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Owner’s Installation Guide for the
Paxton Automotive Novi 2000
Supercharger Kit
for the
1997/2001 5.2/5.9L DODGE
Paxton Automotive Corp . 1300 Beacon Place . Oxnard CA 93033
(805)604-1336 . FAX (805)604-1337
DP/N: 4809625 - 97-01 5.2/5.9 Dodge v2.0 11/25/03
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FOREWORD his manual provides information on the installation, maintenance and service of the Paxton supercharger kit expressly designed for the 1997-2001 5.2/5.9L TDodge. Contact Paxton Automotive Corporation for any additional information regarding this kit and any of these modifications at (805) 604-1336 7:00am-3:30pm 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 f
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TABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv 1.1 - INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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RECOMMENDED TOOLS FOR INSTALLATION: 1. Metric and Standard sockets sets 2. Metric and Standard combination wrenches 3. Phillips and common screwdrivers 4. 12” crescent wrench or 36mm open end wrenches 5. Pliers 6. Wire cutters and wire crimping tool 7. Hose cutters 8. 1/8” and 37/64” drill bit and hand drill 9. 12mm allen wrench 10. Small heat source 11. 3/8 NPT Tap 12. Ruler 13. Air Hammer 14. Air Compressor P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured iv 25NOV
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Section 1 INTRODUCTION ongratulations! You have purchased the engine and compartment with a pressure washer finest street Supercharger available for the (such as those used at self serve car washes) and C1997/2001 5.2/5.9L Dodge engine. The a safe-for-aluminum cleaner/degreaser. Cover the centerpiece of this kit is the highly efficient and distributor with a plastic bag to prevent water reliable Paxton Automotive Corp. NOVI 2000 from entering. supercharger. A mechanically driven (by belt) *** CA
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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 (-) termi- nal of the battery when doing any electrical, fuel system or under dash work. We look forward to hearing from you, particular- ly if you have any comments or suggestions regarding this manual at (805) 604-1336 Paxton Automotive Corporation, 1300 Beacon Place, Oxnard, CA 9
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Section 2 INITIAL PREPARATION AND DISASSEMBLY Begin the initial preparation and disassembly 2-2 FAN AND FAN SHROUD REMOVAL process by disconnecting the battery cables. A. Start by removing fan clutch nut. (See Fig. 2-c.) 2-1 AIR INTAKE ASSEMBLY A. Remove the nut from the top of the intake bonnet and release clips holding the top of the air box. B. Remove plastic bonnet and air box cover assembly. (See Fig. 2-a.) Fig. 2-c *** NOTE *** Use factory tool or a 1 1/16 open-end wrench or a large cresce
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2-3 DISASSEMBLY OF ACCESSORY BELT, COIL, AND BELT TENSIONER A. Using a wrench on the accessory belt ten- sioner, rotate the tensioner counter-clock- wise and remove the accessory belt. (See Fig. 2-e.) Fig.. 2-g *** NOTE *** The coil bracket can be discarded, but the tensioner and tensioner bracket will be re-used. Fig. 2-e D. Remove the nuts and bolts(3) attaching the tensioner bracket, coil bracket, stud and B. Remove the bolt attaching the dipstick to nut from the front of the engine. (See t
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Section 3 RELOCATION AND MODIFICATION *** NOTE *** On '99-'01 vehicles, this step does not apply. 3-1 A/C DRIER RECEIVER RELOCATION B. Cut these three mounting tabs just above the case retaining screws. (See Fig. 3-c.) A. Use a 2 1/2" hole saw and cut a hole between the horns. (See Fig. 3-a.) B. Remove the receiver/drier from the stock location and re-install into the new hole. You will need to bend the hard lines. (See Fig. 3-b.) Fig. 3-c C. Re-mount the computer to the factory bracket and r
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Section 4 SUPERCHARGER INSTALLATION AND ASSEMBLY 4-1 S/C MOUNTING BRACKET A. Remove the pulley from the stock acces- sory belt tensioner and the tensioner from the stock bracket for re-installation. B. This is how the bracket should look before you install it. (See Fig. 4-a.) Note the accessory belt tensioner bracket. This spacer will have to be removed before you install the bracket. The dipstick goes between the tensioner and the spacer. *** NOTE *** The idler pulley and pulley stand off have
