Paxton Superchargers V-10 User Manual

DP/N: 4800019 - Dodge V-10 v2.0 09/25/03

Kit # 1201210

Owners Installation Guide for the

Paxton Automotive

NOVI 2000 Supercharger

for the

1994-2001 Dodge

V-10 Truck

PAXTON Automotive . 1300 Beacon Place . Oxnard CA 93033

(888) 9-PAXTON . FAX (805) 247-0669

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

his manual provides information on the installation, maintenance and servicing of the Paxton NOVI-2000 Supercharger kit expressly designed for the 1994-2001 Dodge V-10 truck. Contact Paxton for information regarding these modifications at (805)604-1336 7:00 a.m.-3:30p.m.

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 or 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 the publication. The right is reserved to make changes at any time without notice.

KIT P/N: 1201210

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.

iii

P/N: 4800019

25SEP03 v2.0 Dodge V-10(4800019v2.0)

TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TC-I

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

2.0 INITIAL PREPARATION AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .2-1

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

4.0 ADDITIONAL INJECTOR CONTROLLER INSTALLATION. . . . . . . . . . . . . . .4-1

5.0 FINAL CHECK AND START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

APPENDICES

Appendix A PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Appendix B ASY, NOVI 2000 SUPERCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Appendix C ASY, SUPERCHARGER MOUNTING BRACKET . . . . . . . . . . . . . . .A-4

Appendix D ASY, CRANK PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Appendix E ASY, AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Appendix F ASY, AIR DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Appendix G ASY, COMPRESSOR BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

Appendix H ASY, SPRING LOADED TENSIONER . . . . . . . . . . . . . . . . . . . . . . . .A-9

Appendix I ASY, AUXILIARY FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10

Appendix J ASY, FUEL ENRICHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-11

Appendix K ASY, OIL SUPPLY AND RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12

Appendix L ASY, HEATER HOSE RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . .A-13

Appendix M RADIATOR HOSE EXTENSION ASSEMBLY . . . . . . . . . . . . . . . . . . .A-14

Appendix N ASY, WASHER BOTTLE RELOCATION . . . . . . . . . . . . . . . . . . . . . . .A-15

This Page Left Intentionally Blank

P/N: 4800019

25SEP03 v2.0 Dodge V-10(4800019v2.0)

1-1

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

1994-2001 Dodge V-10 truck. The centerpiece of the kit is the highly efficient and reliable PAXTON NOVI-2000 supercharger - a mechanically driven (by belt) centrifugal blower (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 Dodge truck shop manual and become familiar with the details of your car’s systems. Manuals may be obtained from your local Dodge dealer or you can order one from Helm Publications at (800) 782-4356.

For best results, follow the instructions closely and 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 avail- able for technical assistance at (805) 6041336, 7 AM-3:30 PM 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 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. Please check the box for small parts.

Paxton makes every effort to insure that all parts are included in the box. However, if you discov-

er 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 and 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 risks and to encourage a safety conscious approach to all work you do on your vehicle.

• Never rely solely on a jack when working under a vehicle. Always use approved jackstands to support the vehicle and place them under the recommended lift points.

• When jacking the vehicle, make sure it is on a level surface, preferably concrete or asphalt. The transmission should be in

Section 1.0

INTRODUCTION

1-2

“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 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 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 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.

NOTE: Throughout 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.

RREECCOOMMMMEENNDDEEDD

TTOOOOLLSS FFOORR

IINNSSTTAALLLLAATTIIOONN::

9/16” Wrench 3/8” Ratchet 9/16” Socket 3/8” Drive 5/8” Socket 3/8” Drive Pliers Hacksaw Wire Cutters 13mm Socket 3/8” Drive 10mm Socket Long Extension Wire Crimper/Strippers 13mm Wrench Medium Extension Drill Motor 1/8” Drill Bit 13/64” Drill Bit” 1/4” Drill Bit 5/16” Nut Driver or Slot Screwdriver 1/4” Allen Wrench or Socket 3/4” Socket 8mm Wrench Hose Cutter or Sharp Knife #2 Phillips Screwdriver 13mm Socket 3/8” Drive Air Chisel/Hammer Harmonic Balancer Puller Power Steering Pulley/Puller Installer

Section 2.0

INITIAL PREPARATION AND DISASSEMBLY

2-1

P/N: 4800019

25SEP03 v2.0 Dodge V-10(4800019v2.0)

Fig 2-a

Fig 2-b

Fig 2-c

n this section, you will be preparing for the installation procedure by disconnecting the

battery cables and removing and relocating a few pieces to make room for your new Paxton supercharger.

