Paxton Automotive Automobile Parts 2002 Dodge Ram 1500 User's Manual
Contents
1. AYY 30000 1 7 2002 0091 MO NA Yd 5 5 S IVAOHddV 00 S IVINIO3Q 4221 09 S08 9221 09 G08 181 X 0 FXX 3uv S3oNVH310L 22026 39V Td NOOV38 0061 A 204 S3HONI NI SNOISNI NIG 4 Q31VU3N39 QVO 0910395 ASIMYSHLO SSTINN GI X lt 12 9 X 970 060 0 00 lt lt 12 2 2 X 66 9 NNNOVA 14 0 17 66 2 080 95 4 1 NNNOVA 66 9 3S0H 17 4 10 91 SSVd A8 SATIVA 8 NOILdIH9S3q ON LHVd MO ON WALI 1908 OL ASV 39uvH9SIQ HIY 1 A 10 NOILVOHIGON WAL 90 00 Q IO3INV IN NO 1008 WANOVA OL gt SE co Q SE Q LO w gt S gt TD S O G gt WY D Z rs x E 2 3 x S A P N 4809641a LNAWASDVNVIW ANTON 98122101 1108 HOIO3NNOO 010 100 4 SE TE 5 re 5 5 5 31706 LON 06 31 05 1HOBM SDN 5 258 8177101 ON 8 HSINH SNS2. 42538 ON LHVd ON Wall 45001 dIHS SLYVd 5 031512345 3SIMH3HLO SS3TNf S310N A 6 gt SE co Q SE Q LO w gt S TD S O G gt WY D Z rs x E 2 3 x S A P N 4809641a TIO ASV 6101 A S OBS a 30 18865 31 25 ION OG 21 9190 6 2 ON S 96101 ON OMG d 321 10 01 60 NOLd NOD 9 HddV MOINE SS ud 0844 ASV 10 01 60 3935 1 1811 SLHVd 335 89 soeg 10 91 10 NOLdWOO 9 po 0091 39000 1Z 2002 QI LF Geo 00 10 01 01000 V X 6 261 09 G08 Xv4 9801 09 908 AL TE Y ESI MM 21011 SSE Hi 3ivddn ATIVANVW LON OG 10 FXX S3ONVHU3 TOL 22026 VO 3014 NOOV38 0061 rs v EINER CIN S3HONI NI HV SNOISN3 NIG JE 45 3SIMH3HIO 5631 0 8 1 331 H1dvOv 914 12 14 9 1 HOLOANNOO 14 mp NV 06 MOG 914 1 1HOd 5 SS 2 O
3. SHO O3fNI Gal IddNS OL N33H9 49V 18 MOTTAA NVL MOV 1g AVvH9 NOILINOI 8 4173114 NOLXVd HOSN3S cO 96 Nid HOSN3S 60 I 2 ms 2 O D gt gt Z o m c 2 m D O JJ ov 18 HOLO3NNOO WOd SUPERCHARGERS 1300 Beacon Place Oxnard CA 93033 9901 805 604 1336 FAX 805 604 1337 paxtonautomotive com M F 8 00 AM 4 30 PM PST P N 4809641a 2006 Paxton Automotive All Rights Reserved Intl Copr Secured 01 06 v1 1 Dodge Ram 1500 4809641a v1 1
4. 3uv S3oNVH3T10L 6 5 69096 VO JOVTd NOOV3G 00 P Cl 22 S3HONI NI 3HY SNOISNAWIG Ase 2 0348 3SIMYSHLO 5531 0 eo 28 A389 0008 dvO 822116 SO 00 11 2 8 6 MIYOS 8 6 0 8 138 6 T lt d3MO 18 GYVMOL NOILVLOY 5 5 ONILNNOW 1108 1 5 ONIMVHQ LON OQ du 669910 ON 841101 INU DIN ASV L0 cV c NOLd WOO ANON HSINI3 299101 1x88 DLW ASV L0 cV c 033 894 0091 39400 1 7 2000 0 2171 NOLd WOO 9 ONIB33NION3 1511 51474 335 2061 09 G08 9221 09 908 1 22026 VO 3OV 1d NOOV38 0061 u3xuvd Z v 9NIH O 90 001LNZ L0 01 1 010000 V S IVAOuddv ALVddN ATIVNNVN LON OQ ONIMVHG G31VH3N39 AY L 1104 17 dalv 1dH3HSVM 9 660 900 819 Ot X 01 90 070 0902 60113 GHXH 0S X 91 x 0 GS0 01002 G31V ld H3HSVM 0 200 010 088 X dO 528 H30vdS 71 928 21072 849 QHXH 7 1 6 X 91 B E 400 41 6 1 2 5 10 070 2 HLOOWS 44101 091 910837 4
5. NEW Spark Plugs 2 27 7 l 2 2 A 206 0 W P N 4809641a IV 2006 Paxton Automotive All Rights Reserved Intl Copr Secured 01 06 v1 1 Dodge Ram 1500 4809641a v1 1 Section 1 INTRODUCTION 1 1 INTRODUCTION finest street Supercharger available for the 2002 4 7L Dodge Ram 1500 The centerpiece of this kit is the highly efficient and reliable Paxton Automotive Corp NOVI 1000 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 Photos and drawings accompany the text allowing quick orientation and parts iden tification Installation requires