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Kit # 1201219
Owner’s Installation Guide for the
Paxton Automotive
Novi 2000 Supercharger
for the
2002 Dodge 5.9L Ram 1500
Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033
888 9-PAXTON . FAX (805) 604-1337
DP/N: 4809621 - Ram 1500 v1.0 09/18/03
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FOREWORD his manual provides information on the installation, maintenance and service of the Paxton supercharger kit expressly designed for the 2002 5.9L Dodge Ram 1500. TContact 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 experi- enced technicians, to correctly install and receive the greatest possible benefit
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TABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii RECOMMENDED TOOLS FOR INSTALLATION: . . . . . . . . . . . . . . . . . . . . . . . . . . .iv 1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 2.1 INITIAL PREPARATION AND DISAS
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RECOMMENDED TOOLS FOR INSTALLATION: 1. Metric and Standard sockets sets 2. Metric and Standard combination wrenches 3. Phillips and common screw drivers 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. 12 mm allen wrench 10. Small heat source 11. 3/8 Tap NPT 12. Ruler 13. Air compressor 14. Air hammer P/N: 4809621 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured iv 18
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Section 1 INTRODUCTION 1.1 INTRODUCTION ongratulations! You have purchased the ***WARNING*** finest street Supercharger available for DO NOT attempt installation if any part(s) are missing from this kit. Failure to contact Paxton prior to beginning Cthe 2002 5.9L Dodge Ram 1500. The installation will result in a charge for any missing parts. centerpiece of this kit is the highly efficient and reliable Paxton Automotive Corp. NOVI- Before starting the installation, we suggest 2000 supercharger. A
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• Never rely solely on a jack when working under a vehicle. Always use an approved set of jackstands to support the vehicle and place them under the recommended lift points. • When jacking a vehicle, make sure it is on a level surface, prefer- ably concrete or asphalt. The transmission should be in “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
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Section 2 INITIAL PREPARATION AND DISASSEMBLY egin the initial preparation and disassembly E. Reinstall the inner fender liner bolts and clips. process by disconnecting the battery cables. B 2.2 FAN AND FAN SHROUD REMOVAL 2.1 AIR INTAKE ASSEMBLY REMOVAL A. Start by draining coolant in to a suitable A. Remove the spring clips that retain the top container. Locate the coolant petcock on the drivers side of the truck attach a piece of cover of the air assembly. And remove the hose to the petcock an
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2.3 ACCESSORY BELT, AND BELT TENSIONER REMOVAL A. Remove the Accessory belt by detensioning the Factory tensioner rotate the tensioner in a clock wise direction using a 15 mm wrench (See Fig. 2-d.) Fig. 2-f D. Remove the three bolts and nuts that retain the tensioner bracket and set aside to be reused in a later step of the installation. (See Fig. 2-g.) Fig. 2-d B. Remove the bolt attaching the dipstick to the alternator bracket and set the bolt aside to be reinstalled in a later step. (See Fig.
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Section 3 CRANK PULLEY AND COIL REMOVAL AND INSTALLATION coil from the existing coil bracket. Remove 3.1 CRANK PULLEY REMOVAL AND the factory coil bracket from the cylinder INSTALLATION head and set aside the coil bracket will be A. Loosen the large crank pulley-retaining bolt. replaced with a supplied coil bracket. B. Using a three jaw puller slowly remove the B. Attach the supplied coil bracket to the coil pulley you will have to use the retaining bolt with the supplied fasteners and install t
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This Page Left Intentionally Blank. P/N: 4809621 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 3-2 18SEP03 v1.0 Dodge Ram 1500(4809621v1.0)
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Section 4 SUPERCHARGER BRACKET ASSEMBLY 4.1 SUPERCHARGER MOUNTING BRACKET A. Remove the pulley from the stock accessory belt tensioner and the tensioner from the stock bracket for re-installation. B. This is how the bracket should look prior to installation. (See Fig. 4-a.) Note the acces- sory belt tensioner bracket. This spacer will have to be removed before you install the bracket. The dipstick goes between the ten- sioner and spacer. ***NOTE*** The idler pulley and pulley stand-off have bee
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4.2 ACCESSORY BELT TENSIONER 4.3 IDLER PULLEY STAND-OFF A. Install the tensioner using the factory nut A. Install the idler pulley stand-off. (See Fig. and washer. (See Fig. 4-d.) 4-g.) B. Install the idler pulley on the idler pulley stand-off and tighten to approximately 35 ft/lbs. Fig. 4-d B. Reinstall the factory tensioner pulley and Fig. 4-g factory accessory belt. (See Figs. 4-e, 4-f.) C. Install the oil drain hose to the supercharger using the hose and hose clamp provided. (See Fig. 4-h.
