Paxton Superchargers Ford Mustang GT User Manual

DP/N: 4809628 - V2.1 06/05/03

Owner’s Installation Guide for the

Paxton Automotive

Novi 1000 Supercharger

for the

2001-2003 4.6L SOHC Mustang GT

Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033

805 604-1336 . FAX (805) 604-1337

FOREWORD

Before you start the installation of your supercharger Paxton supercharger kit, you will have to find the Paxton Computer Chip Voucher located in your information packet. The 2001-2003 Mustang GT Supercharger Kit requires a computer chip upgrade. You will need to fill out the chip voucher and send it and your computer to Paxton Automotive to receive your chip upgrade. Please refer to section 7 of this manual for the procedure for removing your engine control module.

Complete the Paxton Automotive/Ford Computer Chip Voucher and return it to Paxton Automotive to receive the proper computer module for your vehicle.

All rights recerved. No parts of this publication may be reproduced, transmitted, transcrived, 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

1.1 INITIAL PREPARATION AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

2.1 SUPERCHARGER MOUNTING BRACKET ATTACHMEMT . . . . . . . . . . . . . . . . . . . . . . . .2-1

3.1 FAN RESISTOR RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

4.1 PREPARING TO MOUNT THE SUPERCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

5.1 OIL FEED AND DRAIN LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

6.1 INTAKE TRACT MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

7.1 ENGINE CONTROL COMPUTER REMOVAL AND MODIFICATION . . . . . . . . . . . . . . . . .7-1

8.1 IN-TANK FUEL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

9.1 FINAL ASSEMBLY AND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

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

List of Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Appendix A 1011816 ASY, S/C NOVI 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Appendix B 1015309 ASY, RADIATOR HOSE MODIFICATION . . . . . . . . . . . . . . . .A-4

Appendix C 1016630 ASY, S/C MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . .A-5

Appendix D 1015933 ASY, AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Appendix E 1017017 ASY, AIR DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Appendix F 1019336 ASY, OIL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

Appendix G 1019328 ASY, OIL RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9

Appendix H 1015506 ASY, COMPRESSOR BYPASS . . . . . . . . . . . . . . . . . . . . . . . . .A-10

Appendix I 1015530 ASY, FAN RESISTOR RELOC. . . . . . . . . . . . . . . . . . . . . . . . .A-11

Appendix J 1017734 ASY, FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12

Appendix K 7000170 DIAGRAM, BELT ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . .A-13

IMPORTANT NOTES

ongratulations! You have purchased the finest street supercharger available 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 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 trouble-shooting. Once again, we recommend reading the manual before beginning the process. We are available for tech support at (805) 604-1336, 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.

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ou 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 precau-

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

tions, 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 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 proper ly. Pets, wild animals, and children may die if they ingest the liquid.

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Section 1

INITIAL PREPARATION AND REMOVAL

B. 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 (C) and mass air flow sensor (D). (See Fig. 1-a.)

***NOTE***

(2002-2003 GT only) The air intake temperature sensor is now located in the MAF. (Step “C” no longer applies.)

Fig. 1-a

1.1 INITIAL PREPARATION AND REMOVAL

A. Begin the initial preparation and disassem-

bly process by first disconnecting the negative side of the battery, and draining one gallon of coolant from the coolant reservoir. To do this, open the valve at the bottom of the radiator and allow to drain into a suitable container. DO NOT allow coolant to drain onto floor, and be sure to mop up any coolant splatter immediately. Animals like the taste of coolant, and if they drink it, it will kill them.

1-2

Fig. 1-b

Fig. 1-c

E. Once the assembly is out of the car, use a

10mm socket to remove the mass air flow sensor and screen from the air filter housing (see Fig 1-d). Place the mass air flow sensor aside to be re-installed in a later step.

C. Using a flat-head screwdriver, loosen the

hose clamps at the mass air flow sensor and the throttle body, and remove the air intake hose (see Fig 1-b). Remove the air temperature sensor from the air intake hose and place it aside—it will be re-installed in a later step.

