Paxton Automotive Nov1 User's Manual
Contents
1. 30 13395 31995 ION 00 3198 9180 ON 770100 HSINE ASY 77 a324 1511 SLYYd 335 el WHW 01 18 9 GHO4 1002 8661 01 8 9 nuda STONY 5 5139 5 31v0 81 SOO FXXX STIWINIO3O E IG 2561 09 808 9861 09 908 EL q 3LYddN ATIVANVIA LON 10 FXX SUV SSONVHSTOL 86066 VO 1 NOOV3E 0081 ONIMVHG avo SSHONI SNOISNSWIG 8 345 3SIMESHIO 5531 TIO HONNd 110 092 018 ISOH 010 200 8 9 14 8 6 ONI ISOH 914 6680 8164 2 91 862 X 8 9 10 ISOH 000 0N4 9 53 18 4 ON Wall ASV I S OL 38007 WALI SIHL dIHS 931519349 SSIMYAHLO SSJINN SALON NYd IO OL 110 30 1 2 WALI NOLLVIO1 WALI NYd 110 oh mh oh sh 001 91 gt 10 All Rights Reserved Intl Copr Secured O6SEP05 v4 0 FordV10 4809606v4 0 2005 Paxton Automotive P N 4809606 0333 110 UIDUVHIBIANITS ASY 09762101 y2. NOOW38 0061 4 1 TO 15 ASY 122 101 1 salve 1H93M ANON HSINIJ 1SITSLEVA 33S or SOOFXXX 5 079 9 45 3SIMESHIO 5531 1 ONIY 570 100 5 52 91 01 ONIS 110 100 5 ve 91 00 22 1 WOOTATOd 11148 ONIGNL 260 1009 91 7 1118 10 1008 22 797 00722 8 81M 010 810 5 1 91 00 24 8 81M 020 10 8 02 8 91 00 8 9 SHIM 020 810 5 6l 91 00 96 THIM 060 810 8 81 91 00 7 010 810 8 Zh 21 01 30 46 NH LOANNOOSIG 990 100 8 91 ANYOS AY BY 910 100 5 GI 5 ISOH OL TAN 206 DIA 020 21641 a 350 91 6 LHOIWHLS BN 914 910 21642 350 700 1008 91 0002 741 9 5 1909 ISOH 810 16001 i 18851 NOTAN M SHO 26 9 LNN 100 900472 01 LHS NYd 09 018 48825 250 01034 6 13001014 100 0101 8 gava Wwe 9 21021692 1 48 6 U3ddO9 20 SZErZ 9
3. NOTAN M 02 7 1 LAN 120 0837 6 3VS 1 7 2 220 052 0015 09 02 9 092 00 001 INNON 200 7102 E 011 9 1 GINOISND 4001 620 008Z 2 ANITINI 200 10048 5 ON WALI SL WALI 14130 06 98 98 Teta i 18 E Lota 25 ae aasn LON 1804 OL NO TYNI WHL og IL SOd 3505 OL OY 188 WHAL 1905 988 HAL TWNIWHAL 9 604 OL 5 8399181 AYAY 1905 304005 GSHOLIMS OL 8 0 02 886 831 ANNOYS SISSVHO OL 9 01 08 LNAWdIHS OL 1105 38 LSNW SON ATEVLINS OL ISOH LND ANY 31NOH HAWOLSNO ATIWNOLLNSLNI 1437 51 1 ISOH LL WALI 380017 dIHS SWALISSSHL 7 7809 Tlv 031519399 SSIMYAHLO 5537100 SILON 01 02 a 2 ONILSIXA 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 065 5 v4 0 FordV10 4809606v4 0 A 9 110 15 ASV 661101 xipueddy
4. P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 065 5 v4 0 FordV10 4809606v4 0 40 1 AAHS 31998 ION 3105 1 88120 NON 036610 77 HSINH AlddNSTIOD S ASY 2 ae 98 1611 81 4 338 i ee ONIYSANIONS VHN 01 18 9 1002 8661 5 0 NOLaNOO 9 1771 4 2861 09 808 9661 709 008 EL ae ATIVANVW LON 10 FXX SIONVE3IOL 86066 WO 0061 GALVHANSD avo S3HONI SHV SNOISNI NIG 0348 3SIMESHIO SSFINN ASY O S OL 14 8 1 X MOSTE 006 914 00 5214 2 2 91 899 PNY X SS 110 ISOH 997 000 09202 5 1864 ALO ON WALI OL A 11 SUPERCHARGER Paxton Automotive 1300 Beacon Place Oxnard CA 93033 888 9 PAXTON FAX 805 604 1337 www paxtonautomotive com 09 06 05
5. SNOISNAWIG 9919398 36 5531 0 301 8 1 1 0 72 909 104 9 8 1188 0 2 870 2 v MHL 11 0 LWT 200 010 6 6 8811 SOHS X 6 x 0 43898 860 01092 6 2 0574 17 5 86 26 AUD 8 ANVEO 3 110 8109 NOILdIOS30 838 WNN MO WALI A 4 YHAONV IVE MOOLS P N 4809606 2005 Paxton Automotive v4 0 FordV10 4809606V4 0 All Rights Reserved Intl Copr Secured 065 HINOISNFL 1738 ASY 1169101 3 301 13995 319985 ION 51908 881 THOM 118801 ON Oma 328 7 HSINE 11887 a24 1511 SLHYd 335 ES ONIYSINIONS WHN OLA 189 1002 8661 oar 1511 SWAOUdEW SO0FXXX STVINIOZO 1861 0909 808 9661 0909 908 EL ATIVANYW LON 10 SSONVHSIOL 66066 VO SOW 1d NOOV38 0061 03148339 090 S3HONI NI SNOISNAWIG 0346 3SIME3HIO 5631 01 8 8 SSV19 90 MIHIS 360 08092 4 HANOISNAL DNIEAS 110 210 049 YANOISNAL 45 228 20 AYD 8 ATINA ASV
6. 2 2 FEED ASSEMBLY INSTALLATION A Locate the supplied oil feed line in the Assy 1019350 On the passenger side cylinder head there is a small pipe plug near the front and below the oil fill neck B Using a 3 16 allen wrench remove the allen plug Install the 1 8 NPT x 4 x 90 supplied fitting The 1 8 NPT x 4 x 90 fitting when installed should be pointing straight up See Fig 2 2 a Fig 2 2 Attach the oil feed line and route it over to the driver side underneath the alternator Supercharger and oil feed line will be installed during a later stage of the installation Install the 1 8 NPT x 4 x 90 oil feed line fitting into the brass oil jet fitting into the blower Use only engine oil on the oil feed jet fitting Using a thread sealant may clog the oil jet orifice and damage the supercharger aK NOTE aK Support the oil jet with an open end wrench to prevent snapping off the fitting during installation of the 1 8 NPT 4 x 90 fitting 2 3 CRANK PULLEY ASSEMBLY INSTALLATION A Locate the supercharger crank pulley Assembly 1015611 that is provided Bolt the Paxton Supercharger crank pulley to the face of the stock crank pulley using the 3 supplied allen head bolts See Fig 2 3 a aK NOTE aK Apply Loc Tite thread lock to threads aE 2 After the supplied pulley is installed check and confirm that the pulley is sittin
