Paxton Superchargers Mustang Novi 1220 User Manual

DP/N: 4809631 - v1.0 05/23/07

Owners Installation Manual for the

PAXTON NOVI 1220 Supercharger

for the

1986-1993 5.0L Mustang

Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033

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

FOREWORD

Take note of the following before proceeding:

1. Proper 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 contact your dealer or

Paxton Automotive for possible installers in your area.

2. This product was designed for use on stock (

un-modified, OEM

) vehicles. The PCM (com-

puter), engine, transmission, drive axle ratios and tire O.D. must be stock. If the vehicle or engine has been modified in any way, check with Paxton prior to installation and use of this product.

3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).

4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use (no boost)

until the problem is resolved.

5. Paxton is not responsible for any clutch, transmission, drive-line or engine damage.

Exclusions from Paxton warranty coverage considerations include, but not limited to:

1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.

2. Continued operation with an impaired vehicle or sub-system.

3. The combined use of Paxton components with other modifications such as, but not limited to,

exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes.

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

his manual provides information on the installation, maintenance and service of the Paxton supercharger kit expressly designed for this vehicle. All information, illustrations and specifi-

cations contained herein are based on the latest product information available at the time of this publication. Changes to the manual may be made at any time without notice. Contact Paxton Automotive for any additional information regarding this kit and any of these modifications at (805) 888-PAXTON 8:00am-4:30pm PST.

STOP

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

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

NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

TOOL & SUPPLY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

PA RTS LIST ('86-'93 Mustang). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

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

1.0 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.0 CRANKSHAFT PULLEY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

3.0 ADDING OIL DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4. OIL FEED LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.0 OIL FEED LINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5. FUEL MANAGEMENT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.0 FUEL MANAGEMENT UNIT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6. MAIN BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.0 MAIN BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7. SMOG PUMP HOSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.0 SMOG PUMP HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8. RADIATOR HOSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.0 RADIATOR HOSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9. ACCESSORY BELT TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.0 ACCESSORY BELT TENSIONER MOUNTING BRACKET . . . . . . . . . . . . . . . . 9-1

10. SUPERCHARGER MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.0 SUPERCHARGER MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

11. SUPERCHARGER DRIVE BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.0 SUPERCHARGER DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

12. AIR FILTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12.0 AIR FILTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

13. CHECK-OUT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

13.0 CHECK OUT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

This Paxton 5.0 supercharger kit was designed for installation and use on Mass Air Flow (MAF) equipped vehicles.The model years include 1988 California and all 1989-1993 models. All other years not equipped with MAF systems (factor y or after market) require the installation of a MAP sensor) check valve assembly (Paxton part number 4FD113-010). This allows proper function of early (1986-1988) models equipped with speed density processors.

This product is protected by state common law, copyright and/or patent. All legal rights therein are reserved. The design, layout, dimensions, geometry, and engineer ing 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 Inc.

NOTICE

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Paxton supercharger systems are performance improving devices. In most cases, increases in torque of 3035% and horsepower between 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 the problem

is resolved.

5. Perform an oil and filter change upon completion 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 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 one year or 15,000 miles with original heat range plugs as specified by the manufacturer and reset timing to factor y specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spar k plugs unless they are original equipment.

Change spark plugs every 20,000 miles.

TOOL & SUPPLY REQUIREMENTS

• Factor y repair manual

• Timing light

• 3/8" socket and drive set: SAE & metric

• 1/2" socket and drive set: SAE & metric

• 1/2" breaker bar and 4" extension

• 1/8" NPT tap, 3/8" NPT tap, 3/8-16 tap & handle

• Adjustable wrench

• Open end wrenches: 3/8", 7/16", 1/2", 9/16" "Slimline"

19mm - Snap-On #LTAM1719

• Center punch and a 5/8" tapered punch

• Ford springlock 3/8" fuel fitting disconnect tool

• 5 quarts SF rated quality engine oil, oil filter and wrench

If it has been 10,000 miles or more since your vehicle's last spark plug change,

• Spark plug socket

• NEW spark plugs

1986 - 1993

FORD 5.0L MUSTANG

Installation Instructions

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the PAXTON® supercharger!

