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Owners Installation Manual for the
PAXTON NOVI Supercharger
for the
1996-2003 4.6L SOHC
MUSTANG GT
Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033
805 604-1336 . FAX (805) 604-1337
DP/N: 4809655 - v1.0 08/16/07
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FOREWORD his manual provides information on the installation, maintenance and service of the Paxton supercharger kit expressly designed for this vehicle. All information, illustrations and specifi- Tcations contained herein are based on the latest product information available at the time of this publication. Changes to the manual may be made at any time without notice. Contact Paxton Automotive for any additional information regarding this kit and any of these modifications at (805) 888-PAXTON
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TABLE OF CONTENTS FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii CONGRATULATIONS ON YOUR PURCHASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv SAFETY FIRST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v TOOL & SUPPLY REQUIREMENTS
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ongratulations! You have purchased After reading the manual, verify that all the finest street supercharger avail- major assembly groups are present in the Cable for the Mustang GT. The center- main kit box. As you remove a box or bag, piece of this kit is the High-Efficiency note the identification label and compare it PAXTON Supercharger, a mechanically to the parts list. driven centrifugal blower. This kit comes with all the parts you will PAXTON AUTOMOTIVE makes every effort need to instal
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SAFETY FIRST Never rely solely on a floor jack when working underneath a vehicle. Always use jack stands that are rated for the weight of your vehicle, place them at the recommended lift points, and place your vehicle in “PARK” or “FIRST” gear with the parking brake set. Always use eye protection when using power tools, such as drills, saws, and grinders, or when working underneath a vehicle. Never smoke, use an open flame, or have spark producing items around gasoline or flammable objects.
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S U P E R C H A R G E R S 1996-2003 FORD 4.6L SOHC MUSTANG Installation Instructions 50 State Smog Legal, as per CARB EO #D-195-20 Congratulations on selecting the best performing and best backed automotive supercharger available today! Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Automotive Limited Warranties Program and the Warranty Registration form. Paxton supercharg
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1.0 ECM REMOVAL C. Contact the Paxton Service Department for a Return Authorization Number. Send both the ECM and supplied credit tag to Paxton using *** NOTE *** Before removing the ECM, disconnect the positive the enclosed shipping box. cable from the battery. 1.1 AIR INLET REMOVAL A. Remove the passenger’s side front kick-panel A. Before the air intake assembly can be removed, from the interior of the vehicle. Remove the you must first disconnect the plastic crankcase sound deadening materia
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*** NOTE *** E. Once the assembly is out of the car, use a This manual covers model years 1996-2003. Some 10mm socket to remove the mass air flow of the photographs and illustrations may be different sensor from the air filter housing. (See Fig. but the removal and installation of components are 1.1-d.) Place the mass air flow sensor aside to similar. be re-installed in a later step. *** NOTE *** 2002-2003 models do not have a separate IAT sen- sor. (The IAT sensor is integrated with the factor
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G. Use a 7mm socket to remove the four coil pack bolts and move the coil pack toward the passenger’s side and out of your way. H. Remove the 13mm bolt, nut and stud bolt securing the coil bracket to the cylinder head. (See Fig. 1.1-f.) Fig. 1.1-f 1.2 COOLANT RESERVOIR REMOVAL C. The coolant reservoir is secured by three nuts. (See Fig. 1.2-a.) Use a 10mm socket, remove A. Drain approximately one gallon of coolant the reservoir by removing these nuts and place from the radiator into an appropriat
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1.3 FACTORY TENSIONER AND RELATED PARTS REMOVAL A. Using a 13mm socket, remove the two nuts securing the tensioner limiting bracket. Set the bracket and hardware aside as they will not be reused. (See Fig. 1.3-a.) *** NOTE *** Some models and some model years may not have this bracket. (See Fig. 1.3-a.) REMOVE 13mm NUTS Fig. 1.3-a P/N: 4809655 ©2007 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 1-4 16AUG07 v1.0 96-03MusGT(4809655v1.0)
