Paxton Superchargers Mustang Novi 2000 User Manual

DP/N: 4809610 v2.0 11/14/03

Owner’s Installation Guide for the

Paxton Automotive

Novi 2000 Supercharger

for the

1986-1993 5.0L Ford Mustang

Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033

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

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

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

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

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

1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

2.1 INITIAL PREPARATION AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

3.1 SUPERCHARGER INSTALLATION AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

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

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

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

Appendix A 1011810 KIT, PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Appendix B 1016410 ASY, S/C NOVI 2000 FORWARD ROTATION . . . . . . . . . . . . .A-4

Appendix C 1016611 ASY, S/C MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . .A-5

Appendix D 1016710 ASY, CRANK PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Appendix E 1017110 ASY, AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Appendix F 1017010 ASY, AIR DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

Appendix G 1017200 ASY, UPPER RADIATOR HOSE MODIFICATION . . . . . . . . .A-9

Appendix H 1017400 KIT, BELT TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10

Appendix I 1017702 KIT, FUEL CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-11

Appendix J 1015515 ASY, COMPRESSOR BYPASS . . . . . . . . . . . . . . . . . . . . . . . . .A-12

Appendix K 7009308 OIL RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-13

Appendix L 7009312 ASY, OIL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-13

Appendix M 7002718 ASY, FAN SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-13

Appendix N 7007300 ASY, SMOG PUMP MODIFICATION . . . . . . . . . . . . . . . . . . .A-13

his manual provides information on the installation, maintenance and service of the Paxton supercharger kit expressly designed for the 1986-93 5.0 Ford

Mustang Contact Paxton Automotive Corporation for any additional information regarding this kit and any of these modifications at (805) 604-1336 7:00am3:45pm PST.

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.

IMPORTANT NOTES

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ever rely solely on a hydraulic lift, when working under a vehicle. Always use

approved jackstands to support the vehicle and place them under the manufactures recommended lift points.

When lifting the 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 with out first verifying that the transmission is in neutral and the parking brake is set.

Never remove the radiator cap while the engine is still 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 sparkproducing 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 a well ventilated area.

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 under dash work.

We look forward to hearing from you, particularly if you have any comments or suggestions regarding this manual at (805) 604-1336 Paxton Automotive Corporation, 1300 Beacon Place, Oxnard, CA

93033. E-mail Address:

info@paxtonauto.com

***NOTE***

Through these procedures the word “discard” is used periodically in relationship to items that will no longer be utilized in conjunction with the supercharger installation. It is recommended that these items be saved for future use should it become necessary.

RECOMMENDED TOOLS

FOR INSTALLATION:

1. Metric and Standard sockets sets

2. Metric and Standard com- bination wrenches

3. Phillips and common screw drivers

4. 12” crescent wrench or 36mm open end wrench

5. Pliers

6. Wire cutters and wire crimping tool.

7. Hose cutters

8. 1/8” drill bit and hand drill

37/64 drill bit

9. Allen wrenches

10. Small heat source

11. 3/8 Tap NPT

12. Air Hammer

13. Air Compressor

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ongratulations! You have purchased the finest street Supercharger available for the

1986-1993 Ford Mustang 5.0. The centerpiece of this kit is the highly efficient and reliable Paxton Automotive Corp. NOVI-2000 supercharger. A mechanically driven (by belt) centrifugal supercharger. This kit comes with all of the parts you’ll need for a successful installation. The operations required have been grouped in order of sequence. Photos and drawings accompany the text, allowing quick orientation and parts identification.

Installation requires a selection of tools which are listed in a table at the end of this section.

We also suggest that you obtain a Ford shop manual and become familiar with the details of your cars systems. Manuals may be obtained from your local Ford dealer or you can order one from Helm publications at (800) 782-4356.

For best results follow the instructions closelyand in sequence. The average installation time for this kit is 8-10 hours. Your actual installation time will depend on skill level and working conditions. The estimate does not include time for initial vehicle inspection, cleaning, fine

tuning or troubleshooting. Before even picking up a wrench, read this entire manual. We are available for technical assistance at

(805) 604-1336, 7am-3:30pm pacific time.