7. SIONVE3 TOL SAHONI SNOISNI NIG 3SY3 84 INN HN 1001 100 2611 91 96 01 26 380 81 06004 ISOH 8 6 X X 8 331 090 9 64 IAON M OLA 0864 86 1 18 1903 914 810 01642 3801 46 X ISOH WWE s ISOH OL ANd 06 NNOO DA 020 1642 ISOH 411919 700 1009 INON M OLA 0864 86 97 06 X TANS 1120101 18388 NOTAN M 589 02 7 1 LAN 120 0904 989 JYS 200 098 1 52 X 02 0 1 143898 st 0 00 gt 720 052 LINA 1303 ASV Ast aaa iio 9081121 141 2530 D E ON 19 ALO 579 OL lt 4315009 8 ANY N33M138 TIVLSNI SLON 338 ATEVLINS OL ISOH 1 9 ANY TIM HAWOLSND XTIVNOILNALNI NOT L437 SI HLONST ISOH 1120101 3791H3A 8 All Rights Reserved Intl Copr Secured 065 05 v4 0 FordV10 4809606v4 0 2005 Paxton Automotive P N 4809606 30 31 085 LON OG 21 31 05 nad 110 ON Oma 3716 WALSAS 1905 ASV 01 18 9 0804 002 8661 1861 0909 808 9661 09 908 181 66086 VO
8. O6SEP05 v4 0 FordV10 4809606 v4 0 Ford 6 8L Super Duty IMPORTANT NOTES 1998 2001 Models This kit requires ECM modification and the installation of a Paxton ECM Module The ECM must be sent directly to Paxton by the installing customer the charge for this service with module installation has been included in the purchase price Included in this kit is a prepaid next day air shipping box and a credit tag for one 1 Paxton ECM Module The modules are made specifically for each individual vehicle with respect to the factory ECM calibration Simply contact the Paxton Service Department at 805 247 0226 to request a Return Authorization Number see ECM Module Credit Tag for more details Mail to Paxton the enclosed ECM Module Credit send original tag no photocopies will be accepted and ECM in the supplied box Turnaround time will be 1 2 days each application varies Paxton will give an estimate at the time of your order Your Paxton ECM Module comes with a twelve 12 month limited warranty from the original date of purchase of your supercharger system see Owner s Manual for details P N 4809606 2005 Paxton Suto ate All Rights Reserved Intl Copr Secured 5 5 v4 0 0 IV INTRODUCTION ongratulations You have purchased the finest street supercharger available for the Ford V10 The centerpiece of this kit is the High Efficiency NOVI 2000 S
9. 1 0 090 2 MHL 01 ONILVW 0 0 090 2 1 660 DNILVIN 160 090 MHL OL0 WIHS 010 00 800 900 00 1 00 5 600 001 2 1 060 DNILVIN 080 090 2 ONIddIHS 022800 5065 09 00 9 1 090 09272 d WYO 970 00 1 120 710 2 281 MAYOS JAYA 120 00102 0002 IAON SLVId WYN S 0 001He o of o olol o ONIddIHS 612800 1 ONIddIHS 902800 91 HLS AZN HOV 190 810 2 101001 X YZ ANNYZ 8 MIYOS 011 946882 vl Had WYL 812800 El O S A3T1INd 110 090 18 138 120 090 2 5 1 104 80 5 521 210 2 6 791 601 X08 8 1 AJA 5 0 0011 2 8 217 5 70 800 1 1910071 2 0 091 8 6 AHIS 5 01 5 64 9 9NO1 110 060 S2EddZ 6 8 6 5 YAddOO 720 52672 2 J3NOVIN 1dN 8 ON Id 914 910 8 84 Z 6 380H 8 9 14 8 6 FIddIN 9 529 5 64 6 LVS AZN ASV 38 9 9
10. 1 4 b Fig 1 4 d C Next unbolt the bracket that held the two elec trical connectors and modify the bracket as in See Fig 1 4 c P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 1 3 065 05 v4 0 FordV10 4809606v4 0 the two large connectors back onto the modified stock bracket from Step E Attach the bracket and connectors with the two sup plied wire ties to the heavy duty plastic wire loom as shown See Fig 1 4 e G Located on the driver s side in front of the cylinder head is the cam sensor Extend the two wires coming from the cam sensor along with the shielded white wire that runs parallel with the cam sensor wires using the supplied three wires and six Butt connectors See Fig 1 4 1 r 1 Fig 1 44 Then cover the wires with the supplied split loom Route the extended wires under the upper most stud sticking out of the front of the engine then back over toward the harness P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 06SEP05 v4 0 FordV10 4809606v4 0 1 4 2 1 2 SUPERCHARGER ASSEMBLY INSTALLATION OIL DRAIN LINE INSTALLATION Locate the supplied oil drain assembly 1019344 Mark the front of the oil pan 1 inch below the pan rail and between the two pan rail bolts directly in the center of the small hump see Appendix J Dri
11. 000 868 2 12919953 ON LUVd JO Wall NOILVLOY 9 8 409 2 5 WOU 8 2 All Rights Reserved Intl Copr Secured O6SEP05 v4 0 FordV10 4809606v4 0 2005 Paxton Automotive P N 4809606 LAYOVYE ONILNNOW ASY 1169101 2 130 1 133 5 9 31905 ION 04 SET 51995 881921 HOM INON 1990 oma 8 HSINI DEB 910 9 8 AY LT 1727 098 1811 81 335 _________ 1 01 189 1002 8661 86 92 01 our STWAOUdAV aah S00 FXXX STWWIO3O alvadn ATIVANVIN LON SSONYUSTOL 1NI SNOISN3WIG SNE 079 0348 3SIMESHLO SSIINN 6 01 SSV10 X X wwr 7 5 590 0712 MHL 60 X 70 677 7011 626 9270 9287 999 GHXH 00 2 X 91 8 6 MAYOS OOe SLEVL 9 8 GHL M 4316 180 210 88 60 3074 HLOOWS A311Nd 837101 ASV 2050121 YOOTAN M 188 0071 X 2 91 9 MIYOS 001 2168 1 4 837101 120 1009 9 9900 AY9 8 Y43101 ASY 1040121 621 88919 8 62 8 05 20 08002 SYD SHH 0071 X 02 1 5 001 052 SYD JYS 94 9 5 000 216 2
