paxton automotive novi 1000 supercharger 2001-2003 4.6l sohc

DP/N: 4809628 - V2.1 06/05/03

Owner’s Installation Guide for the

Paxton AutomotiveNovi 1000 Supercharger

for the

2001-2003 4.6L SOHC Mustang GTPaxton Automotive . 1300 Beacon Place . Oxnard CA 93033

805 604-1336 . FAX (805) 604-1337

P/N: 4809628©2003 Paxton AutomotiveAll Rights Reserved, Intl. Copr. Secured05JUN03 v2.1 MusGT(4809628 v2.1)

ii

FOREWORD

Before you start the installation of your supercharger Paxton superchargerkit, you will have to find the Paxton Computer Chip Voucher located inyour information packet. The 2001-2003 Mustang GT Supercharger Kitrequires a computer chip upgrade. You will need to fill out the chip vouch-er and send it and your computer to Paxton Automotive to receive yourchip upgrade. Please refer to section 7 of this manual for the procedure forremoving your engine control module.

Complete the Paxton Automotive/Ford Computer Chip Voucher andreturn it to Paxton Automotive to receive the proper computer module foryour vehicle.

© 2003 PAXTON AUTOMOTIVEAll 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: 4809628©2003 Paxton Automotive

All Rights Reserved, Intl. Copr. Secured05JUN03 v2.1 MusGT(4809628 v2.1)

iii

TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iiTABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iiiIMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv1.1 INITIAL PREPARATION AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12.1 SUPERCHARGER MOUNTING BRACKET ATTACHMEMT . . . . . . . . . . . . . . . . . . . . . . . .2-13.1 FAN RESISTOR RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14.1 PREPARING TO MOUNT THE SUPERCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15.1 OIL FEED AND DRAIN LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16.1 INTAKE TRACT MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17.1 ENGINE CONTROL COMPUTER REMOVAL AND MODIFICATION . . . . . . . . . . . . . . . . .7-18.1 IN-TANK FUEL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-19.1 FINAL ASSEMBLY AND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

List of Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Appendix A 1011816 ASY, S/C NOVI 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Appendix B 1015309 ASY, RADIATOR HOSE MODIFICATION . . . . . . . . . . . . . . . .A-4Appendix C 1016630 ASY, S/C MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . .A-5Appendix D 1015933 ASY, AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6Appendix E 1017017 ASY, AIR DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7Appendix F 1019336 ASY, OIL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8Appendix G 1019328 ASY, OIL RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9Appendix H 1015506 ASY, COMPRESSOR BYPASS . . . . . . . . . . . . . . . . . . . . . . . . .A-10Appendix I 1015530 ASY, FAN RESISTOR RELOC. . . . . . . . . . . . . . . . . . . . . . . . .A-11Appendix J 1017734 ASY, FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12Appendix K 7000170 DIAGRAM, BELT ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . .A-13


iv

IMPORTANT NOTES

Congratulations! You have purchased thefinest street supercharger available for theMustang GT. The centerpiece of this kit is

the High Efficiency PAXTON Supercharger, amechanically driven centrifugal blower.

This kit comes with all the parts you will need toinstall the supercharger. The instruction manual hasbeen edited in order of sequence, and photographsand drawings have been included to illustrate thetext. This will allow you quick part identificationand orientation.

The installation will require metric and SAE sock-ets and wrenches, a hand drill and bits, an AirHammer (and compressor), a 3/8” x 18 NPT tap,screwdrivers, and a supply of buckets for thereserve of coolant and oils.

We suggest that you obtain a copy of a Mustangshop manual for your model of car. This may beobtained from your dealer, or may be ordered by

mail from Helm Publications at (800) 782-4356.Become familiar with the details of your car’s sys-tem. If it is not operating within normal parame-ters, we do not recommend the installation or useof the supercharger.

For the quickest installation time, we suggest thatyou read this manual thoroughly before beginning.Make sure that you understand the process, haveidentified the areas of the car that you will beworking on, and have the tools that you will needon hand. The average installation time is 8 to 10hours, but your time will depend on your workingconditions, experience installing superchargers,personal skill level, and preparedness for the job.This estimate does not include time for the initialvehicle inspection, cleaning, fine tuning, or trou-ble-shooting. Once again, we recommend readingthe manual before beginning the process. We areavailable for tech support at (805) 604-1336,Monday through Friday, 7AM - 3 PM PST.

