Paxton Superchargers RT-10 User Manual

DP/N: 4809646 - v2.0 02/17/06

Owner’s Installation Guide for the

Paxton Automotive

Novi 2000 Supercharger

for the

1992-1996 Dodge Viper RT/10

Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033

805 604-1336 . FAX • 805 604-1337

KIT # 1201810

FOREWORD

roper 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 call Paxton Automotive for installers in your area.

2006 PAXTON AUTOMOTIVE

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

of Paxton Automotive.

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iii

FORWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

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

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

RECOMMENDED TOOLS FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

PA RTS LIST (1992-1996 Dodge Viper RT10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

1. PREPATATION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. OIL FEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

4. CRANK PULLEY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5. REPLACEMENT SHOCK TOWER SUPPORT INSTALLATION . . . . . . . . . . . . . . . . . . . . 5-1

6. SUPERCHARGER MOUNTING BRACKET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 6-1

7. ALTERNATOR RELOCATION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8. SUPERCHARGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9. CHARGE AIR COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

10. AIR INLET DUCT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

11. TIMING CONTROLLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

13. FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

14. FINAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

his product is protected by state common law, copyright and/or patent. All legal rights therein are reserved. The design, layout, dimensions, geome-

try and engineering 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.

This supercharger kit is designed to work on stock vehicles. Vehicles with modifications may not be compatible with this kit as delivered and should be tested with a wide band oxygen sensor and fuel pressure gauge to determine if the air/fuel ratio is safe. Detonation will quickly damage an engine.

1992-1996 Dodge Viper

IMPORTANT NOTES

When driving the vehicle on non-public roads (off-road applications such as racing/high rpm) it it recommended that the spark plugs be gapped down to .032".

P/N: 4809646

17FEB06 v2.0 92-96Viper(4809646v2.0)

efore beginning this installation, please read through this entire instruction book-

let 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 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 com-

pletion 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 every 3,000 miles or less. 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 1 year or 10,000 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 plat-

1. Factory Repair Manual

2. 3/8" Socket and Drive Set: SAE & Metric

3. 1/2" Socket and Drive Set: SAE & Metric

4. 3/8" NPT Tap and Handle

5. Adjustable Wrench

6. Combination Wrench Set

7. Center Punch

8. Springlock 3/8" and 5/8”Fuel Fitting

Disconnect Tool

9. 10 Quarts SH/CF Rated Quality Engine Oil

10. Oil Filter and Wrench

11. Flat #2 Screwdriver

12. Phillips #2 Screwdriver

13. Heavy Grease

14. Silicone Sealer

15. Drill Motor / Pneumatic Right Angle

16. 1/8", 13/32", 5/16" Drill Bits

17. Stepless Clamp Pliers

18. 3/16" Allen Wrench

19. Wire Strippers and Crimpers

20. Utility Knife

21. Ø1-1/8" Hole Saw

22. Pliers

If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need:

24. Spark Plug Socket

25. NEW Spark Plugs

1992-1996 Dodge Viper

inum spark plugs unless they are original equipment. Change spark plugs at least

every 15,000 miles and spark plug wires at least every 50,000 miles.

RECOMMENDED TOOLS

FOR INSTALLATION

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

1011830 VIPER SUPERCHARGER ASY 1

4PCW038-375 S/C PLY, 8-GRV 3.75" PAXTON 1 2A048-485 BELT, K080485-GATES 1

4PCV118-011 CRANK PULLEY ASY, VIPER 1

4PCV016-011 PULLEY, VIPER 7-GRV 1 4PCV018-011 PULLEY, VIPER 8-GRV 1 4CV110-010 FIXTURE w/GUIDE, DOWEL PIN 1 7A312-100 5/15-18 x 1" HXCS GR5P 6 7A312-101 5/16-18 x 1" SOC 6 7K312-001 5/16"AN WASHER 12 7T100-120 DRILL BIT, #31, Ø.120", HSS 1 7T110-125 REAMER, Ø.1247", HSS 1

