Paxton Superchargers Ford Mustang Cobra NOVI 2000 User Manual

COPYRIGHT 2000 PAXTON AUTOMOTIVE

Kit # 1001814-1

P/N 4809609d

Owner’s Installation Manual

for the

PAXTON AUTOMOTIVE

NOVI 2000 SUPERCHARGER

for

1996-1998

MUSTANG COBRA

(NON-TUNED KIT)

PAXTON AUTOMOTIVE .1300 Beacon Place .Oxnard, CA 93033

[phone] .FAX [phone]

Congratulations! You have purchased the finest street supercharger available for the
Mustang Cobra. 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 edited in order of sequence, and photographs and drawings have been
included to illustrate the text. This will allow you quick part 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 reserve 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 [phone], Monday through Friday, 7AM - 3 PM
PST.

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 beginning 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 a pressure washer that is found at self-serve car washes. Use a safe-for-alu­minum cleaner/degreaser, and cover the distributor and any electronics with a plastic bag to
prevent water from entering.

COPYRIGHT 2000 PAXTON AUTOMOTIVE

PAGE 1

ASSEMBLY MANUAL for the

1996-98 MUSTANG COBRA

P/N 4809609

Introduction

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 a serious injury to you, or
to someone else who happens to be standing around. 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.

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, use 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 or 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. Pets, wild animals, and

children may die if they ingest the liquid.

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

COPYRIGHT 2000

PAX TO N AUTOMOTIVE

PAGE 2

ASSEMBLY MANUAL for the 1996-98 MUSTANG COBRA

P/N 4809607

DISASSEMBLY-- Preparing your vehicle.

NOTE: Beware of coolant spills. Mop up any spilled coolant

immediately. Radiator coolant very attractive to animals,

and highly poisonous.

1. Drain approximately one gallon of coolant from the radiator and disconnect the negative
side of the battery. Disconnect the MAF sensor, air inlet temp sensor and air idle bypass hose
from the air inlet tube, then remove the inlet tube and air filter housing by removing the single
8mm bolt. (Fig. 1. Fig 2)

2. Remove the coolant reservoir, upper radiator hose and disconnect the lower hose from the
coolant transfer manifold (CTM). Remove the spark plug wire retainer atop the alternator, fol­lowed by the stud and nut arrangement that holds the CTM in place. Unplug the two sensors,
and remove the CTM (it is press-fit and sealed with O-rings, so it will take some wiggling to
get it free). (Fig 3, Fig 4)

COPYRIGHT 2000 PAXTON AUTOMOTIVE

PAGE 3

ASSEMBLY MANUAL for the

1996-98 MUSTANG COBRA

P/N 4809609

INSTALLATION

1996-1998 MUSTANG COBRA

NOVI 2000RR SUPERCHARGER

FIG 1

FIG 2

FIG 4FIG 3

3. Unplug the coil pack and remove the four 7mm bolts that secure the coil pack to its
mounting bracket. Place the coil pack aside and remove the mounting bracket by removing
the three bolts. (Fig 5, Fig 6)

4. Remove the tensioner limiting bracket . Loosen but do not remove the four bolts securing
the water pump pulley. (Fig 7, Fig 8)

5. Using a 1/2” ratchet or breaker bar, rotate the belt tensioner clockwise then remove and
discard the drive belt. (Fig 9)

6. Remove the uppermost stud bolt on the tensioner. It will be used as a mounting point for
the supercharger bracket.(Fig 10)

COPYRIGHT 2000 PAXTON AUTOMOTIVE

PAGE 4

ASSEMBLY MANUAL for the

1996-98 MUSTANG COBRA

P/N 4809609

FIG 5

FIG 9

FIG 10

FIG 8

FIG 7

FIG 6

7. Remove the water pump pulley, followed by the idler pulley (Fig 11), which will be re­installed in a later step.

8. Remove the four 18 mm bolts at the front of the engine (marked with arrows in FIG 12).
Replace the bolt in the water pump with the supplied bolt and small diameter washer.
Replace the topmost bolt with the supplied low profile bolt. The remaining holes will be used
as attachment points for the idler support bracket in step 10.

PREP

ARING TO INSTALL THE SUPERCHARGER

9. Use a tubing bender to bend the metal A/C line. It is first bent upwards, then rotated down­ward to clear the bottom portion of the supercharger. (Fig 13) NOTE: Use extreme caution
during this step. The refrigerant contained within this line is under high pressure and can
cause injury if the line ruptures. Use a tubing bender such as the one shown, as well as safe­ty glasses/goggles. Gloves are also recommended.

10. Install the idler support bracket using the holes from step 8. It serves as a support for the
main supercharger bracket and mounting point for the supplied idler pulley. (Fig 14)

COPYRIGHT 2000 PAXTON AUTOMOTIVE

PAGE 5

ASSEMBLY MANUAL for the

1996-98 MUSTANG COBRA

P/N 4809609

FIG 11

FIG 13

FIG 14

FIG 12

REMOVE

LOW PROFILE BOLT