Paxton Superchargers Ford V-10 Super Duty Truck User Manual

P/N 4809606 v4.0

09/06/05

SUPERCHARGERS

Owners Installation Manual for the

PAXTON AUTOMOTIVE

NOVI 2000 Supercharger

for

1998-2001 Ford

6.8L V10

PAXTON AUTOMOTIVE 1300 BEACON PL. OXNARD CA 93033

(805) 604-1336 • FAX (805) 604-1337

FOREWORD

his manual provides information on the installation, maintenance and service of the Paxton supercharger kit expressly designed for

the 1998-2001 Ford 6.8L V-10 F-250, F-350/Excursion. Contact Paxton Automotive Corporation for any additional information regarding this kit and any of these modifications at (805) 604-1336 8:00 a.m. - 4:30 p.m. P.S.T.

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.

2005 PAXTON AUTOMOTIVE

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

of Paxton Automotive.

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

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

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

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

TOOL & SUPPLY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

1. INITIAL PREPARATION AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.1 AIR INTAKE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 FAN AND FAN SHROUD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.3 POWER STEERING LINES MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.4 WIRE ROUTING AND MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

2. SUPERCHARGER ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.1 OIL DRAIN LINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 OIL FEED ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.3 CRANK PULLEY ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.4 S/C MOUNTING PLATE ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . .2-3

2.5 BELT TENSIONER/BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

3. DISCHARGE DUCT ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.1 DISCHARGE DUCT ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . .3-1

4. SUPERCHARGER AIR INLET ASSEMBLY INSTALLATION . . . . . . . . . . . . . . .4-1

4.1 SUPERCHARGER INLET DUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2 AIR FILTER ENCLOSURE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

5. REINSTALLING FAN & SHROUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.1 REINSTALLING FAN & SHROUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

6. FUEL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.1 FUEL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.3 FUEL CONTROL UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.4 FUEL CONTROL UNIT VACUUM LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

7. CHECK-OUT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.1 CHECK-OUT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

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

A. APPENDIX TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

B. 1016111 ASY, NOVI 2000 SUPERCHARGER . . . . . . . . . . . . . . . . . . . . . .A-2

C. 1016311 ASY, MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

D. 1015611 ASY, CRANK PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

E. 1016911 ASY, BELT TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

F. 1015911 ASY, AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

G. 1016011 ASY, AIR DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

H. 1017711 ASY, FUEL CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

I. 1017721 ASY, AUXILIARY FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . .A-9

J. 1019344 ASY, SUPERCHARGER OIL RETURN . . . . . . . . . . . . . . . . . . .A-10

K. 1019350 ASY, SUPERCHARGER OIL FEED . . . . . . . . . . . . . . . . . . . . . .A-11

This kit requires ECM modification and the installation of a Paxton ECM Module.The ECM must be sent directly to Paxton by the installing customer (the charge for this service with module installation has been included in the purchase price).

• Included in this kit is a prepaid next-day air shipping box and a credit tag for one (1) Paxton ECM Module.

• The modules are made specifically for each individual vehicle with respect to the factor y ECM calibration.

• Simply contact the Paxton Service Department at (805) 247-0226 to request a Return Authorization Number (see ECM Module Credit Tag for more details).

- Mail to Paxton the enclosed "ECM Module Credit Tag" (send original tag - no

photocopies will be accepted) and ECM in the supplied box.

- Turnaround time will be 1-2 days (each application varies). Paxton will give an

estimate at the time of your order. Your Paxton ECM Module comes with a twelve (12) month limited warranty from the original date of purchase of your supercharger system (see Owner's Manual for details).

IMPORTANT NOTES

1998-2001 Models

Ford 6.8L Super Duty

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INTRODUCTION

ongratulations! You have purchased the finest street supercharger available for the Ford V10. The centerpiece of this kit is the High Efficiency NOVI 2000 Supercharger, a mechanically driven centrifugal supercharger.

This kit comes with all of the parts you will need to install the supercharger. This instruction manual has been grouped in order of sequence, with photographs and drawings to illustrate the text. This will allow you quick part identification and orientation.

We suggest that you obtain a Ford shop manual and become familiar with the details of your car’s system. Manuals may be obtained from your local Ford dealer, or you can order one from Helm Publications at (800) 782-4356. If your vehicle is not within the normal operating parameters, we do not recommend the use of a supercharger.