12. a 10mm socket and ratchet remove cleaner by loosening the two hose clamps the three bolts securing the air filter bracket and Disconnect the two rubber hoses attached to the remove it from the vehicle See Fig 1 1 c side of the tube See Fig 1 1 Fig 1 1 Fig 1 1 a D Gently pry the air flow meter cover plate from B Carefully pull the air inlet temperature sensor the air filter housing using a screwdriver Next out of the black rubber hose attached to the side push the large rubber grommet surrounding the of the plastic inlet tube See Fig 1 1 6 4 Mass Airflow Meter wires into the housing and finish removing the Mass Airflow Meter NOTE See Fig 1 1 d Model Year 2000 will NOT have this sensor Fig 1 1 d Fig 1 1 b Un snap the large clamp which holds the air cleaner housing together and remove the sec P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 1 1 065 05 v4 0 FordV10 4809606v4 0 Remove the two 10mm nuts retaining the MASS AIR FLOW METER and separate the two pieces See Fig 1 1 Fig 1 1 The MASS AIR FLOW METER will be used in a later step Discard the MASS AIR FLOW Remove the fasteners that secure the fan shroud to the radiator After you remove the fan from the water pump lift the fan and fan shroud together from the engine compartment and set it aside to be rein stalled at a
13. around the supercharger pulley You will need to rotate the tensioner out of the way to do this The belt must be positioned so it is against the face of the two idler pulleys The belt will be twisted sideways when it goes over the front of the idlers Next with the tensioner rotated out of the way slip the belt under the grooved idler then under the smooth idler See Appendix 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured O6SEP05 v4 0 FordV10 4809606v4 0 This Page Left Intentionally Blank P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 065 5 v4 0 FordV10 4809606v4 0 2 4 SECON 4 DISCHARGE DUGT ASSEMBLY INSTALLATION 3 1 DISCHARGE DUCT ASSEMBLY A B E INSTALLATION Locate discharge Assembly 1016011 Install the supplied 3 0 x 2 0 L sleeve to the discharge duct by pushing the sleeve all the way onto the discharge tube Attach the 4 25 x 2 0 L sleeve to the throttle body with the clamps provided Position the discharge tube between the throttle body and the supercharger Slide both sleeves into position and secure with the supplied hose clamps See Fig 3 1 THROTTLE BODY Fig 3 1 a Attach idle air bypass hose to the nipple on the discharge tube with the supplied clamp See Appendix G P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Sec
14. belts for proper tension and alignment Cycle ignition key from off to the on position Check the entire fuel system for possible leaks Start engine and verify that the oil pressure is within normal range Allow the engine to come up to normal operating temperature Check the coolant level in the coolant recovery bottle and top off as needed Check the following e Fluid Leaks e Fluid Levels e Belt Slippage e Throttle Response P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 7 1 065 05 v4 0 FordV10 4809606v4 0 This Page Left Intentionally Blank P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 065 5 v4 0 FordV10 4809606v4 0 7 2 APPENDIX Please understand that Paxton Automotive is constantly improving the NOVI supercharger system As a result some of the parts in your kit may not look exactly like the parts pictured in this manual This may be due to pictures taken in pre production a change in materials or even in a change in the design in the vehicle from one model year to the next Rest assured that your supercharger kit is the most up to date kit that Paxton produces for your vehicle at this time All of the parts will install in the same manner as shown in this manual APPENDIX TABLE OF CONTENTS APPENDIX DRAWING NO REV A 1001911 H B 1016111 D 1016311 1015611 E 1016911 E F 10
15. 08 TAL f 66086 VO NOOW38 0061 AlvddN ATIVANVIN LON Od AY S00 FXXX SIVWIO3O 107 SIONVEJTOL S3HONI SNOISNI NIG 346 3SIMYSHLO 5531 0 X18 97 7 X 01 006 OBUNL ISOH 002 00684 9 803 ISOH 870 20082 2 9 OLA 0884 86 810 381 150 020 2101447 244 ISOH 210 20082 6 97 2 X 0 1 52 p 350 002 927981 2 248 ISOH 4110 240 200892 2 5 ON LaWd ALO WALI ISOH 3101 9015 240 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured O6SEP05 v4 0 FordV10 4809606v4 0 A 7 LINN 1 TINA ASY 1144101 zr 1 5_ 31 25 JON Od ANON 51908 881 Aad ON 8 OHLNOD 0177 0110 0277 181181 338 OLA 189 GHO4 1002 8661 862111 our vda S31ONV 5 3405 1861 0909 908 9661 0909 908 EL AA Mie 66086 VO NOOW38 0061 51 ATIVANYW LON AY 09119395 35 5531 0 5 S00 FXXX SIVWIO30 107
16. 15911 G 1016011 H 1017711 1017721 J J 1019344 NC K 1019350 NC L 1018006 M 1018011 NC TITLE OF DRAWING KIT PARTS LIST ASY NOVI 2000 SUPERCHARGER ASY MOUNTING BRACKET ASY CRANK PULLEY ASY BELT TENSIONER ASY AIR INTAKE ASY AIR DISCHARGE ASY FUEL CONTROL UNIT ASY AUX FUEL SYSTEM ASY S C OIL RETURN ASY S C OIL FEED ASY WIRE EXT CAM SENSOR ASY CRUISE CONTROL SENSOR RELOC A 1 P N 4809606 2005 2 All Rights Reserved Secu O6SEP05 v4 0 80960014 9 8 0002 IAON ASY 1119101 8 XIpuaddy 130 133HS 41 98 JON 43 31 25 38 119101 3215 NILVS 18 9 1002 8661 NOILWLOY 0002 IAON 9 S AS 086 4 1879 1002 8661 1661 09 908 9661 0909 908 660686 VO NOOW38 0061 5818 12 LHOIM INON a 65 UN HSINI tS 1911915 4 33S ONINSINIONS ___WIdalWW 86 7 1 01 SWAIN SNOILOVHH alva S00 FXXX STvWI0ga sn 0348 3SIMESHIO SSIINN 326 AY9 8 9 S ATINA 149 18 1 8 6 LAN 20 5 64 MOO We INON Wa 112 120 1 00 00 00 1 060 ONLLV 080 090 ONIY ONILVW