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B. Install the spacer and pulley. Re-use the H Install the tensioner using the factory nut factory center bolt and install the six bolts and washer. (Fig. 4-e.) and washers that are supplied in the kit. Torque to factory specifications. (See Fig. 4-d.) *** NOTE *** On 1999-2001 vehicles follow the procedures below. 4-3. CRANK PULLEY REMOVAL AND INSTALLATION. A. Loosen the large crank-pulley retain- ing bolt. B. Using the three-jaw pulley, slowly Fig. 4-e remove the pulley. You will have to use t
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4-4 SUPERCHARGER INSTALLATION A. Install the idler Pulley Stand-off with the hardware provided. Attach the supercharg- er to the mounting bracket using the six bolts provided. B. Install the idler pulley stand off. (See Fig. 4-i.) Fig. 4-j C. Install the straight fitting for the oil feed using sealant on the threads. Re-install the factory sending unit in the outlet of the Fig. 4-i brass TEE facing up. C. Install the idler pulley on the idler pulley D. Attach the 40" braided hose to the straig
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4-8 AIR INTAKE *** NOTE *** On 1999-2001 vehicles, step ‘A’ will not apply. Refer to Appendix 1015935. A. Raise the car up on jack stands. Remove the right front tire and the fender liner. Using the air intake bracket as a template, mark the area on the inner fender well where the 3 1/2" hole and the 4 holes will be drilled. (See Fig. 4-l.) Fig. 4-n E. Relocate the stock air temp sensor from the intake manifold to the air intake duct. Use the supplied pipe plug in place of the air temp sensor. (
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4-11 FAN AND FAN SHROUD REINSTALLATION B. Attach the bonnet with the supplied bolt A. Install the new fan spacer to clear the new and washer. lower crank pulley. (Fig. 4-s.) C. Connect the air dicharge tube to the bon- net. D. Connect the other end of the discharge tube to the supercharger. E. Attach the fuel enrichment line to the fuel fitting on the driver’s side fuel rail. You will have to remove a plastic cap and a schraeder valve to make this connection. (See Fig. 4-q.) Fig. 4-s B. You wil
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Section 5 FUEL SYSTEM MODIFICATIONS 5-1 FUEL ENRICHMENT A. Disconnect the stock fuel supply fitting at D. Route the fuel lines between the fuel the fuel rail. pump and fuel pressure regulator. Connect the fuel line between the fuel pressure reg- B. Using the fuel pressure regulator as a tem- ulator and the fuel rail using the supplied plate, drill two .Ø145. holes and mount fitting. Connect the fuel line from the fuel the fuel pressure regulator to the firewall. pump to the stock fuel line. Ref
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5-3 PAXTON ADDITIONAL INJECTOR CONTROL INSTALLATION D. Using the relay as a template, drill a hole in the fender well next to the MDS timing A. Remove the fuse box cover located on the master and mount relay with supplied driver’s side near the firewall. Using the screws. Paxton Injector Controller as a template, drill two holes and connect the fueler to E. Hook up the vacuum lines as shown in the fuse box cover with the supplied hard- appendix. (Per schematic.) ware. (See Fig. 5-d.) *** NOTE **
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ORIGINAL WIRE SAMPLE APPLICATIONS The following are samples of popular installations: Follow the procedure shown below for vehicles with the TFI (thick film ignition). This system is identified by the square coil with a single connector. Connect the MSD Boost Timing Master Cable Assembly in the following manner: 1. Cut the wire between the coil connector and original wire harness. 2. Install the insulated male fastener (supplied in the parts kits) onto the ends of the cut wire. 3. Plug the MSD B
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Congratulations!!! Here is your finished supercharger equipped engine! Fig.5-h / Completed Engine Shot P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 5-4 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0)
