 VIPER, SC 1 4PCW012-020 BRKT, AIR FILTER RETAINER 1 7A250-104 1/4-20 x 1" BHCS SS 4 7F250-040 1/4-20 NUT PLATE 2 7P375-113 PCV VALVE, VIPER, 3/8-1/2" HOSE 90 1 7P500-001 1/2" HOSE UNION 2 7P500-003 1/2"-3/8" REDUCER BARB UNION 1 7PS400-225 BUMP SLEEVE, BLACK, 4D x 2.25" 1 7R002-064 #64 GOLDSEAL HOSE CLAMP 2 7U030-056 3/8" PCV HOSE 0.167' 7U037-030 -8 USCG FUEL HOSE, PUSH-ON 2' 7U100-065 GROMMET, .5"ID, .187" GRV 1 8H040-210 AIR FILTER, 7.5" x 23.75" PANEL, '03 VIPER 1

4809644 VIPER MANUAL, 2003-2004 1 5A001-076 TIMING CONTROL BOX, VIPER 1

5A001-070 TIMING CONTROL BOX, VIPER 1 5W001-017 3/8" RING TERMINAL, 12GA 1 7P156-119 5/32" UNION (Ø.156"OD) 1 7U375-001 VELCRO-HOOK, 1" BLACK 0.22YD 7U375-002 VELCRO-LATCH, 1" BLACK 0.22YD

4PCW101-003 FUEL PUMP ASSY. VIPER 1

SW001-005 3/8" PLASTIC WIRE LOOM 6' 5W001-011 16-14GA RING TERM. .26" HOLE 2 5W014-030 14GA STRD WIRE, BLACK 1.5' 7E010-075 #12 x 3/4" SHT METAL SCRW, HEX 4 7P375-072 3/8" FEMALE FUEL FTG. STEEL 1 7P375-006 3/8" GM FUEL TO 5/16" BARB FTG. 1 7P312-017 5/16" HOSE BARB TO PBURG OUT 2 7P312-082 5/16" TEE HOSE BARB 4 7R004-001 STEPLESS CLAMP, 15.7-70 22 7U031-018 5/16" FUEL HOSE, HI-PSR 8 7U100-044 TIE-WRAP, 4" NYLON 10 7U100-055 TIE-WRAP, 6" NYLON 5 8F001-068 INLINE FUEL PUMP 2 7U375-001 VELCRO-HOOK, 1" BLACK 0.25YD 7U375-002 VELCRO-LATCH, 1" BLACK 0.25YD

4PCV238-068 FMU ASSY, VIPER w/SPRING 1

7P156-082 5/32" TEE 2 7U030-046 5/32" VACUUM LINE 8' 6Z050-191 FMU WASHER, 8:1 PLATED 1 6Z070-030 FMU, 8:1 RING SPACER 1

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8PN301-040 POWER COOLER ASSY. ' VIPER 1 8PN201-040 DISCHARGE ASSY. '03 VIPER 1

8PN101-040 CAC ASSY, '03 VIPER, AIR/WATER 1 4PCW012-030 DUCT, DISCHARGE, '03 VIPER 1 7J006-093 6mm WASHER, PLATED 4 7P125-025 1/8"NPT x 5/32" HOSE 90 1 7P375-250 3/8" x 3/8" x 1/4" MALE BARB TEE 1 7P500-034 1/2"NPT 3/4" BARB 90° 2 7PS300-200 SLEEVE, BLACK, Ø3.00" x 2.00"L 1 7PS375-200 SLEEVE, BLACK, Ø3.75" x 2.00"L 1 7PS450-200 SLEEVE, BLACK, Ø4.5" x 2.0"L 1 7R002-048 #48 GOLDSEAL HOSE CLAMP 2 7R002-060 #60 GOLDSEAL HOSE CLAMP 2 7R002-072 #72 GOLDSEAL HOSE CLAMP 2 7U030-046 5/32" VACUUM LINE 8' 7U100-065 GROMMET, 5"ID, .812"OD, .187" GRV 1 7U133-060 3/4" x 90° HOSE, LONG 1 8D204-010 RACE BYPASS VALVE, BLACK 1 8H040-175 FILTER, 1-3/4"ID, MFRB 1 8N055-050 PLASTIC CAP, SURGE TANK 1