a selection of tools which are listed in a table at the end of this section We also suggest that you obtain a Dodge shop manual and become familiar with the details of your cars systems Manuals may be obtained from your local Dodge dealer or you can order one from Helm publications at 800 782 4356 For best results follow the instructions closely and in sequence The average installation time for this kit is 8 10 hours Your actual installa tion time will depend on skill level and work ing conditions The estimate does not include time for initial vehicle inspection cleaning fine tuning or troubleshooting Before even picking up a wrench read this entire manual We are available fo
6. ON 3715 Hdd 5 5 1 ASV 198 005 900 00 QL LF SES 39000 1 77 0000 Gc np 5 9 3 TT 81 S003XXX S1VWIO3Q SEL 2861 09 908 9661 709 208 T1 10 3uv S3ONVH3TTOL gt 22026 VO QHVNXO FOV Id NOOV38 0061 Ci oa S3HONI NI 38V SNOISN3WIG c LEE 091510395 ASIMYSHLO 5537131 no eO 91 96 X 1 INOO1 A10d 11145 L60 L00MS en 3911dSH91N0 HOIO3NNOO L00 L00MS X ceo x LOANNOOSIC 070 L00MS ssanuyu 00040080 070 0913067 30 01 WIH S Elie 4 2 gt X 01 MIYOS 190 0103 985 05 21 21 82 ONN2 01 LAN ao X VZ ONNZ 0 GH Nvd MIYOS 250 0100 3 51 2 05 97 ASY 110 0913049 9 1 9 OL 9 16 11 1 NOILdIH9S30 oit gt Ts gt SS3NHVH 070 100 84114408 NO 28 TWNINYSLOL n au 12 5 20 110 HOSN3S cO 110 HOSN3S cO N33H89 1H9 1 N33H9 PIdVQ 1 WYO NYL AVHD NI HNVHO NI HOSN3S cO NI HOSN3S cO MOV 1g Avd9 MOTBA NV L N3349 H9V 18 Qq38 N3HH9
7. A RD L 4 gt 1 8 E e d 2 Le i 4 6 E E E 40 E 030300 LIES TAM L Ls J d a if Fig 3 3 c E Bolt the belt tensioner assembly to the front of the supercharger using a 7 32 allen wrench or socket See Fig 3 3 d Fig 3 3 a C Lower the supercharger into place making sure that the drain hose goes over the A C line See Fig 3 3 b This step may be different with some models Make sure the drain hose has no kinks and is not lower than the drain fitting The oil drain fitting will be installed in Section 4 P N 4809641 2006 Paxton Automotive All Rights Reserved Intl Copr Secured 3 4 01 06 v1 1 Dodge Ram 1500 4809641 v1 1 H Tighten the nut on the tensioner pulley using 3 4 wrench You will have to bend the upper most a c line up slightly to clear the belt See Fig 3 3 g Also bend it up slightly at the radi ator end until it clears Your air conditioner lines may differ from the picture and some steps may not be needed Fig 3 3 e F Install the supplied longer accessory drive belt Use the factory belt routing with the exception of going around the supplied idler and S C drive pulley See Fig 3 3 e G Tighten the supercharger drive belt and ten sioner
8. 1 5 1 AIR DISCHARGE INSTALLATION 5 1 5 2 AIR INLET INSTALLATION 5 1 6 ENGINE MANAGEMENT UNIT INSTALLATION 6 1 6 1 ENGINE MANAGEMENT UNIT INSTALLATION 6 1 7 FINAL CHECK OUT AND 7 1 7 1 FINAL CHECK OUT AND START 7 1 APPENDIX 2 0 20 00 5 000 0 _____ _ 1 APPENDIX KIT CHART A 2 B 1016416 Asy S C NOVI 1000 Forward Rotation A 3 C 1016623 Ass Mounts Braeckel 2 22 222 2242 09 4 D 1015937 AG AR to 5 1017410 Asc DO TENSIONE cane mada A 6 F 1019342 Asy Oil Feed A 7 G 1019343 Oil Drain bE Ee a 8 1020116 Asy Air Discharge w Fuel Enrichment A 9 1 1015511 Asy Compressor By Pass A 10 J 1017718 Engine Management Wiring Diagram 11 iii P N 4809641a 2006 Paxton Automotive All Reserved Intl Secured 01MAY06 v1 1 Dodge Ram 1500 4809641a v1 1 2002 4 7L DODGE RAM Installation Instructions 50 State Smog Legal as per CARB EO D 195 19 D 213 20 Congratulations on sel
