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Installation Manual for the PAXTON Automotive Intercooler
Installation Manual for the
PAXTON Automotive
Intercooler Kit #1300001
for the
1999-2003 Ford Mustang GT
Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033
805 604-1336 . FAX (805) 604-1337
P/N 4809638 v2.0 11/10/03
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© 2003 PAXTON AUTOMOTIVE 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. P/N: 4809638 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured ii 10NOV03 v2.0 99-01 MusGT(4809638 v2.0)
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TABLE OF CONTENTS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv 1.1 INITIAL PREPARATION AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 2.1 AFTERCOOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 3.1 FINAL
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IMPORTANT NOTES ongratulations! You have purchased the beginning. Make sure that you understand the finest street charge cooler available for process, have identified the areas of the car that Cthe Mustang GT. The centerpiece of this you will be working on, and have the tools that kit is the Highly Efficiency PAXTON charge you will need on hand. The average installation cooler. time is 6 to 8 hours, but your time will depend on your working conditions, experience This kit comes with all the part
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ou are undoubtedly eager to get started, simple safety precautions, you can avoid many but please take a little more time to potential dangers. The following list is not meant Yinsure that your safety is not in jeopardy. to be a comprehensive list, but rather it is meant A moment’s lack of attention may cause a seri- to make you aware of some of the risks, and ous injury to you, or to someone else who hap- encourage you to take a safety minded approach pens to be standing around. By following so
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Section 1 INITIAL PREPARATION AND REMOVAL 1.1 INITIAL PREPARATION AND REMOVAL A. Remove the plastic clips(4) that hold the C. Place car on lift or jackstands. grill cover in place. (See Fig. 1-a.) D. Remove the screw at the bottom of the sup- port bar. (See Fig. 1-c.) CLIPS Fig. 1-c Fig. 1-a E. Remove the power steering cooler line sup- B. Remove the hood latch support screw using port screw. (See Fig. 1-d.) a T-30 torx bit. (See Fig. 1-b.) SCREW Fig. 1-d Fig. 1-b P/N: 4809638 ©2003 Paxton Autom
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E. Remove the plastic clips (4) that hold the air H. Pop loose the clips on the air deflector to the deflector in place. (See Fig. 1-e) left and right sides of the radiator. (See Fig. 1-h.) Fig. 1-e Fig. 1-h F. Remove the plastic clips(2) that attach the I. Disconnect the rear radiator reservoir sup- front bumper to the frame. (See Fig. 1-f.) port brace from the bottom of the frame. (See Fig. 1-i.) Fig. 1-f G. Remove the screw that holds the power steering cooler bracket in place. Set the line
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Section 2 INTERCOOLER INSTALLATION 2.1 INTERCOOLER INSTALLATION A. Install the intercooler and support with jack- C. Drill one more 1/8" hole and re-attach the stands or wood blocks. (See Fig. 2-a.) rear radiator overflow reservoir support in its new location with a 1/4" sheetmetal screw. (See Fig. 2-c.) Fig. 2-a Fig. 2-c B. Drill two 1/8” holes as shown in Fig. 2-b. Install two 1/4" sheetmetal screws. D. Re-attach the powersteering cooler line to the intercooler. E. Re-attach the front bumper t
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F. Attach the supplied intercooler mounting J. Disconnect the supercharger. You will need bracket with the bolts supplied in the kit. to loosen the two bolts on the coolant reser- (See Fig. 2-g.) voir and move the reservoir to the side to gain access to the supercharger. (See Fig. 2-i.) Fig. 2-g G. Remove the discharge tube, bypass valve Fig. 2-i and air intake tube. (See Fig. 2-h.) Fig. 2-h H. Disconnect the oil lines. Disconnect the oil return at the pan and the oil feed at the supercharger.
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Section 3 FINAL ASSEMBLY 3.1 FINAL ASSEMBLY E. Re-install the air intake tube between the air A. Re-clock the supercharger scroll. Refer to filter/mass air meter and the supercharger. the supercharger assembly drawing in the (See Fig. 3-c.) back of the installation manual for position- ing. B. Re-attach the oil lines. C. Connect the discharge tube between the intercooler and the supercharger. (See.Fig. 3-a.) Fig. 3-c F. Re-install the bypass valve from air intake to discharge tube. (See Fig. 3-d
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G. Install inlet air control to discharge tube at the throttle body. (See Fig. 3-e) Fig. 3-e Here is your completed installation. P/N: 4809638 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 3-2 10NOV03 v2.0 99-01 MusGT(4809638 v2.0)
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APPENDIX P/N: 4809638 ©2003 Paxton Automotive A-1 All Rights Reserved, Intl. Copr. Secured 10NOV03 v2.0 99-01 MusGT(4809638 v2.0)
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Please understand that PAXTON Automotive is constantly improving the performance and appearance of its various components. The parts in your kit may appear differently than what is pictured in this manual. This may be due to photographs being taken in pre-production, changes in mate- rials, or improvements in performance. Rest assured that you have purchased the best quality kit that PAXTON Automotive manufactures at this time. The instal- lation of the materials will remain the same. LIST OF AP
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1300001 FORD, 4.6L MUST A/A COOLER ASSEMBLY Part Number Description Qty/Parent ------------------------------------------------------------------------------------------------- .8PN101-001 COOLR CORE,W/CAPS/DUCTS,A/A 1 .8PN012-010 DISCH TUBE A,COOLR TO TB 4.6 A 1 .8PN012-020 DISCH TUBE B, S/C TO COOLR INL 1 .8PN012-030 DISCH TUBE C, FROM COOLR DISCH 1 .7PS300-400 BUMP HOSE, 3.00D x 4.00L 2 .7PS300-401 SLEEVE, BLACK 3.00D x 4.00 3 .7R002-048 #48 SAE TYPE F SS HOSE CLAMP 10 .7A250-400 1/4
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P/N: 4809638 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured A-4 10NOV03 v2.0 99-01 MusGT(4809638 v2.0) NUT CORNER IN LINE WITH EDGE S/C ROTATION RE- CLOCK SCROLL AS SHOWN UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING, DIMENSIONS ARE IN INCHES 1300 BEACON PLACE OXNARD, CA 93033 TOLERANCES ARE: DO NOT MANUALLY UPDATE .XX± .01 TEL: (805) 604-1336 FAX: (805) 604-1337 DECIMALS: .XXX±.005 APPROVALS DATE FRACTIONS: ±1/2• DRAWN ----- ----- ANGLES: ±1/16 PAXTON AUTOMOTIVE I
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Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033 805 604-1336 . FAX (805) 604-1337 P/N: 4809638 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured A-6 10NOV03 v2.0 99-01 MusGT(4809638 v2.0)