8PN105-040 WATER TANK MTG ASSY, VIPER 1

8PN010-170 SUPPORT,WATER TANK, '03 VIPER 1 7A250-051 1/4-20 x .50" HXHD ZN PLT 2 7A250-075 1/4-20 x .75" SHCD PLTD 1 7F250-021 1/4-20 NYLOCK NUT 1 7J250-001 1/4" SAE WASHER, PLTD 4 7P375-075 3/4" HOSE UNION 2 7P500-026 1/2"NPT, 3/4" BARB, 90° 6 7R007-001 NYLON CLAMP, 1-1/8" 12 7U038-000 3/4" HEATER HOSE 6' 7U038-012 HOSE, Ø3/4" 90°, 4 x 12" 3 8N055-030 TANK, LT1 AFTERCOOLER 1

8PN106-040 WATERCOOLER ASSY, VIPER 1

7A250-074 1/4-20 x 3/4" HXHD PLT 6 7F250-021 1/4-20 NYLOCK NUT ZINC PLTD 6 7J250-001 1/4" SAE WASHER, PLTD 12 8N006-010 WATERCOOLER 1 8PN010-150 SUPPORT, DS VIPER, SRT10 1 8PN010-160 SUPPORT, PS VIPER, SRT10 1

8PN107-020 WATER PUMP ASSY, VIPER 1

5W001-005 3/8" PLASTIC WIRE LOOM 7' 5W001-009 16-14GA MALE SLIDE INSULATED 1 5W001-010 16-14GA FEMALE SLIDE INSULATED 3 5W001-011 16-14GA EYELET .25" HOLE 2 5W001-013 14-16AWG, SOLDERLESS CONNECTOR 2 5W001-014 FUSE HOLDER, 10GA WIRE 1 5W001-015 FUSE, BLADE TYPE 20AMP 1 5W001-016 RELAY, BOSCH 1 5W001-017 3/8" RING TERMINAL 12GA 1 5W001-040 12-10GA FEMALE SLIDE INSULATED 1 5W014-010 14GA STRD WIRE RED, UL1015 7' 5W014-030 14GA STRD WIRE, BLACK 2' 5W014-030 14GA STRD WIRE, BLACK 7' 5W016-010 WIRE, STRND, 16AWG, YELLOW 2' 7GL10-150 10mm x 1.5" NYLOCK NUT 1 7U100-044 TIE-WRAP, 4" NYLON 8 8F001-402 PUMP, WATER PIERBURG 1

2003-2005 Dodge Viper

Part No. 1201840

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

ages or damaged parts immediately.

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY

PARTS LIST

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1-1

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Section 1

COMPONENT REMOVAL

A. Disconnect the Idle Air Control (IAC) motor

hose and the valve cover breather hose from the air box (air filter housing).

B. Remove the air box and all of the inlet duct-

ing up to but not including the throttle body.

C. Remove the air temperature sensor from the

air box and set aside.

D. Jack the front of the vehicle up and support

with a jack stand under each frame rail.

E. Remove the front lower splash pan from

underneath the vehicle (composite pan underneath the steering rack).

F. Remove the nut securing the alternator pul-

ley. Remove the accessory drive belt. Remove the alternator pulley.

G. Remove the six 5/16" screws securing the

crank pulley to the harmonic damper and remove the crank pulley (the harmonic damper need not be removed).

1. PREPARATION/REMOVAL

1-2

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+ 22 hidden pages

Paxton Superchargers Dodge Viper User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

TABLE OF CONTENTS

IMPORTANT NOTES

RECOMMENDED TOOLS

1. PREPARATION/REMOVAL