9. c i E Fig 4 2 4809641 2006 Paxton Automotive 4 2 All Rights Reserved Intl Copr Secured 0 01 06 v1 1 Dodge Ram 1500 48096418 v1 1 SECON AIR INLET amp DISCHARGE INSTALLATION 5 1 AIR DISCHARGE INSTALLATION C Attach the straight end of the fuel line to the A Locate the fuel pressure test port directly fuel rail and the 90 end to the injector under the dipstick on the passenger side fuel RS I using a 9 16 wrench See rail See Fig 5 1 a Fig 5 1 5 2 AIR INLET INSTALLATION Fig 5 1 a Remove the plastic cap and place over the port Hold the rag with one hand and Attach the air filter housing using the sup depress the valve with a small screwdriver plied sheet metal screws to the frame rail to relieve fuel system pressure Use caution next to the radiator Install the air filter when prforming this step to avoid getting assembly and attach with the screws sup fuel in your eyes Remove the valve core plied See Fig 5 2 a using a small screwdriver or valve core i removal tool Attach the discharge tube so the injectors situated under the throttle linkage See Fig 5 1 b P N 480964 1a 2006 Paxton Automotive 9 1 All Rights Reserved Intl Copr Secured 01MAY06 v1 1 Dodge Ram 1500 4809641av1 1 B Attach the 1
10. e Never remove the radiator cap while the engine is hot e Always wear eye protection when using power tools such as drills saws grinders etc or when working under a vehicle e Never smoke use an open flame or have spark producing items around gasoline or flammable solvents Always have a fire extin guisher rated for chemical and electrical fires handy when working on motor vehicles Run engines only in well ventilated areas Carbon monoxide gaso line 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 Paxton Automotive makes every effort to insure 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 is damaged in transit please call Paxton Automotive 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 We look forward to hearing from you particularly if you have any comments or suggestions regarding this manual P N 4809641a 1 2 2006 Paxton Automotive All Rights Reserved Intl Copr Secured 01 06 v1 1 Dodge Ram 1500 4809641a v1 1 Section 2 FAN GOOLANT OVERFLOW WASHER BOTTLE REMOVAL B egin the initial prepa
11. of Paxton Automotive P N 480964 1a Il 2006 Paxton Automotive All Rights Reserved Intl Copr Secured 01 06 v1 1 Dodge Ram 1500 48096414 v1 1 TABLE OF CONTENTS FOREWORD 221 dud pd tr es ii TABLE OF CONTENTS iii TOOL amp SUPPLY REQUIREMENTS iv INIRODUCTION 455253393939 35 9 3 59 734 38 9 1 1 LI INTRODUCTION 8 do i3 3e d 1 1 2 FAN COOLANT OVERFLOW WASHER BOTTLE REMOVAL 2 1 2 1 FAN COOLANT OVERFLOW AND WINDSHIELD WASHER BOTTLE REMOVAL 2 1 2 2 WASHER BOTTLE RELOCATION AND INSTALLATION 2 1 225 AIRFLIERREMOVAL a 7 2 2 3 SUPERCHARGER INSTALLATION AND ASSEMBLY 3 1 3 1 SUPERCHARGER MOUNTING BRACKET PREPARATION 3 1 3 2 SUPERCHARGER MOUNTING BRACKET INSTALLATION 3 2 3 3 SUPERCHARGER INSTALLATION 3 4 4 DRAIN amp FEED 4 1 41 DRAIN INSTALLATION 0546405505505 4 4 2 FEED INSTALLATION 4 5 AIR INLET amp DISCHARGE INSTALLATION 5