After reading the manual, verify that all major assembly groups are present in the main kit box. As youremove a box or bag, note the identification label and compare it to the parts list.

PAXTON AUTOMOTIVE makes every effort to insurethat all parts are included in the box. If you

discover that you are missing any part, or that a part was damaged in shipping, call PAXTON

immediately. DO NOT begin installation if a part is missing. Failure to contact PAXTON prior tobeginning installation will result in a charge for

the missing part.

We suggest that the engine compartment becleaned before the installation. You can clean theengine with a pressure washer that is found at self-

serve car washes. Use a safe-for-aluminum clean-er/degreaser, and cover the distributor and anyelectronics with a plastic bag to prevent water fromentering.

P/N: 4809628©2003 Paxton Automotive

All Rights Reserved, Intl. Copr. Secured05JUN03 v2.1 MusGT(4809628 v2.1)

v

You are undoubtedly eager to get started, butplease take a little more time to insure thatyour safety is not in jeopardy. A moment’s

lack of attention may cause a serious injury to you,or to someone else who happens to be standingaround. By following some simple safety precau-

PAXTON Automotive thanks you for your purchase. We welcome yourcomments and suggestions to help us improve our product.

tions, you can avoid many potential dangers. Thefollowing list is not meant to be a comprehensivelist, but rather it is meant to make you aware ofsome of the risks, and encourage you to take asafety minded approach to your work area.

• Never rely solely on a floor jack when working under-neath a vehicle. Always use jack stands that are ratedfor the weight of your vehicle, use them at the recom-mended lift points, and place your vehicle in ‘PARK’ or‘FIRST’ gear with the parking brake set.

• Always use eye protection when using power tools, suchas drills, saws, and grinders, or when working under-neath a vehicle.

• Never smoke, use an open flame, or have spark produc-ing items around gasoline or flammable objects. Alwayshave a fire extinguisher that is rated for chemical andelectrical fires handy when working on motor vehicles.Also, make sure that the extinguisher is fully charged.

• Operate engines only in a well ventilated area. CarbonMonoxide, gasoline, and solvent vapors are colorlessand sometimes odorless, and may asphyxiate andexplode without warning.

• Always disconnect the battery from your engine beforedoing work on the electrical or fuel systems, or doingunderdash work.

• The chemicals used in the vehicle systems, such as oilsand coolants, are poisonous. Clean up any spills imme-diately, and dispose of waste materials properly. Pets,wild animals, and children may die if they ingest the liq-uid.


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05JUN03 v2.1 MusGT(4809628 v2.1)

Section 1INITIAL PREPARATION AND REMOVAL

B. Before the air intake assembly can beremoved, you must first disconnect the plas-tic crankcase breather hose (A) and air idlebypass hose (B). Unplug the air temperaturesensor (C) and mass air flow sensor (D).(See Fig. 1-a.)

***NOTE***(2002-2003 GT only) The air intake temperature sen-sor is now located in the MAF. (Step “C” no longerapplies.)

Fig. 1-a

A

B

C

D

1.1 INITIAL PREPARATION AND REMOVAL

A. Begin the initial preparation and disassem-bly process by first disconnecting the nega-tive side of the battery, and draining one gal-lon of coolant from the coolant reservoir. Todo this, open the valve at the bottom of theradiator and allow to drain into a suitablecontainer. DO NOT allow coolant to drainonto floor, and be sure to mop up anycoolant splatter immediately. Animals likethe taste of coolant, and if they drink it, itwill kill them.

1-2P/N: 4809628©2003 Paxton AutomotiveAll Rights Reserved, Intl. Copr. Secured05JUN03 v2.1 MusGT(4809628 v2.1)

Fig. 1-b

Fig. 1-c

E. Once the assembly is out of the car, use a10mm socket to remove the mass air flowsensor and screen from the air filter housing(see Fig 1-d). Place the mass air flow sensoraside to be re-installed in a later step.