For best results, we suggest that you read this entire manual before beginning. Familiarize yourself with the process and identify the areas of the car that you will be working on. The average installation time is 8

- 10 hours. Your actual install time will depend on your personal skill level, experience installing superchargers, working conditions, and preparedness for the job at hand. This estimate does not include time for the initial vehicle inspection, cleaning, fine tuning, or troubleshooting. Once again, before picking up a wrench, read this entire manual. We are available for technical assistance at (805) 604-1336.

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

Paxton makes every effort to ensure 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 was damaged

in transit, please call Paxton 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.

You are undoubtedly eager to get started with your project, but take a little more time to insure that your safety is not in jeopardy. A moment’s lack of attention can result in an accident, as can failure to observe some simple safety precautions. The possibility of an accident always exists, and the following points should not be considered a comprehensive list of all of the dangers. They are only intended to make you aware of the risks and to encourage you to take a safety conscious approach to all of the work that you will be doing on your vehicle.

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.

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Before beginning this installation, please read through this entire instruction booklet 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 Automotive 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 vehi-

cle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter at least every 3,000 miles. 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 2 years or 30,000 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 30,000 miles.

TOOL & SUPPLY REQUIREMENTS:

• Metric and standard - socket set, wrench set

• Ratchet - 1/2" drive

• Extension

• 1/2" drive breaker bar

• Ford springlock tool 3/8" & 1/2"

• Pliers

• Drill motor

• Ø1/16" and #30, Ø9/32", and Ø11/16" drill bits

• Test light

• Rubber mallet or dead blow hammer

•Wire cutters and crimping tool

• Standard hex key set (Allen wrenches)

• Silicone sealer/RTV

If your vehicle has in excess of 30,000 miles since its last spark plug change, then you will also need:

• Spark Plug Socket

• NEW Spark Plugs

1998-2001

FORD SUPER DUTY

Installation Instructions

1998-2001 50 State Smog Legal, as per CARB EO #P-195-19

Congratulations on selecting the best performing and best backed automotive supercharger available

today... the NOVI 2000 Supercharger!

viii

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

TRANSMISSION WARNING/DISCLAIMER:

Due to the increased horsepower and torque generated by the Paxton Novi 2000 supercharger, your transmission may require modification to prevent premature wear or damage—especially if plan to use your vehicle in high demand situations, such as towing. In any case, it is a good idea to consider purchasing a transmission valve body kit (commonly known as a shift improver kit) to improve transmission performance and durability. Several companies offer valve body kits, including TransGo Performance. Please contact TransGo or the valve body kit manufacturer of your choice for more information, pricing, labor involved, etc.

TransGo Performance

2621 Merced Ave.

El Monte, CA. 91733

(818) 443-4953

FAX: (818) 443-1079

NOTE:

This information is provided for customer convenience only. Paxton Automotive does not endorse any valve body kit manufacturers and does not provide warrantee or service on said products.

PLEASE NOTE:

The 2000 Ford 6.8L V10 has several minor changes in the design of the engine. Those changes have been included in this manual. Please be aware of the model year of the vehicle, and follow the proper set of directions.

1-1

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A. Using a screwdriver, remove the black rubber

tube between the throttle body and the air cleaner by loosening the two hose clamps. Disconnect the two rubber hoses attached to the side of the tube. (See Fig. 1.1-a.)

B. Carefully pull the air inlet temperature sensor

out of the black rubber hose attached to the side of the plastic inlet tube. (See Fig. 1.1-b.)

tion between the throttle body and front air filter enclosure. You will need to unplug the Mass Airflow Sensor connector on the inner fenderwell. Using a 10mm socket and ratchet, remove the three bolts securing the air filter bracket and remove it from the vehicle. (See Fig. 1.1-c.)

D. Gently pry the air flow meter cover plate from

the air filter housing using a screwdriver. Next, push the large rubber grommet (surrounding the 4 Mass Airflow Meter wires) into the housing and finish removing the Mass Airflow Meter. (See Fig. 1.1-d.)

*** NOTE ***

Model Year 2000 will NOT have this sensor.

Section 1

INITIAL PREPARATION AND DISASSEMBLY

1.1 AIR INTAKE DISASSEMBLY

C. Un-snap the large clamp which holds the air

cleaner housing together and remove the sec-

Fig. 1.1-a

Fig. 1.1-b

Fig. 1.1-c

Fig. 1.1-d

IAT SENSOR

1-2

The MASS AIR FLOW METER will be used in a later step. Discard the MASS AIR FLOW METER housing, face plate and air cleaner assembly.