7U250-023 DOWEL PIN 1/8" x 1.25" 2

4PCV110-260 ALTERNATOR RLCT ASY, G1 VIPER 1

2A017-101-121 SPACER, FORD ALT. SBF CARB 3 2A017-102-900 SPACER, .900" G1 VIPER IDLER 1 2A017-102-740 SPACER, .740"L, C5 ALT. PLATE 3 2A017-875-02 SPACER, .875"OD x 1.565 LONG 2 2A017-875-04 SPACER, .875"OD x 3.457 LONG 1 4HS017-021 SPACER, S/C BOSS S2000 2 4PCV010-260 PLATE 1 PS ALT, RT10 1 4PCV010-270 PLATE 2 PS ALT, RT10 1 4PCV010-280 PLATE 3 PS ALT, RT10 1 4PCV010-291 PLATE DS ALT, '92-'96 RT10 1 7A375-175 3/8-16 x 1-3/4" HXHD GR5 PLT 1 7A375-225 3/8-16 x 2-1/4" HXHD G8 1 7A375-276 3/8-16 x 2-3/4" HXHD ZINC 2 7A375-350 3/8-16 x 3-1/2" HXHD 2 7A375-451 3/8-16 x 4.50" HXHD GR5 ZINC 1 7A375-475 3/8-16 x 4.75" HXHD GR8 PLTD 1 7C080-035 M8 x 1.25" x 35 BLT CL8.8 1 7J312-000 5/16" FLAT WASHER-SAE 1 7J375-044 3/8"SAE WASHER, PLTD 8

4PCV111-023 MTG BRKT ASY, VIPER RT10 1

4PCV011-023 MTG BRKT, VIPER, MACH 1 4PCV010-044 PLATE, VIPER S/C MTG 1 2A017-101-400 SPACER, SBF MOUNTING PLATE 2 7A375-575 3/8-16 x5-3/4" HXCS 2 7A375-126 3/8-16 x 1.25" HXHD 5 7A375-175 3/8-16 x 1-3/4" HXHD 2 7J375-044 3/8" SAE WASHER, PLTD 12 4FA016-170 IDLER PULLEY, 8-RIB SMOOTH 1 7A375-224 3/8-16 x 2.25" GR5 HX 1 4GF017-011 SPACER, IDLER 3 4PCV011-052 SPRING TENSIONER 1 7C010-035 M10-1.5 x 35 HXCS 1

4PCV210-220 BRACE ASY, VIPER SHOCK 1

4PCV110-220 ASY, VIPER BRACE, DRIVER RT10 1 4PCV110-230 ASY, VIPER BRACE, PSGR RT10 1 4PCV110-180 ASY, VIPER BRACE, XBAR 1 7A437-150 7/16-14 x 1-1/2" G8 2 7B437-001 ROD END, RH, 7/16" 1 7B437-002 ROD END, LH, 7/16" 1 7C010-025 M10-1.5" x 25mm HXCSP 4 7F437-000 7/16-14 HEX NYLOCK NUT 2 7F438-001 7/16-20 JAM NUT, PLTD 1 7F438-002 LH 7/16-20 HEX THIN NUT, ZINC 1 7GL10-150 10mm x 1.5" NUT NYLOCK 4 7J010-002 10mm WASHER, ZINC PLTD 10 7K437-001 7/16" AN WASHER 6

1992-1996 Dodge Viper RT10

Part No. 1201830

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any short-

ages or damaged parts immediately.