C. Using a flat-head screwdriver, loosen thehose clamps at the mass air flow sensor andthe throttle body, and remove the air intakehose (see Fig 1-b). Remove the air tempera-ture sensor from the air intake hose andplace it aside—it will be re-installed in alater step.

NOTE: On 2002-2003 GTs this step will not bedone.

D. Use an 8mm socket to remove the single airfilter housing retaining bolt. The air filterand mass air sensor can then be removed asan assembly. (See Fig 1-c.)

Fig. 1-d

E. The coolant reservoir is secured by threenuts (see Fig 1-e). Use a 10mm socket toremove these, and place the reservoir aside.Remove the upper radiator hose.

Fig. 1-e

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Section 2SUPERCHARGER MOUNTING BRACKET ATTACHMENT

2.1 SUPERCHARGER MOUNTING BRACKET ATTACHMENT

Fig. 2-a

A. Loosen (but do not remove) the four 10 mmhead bolts securing the water pump pulley.Next, remove the accessory drive belt usinga 3/8-inch drive ratchet or breaker bar intothe square at the end of the tensioner, androtate the tensioner clockwise. This willrelieve the tension on the belt so it can beremoved. It will not be re-used. (See Fig. 2-a.)

B. Use a 13 mm socket to remove the idler pul-ley, located above the belt tensioner (see Fig2-b). Place the pulley aside to be used in alater step. Now, you may finish removingthe four 10mm bolts securing the waterpump pulley, and place the pulley and itsfasteners aside for use in a later step.

IDLER PULLEY

Fig. 2-b

C. Next, remove three bolts at the front of theengine (see Fig 2-c). A 10mm alternatormounting bolt (A), and two 13 mm timingcover bolts (B and C).

Fig. 2-c

C

B

A


D. Remove both nuts using a 10mm and 13mmsocket. Then remove both studs using a13mm and 18mm socket. Enlarge the hole inthe tab that held the wiring harness to theoutermost stud. Using a round file, enlargethe hole so that it will slip over the largediameter of the stud. This tab will get sand-wiched between the cylinder head and aspacer in a later step.(See Fig 2-d.) Note thaton some of the 2001-2003 GTs this step willnot be required and a .065 shim will go inits place.

REMOVE THESE TWO STUD BOLTS

Fig. 2-d

E. Install the supercharger idler pulley bracketusing the supplied hardware. Be sure toinstall spacer between bracket and alternator.(See Fig 2-e)

Fig. 2-e

***NOTE***This photo is for illustration purposes. It will be easi-er for you to install this bolt/spacer first, then installthe other two mounting bolts.

F. Re-install the factory idler pulley using thefactory hardware (see Fig. 2-f), followed bythe supplied supercharger idler pulley (seeFig. 2-g).

Fig. 2-f

Fig. 2-g

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G. Install the supercharger rear support bracketas shown in Fig 2-h. Temporarily install thelong 10mm bolt to line up the bracket.Leave the bolts finger tight, as it will benecessary to move the bracket when youinstall the main supercharger bracket.(This photo is for illustration only. You willhave to install the supercharger and acces-sory belt before installing the bracket. Therewon’t be clearance after the bracket isinstalled.)

Fig. 2-h

Fig. 2-i

H. Modify the previously removed upper radia-tor hose with supplied hose, aluminum cou-pler and clamps. See Appendix ‘B’(1015309) for diagram of modification.

***NOTE***The radiator hose assembly needs to clear the super-charger, so it is better to leave it long and trim theassembly later than to end up short. The finishedradiator assembly is shown in Fig. 2-i.

I. Before installing the main superchargerbracket, the A/C refrigerant refilling portmust be bent from its upright position down-ward, so that the cap is facing the driver’sside fender. (See Fig 2-j.)

Fig. 2-j

***NOTE***If possible, use a proper tubing bender for this step.If one is not available, the line can be bent by hand,but extreme care must be taken as the refrigerantwithin the line is under very high pressure. In anycase, use a pair of heavy gloves and eye protection toprevent injury in the event of a ruptured line.