*Legal in California only for racing vehicles which may never be used upon a highway.

Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Limited Warranty Program, the Warranty Registration form and return envelope.

• Large screwdriver or pry bar

• Flat #2 screwdriver

• Phillips #2 screwdriver

• Heavy grease

• Silicone sealer

• Drill motor

• 3/32", “R”or 5/16",

7/16" drill bits

S U P E R C H A R G E R S

1016142 NOVI 1220 SUPERCHARGER ASY 1

4FA111-042 SUPERCHARGER BELT TENSIONER ASY 1

7J012-092 12mm FLAT WASHERS 3 4FA011-032 BELT TENSIONER PLATE 1 7C012-065 12mm-1.75 x 65mm BOLT 1 4FA016-170 SMOOTH PULLEY TENSIONER 1 2A017-011 IDLER PULLEY SPACER 1 7C012-020 12mm-1.75 x 20mm BOLTS 3 7G010-175 12mm-1.75 NUT 1

4PFA112-010 AIR INTAKE ASY 1

7PS350-200 3-1/2" x 2" SLEEVE 1 4FA012-012 90° INTAKE ELBOW 1 4PFA013-012 AIR CLEANER COVER 1 7J006-093 6mm WASHERS 2 7P375-097 3/8"NPT x 3/8" BARB 1 7S300-100 3" x 1" SLEEVE 1 7E010-046 #8 x 3/4" SHEET METAL SCREWS 2 8H040-010 AIR FILTER 1 7R002-056 #56 HOSE CLAMPS 2 7R002-052 #52 HOSE CLAMPS 2 7U035-000 3-1/2" x 12" FLEX HOSE 1

4PFA112-020 AIR DISCHARGE ASY 1

4FA012-020 DISCHARGE TUBE 1 7PS275-200 2-3/4" x 2" SLEEVE 1 7PS300-200 3" x 2" SLEEVE 1 7R002-044 #44 HOSE CLAMPS 2 7R002-048 #48 HOSE CLAMPS 2

4FA139-096 PCV BYPASS KIT 1

8H040-020 3/8" INLINE FILTER 1 7U375-052 3/8" VACUUM CAP 1 7U030-056 3/8" x 22" FUEL HOSE 1

4PF238-068 FMU (WITH LINES) 1

1211808 12:1 BLACK FUEL MANAGEMENT UNIT 1 4FA145-010 MALE FUEL LINE ASY 1 4FA145-020 FEMALE FUEL LINE ASY 1 7U030-046 5/32" x 54" VACUUM LINE 1 7E010-046 #8 x 3/4" SHEET METAL SCREWS 2 7U100-055 6" NYLON TIE-WRAPS 2

4FA130-036 OIL DRAIN ASY 1

7R001-008 #8 STAINLESS HOSE CLAMPS 2 7P375-017 3/8"NPT x 1/2" STRAIGHT HOSE BARB 1 7U030-036 1/2" x 28" OIL DRAIN HOSE 1

4FA114-023 RADIATOR HOSE ASY 1

4FA014-011 RADIATOR PIPE-POLISHED 1 7R002-024 #24 SAE TYPE “F” SS HOSE CLAMP 2 70000 INSPECTOR NUMBER 0

PART NO. DESCRIPTION QTY PART NUMBER DESCRIPTION QTY.

4FA110-011 SPRING TENSIONER MOUNTING ASY 1

4FA010-011 TENSIONER MOUNTING BRACKET 1 7A375-100 3/8-16 x 1" BOLTS 2 7J375-044 3/8"SAE WASHERS 3 7F375-016 3/8-16 NUT 1 7A500-350 1/2-13 x 3-1/2" CARRIAGE BOLT 1 7F500-013 1/2-13 NUT 1 7J012-092 12mm FLAT WASHER 1 4FA114-023 RADIATOR HOSE ASY 1 4FA014-011 RADIATOR PIPE 1 7R002-024 #24 HOSE CLAMPS 2