PAR

T NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY

PARTS LIST

4PCV130-028 OIL FEED LINE ASY, VIPER 1

7P125-004 1/8"NPT 90° x -4 JIC FTG 2 7P125-034 1/8"NPT x 1/8"NPT STRT T 1 7U100-055 TIE-WRAP, 6" NYLON 2 7U250-220 OIL FEED HOSE, 22" -4 STRT 1

4PCV130-036 OIL DRAIN LINE ASY, VIPER 1

7P375-017 3/8"NPT x 1/2" BEADED 1 7R001-008 #8 STNLS HOSE CLAMP 2 7T560-001 CUTTER, 9/16" ROTABROACH 1 7T560-002 ARBOR, ROTABROACH 1 7U030-036 1/2" OIL-DRAIN HOSE 1.75' 7U100-066 TIE-WRAP, 11" NYLON 2

4PCV112-040 AIR INTAKE ASY, VIPER RT10 1

4PCV012-040 INLET DUCT, VIPER SC RT10 1 7C010-077 10-24 x 3/4" BHCS 12 7R002-064 #64 GOLDSEAL HOSE CLAMP 1 7R002-104 #104 HOSE CLAMP 1 7PS400-650 INLET SLEEVE, VIPER RT10 1 7P625-091 5/8" x 5/8" x 90° BARB ELBOW 1 7U033-000 5/8" FUEL/PCV HOSE .75' 7U100-050 GROMMET 5/8"ID x 7/8" HOLE 1 8H017-021 AIR FILTER RET. RT10 1 8H040-230 AIR FILTER, 4.75" x 15, RT10 1

5A001-074 TIMING CONTROL BOX, VIPER '96-'99 1

5A001-070 TIMING CONTROL BOX, VIPER 1 5W001-017 3/8" RING TERMINAL, 12GA 1 7U375-001 VELCRO-HOOK, 1" BLACK .22YD 7U375-002 VELCRO-LATCH, 1" BLACK .22YD 5W014-010 14GA STRD WIRE, RED 8'

4PCV101-003 FUEL PUMP ASY, VIPER 1

5W001-005 3/8" PLASTIC WIRE LOOM 6' 5W001-011 16-14GA RING TERMINAL, .26" HOLE 2 5W014-030 14GA STRD WIRE, BLACK .75' 7E010-075 #12 x 3/4" SHT METAL SCREW H 4 7P312-005 5/16" FEMALE FUEL CONCT 1 7P312-007 FUEL FITTING, MALE 1 7P312-017 5/16" HOSE BARB TO PBURG 2 7P312-082 5/16" TEE HOSE BARB 4 7R003-027 ADEL CLAMP, 1-11/16" 4 7R004-001 STEPLESS CLAMP, 15.7-70 22 7U031-018 5/16" FUEL HOSE, HI-PRESSURE 8' 7U100-044 TIE-WRAP, 4" NYLON 10 7U100-055 TIE-WRAP, 6" NYLON 5 8F001-068 155 INLINE FUEL PUMP 2

4PCV238-108 FMU ASY, VIPER 1

7P125-025 1/8"NPT x 5/32" HOSE 90° 1 7P125-031 1.8"NPT 90° 5/16" BARB 1 7P125-032 1/8"NPT - STR, 5/16" BARB 1 7P156-082 5/32" TEE 2 7U030-046 5/32" VACUUM LINE 9 6Z050-191 FMU WASHER 8:1 1 6Z070-030 FMU 8:1 RING SPACER 1

4PCV145-040 POWER STEERING HOSE ASY 1

7U030-028 -6 HI-PRESS PWR STR HOSE 1 7P375-216 -6 JIC x M16 x 1.5" BUMP FTG 1 7P375-218 -6 JIC x M18 x 1.5" BUMP FTG 1 7U100-055 TIE-WRAP, 6" NYLON 5 7U100-045 O-RING, .301" 2

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vii

8PN201-020 DISCHARGE ASY, VIPER 1

8PN101-020 CAC ASY, VIPER, AIR/WATER 1 5W001-005 3/8" PLASTIC WIRE LOOM 1.6' 7PS263-090 2-5/8" 90° ELBOW 2 7PS300-300 SLEEVE, BLACK, Ø3.00" x 3.00" 1 7R002-040 #40 STAINLESS HOSE CLAMP 4 7R002-048 #48 GOLDSEAL HOSE CLAMP 2 7U030-046 5/32" VACUUM LINE 3.5' 7U038-012 HOSE, Ø3/4", 90°, 4" x 12" 1 7P375-075 3/4" HOSE UNION 1 7R007-001 NYLON CLAMP 1-1/8" 2 7P500-026 1/2"NPT - 3/4" BARB 90° 1 8D204-010 BYPASS VALVE-BLACK 1 8H040-175 FILTER, 1-3/4"ID, MFRB 1