17. 9 55710 JONV 031 38 9 82 1 X WWE LNN 120 80042 701 907 91 08 X 0 0 8 2 6 01 5 8 710 2 NIVHO 91M 9 5 32018 120 010144 0015 qO 160 869 1 601 SSV10 06 X z X 8 05 190 07 192 1 04408 3018 1988 061 0101447 849 99 2 91 81 ALNG 91 2 5 220 86 8489 GHXH 9271 X 71 91 2 MIYOS 901 26 2 915 31914 6169087 aos o a gt 89530 ON Lud 0115 ANIONS OL P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 065 5 v4 0 FordV10 4809606v4 0 A 3 ANVEO ASV 1196101 301 133HS 31 06 LON 1795 88144 1 8 INON 119810 ON 3 HSINH ONILAOY 1798 2 5 WNVHOOIS 1 1511 515 4 335 O 1 SS 9 __WI8SLVW OLA 18 9 1002 8661 36 08 01 Aur STOW 81 0 44 ATIVANVIN LON Od ONIMVYG 031V83N39 avo S00 FXXX SIVWIO30 107 SSONVHA TOL
18. 9190121 889 HXH 9272 91 8 8 8 920 816 1 AHL91 1 00 91 61 1 78 8 6 HIHSVM 990 426 1 031510 038901 9 8 1138 HANOISNAL 190 110194 849 SHH 52 91 8 6 MIYOS 140 416 1 OLA 0864 86 U3NOISN3L 1138 31914 260 1101449 953 ON LuWd ALO WALI ol 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured O6SEP05 v4 0 FordV10 4809606v4 0 A 5 ASY 1168101 J Xipuaddy 40 13395 31908 LON OG 9 118810 3 N M My ON 3716 1090 JAYA 0018 SI 21 WALI TT 77 1811 SLUVd 338 031310348 351 0 8831 0 SALON A WIEN 041 1189 10082 466 83 Pe NANSO ve SENP alva 5 1 2861 09 908 4 9661 0909 808 1 40 ATIVANVW LON 10 FXX SFONVYSTOL 66066 VO 30W1d 0061 GALVHANSO 092 S3HONI SNOISNSWIG 031510395 35 0 5531 MOTA 914 100 S Edd L 13 INYA 901 5 4 ay 8 6 IS
19. NSTALLING FAN SHROUD 5 1 REINSTALIING TAN SHROUD 5 1 FUEL PUMP INSTALLATION cosas 6 1 61 FUEL PUMP INSTALLATION 6 1 82 1018 015816 seroren irora ranan eA 6 1 63 FUEL CONTROL UNIT INSTALLATION condones epic 6 1 84 FUEL CONTROL UNIT VACUUMUINE econo 6 1 7 CHECK OUT PROCEDURES 7 1 Ti CHECK OUT PROCEDURES 7 1 APPENDIX 1 A APPENDIX TABLE OF CONTENTS 1 B 1016111 _ 12000 2 1016311 ASY MOUNTING BRACKET 3 D 1015611 4 E 1016911 ASY 5 MSIE 6 1016011 ASY 7 H 1017711 ASY FUEL CONTROL UNIT 8 1017721 ASY AUXILIARY FUEL SYSTEM A 9 J 1019344 ASY SUPERCHARGER OIL RETURN A 10 K 1019350 ASY SUPERCHARGER OIL FEED 4809606 2005 Paxton Automotive a All Rights Reserved Intl Copr Secured
20. OH 14 09 9 0 52982 t 9 5 X 8 5 4 350 000 6600 486 si OILSV1d ISOH 8 5 X 8 90 501 MOST 914 529 52944 L OLA 0564 86 COW 06 13151 MOSS 910 2101 El 798 ISOH 790 20082 2 38N 152 010 2101449 L 41370186 350 100 560 ab 0 S 3SOH 90 20092 2 6 OLA 0864 86 3NVLNI 12 153 110 2101449 8 18 2 058 ISOH 002 05854 L 4 968 ISOH 990 0092 2 9 91 0 096 b t HIHSVM 660 900 5 OG 969 GHXH 52 X 02 9 1 MIYIOS 710 052 b OLA 0864 86 010 0101449 L 6 OLA 0864 86 14 0 1090 01099 2 dINV19 M 0 S 131 09 6378 560 00 8 L 1 5 838 LHVd ALO WALL 9 9015 NINO BAON 1002 0002 6 P05 v4 0 FordV10 4809606V4 0 2005 Paxton Automotive Al Reserved Intl Copr Secured P N 4809606 3DEVHOSIO ASY 1109101 5 xipueddy IHS 31925 ION OG 31908 881 10980 8 325 0217 HSINIJ 177 151191 235 189 0804 2 an aa 86 82 01 Cie 51 GIE 4661 09 908 9661 0909 9
21. Owners Installation Manual for the PAXTON AUTOMOTIVE NOVI 2000 Supercharger for 1998 2001 Ford 6 8L V10 PAXTON AUTOMOTIVE 1300 BEACON PL OXNARD CA 93033 805 604 1336 FAX 805 604 1337 P N 4809606 v4 0 09 06 05 FOREWORD his manual provides information on the installation maintenance and service of the Paxton supercharger kit expressly designed for the 1998 2001 Ford 6 8L V 10 F 250 F 350 Excursion Contact Paxton Automotive Corporation for any additional information regarding this kit and any of these modifications at 805 604 1336 8 00 a m 4 30 p m 5 An understanding of the information contained herein will help novices as well as experienced technicians to correctly install and receive the greatest possible benefit from their Paxton supercharger When reference is made in this manual to a brand name number specific tool or technique an equiva lent product may be used in place of the item mentioned All information illustrations and specifications contained herein are based on the latest product information available at the time of this publication All rights reserved to make changes at any time without notice 2005 PAXTON AUTOMOTIVE All rights reserved No part of this publication may be reproduced transmitted transcribed or translated into another language in any form by any means without written permission of Paxton Automotive P N 4809606 2005 Paxton Automotive All
22. Rights Reserved Intl Copr Secured O6SEP05 v4 0 FordV10 4809606v4 0 Il TABLE OF CONTENTS FOREWORD ii TABLE OF CONTENTS IMPORTANT NOTES iv INTRODUCTION v TOOL amp SUPPLY REQUIREMENTS vii 1 INITIAL PREPARATION AND DISASSEMBLY 1 1 11 AIRINTARE DISASSEMBLY 1 1 12 FANAND FAN SHROUD 1 2 13 POWER STEERING LINES MODIFICATION 1 2 14 ROUTING AND MODIFICATIONS 1 3 2 SUPERCHARGER ASSEMBLY INSTALLATION 2 1 Ol DRAIN ENE INSTALLATION 2 1 22 OIL FEED ASSEMBLY INSTALLATION so ieser ierse r reenn 2 2 23 CRANK PULLEY ASSEMBLY INSTALLATION 2 2 24 S C MOUNTING PLATE ASSEMBLY INSTALLATION 2 3 25 BELT TENSIONER BELTINSTALLATION 2 3 3 DISCHARGE DUCT ASSEMBLY INSTALLATION 3 1 31 DISCHARGE DUCT ASSEMBLY INSTALLATION si isoeo 3 1 4 SUPERCHARGER AIR INLET ASSEMBLY INSTALLATION 4 1 Ad SUPERCHARGER INLET DUCT 5 58669 4 1 42 ATR FICTER ENCLOSURE INSTALLATION i 4 1 5 REI