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Section 3FAN RESISTOR RELOCATION

3.1 FAN RESISTOR RELOCATION

A. Disconnect the wiring harness from the fanresistor. (See Fig. 3-a.) Remove clips hold-ing the fan resistor to the fan shroud. Attachthe fan resistor to the supplied bracket usingthe supplied hardware.

Fig. 3-a

B. Trim the fan resistor mounting tabs on thefan shroud to provide clearance for the airintake assembly.(See Fig. 3-b.) The fanshroud should look like this after trim-ming.(See Fig. 3-c.)

Fig. 3-b

Fig. 3-c

C. Re-attach the fan resistor to the wiring har-ness to ensure adequate wire length. (SeeFig. 3-d.) Position the fan bracket on thepassenger side of the lower fan shroud.Mark two mounting points along the fanshroud and drill the holes. Attach the mount-ing bracket with the supplied hardware.

Fig. 3-d

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Section 4PREPARING TO MOUNT THE SUPERCHARGER

A. Mount the main supercharger bracket,installing the two 3/8 bolts and spacers inthe upper portion of the bracket. Install thelong 6mm bolt and spacer in the lower mid-dle portion of the bracket, sandwiching theA/C support between the spacer and rearmounting bracket. Next, install the lowermost bolt and two spacers: one in betweenthe support and main brackets, one inbetween the two brackets and the otherbetween the rear bracket and the cylinderhead. The small metal tab securing thewiring harness gets sandwiched between thecylinder head and the spacer. Leave every-thing finger tight at this point.

***NOTE***The drive belt, shown in this picture, should beinstalled at this point.(See Fig. 4-a.)

4.1 PREPARING TO MOUNT THE SUPERCHARGER

Fig. 4-a

B. Next, install the bolt and spacer at lowerright portion of the bracket. (See Fig. 4-b.)Go back and tighten all bolts on the mount-ing bracket, being careful not to over torquethe small 6mm bolt. Install the supplieddrive belt as shown. (See Fig. 4-a.)

Fig. 4-b

C. Install the supercharger oil drain-back hoseon the supercharger. (See Fig. 4-c.)

***NOTE***The hose clamp screw head should be parallel tothe supercharger mounting base.

Fig. 4-c


D. Remove the drive belt from the alternatorpulley. Install the supercharger into the mainbracket, while looping the drive belt aroundthe supercharger pulley. (See Fig. 4-d.)

Fig. 4-d

E. Tighten the supercharger mounting bolts.Once the supercharger is installed, releasethe belt tensioner and loop the belt backaround the alternator pulley. (SeeAppendix K for a diagram of the drive beltrouting.)

***NOTE***For maximum performance, PAXTON Automotive rec-ommends the factory stock platinum spark plugs bereplaced with a copper spark plug (Autolite 764 orequivalent) gapped to .035.

F. Remove the two 8mm bolts on either end ofthe Fuel Injector Rail and lift the unit out.Replace the stock injectors with the suppliedinjectors. Use white lithium grease on the O-rings to insure a smooth fit.

Fig. 4-e

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Section 5OIL FEED AND DRAIN LINES

5.1 OIL FEED AND DRAIN LINES

A. Your Paxton Automotive NOVI 1000 super-charger uses pressurized engine oil for lubri-cation. Use an oil sending unit socket (Snap-On tools; part number 6152 or equivalent) toremove the oil sending unit on the undersideof the oil filter housing (see Fig 5-a). Installthe supplied brass junction fitting using asmall amount of Teflon paste. DO NOTUSE TEFLON TAPE. Once installed, thejunction fitting should be oriented so thatthe opening faces toward the front of the car.

Fig. 5-a

B. Install the oil sending unit in the end of thebrass junction. Install the 90 degree 1/8-inchto -4 fitting into the side of the brass junc-tion, and orient this fitting to face towardsthe driver’s side frame rail. Attach the sup-plied length of braided stainless steel feedline, and route upwards to the 90 degree fit-ting on the supercharger.

***NOTE***Be sure to stay clear of any moving parts or coolanthoses (engine vibration can cause the stainless lineto chafe the rubber coolant hose, creating a leak overtime). Install the line, and tighten moderately—nosealant is required. (See Fig. 5-b.)

Fig. 5-b

C. Mark the front of the oil pan 1" inch belowthe pan rail and between the the two pan railbolts, directly in the center of the small‘hump’. (See Appendix G.) Cover a 3/16-inch drill bit with heavy grease and drill apilot hole (see Fig. 5-c). The grease willhelp prevent metal particles from falling intothe pan. Once the hole has been drilled,insert a straight length of welding rod orheavy wire (such as a coat hanger) into thehole approximately three inches to makesure no interference is encountered. If thepath is blocked, turn the engine over untilthe pathway is clear.

Fig. 5-c


D. Next, apply a small amount of anti-seizelubricant to the tip of the punch, and insert itinto the pilot hole. Hit the punch with an airhammer carefully using small bursts, untilthe punch is inserted up to its shoulder. Thehole should measure 9/16". (See Fig 5-d.)

NO DEEPER THAN THIS

Fig. 5-d

***NOTE***Do not use hand tools. Using an ordinary hammerwill dent the pan. Use extreme caution not to makethe hole to big, or the drain fitting will not fit and thepan will be ruined.

E. Apply a liberal amount of heavy grease to a3/8 inch x 16 NPT tap (not included), andgradually thread into the hole. Clean thethreads using a clean rag and an approvedsolvent, such as carburetor cleaner.

F. Apply a ample amount of silicone RTV tothe threads of the supplied 3/8-inch pipe to -8 fitting and insert into the hole, being care-ful not to over-tighten. (See Fig. 5-e.)

Fig. 5-e

G. Install the supercharger drain-back hose fit-ting so that the elbow is oriented toward thepassenger side, away from the harmonic bal-ancer/crank pulley.(See Fig 5-f.)

Fig. 5-f

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05JUN03 v2.1 MusGT(4809628 v2.1)

Section 6INTAKE TRACT MODIFICATIONS

6.1 INTAKE TRACT MODIFICATIONS

A. Install the discharge tube assembly asshown, using the supplied rubber sleevesand stainless steel clamps. (See Fig. 6-a.)

Fig. 6-a

B. Install the supplied length of rubber hose tothe end of the hard crank case ventilationline that runs from the driver’s side valvecover across the engine, (see Fig 6-b). Routethe hose over the passenger side valve coverand towards the front of the engine.

Fig. 6-b

C. Install the idle air control valve to the throt-tle body housing with the original hose, andto the discharge tube with the suppliedlength of rubber hose and hose clamps. (SeeFig 6-c.)

Fig. 6-c

D. The supercharger bypass valve requires avacuum source. Remove the existing plasticcoupler in the vacuum hose that runs alongthe firewall on the passenger side. Replacewith the supplied vacuum ‘T’.( See Fig 6-d.)Attach the supplied length of vacuum hose,and route along the passenger side frame railtowards the supercharger. It will be connect-ed to the bypass valve assembly in a laterstep.

Fig. 6-d


E. Remove the screen from the MAF, whichwas removed in step 4.(See Fig. 6-e.)

Fig. 6-e

F. Assemble the MAF, mounting bracket,MAF/air filter adapter and air filter. TheMAF bracket assembly may look differentfrom what you receive in your kit, but theassembly procedure is the same.

G. Using the supplied 1/4-20 hardware, mountthe MAF meter to the MAF bracket andsecure. Remove the factory MAF screenbefore attaching the meter to the new brack-et.

Fig. 6-f

Fig. 6-g

H. Attach the supplied K & N air filter, 3-1/2”sleeve, 90° 3-1/2” elbow and #56 hoseclamps to the MAF and secure.

I. Insert the factory air temperature sensor intothe rubber grommet located on the side ofthe supplied 3-1/2" x 90° elbow. Lubricatefor easier fit.

***NOTE***2002-2003 models do not have a separate IAT sen-sor. Use the supplied elbow without a hole or grom-met for 2002-2003 models only.

J. Using a #52 hose clamp, connect the pieceof 3-1/2” flex hose to the elbow attached tothe MAF meter and route it through theopening in the right side inner fender towardthe supercharger. Make sure the 3 1/2” flexhose does not contact or rub on the edge ofthe inner fender opening. (Eventual hosefailure will result if the hose is not properlyrouted.)

K. The MAF/air filter assembly will be relocat-ed inside the passenger fender. Remove thetwo nuts that secure the passenger sidebumper cover to the inner fender. (See Fig. 6-g.) Next, locate the screw at the forward,lower edge of the passenger side wheelopening and remove it. This will allow theplastic inner fender to be pulled back so theMAF/air filter assembly can be installed.

MAF BRACKET MOUNTING LOCATION

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Fig. 6-h

L. Place the MAF/air filter bracket over theexisting studs, then secure with the originalnuts. (See Fig. 6-h.)

M. Carefully open the main wiring harness(runs from the passenger side inner fenderinto the engine compartment) with a razorblade, making an incision that is approxi-mately 6-inches long. Pull the MAF wiringupwards, until the wires are long enough tobe routed back through the opening in theinner fender, and down to the MAF. (SeeFig. 6-i.)

Fig. 6-i

P. Connect the plastic inlet duct (with bypassvalve and hoses attached) to the supercharg-er inlet. This is to illustrates what the MAFassembly should look like after assembly.(See Fig. 6-k.)

FRONT

INSIDERIGHT FRONTPASSENGERFENDERWELL

#56 CLAMPS

FACTORY AIRTEMPERATURE SENSOR

(NOT ON 2002+ MODELS)

3-1/2" ELBOW

SLEEVE

FACTORYSTUDS & NUTS

Fig. 6-k

N. Insert the 1" x 10" rubber hose to the inlet ofthe compressor bypass valve. Secure bothhoses with the supplied #16 hose clamps.

O. Install the bypass valve assembly on theunderside of the secondary intake tube. (SeeFig. 6-j.) Tighten the hose clamp to securethe valve assembly to the intake tube.

Fig. 6-j


Fig. 6-l

T. Place the secondary intake tube/bypassvalve assembly on the supercharger inlet,and attach it to the flex hose. Attach theother end of the bypass valve to the dis-charge tube. Connect the hose that was pre-viously installed on the hard plastic crankcase ventilation line to the brass fitting onthe intake tube. Tighten the clamps. The fin-ished installation appear as in Fig. 6-m.

Fig. 6-m

Q. Join the supercharger inlet duct to the previ-ously installed MAF hose with the supplied#52 hose clamp.

R. Connect the opposite ends of each hose tothe crankcase breather fitting on the driver’sside valve cover (5/8” hose) and the idle aircontrol resonator (3/x4” hose). Trim hoselength if required.

S. Install the 5/8” hose union into thecrankcase breather line. It may be necessaryto trim this line to ensure a proper fit. (SeeFig. 6-l.)

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Fig. 7-a

Section 7ENGINE CONTROL COMPUTER REMOVAL AND MODIFICATION

7.1 ENGINE CONTROL COMPUTERREMOVAL AND MODIFICATION

B. Pull the harnesses down and out of the way,creating unobstructed access to the comput-er. Remove the 7/32 screw that secures theretention strap (see Fig. 7-b) and pull thecomputer out of the foot well.(see Fig. 7-c.)

A. Remove the passenger side door sill plate,followed by the passenger side kick panel.This will reveal the engine control computerand its harnesses. The harnesses are securedusing clips, which are attached to a smallmetal bracket. Pull the harnesses off thebracket, then remove the two 7/32-inch boltsthat secure the bracket itself. Remove thebracket.(See Fig. 7-a.)

Fig. 7-b

Fig. 7-c


D. Remove the 10mm bolt that secures themain harness to the computer, and removethe harness. (See Fig. 7-d.)

E. Once the computer is removed from the car,you will need to send your computer and thechip voucher to Paxton Automotive. Thecomputer will be cleaned, a computer chipinstalled and returned to you, ready to beinstall back into your vehicle.

Fig. 7-d

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Section 8IN-TANK FUEL PUMP INSTALLATION

8.1 IN-TANK FUEL PUMP INSTALLATION (2001-2002 Models Only)

A. Raise the rear of the car and support it withjack stands.

B. Open the fuel door and remove the fuel capand the three filler neck screws using a10mm socket.

C. Remove the fuel filter inlet line with a 3/8"spring-lock tool.

D. With the weight of the fuel tank supportedwith a jack, remove the bolts securing thetwo fuel tank straps.

E. Slowly lower the fuel tank, allowing it tolean over with the filler side up until theelectrical connections leading to the centermounted fuel pump are revealed. Disconnectthese two electrical connections.