8PN104-030 SUPPORT COMPONENTS, VIPER RT10 1

7A250-051 1/4-20 x .5" HHCS 2 7A250-074 1/4-20 x 3/4" HXHD PLT 5 7A312-075 5/16-18 x 3/4" HXCS GR5 ZINC 1 7F250-021 1/4-20 NYLOCK NUT ZINC PLT 1 7F312-017 5/16-18 NYLOCK NUT 1 7J250-001 1/4"SAE WASHER, PLTD 8 7K312-001 5/16"AN WASHER, PLATED 2 7U038-150 HOSE 3/4" x 150 MOLDED 1 8N010-100 MTG TAB, RT10 SURGE TANK 1 8N010-120 SUPPORT, RT10 WATER COOLER 2 7F250-021 1/4-20 NUT PLATE 4 7U100-055 TIE-WRAP, 6" NYLON 10 8N055-050 PLASTIC CAP, SURGE TANK 1 8N056-060 SURGE TANK, PLASTIC 1 8PN010-140 SUPPORT, VIPER WATER COOLER 2 7P500-026 1/2"NPT, 3/4" BARB, 90° 1

8PN105-020 WATER TANK MTG ASY, VIPER 1

7A250-050 1/4-20 x 1/2" SHCS ZINC PLTD 2 7J250-001 1/4"SAE WASHER, PLTD 1 7P375-075 3/4" HOSE UNION 2 7P500-026 1/2"NPT - 3/4" BARB 90° 5 7P500-078 1/2"NPT x 3/4" HOSE FITTING 3 7R007-001 NYLON CLAMP 1-1/8" 14 7U038-000 3/4" HEATER HOSE 18 7U038-012 HOSE, Ø3/4" 90°, 4" x 12" 2 8N055-030 TANK, LT1 AFTERCOOLER 1

8N006-010 WATER COOLER 1

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

8PN107-020 WATER PUMP ASY, VIPER 1

5W001-005 3/8" PLASTIC WIRE LOOM 12' 5W001-009 16-14GA MALE SLIDE INSUL 1 5W001-010 16-14GA FEMALE SLIDE INSUL 3 5W001-011 16-14GA EYELET .25" HOLE 2 5W001-013 14-16AWG, SOLDERLESS CONNECTOR 2 5W001-014 FUSE HOLDER, 10GA WIRE 1 5W001-015 FUSE, BLADE TYPE 20AMP 1 5W001-016 RELAY, BOSCH 1 5W001-017 3/8" RING TERMINAL, 12GA 1 5W001-040 12-10GA FEMALE SLIDE INSUL 1 5W014-010 14GA STRD WIRE, RED, UL101 11' 5W014-030 14GA STRD WIRE, BLACK 14' 5W016-010 WIRE, STRND, 16AWG, YELLOW 2' 7A250-074 1/4-20 x 3/4" HXHD PLT 1 7F250-021 1/4-20 NYLOCK NUT ZINC, PLTD 1 7J250-001 1/4"SAE WASHER, PLTD 2 7R003-027 ADEL CLAMP, 1-11/16" 1 7U100-044 TIE-WRAP, 4" NYLON 8 8F001-402 PUMP, WATER, PIERBURG 1

8F060-270 FUEL INJECTOR, GEN2 STK 10

1992-1996 Dodge Viper RT10

Part No. 1201830

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any short-

ages or damaged parts immediately.

