1996-1998 MUSTANG COBRA
Contents
1. three holes left by the coil mounting bracket The bolt spacer assembly arrow bolts into the hole left by the 13 mm bolt stud and sandwiches the A C line tab in place between the head and spacer Fig 16 13 Mount the supplied idler pulley on the idler support bracket using the supplied hardware Trial fit the idler pulley first if it does not fit one of the ribs on the alternator must be ground off Fig 17 When the pulley clears the alternator it can be bolted into place Install the stock idler pulley in its original location followed by the water pump pulley using the factory hard ware Fig 18 P N 4809609 PAGE 6 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA S ae 14 Install the supplied accessory supercharger WF drive belt and route as stock but do not install on alternator pulley until after the supercharger is installed Instead leave a loop in the belt Fig 19 15 The main supercharger bracket comes pre assembled Install it as shown Fig 20 Fig 21 The belt is shown looped around the alternator for clarity FIG 20 16 Insert bolts into the bracket from the back Attach the supercharger oil drain line to the fit ting at the bottom of the supercharger and lower the supercharger into place on the bracket while inserting the drive pulley through the loop in the belt Bolt the supercharger onto the main bracket using the supplied fasteners as shown Fi2. IL SUPPLY G 1019328 C ASY OIL RETURN H 1015406 B ASY COOLANT BOTTLE RELOCATION 1017306 B ASY SMOG PUMP RELOCATION J 1015506 D ASY COMPRESSOR BYPASS K 1015307 E ASY RADIATOR TUBE MODIFICATION L 1015206 B ASY A C LINE SPACER P N 4809609 PAGE 16 COPYRIGHT 2000 PAXTON AUTOMOTIVE
3. Kit 1001814 1 wig oe Hate r i P e o a Owner s Installation Manual for the PAXTON AUTOMOTIVE NOVI 2000 SUPERCHARGER 1996 1998 MUSTANG COBRA NON TUNED KIT PAXTON AUTOMOTIVE 1300 Beacon Place Oxnard CA 93033 805 604 1336 FAX 805 604 1337 P N 4809609d COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA Introduction Congratulations You have purchased the finest street supercharger available for the Mustang Cobra The centerpiece of this kit is the High Efficiency PAXTON Supercharger a mechanically driven centrifugal blower This kit comes with all the parts you will need to install the supercharger The instruction manual has been edited in order of sequence and photographs and drawings have been included to illustrate the text This will allow you quick part identification and orientation The installation will require metric and SAE sockets and wrenches a hand drill and bits an Air Hammer and compressor a 3 8 x 18 NPT tap screwdrivers and a supply of buckets for the reserve of coolant and oils We suggest that you obtain a copy of a Mustang shop manual for your model of car This may be obtained 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 system If it is not operating within normal parameters we do not recommend the installation or use of the supercharger For the qui
4. attach to the angled portion of the Y tube Install the upper portion of the Y tube into the CTM Fig 28 Y TUBE me CONNECTED COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA 20 Relocate the spark plug wire retainer by drilling a 17 64 inch hole across from an existing hole in the bracket Fig 29 arrow and move the bracket forward It will now be secured by only two factory bolts Fig 30 shows the completed spark plug wire retaining bracket in place EXISTING HOLE NEW HOLE pama 7 o o d BRACKET q ul ft al PERETI we 5 j L E 9 16 FIG 29 4 gt FIG 30 21 To provide clearance for the washer bottle modify the driver s side radiator support bracket by cutting a notch in it as shown in Fig 31 22 Relocate the coolant reservoir by widening the notches in the plastic cover and installing the Paxton supplied aluminum relocation tabs using the stock hardware Fig 31 arrows This will move the reservoir over one inch towards the driver s side Install the thick round spacers on the recut reservoir bracket Reinstall the reservoir using the stock nut on the rear notch and the supplied hardware on the front notches 23 From under the vehicle remove the two 8mm head bolts securing the coolant reservoir support rod Relocate the support rod by moving it one bolt hole towards the driver s side and secure with the original bolt Using a 1 4 drill bit dri
5. ckest installation time we suggest that you read this manual thoroughly before beginning Make sure that you understand the process have identified the areas of the car that you will be working on and have the tools that you will need on hand The average installation time is 8 to 10 hours but your time will depend on your working conditions experi ence installing superchargers personal skill level and preparedness for the job This esti mate does not include time for the initial vehicle inspection cleaning fine tuning or trouble shooting Once again we recommend reading the manual before beginning the process We are available for tech support at 805 604 1336 Monday through Friday 7AM 3 PM Pol After reading the manual verify that all major assembly groups are present in the main kit box As you remove a box or bag note the identification label and compare it to the parts list PAXTON AUTOMOTIVE makes every effort to insure that 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 to beginning installation will result in a charge for the missing part We suggest that the engine compartment be cleaned before the installation You can clean the engine with a pressure washer that is found at self serve car washes Use a safe for alu minum cleaner degreaser a