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4.4 OIL DRAIN A. On the passenger side of the truck, locate the engine oil filter just below the oil filter on the oil pan. (See Fig. 4-i.) Measure down 3/4" and make a mark. Make another mark between the two oil pan bolts. Using a 3/16" drill bit, drill a hole with a small piece of wire. A welding rod works well. Confirm there is nothing in the way of the provided punch. You may have to rotate the engine to gain clearance for the punch. Fig. 4-j C. Install the straight fitting for the oil feed
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4.7 SUPERCHARGER BELT A. Route the supercharger belt and accessory drive belt as shown. (See Figs. 4-k, 4-l.) ALT IDLER AC PUMP ACCESSORY TENSIONER WATER PUMP PS PUMP CRANK PULLEY Fig. 4-k / Factory accessory belt routing diagram Fig. 4-l / Supercharger belt routing P/N: 4809621 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 4-4 18SEP03 v1.0 Dodge Ram 1500(4809621v1.0)
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Section 5 AIR INTAKE AND DISCHARGE 5.1 AIR INTAKE ASSEMBLY A. Install the 4" sleeve to the supercharger inlet ***NOTE*** with the supplied clamps. Leave the clamps On some vehicles you may have to trim the retaining loose. ring. (See Fig. 5-c) to achieve best fit. B. Install the 180° plastic intake duct to the sleeve you installed onto the supercharger. With the 1" x 90° plastic barbed fitting installed, attach the factory crank case vent hose to the fitting with the provided hose clamp. C. Atta
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5.2 AIR DISCHARGE ASSEMBLY 5.3 BYPASS VALVE ASSEMBLY A. Remove the four factory inlet duct bolts and A. Assemble the bypass valve as shown in factory inlet duct adapter and set aside. It Fig. 5-f. will not be re-used. S/C DISCHARGE DUCT B. Install the bonnet adapter with the fasteners provided. Using lock tight on this bolt is recommended. (See Fig. 5-d.) AIR INTAKE DUCT Fig. 5-f B. Install the bypass valve with the vacuum/boost port facing downwards and tighten the clamps C. Install the 5/32"
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Section 6 FAN AND WINDSHIELD WASHER BOTTLE INSTALLATION 6.1 FAN AND FAN SHROUD INSTALLA- D. Cut the pump and fluid level sensor plugs leaving an adequate amount of wire away TION from the plug end. Lengthen the wires. A. Start by installing the fan space to the water Using the butt connectors and wire provid- pump and tighten to factory specs using ed, lengthen the wires and attach the plugs either a factory tool or a 1-1/16" wrench. to the pump and level sensor in their new B. With the fan and
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This Page Left Intentionally Blank. P/N: 4809621 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 6-2 18SEP03 v1.0 Dodge Ram 1500(4809621v1.0)
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Section 7 AUXILIARY FUEL PUMP INSTALLATION 7.1 FUEL PUMP ASSEMBLY A. Assemble the fuel pump assembly per Appendix 1017733. B. Install the assembled fuel pump assembly to the transmission cross member with the sup- plied fasteners. (See Fig. 7-a.) The fuel pump inlet should face the front of the vehi- cle. Fig. 7-b B. Attach the wire coming from the #30 termi- nal on the relay to the power distribution box on the driver’s side of the vehicle using a 3/8" ring terminal. Fig. 7-a C. Attach the #86
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E. Attach the #85 terminal wire to a suitable ground location. ***NOTE*** The #87A terminal will not be used. F. Attach a suitable length of wire with ring type terminals to the negative terminal on the additional fuel pump and attach this wire to the fuel pump assembly mounting bolt. G. Cycle the ignition several times to confirm the pump is running and check all fittings for leaks. P/N: 4809621 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 7-2 18SEP03 v1.0 Dodge Ram 1500(480