PAR

T NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY

PARTS LIST cont’d

8PN301-010 POWER COOLER ASY, VIPER 1

viii

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1-1

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17FEB06 v2.0 92-96Viper(4809646v2.0)

Section 1

COMPONENT REMOVAL

A. Disconnect the Idle Air Control (IAC) motor

hose and the valve cover breather hose from the air box (air filter housing).

B. Remove all of the inlet ducting up to but not

including the throttle bodies. Remove the two air box mounting studs from the core support.

C. Remove the air temperature sensor from the

air box and set aside.

D. Jack the front of the vehicle up and support

with a jack stand under each frame rail.

E. Drain the engine coolant sufficiently to

remove the upper radiator hose.

F. Remove the two screws securing the power

steering cooler to the shock tower brace. Jack the front of the vehicle up by placing a jack under the front cross member.

G. Remove the five screws holding the shock

tower brace and remove the brace.

H. Remove the accessory drive belt. I. Loosen the nut on the high pressure power

steering line where it enters the power steering pump.

J. Remove the three screws securing the power

steering pump to the bracket and set aside for later use. Remove the three screws securing the bracket to the head and remove the bracket.

K. Remove the six 5/16" screws securing the

crank pulley to the harmonic damper and remove the crank pulley.

L. Remove the front fascia. Close the rear of

the hood to provide access under the front of the hood. Start by removing the mounting screws from the bottom of the vehicle and in the front of each wheel well. Remove the plastic push connectors from underneath the leading edge of the hood and from the top of the radiator air inlet opening. Unplug the fog and turn signal lights on each side of the vehicle by reaching behind the front fascia. Remove the plastic push connector securing the front fascia to the bumper in front of and below each headlight. Carefully remove and set aside the front fascia.

***NOTE***

Carefully note where any alignment shims are located and replace in the same location when the front fascia is re-installed.

1. PREPARATION/REMOVAL

1-2

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2-1

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Section 2

OIL FEED

A. Remove the oil pressure sender from the

front passenger side of the engine directly above the oil filter.

B. Install the 1/8"NPT TEE in the oil sender

hole. Leave the TEE pointed up. Install the 1/8"NPT x -4 90° fitting in the top of the TEE. Install the oil pressure sender in the front hole in the TEE and re-attach the electrical plug. (See Fig. 2-a.)

C. Temporarily cover one end of the oil feed

line and protect it from debris until connecting it to the supercharger.

D. Connect the open end of the oil feed line to

the -4 fitting. Use tie-wraps to secure the line and protect it from kinking, abrasion and high heat areas.

***IMPORTANT***

Use clean engine oil on the pipe threads. Teflon tape and sealant is NOT recommended as it might loosen and cause blockage of the small oil feed orifice resulting in supercharger failure.

2. OIL FEED

Fig. 2-a

2-2

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Section 3

OIL DRAIN

3-1

P/N: 4809646

17FEB06 v2.0 92-96Viper(4809646v2.0)

A. To provide an oil drain for the supercharger,

it is necessary to make a hole in the front of the oil pan.

B. Remove the oil dipstick retaining screw

from the passenger’s side valve cover bracket.

C. Drain the engine oil. D. Remove the oil pan. E. The hole should be centered .5" from the

bottom of the oil pan lip as shown. Use a center punch to mark the hole location. Use the supplied 9/16" rota-broach to drill the hole.

F. Tap the hole with a 3/8"NPT pipe tap. G. Thoroughly clean the threaded area and the

inside of the oil pan. Apply a small amount of sealer to the new threads. Apply more sealer to the supplied 3/8"NPT x 1/2" hose barb fitting and secure in the hole. Make sure a seal is formed all around the fitting.

***NOTE***

Clean and inspect the oil pan gasket. If it is in good condition it can be used again.

H. Re-install the oil pan. Torque the fasteners to

95 in-lbs (11 N-m).

I. Install a new oil filter and refill the engine

with fresh oil.

Fig. 3-a

3. OIL DRAIN

+ 29 hidden pages

Paxton Superchargers RT-10 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

IMPORTANT NOTES

2. OIL FEED

3. OIL DRAIN