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B. Loosen (but do not remove) the four 10mm F. Use a 13mm socket to remove the idler pulley bolts on the water pump pulley. (See located above the belt tensioner. (See Fig. Fig. 1.3-b.) 1.3-d.) 13mm STUD BOLT REMOVE IDLER PULLEY Fig. 1.3-d Fig. 1.3-b G. Place the pulley aside to be reused in a later C. Remove the accessory drive belt. Insert a 1/2" step. drive ratchet or breaker bar into the square at the end of the tensioner, and rotate the ten- H. Remove three bolts at the front of the engi
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I. Using a 13mm socket, remove the two nuts 1.4 FAN RESISTOR RELOCATION and stud bolts located at the top of the passen- 2001-2003 Models Only ger’s side cylinder head. (See Fig. 1.3-i.) A. Disconnect the wiring harness from the fan resistor. (See Fig. 1.4-a.) Remove the clips holding the fan resistor to the fan shroud. Attach the fan resistor to the supplied bracket using the supplied hardware. CONNECTOR REMOVE MOUNT Fig. 1.3-f J. Remove the electrical connector mount. Set the mount aside to
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Fig. 1.4-c C. Re-attach the fan resistor to the wiring har- ness to ensure adequate wire length. (See Fig. 14-d.) Position the supplied fan bracket and hardware on the passenger’s side of the lower fan shroud. Mark two mounting points along the fan shroud and drill the holes. Attach the mounting bracket with the sup- plied hardware. Fig. 1.4-d P/N: 4809655 ©2007 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 1-7 16AUG07 v1.0 96-03MusGT(4809655v1.0)
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This Page Left Intentionally Blank P/N: 4809655 ©2007 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 1-8 16AUG07 v1.0 96-03MusGT(4809655v1.0)
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2.0 SUPERCHARGER MOUNTING BRACKET ASSEMBLY *** NOTE *** See Appendix for the model year’s supercharger bracket assembly procedure. A. Install the supercharger idler pulley bracket using the supplied hardware. Install the pro- vided spacer between bracket and alternator. (See Fig. 2.0-a.) This operation will be per- formed on all model years. *** NOTE *** This photo is for illustration purposes. It will be easi- er for you to install this bolt/spacer first, then install the other two mounting bo
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D. Before installing the main supercharger brack- *** NOTE *** et, the A/C refrigerant refilling port must be 1996-1998 Models Only - The A/C line bracket should be placed between the spacer and the cylinder bent from its upright position downward so head. (See Fig. 2.0-l.) that the cap is facing the driver’s side fender. (See Fig. 2.0-f.) Note that this operation will be performed on all model years except model year 2000. This hose assembly will be replaced with the provided A/C hose assembl
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G. Reinstall the water pump pulley removed in an earlier step. (See Fig. 2.0-j.) Fig. 2.0-l Completed Supercharger Mounting Bracket Fig. 2.0-j Route the supercharger and accessory drive belt. *** NOTE *** On 2000-2003 models the drive belt needs to be routed before the rear S/C mounting plate is installed. Fig. 2.0-k Fig. 2.0-m *** NOTE *** The belt must be routed BEFORE this bolt and spacer are installed. P/N: 4809655 ©2007 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 2-3 16AUG07
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2.1 SUPERCHARGER INSTALLATION A. Install the supercharger oil return line (see assembly 1019328) to the supercharger drain fitting and secure with the hose clamp provid- ed.. (See Fig. 2.1-a.) *** NOTE *** The hose clamp screw head should be parallel to the supercharger mounting base. OIL FEED FITTING Fig. 2.1-b H. Install the spacer and coil mounting bracket after installing the supercharger. Fig 2.1-a B. Locate the 1/8" x -4 x 90° oil feed fitting. (See assembly 1019327.) Install the fitti
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3.0 SUPERCHARGER OIL FEED AND E. Install the line, and tighten moderately - no DRAIN (1996-2003 Models) sealant is required. (See Fig. 3.0-b.) A. Your Paxton Automotive NOVI supercharger uses pressurized engine oil for lubrication. Use an oil sending unit socket (Snap-On tools; part number 6152 or equivalent) to remove the oil sending unit on the underside of the oil filter housing. (See Fig. 3.0-a.) Fig. 3.0-b 3.1 SUPERCHARGER OIL DRAIN INSTALLATION (1996-2003 Models) A. Mark the front of
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D. Next, apply a small amount of anti-seize G. Install the supplied drain-back hose fitting so lubricant to the tip of the punch, and insert it that the elbow is oriented toward the passen- into the pilot hole. Using the appropriate tool, ger’s side, away from the harmonic balancer/ (an air hammer works the best), use small crank pulley. Attach the supercharger drain bursts until the punch is inserted up to its hose and fitting installed on the supercharger shoulder. The finished hole size shoul