6. d the power steering reservoir bracket under the coolant transfer manifold and attach it to the supercharger Fig 37 Zip tie the oil feed line to the CTM a F FITTING N a t x oo 7 ii eee FIG 36 SMOG PUMP INTAKE SYSTEM MODIFICATIONS These steps illustrate how to relocate the smog pump and install the new intake system 2 Unbolt the smog pump and ignition module from the passenger side fenderwell Bolt the smog pump and the module to the new bracket using the supplied screws for the module and factory bolts with supplied nuts for the smog pump The plug on the module should point straight up Connect the plug to the module and bolt the assembly to the original mounting Fic3s M point using the supplied bolts and spacers between the bracket and the body APPENDIX I DRAWING 1017306 Modify the smog pump hose as shown in Appendix Re use the fac tory couplings and secure with the supplied hose clamp Fig 38 P N 4809609 PAGE 11 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA 28 The mass air meter is removed from the original air box Fig 39 and attached to a Paxton supplied bracket This assembly is then bolted to the air filter adapter and air filter Fig 40 Fig 41 NOTE Be sure to install the MAF screen as shown Fig 40 arrow or the engine will not run properly FIG 40 FIG 41 29 Attach the the short side of the plastic elbow the end with t
7. els Belt Slippage Throttle Response Now that the work is done it s time to enjoy PAXTON Automotive wants to thank you for choosing our product and wants to remind you that the performance and response of your vehicle is now different that what you are used to Please drive cautiously until you have grown accustomed to the feel of your vehicle Please see the service manual included in your kit for information on the service and mainte nance of your PAXTON Supercharger Belt tightening troubleshooting special tuning requirements and warranty information is also included in the Service Manual P N 4809609 PAGE 15 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA APPENDIX Please realize that PAXTON Automotive is constantly improving the performance and look of the NOVI 2000 supercharger Parts in your kit may appear differently than what is pictured in this manual This is due to photographs taken in pre production a change in material costs or an improvement in performance Rest assured that you have purchased to best quality kit that PAXTON Automotive manufactures at this time The installation of the materials will remain the same List of Appendices Appendix Number DWG Number Rev DWG Title A 1001814 1 C KIT PARTS LIST B 1011807 C ASY S C NOVI 2000 C 1016607 ASY S C MOUNTING BRACKET D 1015927 B ASY AIR INTAKE E 1017007 ASY AIR DISCHARGE F 1019327 C ASY O
8. g 22 The lower bolts are easier to tighten from underneath the vehicle The belt can now be permanently installed 17 Install the coil pack onto the mounting bracket as shown fig 23 You will have to recon figure the wires to allow for the relocation of the coil pack J COIL PACK E ee SS a A MOUNTING ae or BRACKET cr i wi wh Ay i call mM Fic23 P N 4809609 7 ae PAGE 7 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA COOLING SYSTEM MODIFICATIONS These modifications are necessary in order to allow clearance for the supercharger 18 The supplied Coolant Transfer Manifold CTM is taller than the original providing nec essary clearance for the supercharger To mount the new CIM Fig 24 trim the 6mm portion of the two mounting stud bolts to 3 4 inch and thread the supplied aluminum spacer stands Fig 25 arrows into place to properly locate the CTM Remove the original coolant temperature sensors from the old CTM and install in the new unit Install the CTM and secure with the supplied fasteners Fig 26 NOTE Some kits may be supplied with a CTM that appears differently than the unit shown Both CTM s mount in the same manner 19 Install the straight portion of the Y tube into the lower radiator hose and orient the angled portion towards the passenger side of the car Fig 27 Install the supplied upper radiator hose and