2.1 INITIAL DISASSEMBLY AND

REMOVAL:

A. With a 1/2” wrench, remove both bat-

tery cables.

B. An 8mm wrench or socket is used to

remove the battery hold-down. Lift the battery out of the tray and set it aside.

C. Unclip the cruise control cable from the

throttle body and mount if equipped. (See Fig. 2-a.)

D. The tray is secured with two bolts and

two nuts above and two more accessible from below. Use a 13mm socket with an extension, and raise the battery tray from the vehicle. (See Fig. 2-b.)

E. Use a 10mm wrench and remove the

cruise control actuator from the bottom of the battery tray. Later it will be modified and reinstalled. (See Fig. 2-c.).

*** NOTE ***

On some later model trucks, the factory relocated the cruise control actuator so this step will not need to be done.

2-2

Fig 2-d

Fig 2-e

Fig 2-f

Fig 2-g

C. Unclip the air cleaner assembly from its

base and remove it along with the air filter element. (See Fig. 2-f.)

B. There are two bolts securing the air horn

to the core support. From the front of the core support, use a 10mm socket and remove the horn from the core support. You will have to bend the bracket in order to remove it. (See Fig. 2-e.)

2.2 AIR INTAKE ASSEMBLY:

A. Disconnect the plastic duct from

between the air cleaner assembly and the air horn on the radiator core support (See Fig. 2-d.).

D. Use a 7/16” deep socket and remove

the four nuts securing the air cleaner base to the throttle body.

E. Pull the base away from the throttle

body and disconnect the crankcase vent hose from it. Set it aside, it will not be reused. (See Fig. 2-g.)

2.3 FAN AND FAN SHROUD:

***WARNING***

Clean up any anti-freeze spillage immediately. Animals like the taste of coolant, and if ingested they can become very sick, and even die.

A. With a pair of pliers, remove the lower

radiator hose and drain the coolant from the vehicle. Replace the hose and resecure with the factory clamp.

2-3

P/N: 4800019

25SEP03 v2.0 Dodge V-10(4800019v2.0)

Fig 2-h

Fig 2-i

Fig 2-j

Fig 2-k

B. Disconnect the upper radiator hose and

fold it back out of the way.

C. Unclip the window washer bottle from

the shroud. Lift the bottle and disconnect the two plugs and the hose from the bottle. Set it aside. (See Fig. 2-h.)

D. With a 36mm wrench or large crescent

wrench, loosen the fan and remove it from the water pump. Set it into the fan shroud.

*** NOTE ***

This nut has right hand threads. (See Fig. 2-i.)

E. Remove the four screws securing the

shroud to the radiator using a 10mm socket. Lift the shroud and fan out of the engine compartment together. (See Fig. 2-j.).

2.4 POWER STEERING BRACKET:

A. Use a 16mm wrench, turn the belt ten-

sioner counter clockwise and remove the stock accessory drive belt. (See Fig. 2-k.)

2-4

Fig 2-l

Fig 2-m

Fig 2-n

Fig 2-o

B. Follow the accompanying instructions

with the power steering pulley puller/pusher and remove the power steering pulley. (See Fig. 2-l.)

C. Use a 15mm socket and remove the

three bolts securing the pump to the bracket. (See Fig. 2-m.)

D. With a 9/16” socket and extension,

remove the four bolts that secure the power steering bracket to the engine. Do not disconnect the fluid lines.

E. On the back of the pump, remove the

two nuts with a 15mm wrench and the two bolts with a 12mm socket. Remove the bracket from the pump and lay the pump on the steering box. Grab the power steering pump with both hands. Bend the pressure line down until it is flat, as shown. (See Fig. 2-n.)

F. Remove the bolt from the upper rod on

the A/C compressor with a 1/2” socket. (See Fig. 2-o.)

DODGE V-10 POWER STEERING PUMP HOSE

FLATTEN OUT

BEND IN

METAL LINE

BEND DOWN

MODIFICATION

P/S/PUMP

REAR VIEW

METAL LINE

SHOULD

LOOK LIKE

THIS AFTER

BENDING.

TOP VIEW

CAP

2-5

P/N: 4800019

25SEP03 v2.0 Dodge V-10(4800019v2.0)

Fig 2-p

Fig 2-q

Fig 2-r

Fig 2-s

G. With a 9/16” socket, remove the four

bolts securing the A/C bracket to the head. (See Fig 2-p.)