12. on the driver side and in front of the battery with a 13mm socket Remove the nut and attach the wire for the 12 Volt power supply for the relay See Fig 6 1 b Fig 6 1 c D Mount the Paxton supplied engine manage ment unit on the rail next to the Power Train Control unit See Fig 6 1 d P N 4809641a 6 1 2006 Paxton Automotive All Rights Reserved Intl Copr Secured 01MAY06 v1 1 Dodge Ram 1500 4809641av1 1 J Locate the crank case breather hose that was originally attached to the factory air filter assembly Towards the back of the engine there is a tube that runs across from the dri ver s side to the passenger s side On the driver s side there is a TEE coupler This was originally connected to the factory air box K Connect the supplied length of hose to the 1 2 nipple that is installed in the air intake assembly and it would be located on most vehicles next to the compressor bypass fit ting This fitting is not installed You will have to drill and tape the hole Because of the variations in vehicles you will have to find a suitable location for your particular application See Fig 6 1 f Fig 6 1 d E Attach the red wire from the supplied engine management unit to the 87 on the relay Again using drawing number 1017718 find the black plug on the factory ECU G Locate the pin numbers and splice in the supplied engine management unit There are eight supplied but
13. the plate using 9 16 3 4 and a 17mm socket See Fig 3 2 d See Appendix Check the tight ness of the small idler attached to the plate with a 9 16 socket Fig 3 2 a B Bolt the oil filler neck to the plate using the supplied hardware See Fig 3 2 b Re attach the PCV hose Fig 3 2 d F Install the new Accessory drive belt See Fig 3 2 e Re install the fan See Fig 3 2 7 Fig 3 2 b C Trim the plastic hose that connects to the oil filler by cutting it off just before the second barb approx 3 4 Do not remove the sec ond barb as this keeps the hose from coming off under boost See Fig 3 2 c Install the supplied longer hose The oil fill will be reinstalled at a later stage of the installation P N 480964 1a 2006 Paxton Automotive 2 All Rights Reserved Intl Copr Secured 3 01 06 v1 1 Dodge Ram 1500 480964 1a v1 1 3 3 P N 4809641a 2006 Paxton Automotive All Rights Reserved Intl Copr Secured 01 06 v1 1 Dodge Ram 1500 4809641av1 1 3 3 SUPERCHARGER INSTALLATION D Fasten supercharger with six bolts See Figs 3 3 A Test fit the supercharger in the mounting bracket You may need to bend the A C lines for a perfect fit B Measure and cut the supplied drain hose Secure hose to drain fitting on supercharger using supplied clamp See Fig 3 3 a Lj Li E d 1 E 4 1 5 E 1 L A
14. the four bolts securing the oil filler neck using a 10mm deep socket to be rein stalled in a later step See Fig 3 1 a L 77 Fig 3 1 b F Remove the three bolts securing the A C compressor using a 13mm and 15mm sock et Lift compressor up and let it rest on top of the valve cover Using a 1 1 8 wrench or socket remove the large bolt on the front of the cylinder head See Fig 3 1 d Fig 3 1 a C Remove the factory installed straight fitting D Using Teflon sealant install the supplied 45 brass fitting so it points back and up slightly Thread the straight hose fitting removed in Step into this using Teflon sealant See Fig 3 1 6 P N 480964 1a 2006 Paxton Automotive 3 1 All Rights Reserved Intl Copr Secured 01MAY06 v1 1 Dodge Ram 1500 4809641av1 1 3 2 SUPERCHARGER MOUNTING D Bolt the A C compressor back in place using BRACKET INSTALLATION the original hardware You may need to bend the A C line slightly to fit in corner of plate See Fig 3 2 c A Attach the rear support plate to the cylinder head using the supplied large bolt See Fig 3 2 a Use at least two of the supplied 6mm bolts to align the bracket with the other mounting holes before tightening Make sure the supplied O ring 15 in place on the rear of the plate FERE Fig 3 2 E Bolt the front plate to
15. 034 1 0091 29000 1 77 2000 00 40 01 NVO9V3U IN ONIH33NIDN3 1511 S1dVd 335 5 lt 10 12 80 S 1 1681 0709 508 Xv4 9661 0709 508 AL 65096 VO GHVNXO FOV Id NOOV38 0061 ONILLH ISOH 9 6 17 3ivdadn ATIVANVW LON OG ONIMVHQ Q31VH3N39 AYO S E X 081 MOS T3 131 010 010 960 0604 5 895 Nvd 86 X vc X 1 660 0102 1196 100 5600 1 OL LAN 2 12 dIAV 19 3SOH 09 50 9 00 02 0 70 15 00c 00 Sd 319 435 01 H3HSVM 100 01012 1 1892 X 960 70 010 dIWV 19 3SOH 17350109 6 00 9NINIVI3H 7 0 090 6 0 431114 48 2 NOILdIH9S3q 0 010 6 0 1 4 9 SNOLLOVEH 900 S1VNI930 107 YW S3ONVH3 TOL SIHONI NI 38V SNOISN3 NIQ 991519395 ASIMYSHLO SSTINN 001 diHS 1 031512345 ASIMYSHLO SSF INN SALON 3N1VA Ad 1 3NTVA SSVdAd OL 2 25 c C A All Rights Reserved Intl Copr S
16. 1101 5 SVdA8 93 WOO ASV 116601 NOILOSPNI 394VHOSIQ ASY 9110201 NYNLAY 110 2 5 ASV 5766101 3SOH AlddNS 110 2 5 ASV 96101 YJNOISNIL 1134 ASV 92101 3MVINI ASV 2665101 198 OLIN 0 5 ASV 6099101 NOILVLOY 0001 IAON 9 S ASV 979101 11 19953 ON 1uVd 2 gt SE co Q SE Q LO w gt S TD S O G gt WY D Z rs x E 2 3 x S A P N 4809641a NOIIVION 404 0001 O S ASV 91F9101 AATINd 13H 86 8 91 601 6001172 GEAYD 92 6 A3TIhd 7 HOSIQ 0001 IAON 8 011419953 ON ALO WALI ope SES mo 40 18885 31VOS LON 04 EL 31908 9 55 581712 LHOBM LE 9179101 ON OMG 0 3715 HSINH TX OO NOLLVLOH Md 0001 IAON 2 8 ASY c83 1 4 XXEXEKREREEE STWAOUdd S00 XXX SVNIO3Q S9 2661 09 908 9221 09 S08 Bl 10
17. 315 1109 09 61 0 1 009 0097 2 dO ZH FX QI 6 1 5 100 008 43101 1104 ASY 8160101 39000 27 8315 1100 889 91 X 8 6 080 4 6 1 SOXH X lt 6 00 G EV 0114 3vS 8 6 5 770 5 6 10191 00521 HAOVdS 1018 L X dO Sc 5 SH L 60528 5 0 8 8 Z10Vc L Y 1000005 HV3H 31V 1d 0 0 Or NON CO LY OLIN 9 5 0119199253 ON 1uVd 39018 3NION3 OL 7 0 01039 3908 ANIONS OL FON WALT 9 15 S319NV CIF SNOILOVE S00 XXX 51 10 SIONVHTTOL S3HONI NI SNOISN3 WIG 9910395 ASIMYSHLO 5537131 9 4 5 OL gt SE co Q SE Q LO w gt S TD S O G gt WY D Z rs x E 2 3 x S A P N 4809641a 2664101 AMVLNI ASV 0 L33HS LON 00 80 31 25 Sg104 LHOBM ON 269101 ON 1715 dddV 3NON ASY 00 90 01 X