9. gement that holds the CTM in place Unplug the two sensors and remove the CIM it is press fit and sealed with O rings so it will take some wiggling to get it free Fig 3 Fig 4 pF N T p n a 4 f n Ae i f ai S FIG 4 P N 4809609 l O PAGE3 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA 3 Unplug the coil pack and remove the four 7mm bolts that secure the coil pack to its mounting bracket Place the coil pack aside and remove the mounting bracket by removing the three bolts Fig 5 Fig 6 fo FGS Sa Sa FG6 4 Remove the tensioner limiting bracket Loosen but do not remove the four bolts securing the water pump pulley Fig 7 Fig 8 m 4 My 3 sd ra FIG 7 FIG8 w 5 Using a 1 2 ratchet or breaker bar rotate the belt tensioner clockwise then remove and discard the drive belt Fig 9 6 Remove the uppermost stud bolt on the tensioner It will be used as a mounting point for the supercharger bracket Fig 10 P N 4809609 PAGE 4 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA 7 Remove the water pump pulley followed by the idler pulley Fig 11 which will be re installed in a later step 8 Remove the four 18 mm bolts at the front of the engine marked with arrows in FIG 12 Replace the bolt in the water pump with the supplied bolt and small diameter washer Replace the topmost bolt
10. he lip to the MAF air filter assembly Fig 42 Leave the hose clamp loose so the elbow can be rotated once the assem bly is mounted in the car 30 Remove the two nuts located in the passenger side inner fender wall Push the mass air meter air filter assembly and inlet tube up into the passenger side fender and attach to the existing studs in the inner fender panel using the two factory nuts Fig 43 P N 4809609 PAGE 12 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA 31 Attach the length of flex hose to the plastic elbow on the MAF air filter assembly inside the fender Fig 44 Install the cast aluminum dis charge tube using the supplied rubber joints and stainless steel clamps 32 Attach the 4 hose to the Idle Air Control IAC tube and retain with the supplied hose clamp Attach the other end to the discharge tube and retain with another supplied hose clamp Use the remaining two hose clamps to secure the hose to the IAC Valve and filter housing Fig 45 Fig 46 P N 4809609 PAGE 13 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA 33 Push the short end of the bypass valve onto the boss underneath the discharge tube The other end will be attached to the boss on the inlet tube Fig 47 34 Install the inlet tube to the flex hose and attach the other end to the supercharger Attach the bypass hose to the inlet tube and secure with the s
11. ll through the remaining mounting hole and secure with the supplied nut bolt and washers FIG 32 You can gain access to the hole through a slot in the body sheet metal directly above the hole you drilled Slide the 3 8 thick round aluminum spacer onto the threaded portion of the support rod Reinstall the reservoir Ea ois p at z a NEW POSITION J TA La E e a amp ORIGINAL PLACEMENT ORIGINAL POSITION ee FIG 32 P N 4809609 PAGE 9 j COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA OIL SYSTEM MODIFICATIONS The Novi 2000RR supercharger relies on pressurized engine oil for its lubrication The follow ing steps show how to install the oil feed and drain lines NOTE Do not attempt this step with a hammer and punch as you will severely dent the front of the pan 24 Mark the front of the engine oil pan 1 1 8 inch below the pan rail and between the two pan rail bolts directly in the center of the small hump Drill a pilot hole with a 3 16 inch drill bit after smearing the drill bit with heavy grease to prevent small metal particles from falling into the pan Fig 33 Once the hole has been drilled insert a straight length of welding rod or heavy wire such as a coat hanger into the hole approximately three inches to see if it contacts any of the recipro cating assembly connecting rod crankshaft counterweight If it does turn the engine over and repeat
12. lvent vapors are colorless and sometimes odorless and may asphyxiate or explode without warning Always disconnect the battery from your engine before doing work on the electrical or fuel systems or doing underdash work The chemicals used in the vehicle systems such as oils and coolants are poisonous Clean up any spills immediately and dispose of waste materials properly Pets wild animals and children may die if they ingest the liquid PAXTON Automotive thanks you for your purchase We welcome your comments and sug gestions to help us improve our product P N 4809607 PAGE 2 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA INSTALLATION 1996 1998 MUSTANG COBRA NOVI 2000RR SUPERCHARGER DISASSEMBLY Preparing your vehicle NOTE Beware of coolant spills Mop up any spilled coolant immediately Radiator coolant very attractive to animals and highly poisonous 1 Drain approximately one gallon of coolant from the radiator and disconnect the negative side of the battery Disconnect the MAF sensor air inlet temp sensor and air idle bypass hose from the air inlet tube then remove the inlet tube and air filter housing by removing the single 8mm bolt Fig 1 Fig 2 2 Remove the coolant reservoir upper radiator hose and disconnect the lower hose from the coolant transfer manifold CTM Remove the spark plug wire retainer atop the alternator fol lowed by the stud and nut arran