23. anties Program and the Warranty Registration form Paxton supercharger systems are performance improving devices In most cases increases in torque of 30 35 and horsepower of 35 45 can be expected with the boost levels specified by Paxton Automotive This prod uct is intended for use on healthy well maintained engines Installation on a worn out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger Paxton Automotive is not responsible for engine damage Installation on new vehicles will not harm or adversely affect the break in period so long as factory break in procedures are followed For best performance and continued durability please take note of the following key points Use only premium grade fuel 91 octane or higher R M 2 The engine must have stock compression ratio If the engine has been modified in any way check with Paxton Automotive prior to using this product Always listen for any sign of detonation pinging and discontinue hard use no boost until problem is resolved Perform an oil and filter change upon completion of this installation and prior to test driving your vehi cle Thereafter always use a high grade SF rated engine oil or a high quality synthetic and change the oil and filter at least every 3 000 miles Never attempt to extend the oil change interval beyond 3 000 miles regardless of oil manufacturer s claims as potential damage to the supercha
24. ber flap against the side of the radiator tube See Fig 4 1 This will help to seal the airbox Remove the three bolts that correspond with the mounting holes in the filter cover and attach re using the same bolts See Fig 4 2 a Fig 4 1 a C Twist and rotate the elbow for the best possible Fig 4 2 a fit B Slide the inlet hose onto the Air Flow Meter oe and secure with supplied hose clamps Plug in The rubber elbow will point straight down the aluminum elbow will point outward slightly NOTE There is a large Venturi that goes in after the MAF sensor This Venturi actually increases bottom D Rotate the rubber elbow toward the engine until and mid range torque while limiting the total there is clearance between the electrical con boost to 8 PSI Removal of this venturi will make your vehicle slower and subject the engine to nection on the master cylinder and the elbow damage due to overboost You will have to relocate the cruise control sen sor with the supplied TEE assembly for clear P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 4 1 065 05 v4 0 FordV10 4809606v4 0 This Page Left Intentionally Blank P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 065 5 v4 0 FordV10 4809606v4 0 4 2 SECON 4 REINSTALLING FAN AND SHROUD 51 REINSTALLING FAN SHROUD Re install the fan shroud re atta
25. ch the coolant reservoir Re install the upper radiator hose to A Install the supplied fan spacer to the factory fan the radiator and the end marked R to the ther clutch See Fig 5 1 a mostat housing reversing the hose This is done to clear the supercharger bracket Fill radi ator reservoir per the manufacturer s specifica tion See Fig 5 1 5 Fig 5 1 a Slide the fan and fan shroud see Fig 5 1 5 simultaneously in place and screw the fan onto the water pump Fig 5 1 b P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 5 1 O6SEPO5 v4 0 FordV10 4809606V4 0 This Page Left Intentionally Blank P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 065 5 v4 0 FordV10 4809606v4 0 5 2 Section FUEL PUMP INSTALLATION 6 1 FUEL PUMP INSTALLATION 6 3 FUEL CONTROL UNIT INSTAL LATION NOTE A Locate the fuel return line quick connect in the Depressurize the fuel system by removing the cap on the schraeder valve and depressing the valve using a pen or small screwdriver to release fuel pressure Cover the valve with a rag while this is being done to prevent fuel spray Locate the fuel filter inside the driver s side frame rail Using the appropriate size fuel dis connect tool disconnect the fuel line on the output side of the fuel filter Connect the fuel pump inlet line to the disconne
26. cted port on the fuel filter and the fuel pump outlet line to the disconnected line going to the engine See Fig 6 1 a Fig 6 1 a Hoses left intentionally long so you have the freedom in mounting frame rail on the driver s side Disconnect the line and install the fuel control unit as per Appendix Route all fuel lines away from any heat source or moving parts and secure using supplied wire ties Drill two 5 16 holes in frame and mount the FCU using supplied hardware See Fig 6 3 a Fig 6 3 a HEN NOTE Some vehicles already have holes on the bottom side of the frame rail that line up with the FCU mounting holes 6 4 FUEL CONTROL UNIT VACUUM B Trim lines as necessary Route all fuel lines LINE away from any heat source or moving parts and secure using supplied clamps and wire ties Next run the supplied vacuum line up to the 6 2 FUEL PUMP RELAY A Mount the relay in a safe dry place in the engine compartment away from any heat source Wire the relay as per Appendix terminal 86 tap in the pink with black stripe wire that is located in the wiring harness labeled FS going to the fuel pump engine compartment On vehicles with vacuum boosted brakes cut the vacuum line going to the brake booster and install the supplied vacu um TEE connect the FCU vacuum line to the TEE On vehicles with Hydro Boost brakes route the FCU vacuu