H. With a pair of pliers, disconnect the

heater hose at the splice. Then, remove the hose at the nipple on the side of the water pump. (See Figs 2-q, 2-r.)

I. Lift the A/C bracket up and out of the

way. Remove the long heater hose nipple from the water pump with a 3/4” wrench. (See Fig. 2-s.)

2-6

Fig 2-t

Fig 2-u

Fig 2-v

J. Install the 45º brass elbow into the water

pump and tighten with a 13/16” wrench. Use Teflon tape and position as shown. (See Fig. 2-t.)

L. Reinstall the A/C bracket using the stock

bolts. When resecuring the rod to the top of the compressor, secure the two ground wires previously secured to the power steering pump bracket. Install the wires between the rod and the compressor. (See Fig. 2-v.)

K. Install the brass nipple into the fitting

installed in step 2-t with Teflon tape and tighten with a 5/8” wrench. (See Fig. 2-u and Appendix M.)

Section 3.0

SUPERCHARGER INSTALLATION AND ASSEMBLY

Fig 3-a

Fig 3-b

Fig 3-c

C. Use the supplied wire, wire loom and

butt connectors to extend the factory harness to the cruise control module. Cut off the plug leaving about 6” of wire.

3.2 WINDOW WASHER BOTTLE

A. The washer bottle will be mounted on

the passenger side firewall. The wire bracket must be bent in order for the bottle to clear the A/C line running across the firewall in that area. Bend an offset in the bracket, set it in place and mark the mounting holes. Use a 1/8” drill and drill the two mounting holes. (See Fig. 3-d.)

B. Secure the cruise control to the two

screws that secure the windshield wiper motor, near the firewall and the washer bottle. (See Fig 3-c.)

ow we start modifying various electrical and mechanical assemblies as well as beginning the supercharger installation.

***NOTE***

On some later model vehicles, this step will not apply.

3.1 MODIFICATION AND INSTALLA-

TION

A. Modify the previously removed Cruise

Control bracket as shown.(See Figs. 3-a, 3-b.) It is not necessary to remove the Cruise Control Actuator from the bracket.

3-1

P/N: 4800019

25SEP03 v2.0 Dodge V-10(4800019v2.0)

LENGTHEN THIS HOLE

CUT LINE

MODIFIED BRACKETORIGINAL PART

3-2

Fig 3-e

3.3 CRANK PULLEY:

A. Using a 1-1/8” socket remove the large

center bolt from the crank pulley.

B. With an adequate puller, pull the crank

pulley off of the crank shaft. (See Fig. 3-f.)

Fig 3-d

B. Remove the pump and sensor from the

factory washer bottle along with their grommets. Use a small amount of clear silicone and install the grommets in the new bottle so that the pump is positioned on the inboard side and the sensor is toward the passenger fender. Push the pump and sensor into their respective holes.

C. Set the bottle in place and secure it to

the firewall with the supplied sheet metal screws.

*** NOTE ***

To save a step, it is recommended at this time, to tap into the factory wiring harness for the additional injector driver. Refer to Appendix L for ECU pin location.

D. Near the brake master cylinder, separate

the washer hose at the splice. Connect the supplied length of washer hose to the piece running to the wipers and route the other end to the pump.

E. In the battery tray area, cut the electrical

connectors for the pump and sensor off of the harness, leave at least 6” of length left with the connectors.

F. Use the supplied lengths of wire, plastic

loom and butt connectors to extend the harness back to the pump and sensor. (Appendix ‘P’)

G. Route the harness extension back and

along the firewall. Use the supplied plastic ties to secure it away from any hot or moving parts. (See Fig. 3-e.)

3-3

P/N: 4800019

25SEP03 v2.0 Dodge V-10(4800019v2.0)

Fig 3-h

Fig 3-g

Fig 3-f

C. Replace the stock crank pulley with the

supplied re-machined pulley. Pull the pulley onto the crank shaft with the stock large center bolt.

D. Remove the center bolt and place the

new center hub into the middle of the crank pulley. Align the two dowel pins and secure with the longer supplied center bolt. Reuse the large washer from the factory center bolt. Torque the bolt to 150ft-lbs. (See Fig. 3-g, Appendix ‘D’)

E. Use a 9/16" socket and install the crank

pulley on the adapter with the four 3/8" bolts. (See Fig. 3-h.)

+ 33 hidden pages

Paxton Superchargers V-10 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual