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DP/N: 4809625 - 97-01 5.2/5.9 Dodge v2.0 11/25/03

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

Summary of content (38 pages)

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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.
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FOREWORD T 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 Dodge. 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.
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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 25NOV03 v2.
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Section 1 INTRODUCTION C ongratulations! You have purchased the finest street Supercharger available for the 1997/2001 5.2/5.9L Dodge engine. The centerpiece of this kit is the highly efficient and reliable Paxton Automotive Corp. NOVI 2000 supercharger. A mechanically driven (by belt) centrifugal blower (supercharger). This kit comes with all of the parts you’ll need for a successful installation. The operations required have been grouped in order of sequence.
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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 (-) terminal of the battery when doing any electrical, fuel system or under dash work.
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Section 2 INITIAL PREPARATION AND DISASSEMBLY Begin the initial preparation and disassembly process by disconnecting the battery cables. 2-1 AIR INTAKE ASSEMBLY 2-2 FAN AND FAN SHROUD REMOVAL A. Start by removing fan clutch nut. (See Fig. 2-c.) 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.
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2-3 DISASSEMBLY OF ACCESSORY BELT, COIL, AND BELT TENSIONER A. Using a wrench on the accessory belt tensioner, rotate the tensioner counter-clockwise 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 B. D. Remove the nuts and bolts(3) attaching the tensioner bracket, coil bracket, stud and nut from the front of the engine. (See Fig. 2-h.
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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. 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.) Cut these three mounting tabs just above the case retaining screws. (See Fig. 3-c.) Fig. 3-c C.
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Section 4 SUPERCHARGER INSTALLATION AND ASSEMBLY 4-1 S/C 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 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.
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B. Install the spacer and pulley. Re-use the factory center bolt and install the six bolts and washers that are supplied in the kit. Torque to factory specifications. (See Fig. 4-d.) H Install the tensioner using the factory nut and washer. (Fig. 4-e.) *** NOTE *** On 1999-2001 vehicles follow the procedures below. 4-3. CRANK PULLEY REMOVAL AND INSTALLATION. A. Loosen the large crank-pulley retaining bolt. B. Using the three-jaw pulley, slowly remove the pulley.
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4-4 SUPERCHARGER INSTALLATION A. Install the idler Pulley Stand-off with the hardware provided. Attach the supercharger 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 brass TEE facing up. D.
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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. Fig. 4-l Install the bracket using the bolts, nuts, and washers supplied in the kit. Attach the air filter in the wheel well. C.
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B. Attach the bonnet with the supplied bolt and washer. 4-11 FAN AND FAN SHROUD REINSTALLATION A. Install the new fan spacer to clear the new lower crank pulley. (Fig. 4-s.) C. Connect the air dicharge tube to the bonnet. 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.
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Section 5 FUEL SYSTEM MODIFICATIONS 5-1 FUEL ENRICHMENT A. Disconnect the stock fuel supply fitting at the fuel rail. B. Using the fuel pressure regulator as a template, drill two .Ø145. holes and mount the fuel pressure regulator to the firewall. (See Fig. 5-a.) D. Route the fuel lines between the fuel pump and fuel pressure regulator. Connect the fuel line between the fuel pressure regulator and the fuel rail using the supplied fitting. Connect the fuel line from the fuel pump to the stock fuel line.
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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 master and mount relay with supplied screws. E. Hook up the vacuum lines as shown in appendix. (Per schematic.) A. Remove the fuse box cover located on the driver’s side near the firewall. Using the Paxton Injector Controller as a template, drill two holes and connect the fueler to the fuse box cover with the supplied hardware. (See Fig. 5-d.
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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.
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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 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.
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Section 6 FINAL CHECK OUT AND START-UP This section covers pre-start checks and inspections, as well as initial start-up. 6.1 INSPECT THE FOLLOWING: A. Wires, harness and electrical connections. Are all items properly dressed, connected and secured? B. Hoses, lines and fittings. Are all items properly dressed, connected and secured? C. Fasteners, brackets, and clamps. Are all items properly installed and tightened? D. Fluid levels.
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APPENDIX Drawing No. . . .1016415 . . . . . . . . S/C Asy, 97-01 Dodge N2K CRV Drawing No. . . .1016621 . . . . . . . . Asy, S/C Mtg Brkt Drawing No. . . .1015932 . . . . . . . . Asy, Air Intake, 97-98 Dodge Drawing No. . . .1015935 . . . . . . . . Asy, Air Intake, 99-01 Drawing No. . . .1020115 . . . . . . . . Asy, Air Discharge Drawing No. . . .1019341 . . . . . . . . Asy, Oil Supply Drawing No. . . .1016070 . . . . . . . . Asy, Oil Drain Drawing No. . . .1017415 . . . . . . . .
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P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) A-2 13 14 12 11 LONG HUB 10 TOWARD S/C S/C ROTATION 25 4 2 33 AS REQD 32 31 30 26 2 AS REQD 29 28 27 2 Drawing No. 1016415 8 9 6 18 4 REQD 19 ALIGN MOUNTING HOLE IN VOLUTE WITH EDGE OF GEARCASE AS SHOWN. 3 3 23 3 REQD 7 21 22 3 2 2 NONE APPR. WEIGHT 21.8 LBS G.
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A-3 P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) 16 15 12 11 9 8 5 10 TO S/C 6 4 PLACES Drawing No. 1016621 5 PLACES 5 TO S/C 5 13 1 ITEM NO. QTY. 1 1 1 2 1 3 1 4 8 5 4 6 2 7 1 8 5 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 FINISH WEIGHT APPR. 7.2 LBS G.
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P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) A-4 NOTES: UNLESS OTHERWISE SPECIFIED 17 TO COMPRESSOR BYPASS VALVE 13 16 11 21 1 12 3 2 15 3x 4 3 10 14 8 15 6 TO S/C 8 11 9 7 1 ITEM NO. QTY. 1 1 1 2 6 3 3 4 3 5 1 6 1 7 2 8 1 9 3 11 1 12 1 13 14 1 2 15 1 16 17 1 1 19 1 20 21 1 FINISH NONE 10/5/00 G. COMPTON Asy, Air Intake WEIGHT APPR. 10/5/00 D SCALE: 1:2.5 SIZE PART NO.
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A-5 P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) 11 8 13 Drawing No. 1015935 10 TO EXISTING MTG BOLT 8 4 TO S/C ASY 3 2 3 12 FINISH NONE .9 LBS G. COMPTON 4/11/01 Asy, Air Intake 99-01 WEIGHT APPR. SCALE: SIZE 1:2 D TO VALVE COVER 1015935 DO NOT SCALE DRAWING DWG. NO. ASY, AIR INTAKE 99/01 5.9L DODGE DURANGO REV.
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P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) A-6 8 1 1 TO THROTTLE BODY 1 1 1 13 6 TO FUEL RAIL 5 4 5 7 10 Drawing No. 1020115 11 TO S/C ASY 10 1 3 6 10 10 2 6 8 ITEM NO. QTY. 1 1 2 1 3 1 4 1 5 1 6 2 7 2 8 1 9 2 10 4 11 2 12 1 13 1 14 1 15 2 16 1 FINISH 4 NONE 5.7 LBS G. COMPTON Asy, Air Discharge WEIGHT APPR. 10/6/00 SCALE: 1:1.25 D 1020115 DO NOT SCALE DRAWING DWG. NO.
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A-7 P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) TO S/C OIL JET 3 Drawing No. 1019341 1 TO STOCK OIL SENDER UNIT 4 QTY. 1 1 1 1 ITEM NO. 1 2 3 4 2 PART NO. 7PP250-034 7P125-004 7P250-031 7U250-090-400 FINISH WEIGHT APPR. .6 LBS G. COMPTON 10/6/00 Asy, S/C Oil Supply Hose NONE UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING, DIMENSIONS ARE IN INCHES DO NOT MANUALLY UPDATE TOLERANCES ARE: .XX± .
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P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) A-8 1. SHIP ITEM LOOSE. NOTES: UNLESS OTHERWISE SPECIFIED TO OIL PAN 3 2 Drawing No. 1016070 2 QTY. 1 2 1 1 FINISH NONE G. COMPTON 0.5 LBS Asy, Oil Drain WEIGHT APPR. 10/6/00 DESCRIPTION C 1:1 1016070 DO NOT SCALE DRAWING DWG. NO. ASY, OIL DRAIN DODGE DURANGO REV.
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A-9 P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) 5 4 3 Drawing No. 1017415 2 10 8 7 6 TENSIONER PIN LOCATION 1 1 1017415 1017415-P FINISH WEIGHT APPR. 5.3 LBS G. COMPTON 10/6/00 Asy, Belt Tensioner (8-Grv) NONE PART NO. SCALE: 1.25:1 SIZE 1017415 DO NOT SCALE DRAWING DWG. NO. ASY, BELT TENSIONER(8 GRV) DODGE DURANGO REV.
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P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) A-10 NOTES: UNLESS OTHERWISE SPECIFIED IDLER PULLEY S/C 5 3 4 Drawing No. 1019715 TENSION PULLEY 1 FINISH NONE 4.1 LBS G. COMPTON Asy, Crank Pulley WEIGHT APPR. 10/6/00 SCALE: 1:1.5 D PART NO. 4PCD018-011 4PCD017-011 7A312-401 7K312-001 2A048-630 SIZE ITEM NO. QTY.
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A-11 P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) NOTES: UNLESS OTHERWISE SPECIFIED 1. SHIP ITEM LOOSE. IDLER S/C 5 9 2 Drawing No. 1019717 TENSION 7 1 ITEM NO. QTY. 1 1 6 2 1 3 1 5 1 6 3 7 6 9 FINISH WEIGHT 13.0 LBS G. COMPTON 4/11/01 Asy, Crank Pulley 99-01 NONE APPR. UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING, DIMENSIONS ARE IN INCHES DO NOT MANUALLY UPDATE TOLERANCES ARE: .XX± .01 DECIMALS: .XXX±.
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P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) A-12 2 3 1. THESE ITEMS SHIP LOOSE. NOTES: UNLESS OTHERWISE SPECIFIED 2x Drawing No. 1020215 1 1 1 1 1 ITEM NO. 1 2 3 4 5 6 7 .8' 4 .7' .8' QTY. 1 2 2 FINISH NONE .2 LBS G. COMPTON Asy, Coil Relocation WEIGHT APPR. 10/6/01 UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING, DIMENSIONS ARE IN INCHES DO NOT MANUALLY UPDATE TOLERANCES ARE: .XX± .01 DECIMALS: .XXX±.
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A-13 P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) 2.75±.06 4 6 4 1 Drawing No. 1015509 TO AIR DISCHARGE ITEM 3 MODIFICATION DETAIL 3 4.00±.06 4 7 8 ITEM NO. 1 4 6 7 8 FINISH APPR. WEIGHT ----1.7 LBS Asy, Compressor Bypass NONE ----- UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING, DIMENSIONS ARE IN INCHES DO NOT MANUALLY UPDATE TOLERANCES ARE: .XX± .01 DECIMALS: .XXX±.
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P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) A-14 21 8 1 5' LG. 15 THE REST OF THE DRAWING. 19 9 13 22 12 TO FRAME RAIL 1. HOSES NOT SHOWN IN PROPORTION TO NOTES: UNLESS OTHERWISE SPECIFIED 9 20 9 1 4 3 10 5 7 4 Drawing No. 1017735 TO STOCK FUEL LINE 11 12 7 2 9 9 1 ITEM NO. 1 2 3 4 5 6 7 9 10 12 13 14 15 16 17 21 20 22 31 32 33 34 35 QTY.
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A-15 P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.0) FUELER 1 2 4x 4 MSD UNIT GREY WIRE NOT USED PURPLE WIRE GREEN WIRE 11 WIRE INSIDE SPLIT POLY LOOM 23 PUMP GROUND WIRE 22 13 8 10 7 3x TO FUELER 21 1 14 TO NEG(-) ON FUEL PUMP 21 16 FINISH NONE G. COMPTON Fuel System WEIGHT APPR. 25 SCALE: 10/12/00 SIZE D 1:1 SCREW TO MOUNT HARNESS EXISTING WIRING TO POS(+) RED WIRE ON FUELER (TERM.
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1300 Beacon Place, Oxnard CA 93033 • Tel: 888 9-PAXTON • www.paxtonautomotive.com P/N: 4809625 ©2003 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25NOV03 v2.0 97-01 5.2/5.9 Dodge(4809625v2.