27. d re attach the reservoir and pump replenish any fluid spilled during the process nut has right handed threads Remove the two 8mm bolts retaining the fan shroud located at the top of the fan shroud on the driver s side and passenger s side Using a 1 2 breaker bar for leverage hold the pulley so it does not move and loosen the fan assembly from the water pump snout P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 065 05 v4 0 FordV10 4809606v4 0 1 2 14 WIRE ROUTING AND MODIFICA TIONS A On the front of the engine driver s side you will find two large black electrical connectors attached to a bracket See Fig 1 4 CUT HERE DISCARD THIS SECTION Fig 1 4 D Discard the part with the two holes in it and retain the section that the electrical connectors clip to The two connectors and wiring harness will now be routed directly in front of the two steel brake lines E Lift the wiring harness in the plastic sheath off the studs on the driver s side valve cover Push B Remove plugs from the bracket see Fig 1 4 b it down into the area between the valve cover and disconnect both plugs one requires a and the intake manifold Now take the large 10mm socket wrench wiring harness and two connectors that runs along the top of the motor and fold the wiring harness back onto itself as shown See Fig 1 4 d Fig
28. e wear or dam age especially if plan to use your vehicle in high demand situations such as towing In any case it is a good idea to consider purchasing a transmission valve body kit commonly known as a shift improver kit to improve transmission performance and durability Several companies offer valve body kits including TransGo Performance Please contact TransGo or the valve body kit manufacturer of your choice for more information pricing labor involved etc TransGo Performance 2621 Merced Ave El Monte CA 91733 818 443 4953 FAX 818 443 1079 NOTE This information is provided for customer convenience only Paxton Automotive does not endorse any valve body kit manufacturers and does not provide warrantee or service on said products PLEASE NOTE The 2000 Ford 6 8L V10 has several minor changes in the design of the engine Those changes have been included in this manual Please be aware of the model year of the vehicle and follow the proper set of directions P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured de O6SEP05 v4 0 FordV10 4809606v4 0 VIII Section 1 INITIAL PREPARATION AND DISASSEMBLY 1 1 AIR INTAKE DISASSEMBLY tion between the throttle body and front air fil 1 ter enclosure You will need to unplug the Mass A Using a screwdriver remove the black rubber Airflow Sensor connector on the inner fender tube between the throttle body and the air well Using
29. g flush with the face of the factory pulley P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured O6SEP05 v4 0 FordV10 4809606v4 0 2 4 S C MOUNTING PLATE ASSEMBLY INSTALLATION Slide the three black aluminum spacers about 1 2 thick over the three studs protruding from the front of the driver s side head Slide the supercharger mounting bracket over the studs and spacers and attach with the sup plied three nuts and one bolt Appendix Hand tighten only at this time Slide the mounting block between the super charger side brace and the cylinder head Secure with the supplied 14mm x 2 x 50mm long bolts inserting through the side support bracket through the mounting block and direct ly into the cylinder head Tighten all of the fas teners that were left finger tight in Step Bolt the supercharger to the mounting bracket using the six 3 8 16 x 2 0 bolts and washers provided See Fig 2 4 a Attach the oil feed line installed during an ear lier step to the 1 4 NPT x 4 x 90 NPT fitting installed in the supercharger Fig 2 4 a 2 5 BELT TENSIONER BELT INSTAL LATION Install the spring loaded tensioner and tensioner mounting plate to the front cover of the super charger using two countersunk allen head bolts and one 3 8 16 x 2 75 L bolt See Appendix E Install the supercharger belt by looping the belt around the crank pulley and then