18. 80 plastic duct to inlet of the supercharger using the sleeve and clamps provided B Next route the flex hose to the 180 elbow attached to the supercharger and tighten the clamps See Figs 5 2 b 5 2 c P N 480964 1a 2006 Paxton Automotive All Rights Reserved Intl Copr Secured 9 2 01 06 v1 1 Dodge Ram 1500 4809641a v1 1 Section 6 ENGINE MANAGEMENT UNIT INSTALLATION 6 1 ENGINE MANAGEMENT UNIT INSTALLATION A Locate the factory ECM It 1s located on the passenger side of the engine compartment at the back of the engine compartment There are two silver boxes The one that 15 attached to the firewall is where you will attach the Paxton Engine Controller There are three plugs on it You want the one with the black plug Look in the assembly draw ings and find drawing 1017718 This draw ing gives the pin locations and wire colors Mount the relay on the passenger side fire wall just to the left of the black plug See Fig 6 1 a Fig 6 1 b C Run the ground wire for the relay 85 and the supplied engine control unit to the stud just to the right of where you mounted the relay This is a factory ground and should be used The trigger wire for the relay 86 1s attached to the red white wire in the large plug on the power train control See Fig 6 1 Fig 6 1 a B Run the power wire 30 on the relay across the firewall to the power distribution box located
19. L 0538 ON LHVd ALO ON WALI HAON3S AHOLOV 5 ay A 7 d ASV 5 5 01 TIO ASV 6101 D 1 5 37105 LON 00 EL ITVS 5419 0 LHOEM ee 7 ON 0 3715 HSINE 10 ASY 1511 SLHVd 335 35001 S1uVd 5 dIHS 1 ONIMSENIONA WIYALV 031510345 351 10 553 SALON 0091 39000 1 77 2002 OL LF 59 5 4 3 9 1 5 31va S IVAOuddV S00 XXX STVWIO3Q 9221 09 908 TL 10 XXX S3ONVH3TOL 808 09 2661 88086 VO GHYNXO FOV Td NOOV38 0061 1 2 S3HONI NI SNOISNSWIG 5 3SIMHIHLO 5541 0 800 10082 9 4785 Nvd 0696008 NV 9 1815 914 8992008 6 0 3801 1N38 06 914 1996008 91 00 2 X Q 1 c L ISOH 00665 0 114182530 ON 1dVd ON NYd OL 8 gt SE co Q SE Q LO w gt S TD S O G gt WY D Z rs E 2 3 x S A P N 4809641a LNANHOTANA DHVHOSIG IV A
20. Owner s Installation Guide for the Paxton Automotive Novi 1000 Supercharger for the 2002 Dodge 1500 Paxton Automotive 1300 Beacon Place Oxnard CA 93033 888 9 PAXTON FAX 805 604 1337 DP N 48096410 Ram 1500 v1 1 05 01 06 FOREWORD Paxton supercharger kit expressly designed for the 2002 4 7L Dodge Ram 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 An understanding of the information contained herein will help novices as well as experi enced technicians to correctly install and receive the greatest possible benefit from their Paxton supercharger When reference 15 made in this manual to a brand name number spe cific tool or technique an equivalent 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 manual provides information the installation maintenance and service of the This is a typical underhood shot after installaton Your engine com partment may look different 2006 PAXTON AUTOMOTIVE All rights reserved No part of this publication may be reproduced transmitted transcrived or translated into another language in any form by any means without written permission