NOTE: On 2002-2003 GTs this step will not be done.

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-c.)

Fig. 1-d

E. The coolant reservoir is secured by three

nuts (see Fig 1-e). Use a 10mm socket to remove these, and place the reservoir aside. Remove the upper radiator hose.

Fig. 1-e

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Section 2

SUPERCHARGER MOUNTING BRACKET ATTACHMENT

2.1 SUPERCHARGER MOUNTING BRACKET ATTACHMENT

Fig. 2-a

A. Loosen (but do not remove) the four 10 mm

head bolts securing the water pump pulley. Next, remove the accessory drive belt using a 3/8-inch drive ratchet or breaker bar into the square at the end of the tensioner, and rotate the tensioner clockwise. This will relieve the tension on the belt so it can be removed. It will not be re-used. (See Fig. 2-a.)

B. Use a 13 mm socket to remove the idler pul-

ley, located above the belt tensioner (see Fig 2-b). Place the pulley aside to be used in a later step. Now, you may finish removing the four 10mm bolts securing the water pump pulley, and place the pulley and its fasteners aside for use in a later step.

IDLER PULLEY

Fig. 2-b

C. Next, remove three bolts at the front of the

engine (see Fig 2-c). A 10mm alternator mounting bolt (A), and two 13 mm timing cover bolts (B and C).

Fig. 2-c

2-2

D. Remove both nuts using a 10mm and 13mm

socket. Then remove both studs using a 13mm and 18mm socket. Enlarge the hole in the tab that held the wiring harness to the outermost stud. Using a round file, enlarge the hole so that it will slip over the large diameter of the stud. This tab will get sandwiched between the cylinder head and a spacer in a later step.(See Fig 2-d.) Note that

on some of the 2001-2003 GTs this step will not be required and a .065 shim will go in its place.

REMOVE THESE TWO STUD BOLTS

Fig. 2-d

E. Install the supercharger idler pulley bracket

using the supplied hardware. Be sure to install spacer between bracket and alternator. (See Fig 2-e)

Fig. 2-e

***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.

F. Re-install the factory idler pulley using the

factory hardware (see Fig. 2-f), followed by the supplied supercharger idler pulley (see Fig. 2-g).

Fig. 2-f

Fig. 2-g

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G. Install the supercharger rear support bracket

as shown in Fig 2-h. Temporarily install the long 10mm bolt to line up the bracket. Leave the bolts finger tight, as it will be necessary to move the bracket when you install the main supercharger bracket.

(This photo is for illustration only. You will have to install the supercharger and accessory belt before installing the bracket. There won’t be clearance after the bracket is installed.)

Fig. 2-h

Fig. 2-i

H. Modify the previously removed upper radia-

tor hose with supplied hose, aluminum coupler and clamps. See Appendix ‘B’ (1015309) for diagram of modification.

***NOTE***

The radiator hose assembly needs to clear the supercharger, so it is better to leave it long and trim the assembly later than to end up short. The finished radiator assembly is shown in Fig. 2-i.

I. Before installing the main supercharger

bracket, 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-j.)

Fig. 2-j

***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.

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Section 3

FAN RESISTOR RELOCATION

3.1 FAN RESISTOR RELOCATION

A. Disconnect the wiring harness from the fan

resistor. (See Fig. 3-a.) Remove clips holding the fan resistor to the fan shroud. Attach the fan resistor to the supplied bracket using the supplied hardware.

Fig. 3-a

B. Trim the fan resistor mounting tabs on the

fan shroud to provide clearance for the air intake assembly.(See Fig. 3-b.) The fan shroud should look like this after trimming.(See Fig. 3-c.)

Fig. 3-b

Fig. 3-c

C. Re-attach the fan resistor to the wiring har-

ness to ensure adequate wire length. (See Fig. 3-d.) Position the fan bracket on the passenger 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.

Fig. 3-d

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+ 30 hidden pages

Paxton Superchargers Ford Mustang GT User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

TABLE OF CONTENTS

IMPORTANT NOTES

3.1 FAN RESISTOR RELOCATION