30. he main kit note the identification label and compare it with the parts list Paxton makes every effort to ensure that all parts are included in the box but mistakes do occur If you discover that you are missing any part or that a part was damaged in transit please call Paxton for service DO NOT attempt installation if any part s are missing from this kit Failure to contact Paxton prior to beginning installation will result in a charge for any missing parts P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured O6SEP05 v4 0 10 4809606 v4 0 You are undoubtedly eager to get started with your project but take a little more time to insure that your safety is not in jeopardy A moment s lack of attention can result in an accident as can failure to observe some simple safety precautions The possibility of an accident always exists and the following points should not be considered a comprehensive list of all of the dangers They are only intended to make you aware of the risks and to encourage you to take a safety conscious approach to all of the work that you will be doing on your vehicle 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 preferably concrete or asphalt The transmission should be
31. 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 radiator cap while the engine is hot Always wear eye protection when using power tools such as drills saws grinders etc or when working under a vehicle Never smoke use an open flame or have spark producing items around gasoline or flammable solvents Always have a fire extinguisher rated for chemical and electrical fires handy when working on motor vehicles Run engines only in well ventilated areas Carbon monoxide gasoline and solvent vapors are colorless and sometimes odorless These can asphyxiate or explode without warning Always disconnect at least the negative or ground terminal of the battery when doing any electrical fuel system or underdash work P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 06505 v4 0 FordV10 4809606v4 0 Vi 1998 2001 FORD SUPER DUTY Installation Instructions 1998 2001 50 State Smog Legal as per CARB EO P 195 19 Congratulations on selecting the best performing and best backed automotive supercharger available today the NOVI 2000 Supercharger Before beginning this installation please read through this entire instruction booklet and the Street Supercharger System Owner s Manual which includes the Automotive Limited Warr
32. later step See Fig 1 2 METER housing face plate and air cleaner Fig 1 2 a assembly 13 POWER STEERING LINES Remove the large nut from the support bracket MODIFICATION on top of the fan shroud cover Next remove the three 8mm bolts securing the coolant reser A Unbolt the charcoal canister and the bracket voir and set the reservoir on the passenger side the large black cylinder unit on the driver s inner fender Next drain the coolant from the side inner fenderwall Swing the bracket back engine by opening the petcock on the bottom of and out of the way the radiator driver s side Mark the ends of the B Next you will need to remove the power steer upper radiator hose with an on the radiator ing reservoir insuring the fill cap is on tight side and a T on the thermostat housing end turn the reservoir upside down and remove both This is required for a later step lines Being careful not to spill any fluid short the 1 hose 1 1 4 and th 1 2 FAN AND FAN SHROUD REMOVAL A A Unscrew the fan from the water pump using a C Reroute both lines under the two steel brake 48mm open end wrench or large crescent lines running toward the front of the engine wrench and the supplied fan removal tool compartment Re attach the two hoses to the Slide the fan removal tool over the four bolts power steering reservoir and the P S Relocation securing the water pump pulley to the water bracket provide
33. ll a pilot hole with a 3 16 drill bit Smear the drill bit with heavy grease first to prevent small metal particles from falling into the pan Insert a straight length of welding rod or heavy wire such as a coat hanger into the hole approximately three inches to make sure no interference is encountered If the path is blocked turn the engine over uintil the pathway is clear Apply a small amount of anti seize lubricant to the tip of the punch and insert it into the pilot hole Hit the punch with an air hammer careful ly using small bursts until the punch is inserted up to the line as shown The finished hole size should be no larger that 9 16 in diameter See Fig 2 1 No deeper than this line Fig 2 1 a Do use hand tools Using ordinary ham mer will dent the pan Use extreme caution not to make the hole to big or the drain fitting will not fit E Apply a liberal amount of heavy grease to a 3 8 18 NPT tap not included and gradually thread into the hole Clean the threads using a clean rag and an approved solvent such as car buretor cleaner See Fig 2 1b Fig 2 1 b Apply an ample amount of silicone RTV to the threads of the supplied 3 8 NPT x 1 2 hose barb fitting installing the fitting in the previous ly tapped hole 2 1 P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured O6SEP05 v4 0 FordV10 4809606v4 0