F. Remove the large nut from the support bracket

on top of the fan shroud cover. Next, remove the three 8mm bolts securing the coolant reservoir and set the reservoir on the passenger side inner-fender. Next, drain the coolant from the engine by opening the petcock on the bottom of the radiator, driver’s side. Mark the ends of the upper radiator hose with an “R” on the radiator side and a “T” on the thermostat housing end. This is required for a later step.

Fig. 1.1-e

Fig. 1.2-a

E. Remove the two 10mm nuts retaining the

MASS AIR FLOW METER and separate the two pieces. (See Fig. 1.1-e.)

A. Unbolt the charcoal canister and the bracket,

(the large black cylinder unit on the driver’s side inner-fenderwall). Swing the bracket back and out of the way.

B. Next, you will need to remove the power-steer-

ing reservoir, insuring the fill cap is on tight, turn the reservoir upside down and remove both lines. Being careful not to spill any fluid, shorten the larger hose 1-1/4" and the smaller hose, 4".

C. Reroute both lines under the two steel brake

lines running toward the front of the engine compartment. Re-attach the two hoses to the power steering reservoir and the P/S Relocation bracket provided, re-attach the reservoir and replenish any fluid spilled during the process.

1.3 POWER STEERING LINES MODIFICATION

C. Remove the fasteners that secure the fan shroud

to the radiator.

D. After you remove the fan from the water pump,

lift the fan and fan shroud together from the engine compartment and set it aside to be reinstalled at a later step. (See Fig. 1.2-a.)

1.2 FAN AND FAN SHROUD REMOVAL

A. Unscrew the fan from the water pump using a

48mm open end wrench or large crescent wrench and the supplied fan removal tool .

B. Slide the fan removal tool over the four bolts

securing the water pump pulley to the water pump.

*** NOTE ***

The nut has right-handed threads. Remove the two 8mm bolts retaining the fan shroud located at the top of the fan shroud on the driver’s side and passenger’s side.

Using a 1/2" breaker bar for leverage, hold the pulley so it does not move and loosen the fan assembly from the water pump snout.

1-3

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A. On the front of the engine, (driver’s side), you

will find two large black electrical connectors attached to a bracket. (See Fig. 1.4-a.)

B. Remove plugs from the bracket (see Fig. 1.4-b)

and disconnect both plugs; one requires a 10mm socket wrench.

C. Next, unbolt the bracket that held the two elec-

trical connectors and modify the bracket as in (See Fig. 1.4-c.)

D. Discard the part with the two holes in it and

retain the section that the electrical connectors clip to. The two connectors and wiring harness, will now be routed directly in front of the two steel brake lines.

E. Lift the wiring harness in the plastic sheath off

the studs on the driver’s side valve cover. Push it down into the area between the valve cover and the intake manifold. Now take the large wiring harness and two connectors that runs along the top of the motor and fold the wiring harness back onto itself as shown. (See Fig.

1.4-d.)

Fig. 1.4-b

Fig. 1.4-c

Fig. 1.4-a

CUT HERE

1.4 WIRE ROUTING AND MODIFICATIONS

Fig. 1.4-d

DISCARD

THIS SECTION

1-4

F. Reclip the two large connectors back onto the

modified stock bracket (from Step E). Attach the bracket and connectors with the two supplied wire ties to the heavy-duty plastic wire loom as shown. (See Fig. 1.4-e.)

Fig. 1.4-e

G. Located on the driver’s side, in front of the

cylinder head is the cam sensor. Extend the two wires coming from the cam sensor along with the shielded white wire that runs parallel with the cam sensor wires, using the supplied three wires and six Butt connectors. (See Fig. 1.4-f.)

H. Then cover the wires with the supplied split-

loom. Route the extended wires under the upper most stud sticking out of the front of the engine then back over toward the harness.

Fig. 1.4-f

+ 26 hidden pages

Paxton Superchargers Ford V-10 Super Duty Truck User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

TABLE OF CONTENTS

IMPORTANT NOTES

INTRODUCTION

1.1 AIR INTAKE DISASSEMBLY

1.2 FAN AND FAN SHROUD REMOVAL