13. nd cover the distributor and any electronics with a plastic bag to prevent water from entering P N 4809609 PAGE 1 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA You are undoubtedly eager to get started but please take a little more time to insure that your 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 standing around By following some simple safety pre cautions you can avoid many potential dangers The following list is not meant to be a com prehensive list but rather it is meant to make you aware of some of the risks and encourage you to take a safety minded approach to your work area 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 use 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 Always have a fire extinguisher that is rated for chemical and electrical fires handy when working on motor vehicles Also make sure that the extinguisher is fully charged Operate engines only in a well ventilated area Carbon Monoxide gasoline and so
14. the process until no interference is encountered Next apply a small amount of anti seize lubricant to the tip of the punch Fig 34 and insert it into the pilot hole Hit the punch with an air hammer carefully using small bursts until the punch is inserted up to its shoulder NOTE Use extreme caution not to make the hole too big or the drain fitting will not fit and the pan will be ruined 3 8 inch by 18 NPT tap not included and er gradually thread into the hole NOTE Only run the tap 2 3 of the way in Otherwise the fit ting will not seal properly Clean the threads using a clean rag and an approved solvent such as carburetor cleaner Apply a small amount of silicone RTV to the threads of the supplied 3 8 inch pipe to 8 fitting and insert into the hole being careful not to over tighten a FIG 35 lt isc The hex nut of the fitting should be clear of W the pan leaving some thread showing Install the supercharger drain hose fitting so that the elbow is oriented toward the passenger side away from the harmonic dampener Fig 35 P N 4809609 PAGE 10 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA 26 The supercharger feed line is attached by removing an existing pipe plug in the bottom of the oil filter housing and installing the supplied inch NPT to 4 90 degree fitting and steel braided hose Fig 36 arrow Run the line up the side of the engine between the valve cover an
15. upplied hose clamp Adjust for the best fit and tighten all hose clamps Remove the rubber hose from the crankcase evacuation plastic barb fitting located on the passenger side valve cover Attach the sup plied hose to the plastic barb fitting and route the hose forward to the 90 degree brass fitting on the plastic inlet tube The supercharger assembly is completed Fig 48 Fig 49 P N 4809609 PAGE 14 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA CHECK OUT PROCEDURES We know that you are anxious to get out and drive your new vehicle but please take a little bit more time to perform these simple check out steps A Inspect all wiring harnesses and electrical connections Make sure that all items are properly routed connected and secured B Check all hoses lines and fittings for properly secured connec tions C Make certain all fasteners brackets and clamps are installed and properly tightened D Check serpentine accessory belt and supercharger drive belts for proper tension and alignment E Cycle ignition key from off to the on position F Check the entire fuel system for possible leaks G Start engine and verify that the oil pressure is within normal range H Allow the engine to come up to normal operating temperature I Check the coolant level in the coolant recovery bottle and top off as needed J Check the following Fluid Leaks Fluid Lev
16. with the supplied low profile bolt The remaining holes will be used as attachment points for the idler support bracket in step 10 a a 2 Es a 7 ty y 5 1 4 REMOVE pag hag i i m r al n n 5 i Fr m i 7 kE d a Tas ol F ET g a 4 e z f FIG 11 PREPARING TO INSTALL THE SUPERCHARGER 9 Use a tubing bender to bend the metal A C line It is first bent upwards then rotated down ward to clear the bottom portion of the supercharger Fig 13 NOTE Use extreme caution during this step The refrigerant contained within this line is under high pressure and can cause injury if the line ruptures Use a tubing bender such as the one shown as well as safe ty glasses goggles Gloves are also recommended 10 Install the idler support bracket using the holes from step 8 It serves as a support for the main supercharger bracket and mounting point for the supplied idler pulley Fig 14 k Fo Se a a j Se ee P N 4809609 PAGE 5 COPYRIGHT 2000 PAXTON AUTOMOTIVE ASSEMBLY MANUAL for the 1996 98 MUSTANG COBRA 11 Remove the 13 mm stud bolt that is located under the lower corner of the passenger side valve cover This bolt stud supports the metal A C line through the use of a small tab Enlarge the hole in the tab to 5 16 inch to accommodate the larger fastening hardware for the rear Supercharger support bracket Fig 15 12 Install the rear supercharger mounting bracket in the
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