34. m line to the capped port on the passenger side of the Intake manifold next to the throttle body 6 1 P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 065 5 v4 0 FordV10 4809606v4 0 This Page Left Intentionally Blank P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 065 5 v4 0 FordV10 4809606v4 0 6 2 7 1 CHECK OUT PROCEDURES secuon i cle is now different than what you are used to Please drive cautiously until you have grown We know that you are anxious to get out and accustomed to the feel of your vehicle C Please see the service manual included in your out steps kit for information on the service and mainte 2 nance of your PAXTON Supercharger Belt Now that the work is done it s time to enjoy tightening troubleshooting special tuning PAXTON Automotive wants to thank you for requirements and warranty information is also choosing our product and wants to remind you included in the Service Manual that the performance and response of your vehi romm Inspect all wiring harnesses and electrical connections Make sure that all items are properly routed connected and secured Check all hoses lines and fittings for properly secured connections Make certain all fasteners brackets and clamps are installed and properly tightened Check serpentine accessory belt and supercharger drive
35. rger may result 6 Before beginning installation replace all spark plugs that are older than 2 years or 30 000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications fol low the procedures indicated within the factory repair manual and or as indicated on the factory under hood emissions tag Do not use platinum spark plugs unless they are original equipment Change spark plugs at least every 30 000 miles TOOL amp SUPPLY REQUIREMENTS Metric and standard socket set wrench set Ratchet 1 2 drive Extension 1 2 drive breaker bar Ford springlock tool 3 8 amp 1 2 Pliers Drill motor 01 16 and 30 09 32 and 011 16 drill bits Test light Rubber mallet or dead blow hammer Wire cutters and crimping tool Standard hex key set Allen wrenches Silicone sealer RTV If your vehicle has in excess of 30 000 miles since its last spark plug change then you will also need Spark Plug Socket NEW Spark Plugs A WN P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured vil 065 05 v4 0 FordV10 4809606 v4 0 We look forward to hearing from you particularly if you have any com ments or suggestions regarding this manual TRANSMISSION WARNING DISCLAIMER Due to the increased horsepower and torque generated by the Paxton Novi 2000 super charger your transmission may require modification to prevent prematur
36. upercharger a mechanically driven cen trifugal supercharger This kit comes with all of the parts you will need to install the supercharger This instruction manual has been grouped in order of sequence with photographs and drawings to illustrate the text This will allow you quick part identification and orientation We suggest that you obtain a Ford shop manual and become familiar with the details of your car s system Manuals may be obtained from your local Ford dealer or you can order one from Helm Publications at 800 782 4356 If your vehicle is not within the normal operating parameters we do not recommend the use of a supercharger For best results we suggest that you read this entire manual before beginning Familiarize yourself with the process and identify the areas of the car that you will be working on The average installation time is 8 10 hours Your actual install time will depend on your personal skill level experience installing super chargers working conditions and preparedness for the job at hand This estimate does not include time for the initial vehicle inspection cleaning fine tuning or troubleshooting Once again before picking up a wrench read this entire manual We are available for technical assistance at 805 604 1336 After reading this manual verify that all major assembly groups are present in the main kit box You should have ample space to lay out the components As you remove a box or bag from t
37. ured 3 1 O6SEPO5 v4 0 FordV10 4809606V4 0 This Page Left Intentionally Blank P N 4809606 2005 Paxton Automotive All Rights Reserved Intl Copr Secured 065 5 v4 0 FordV10 4809606v4 0 3 2 80 4 SUPERCHARGER AIR INLET TUBE 4 1 SUPERCHARGER INLET DUCT ance Attach the flex hose to the aluminum 2 elbow Next connect the factory PCV hose into A Locate the supplied inlet duct Assembly the hose coming from the intake elbow See 1015911 in the kit Plug the air temp sensor Fig 4 1 a previously removed in an earlier step into the open hole on the rubber elbow See Fig 4 1 a 4 2 AIR FILTER ENCLOSURE INSTALLATION Ae 4 il 2 22 Locate the new air filter cover Attach the new where the IAT sensor would be It is recommended wea a 2 that sealant be used on this plug apter using the supplied hose clamp olt the air flow meter to the adapter flange sandwich ing the air filter cover in between See B Slide the inlet hose with the attached aluminum Appendix Next use a razor blade elbow in behind the supercharger and attach to sharp knife to remove the rubber flap with the the inlet of the supercharger with the supplied large hole in it located on the core support next hose clamp See Appendix F The electrical to the radiator on the driver s side Fold the harness will go through the loop in the inlet other rub
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