F. Remove the six bolts securing the fuel pumpaccess cover (on top of the fuel tank) withan 8mm wrench. Depress the two clipssecuring the plastic fuel pump enclosure andslide it out of the tank. The fuel sender floatis attached to the fuel pump enclosure andmust be handled with care. Ensure that thetank has been lowered enough to remove thefuel pump enclosure.

G. Remove the two screws securing the plasticfuel pump outlet manifold to the enclosurecap. Pull the manifold up and away from thefuel pump.

H. Remove the three screws securing the fuelpump enclosure's cover using a 3/16" nutdriver and remove the cover. Modify thefuel pump cover as shown. (See Figs. 8.1-a, 8.1-b.)

I. This allows the larger O.D. pump to fit inthe cover.

J. Remove the stock fuel pump from its enclo-sure. Separate the rubber pump support frombeneath the filter and install it on the sup-plied pump. Secure the support with the newpump provided.

K. Cut the two fuel pump power wires about 1"from the fuel pump electrical connector.Noting the corresponding (+) and (-) con-nections, splice the supplied wiring harnessinto place using two butt connectors.

L. Using the supplied fuel pump, reassemblethe fuel pump assembly and canister withcap. Install the supplied 1/8" spacers beneaththe pump outlet manifold and canister capand install the modified pump assembly.(See Fig. 8.1-c.)

Fig. 8.1-a

Fig. 8.1-b

TRIM TO TABS

BYPASSTUBE

PLASTICFUEL PUMP

OUTLETMANIFOLD

VORTECH SUPPLIED#6 x .75" SCREWS

FUELOUTLETHOSE

FUEL PUMP OUTLET

SUPPLIED 1/8"SPACERS

PUMP CANISTER

Fig. 8.1-c


BYPASSTUBE

PLASTICFUEL PUMP

OUTLETMANIFOLD

FUELOUTLETHOSE

FUEL PUMP OUTLET

PUMP CANISTER

Fig. 8.2-a

M. Remove the screen from the bottom of thecanister assembly being careful not to punc-ture flapper valve. (See Fig. 8.2-b.)

N. Reinstall the fuel tank, reconnect the fuelfilter inlet line, reattach the fuel filler neck,and reinstall the fuel pump.

O. Turn the ignition key on and check for fuelleaks.

The installation is complete.Congratulations!

Fig. 8.2-b

A. Raise the rear of the car and support it withjack-stands.

B. Open the fuel door and remove the fuel-capand the three filler neck screws using a10mm socket.

C. Remove the fuel filter inlet line with a 3/8springlock tool.

D. With the weight of the fuel tank supportedwith a jack, remove the bolts securing thetwo fuel tank straps.

E. Slowly lower the fuel tank, allowing it tolean over with the filler side up, until theelectrical connections leading to the centermounted fuel pump are revealed. Disconnectthese two electrical connections.

F. Remove the six bolts securing the fuel pumpaccess cover (on top of the fuel tank) withan 8mm wrench. Depress the two clipssecuring the plastic fuel pump enclosure andslide it out of the tank. The fuel sender floatis attached to the fuel pump enclosure andmust be handled with care. Ensure that thetank has been lowered enough to remove thefuel pump enclosure.

G. Remove the two screws securing the plasticfuel pump outlet manifold to the enclosurecap. Pull the manifold up and away from thefuel pump. (See Fig. 8.2-a.)

H. Remove the three screws securing the fuelpump enclosure’s cover using a 3/16 nut-driver and remove the cover.

8.1 IN-TANK FUEL PUMP INSTALLATION (2001-2002 Models Only), cont’d.

8.2 IN-TANK FUEL PUMP INSTALLATION (2003 Models Only)

I. Remove the stock fuel pump from its enclo-sure. Separate the rubber pump support frombeneath the filter and install it on the sup-plied pump. Secure the support with the newfilter provided.