After reading the manual, verify that all major assembly groups are present in the main kit box. You should have ample space to layout the components. As you remove a box or bag from the main kit, note the identification label

and compare it with the parts list. Please check the box for small parts.

Paxton makes every effort to insure that all parts are included in the box. However, if you discover any missing or mislabeled parts, please contact Paxton by phone for service.

***WARNING***

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.

Before starting the installation, we suggest your engine compartment be clean. You can clean the engine and compartment with a pressure washer (such as those used at self serve car washes) and a safe-for-aluminum cleaner/degreaser. Cover the distributor with a plastic bag to prevent water from entering.

***CAUTION***

We do not recommend proceeding with the kit installation unless your vehicle is within normal operating parameters.

You are undoubtedly enthusiastic about getting started on your project, but take just a little more time to insure that your safety is not jeopardized. A moment’s lack of attention can result in an accident, as can failure to observe certain simple safety precautions. The possibility of an accident will always exist, and the following points should not be considered a comprehensive list of all dangers. Rather, they are intended to make you aware of the risk and to encourage a safety conscious approach to all work you do on your vehicle.

Section 1

INTRODUCTION

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egin the initial preparation and disassembly process by disconnecting the battery cables.

2.1 Fuel tank/Fuel pump removal

A. The installation of a higher flowing fuel

pump is necessary. Before the removal of the fuel tank, be sure the fuel tank is completely empty.

B. Using a hydraulic lift, lift the rear of the

Vehicle up and place securely on jack stands.

C. Remove the three 10mm hex head sheet

metal screws securing the fill pipe to the quarter panel. (See Fig. 2-a.)

D. Place a jack underneath the fuel tank to

lightly hold pressure on the tank to assist in the lowering of the tank and removal of the retainment straps. (See Fig. 2-b.) When the gas tank is on the ground unplug the fuel pump and sensor wires, from the sending unit.

E. Disconnect the three hoses using the sup-

plied fuel fitting removal tools (fuel feed, fuel return and fuel vapor) up in front of the fuel tank.

F. Twist the retainer ring that is securing the

fuel sending unit in the top of the tank. Lift the pickup/sending unit assembly out of the tank.

G. Carefully pry off the sock on the end of the

pump. Remove the pump from the assembly and install the new pump (it should be a direct replacement). Reinstall the sock on the new pump.

H. Replace the assembly into the tank and

secure it with the retainer ring. Be certain that the O-ring is in its proper place and that the ring is turned all the way to its stop position.

I. Plug the wires/hoses back in and re-install

the fuel tank back up into the vehicle.

Fig. 2-b

Fig. 2-a

Section 2

INITIAL PREPARATION AND REMOVAL

2-2

Fig. 2-e

Fig. 2-f

J. Loosen the petcock at the bottom of the

radiator and drain approximately one gallon of coolant into a drain pan. (Save fluid for

re-use.)

K. Disconnect the overflow hose from the neck

of the radiator and unplug the electrical connector from the coolant bottle.

L. Using a 7/16" combination wrench, loosen

the four bolts that are securing the fan to the water pump. With an18mm combination wrench release the tension on the belt tensioner and remove the factory drive belt. Now remove the four bolts that are securing the fan to the water pump. (See Figs. 2-c.)

M. Using a 10mm socket & ratchet or screw

driver, loosen the clamps and remove the upper radiator hose from the vehicle. Save for re-use.(See Fig. 2-d.)

O. Using a nut driver or screwdriver, remove

the clamps securing the rubber inlet tube to the throttle body and mass air flow sensor and remove the inlet tube.

P. Loosen the clamp securing the mass air flow

sensor to the rubber sleeve at the air filter assembly. Unplug the sensor and un-bolt it from the strut tower with a 7/16" socket.

Q. Using a 7/16" deep socket, loosen the nuts

securing the air filter assembly to its rubber mounts and remove the filter from the vehicle. Unscrew the rubber mounts from the inner fender. (See Fig. 2-f.)

Fig. 2-c

Fig. 2-d

N. Using a 7/16" wrench or socket, remove the

two sheet metal screws securing the fan shroud to the radiator core support and remove the shroud fan clutch from the vehicle. (See Fig. 2-e.)

+ 22 hidden pages

Paxton Superchargers Mustang Novi 2000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

IMPORTANT NOTES

INTRODUCTION