4FA111-021 MOUNTING BRACKET ASY 1

4FA011-021 MOUNTING BRACKET 1 4FA010-034 MOUNTING PLATE 1 4FA015-015 ALTERNATOR STAY 1 4FA017-021 SMOG PUMP SPACER 1 7A375-625 3/8-16 x 6-1/4" BOLTS 2 7A375-700 3/8-16 x 7" BOLT 1 7A437-175 7/16-14 x 1-3/4" BOLT 1 7A375-175 3/8-16 x 1-3/4" BOLT 1 7A375-650 3/8-16 x 6-1/2" BOLT 1 7A375-200 3/8-16 x 2" BOLT 1 7A375-075 3/8-16 x 3/4" BOLT 1 7F375-016 3/8-16 NUTS 2 7A375-100 3/8-16 x 1" BOLTS 7 7K375-040 3/8"AN960 FLAT WASHERS 5 7J375-044 3/8"SAE WASHERS 10 7J012-092 12mm FLAT WASHER 1

4FA130-026 OIL FEED ASY 1

7P525-067 .500" CRIMP FERRULES 2 7P250-066 #4 SWIVEL x 1/4" HOSE BARB FITTING 2 7P125-027 1/8"NPT STRAIGHT FITTING 1 7P125-103 1/8"NPT x -4 x 45° MALE ELBOW 1 7U030-026 1/4" x 25" OIL FEED HOSE 1 7P250-121 3" NIPPLE 1 7P250-122 1/4" TEE 1 7P250-075 45°ELBOW 1 7P250-082 90° FLARE 1

4PFA116-041 CRANK PULLEY ASY 1

2A048-550 BELT, K080550-GATES 1 4FA018-021 6.0/6.87" 8-GV CRANK PULLEY 1 70000 INSPECTOR NUMBER 0 7A375-178 3/8-16 x 1-3/4 HXHD G8 4 7J375-044 3/8"SAE WASHER, PLTD 4 7L375-075 3/8" LOCK WASHER 4

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged

parts immediately.

1986-1993 Mustang

Part No. 1001831

PARTS LIST

S U P E R C H A R G E R S

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Fig. 1.0-a

Section 1

PREPARATION/REMOVAL

A. Disconnect the battery negative cable. B. Remove the accessory drive belt. C. Remove the radiator fan assembly and care-

fully place it in the fan shroud, out of the way.

D. Remove all components that lead to the throt-

tle body including air filter assembly, rubber bellows, mass air flow (MAF) sensor and bracket with rubber mounts and resonator from inner fender. Separate the MAF sensor from the mounting bracket and set aside.

E. The ground wire attached to the radiator sup-

port must be rerouted so as to pass through the hole behind the right headlight and secured from the front. Make sure to clean away any paint that would insulate the end of the ground wire from the grounding point on the vehicle.

F. Drain approximately one gallon of coolant.

Remove upper radiator hose and set aside.

G. Remove the crankcase vent tube from

between oil filter and throttle body.

H. Remove belt tensioner assembly. I. Unplug wire connections and remove alterna-

tor assembly (make sure the battery is disconnected).

J. Remove brace from between the smog pump

and front engine cover.

K. Disconnect hoses and remove smog pump and

cast mounting bracket.

L. Relocate the evaporative canister forward (at

a slight angle) by using only the front bolt in the bracket’s rear hole. (See Fig. 1.0-a.)

1.0 DISASSEMBLY

FRAME

RELOCATED EVAPORATIVE CANISTER ASSY.

1-2

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Section 2

CRANKSHAFT PULLEY

2.0 CRANKSHAFT PULLEY REMOVAL

A. Remove crankshaft pulley. B. Remove the factory crank pulley and replace

with the new high-output crank pulley. Secure with the supplied bolts and washers.

*** NOTE ***

Tighten bolts progressively and evenly in a crisscross pattern so that pulleys align properly.

Fig. 2.0-a

3/8-16 x 2-3/4"

2-2

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+ 22 hidden pages

Paxton Superchargers Mustang Novi 1220 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

TABLE OF CONTENTS

NOTICE

TOOL & SUPPLY REQUIREMENTS

PREPARATION/REMOVAL

1.0 DISASSEMBLY

CRANKSHAFT PULLEY

2.0 CRANKSHAFT PULLEY REMOVAL