J. Using the supplied fuel pump, reassemblethe fuel pump assembly and canister withcap.

K. Reinstall the canister assembly into the fueltank and reattach the electrical connections.

L. Reinstall the fuel tank, reconnect the fuel fil-ter inlet line, reattach the fuel filler neck andreinstall the fuel cap.

M. Turn the ignition key on and check the fuelpump for leaks.

8-3P/N: 4809628


05JUN03 v2.1 MusGT(4809628 v2.1)

Fig. 8-c / Completed Installation

9-1P/N: 4809628


05JUN03 v2.1 MusGT(4809628 v2.1)

Section 9FINAL ASSEMBLY AND CHECK

We know that you are anxious to get outand drive your new vehicle, but pleasetake a little bit more time to perform

these simple check-out steps.

A Inspect all wiring harnesses and electricalconnections. Make sure that all items areproperly routed, connected and secured. Ifavailable, check grounds with an amp meter.If the ground connection is suspect, connectto the battery ground.

B. Check all hoses, lines, and fittings for prop-erly secured connections..

C. Make certain all fasteners, brackets, andclamps are installed and properly tightened.

D. Check serpentine accessory belt and super-charger drive belts for proper tension andalignment.

E. Cycle ignition key from “off” to the “on”position 4-5 times.

F. Check the entire fuel system for possibleleaks.

G. Start engine and verify that the oil pressureis within normal range.

H. Allow the engine to come up to normaloperating temperature.Turn the engine off.

I. Check the coolant level in the coolant recov-ery bottle and top off as needed.

J. Check the following:• Fluid Leaks• Fluid Levels• Belt Slippage• Throttle Response

Now that the work is done, it’s time to enjoy. PAXTON Automotive wants to thank you forchoosing our product, and wants to remind you thatthe performance and response of your vehicle isnow different that what you are used to. Pleasedrive cautiously until you have grown accustomedto the feel of your vehicle.

Please see the service manual included in your kitfor information on the service and maintenance ofyour PAXTON Supercharger. Belt tightening,troubleshooting, special tuning requirements, andwarranty information is also included in theService Manual.

9.1 FINAL ASSEMBLY AND CHECK

A-1P/N: 4809628


05JUN03 v2.1 MusGT(4809628 v2.1)

APPENDIX

A-2P/N: 4809628©2003 Paxton AutomotiveAll Rights Reserved, Intl. Copr. Secured05JUN03 v2.1 MusGT(4809628 v2.1)

Please realize that PAXTON Automotive is con-stantly improving the performance and look of theNOVI 1000 supercharger. Parts in your kit mayappear differently than what is pictured in this manu-al. This is due to photographs taken in pre-produc-tion, a change in material, costs, or an improvementin performance.

Rest assured that you have purchased the best qualitykit that PAXTON Automotive manufactures at thistime. The installation of the materials will remain thesame.

List of Appendices

Appendix Number.... ..DWG Number............... .DWG Title

Appendix A 1011816 ASY, S/C NOVI 1000Appendix B 1015309 ASY, RADIATOR HOSE MODIFICATIONAppendix C 1016630 ASY, S/C MOUNTING BRACKETAppendix D 1015933 ASY, AIR INTAKEAppendix E 1017017 ASY, AIR DISCHARGEAppendix F 1019336 ASY, OIL SUPPLYAppendix G 1019328 ASY, OIL RETURNAppendix H 1015506 ASY, COMPRESSOR BYPASSAppendix I 1015530 ASY, FAN RESISTOR RELOC.Appendix J 1017734 ASY, FUEL PUMPAppendix K 7000170 DIAGRAM, BELT ROUTING

A-3P/N: 4809628


05JUN03 v2.1 MusGT(4809628 v2.1)

SCAL

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ITEM

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PART

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23

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A-5P/N: 4809628


05JUN03 v2.1 MusGT(4809628 v2.1)

SCAL

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PART

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RIPT

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

1 10 6 2 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1 2 1 1 1 1

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LET

1

ITEM

NO.

QTY.

PART

NO.

DESC

RIPT

ION

1 2 4 5 6 7 8 9 11 12 13 14 15 16 17 18 1931 1 2 1 3 1 1 4 4 4 2 1 1 1 1 1 11

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