21. SV 9110201 JO 1 EHS 3128 ION 00 711 27905 58192 3NON 9110201 ON OQ 10 21 20 NOLdWOO D HddV 1N3WHOIBNG 3OUVHOSIC ASY 10 61 60 NOLdWOO D 172 277 0081 39000 1 7 2002 00110 uolDOHd V GEXXEKEEREEKERE S IVAOHddV S003XXX SVWIO3Q 24 1661 0909 G08 9821 09 908 7741 FIPP TES 22026 VO 3OV ld NOOV38 0081 Ae CALE ASV 6168101 3ivddn ATIVANVW LON OG ONIMVHGO Q31VH3N39 GVO ISOH dWV10 870 20082 8 971 00 X 00 006 8 ISOH 002 00654 2 2 1002 0 1 GH 005 ATHS MIHIS GLe 0S Vd2 201 ASV 7709101 8127 070 090 8 38nl 7 5 _ ALO ON WALI ASV 5 5 OL 107 FXX 3uv S3ONVH3 TOL S3HONI NI 38V SNOISN3IWIQ 091519995 3SIMH3HIO 559131 ASV SSVd Ad HOSS3udINOO OL 1903 OL AQO8 31LLOHH L MOOLS OL 2 25 c C A All Rights Reserved Intl Copr Secured 01MAY06 v1 1 Dodge Ram 1500 4809641av1 1 A 9 SSVdAF 8055181602 ASV ITSSIOT 1 3NON SSvd A4 HOSS3Hd WOO ASV 484 1511 SLHYd 335
22. by turning the leadscrew clockwise using a 10mm socket The belt should be very tight as it will stretch after being run See Fig 3 3 f cm Fig 3 3 h f I Reinstall the factory fan and clutch assem bly P N 4809641a 2006 Paxton Automotive 3 5 All Rights Reserved Intl Copr Secured 01MAY06 v1 1 Dodge Ram 1500 4809641av1 1 This Page Left Intentionally Blank P N 4809641a 2006 Paxton Automotive 3 6 All Rights Reserved Intl Copr Secured 01 06 v1 1 Dodge Ram 1500 4809641a v1 1 oection 4 DIL DRAIN FEED INSTALLATION 4 1 OIL DRAIN INSTALLATION E Tap the hole using a greased 3 8 NPT tap Go slowly and make sure the tap goes in straight Stop periodically to clean and re grease the tap A From under the vehicle mark and drill the oil pan in preparation for the oil drain See Fig 4 1 Run the tap in only 2 3 of the way and check to see that the fitting will screw in leaving at least three threads exposed G Clean threads thoroughly and coat the fitting with teflon sealant and install 4 2 OIL FEED INSTALLATION A Under the vehicle near the oil filter you will find the oil pressure sending unit Unplug and remove using an oil pressure sending unit socket available at most auto parts stores B Install the brass TEE fitting using teflon sealant on the threads See Fig 4 2 a The sending unit is now re installed pointing toward the front of the vehic
23. ecting the best performing and best backed automotive supercharger available today Before beginning this installation please read through this entire instruction booklet and the Street Supercharger System Owner s Manual which includes the Automotive Limited Warranties 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 product 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 any way check with Vortech 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 vehicle Thereafter always use a high g
24. ecured 01MAY06 v1 1 Dodge Ram 1500 4809641av1 1 A 5 0 133HS O9NIMVaG 31 25 LON OQ V 9177101 ON OMG YANOISNAL 1144 ASV 581046 NOLd NOO 9 HddY HSINH 9IFLIO0I HANOISNAL 1148 ASV 0 7 0 0091 20000 1 7 2006 L0 v 0L X029 1 agy 2511919 339 L0 v 8 5 5 ZEE 1 709 G08 9 1 09 208 7181 85096 VO FOV Td NOOV38 0061 9 8 NOLdWO9 9 915 SATONY 010080 V NMVHG CIF SNOILOVHH S IVAOuddv S00 XXX SVWIO3Q 9 906 970 2 8 31Vadn ATIVANVW LON OG Tr ONIMVHGO Q31VH3N39 AY 10 S3ONVHH TOL S3HONI NI SNOISN3WIG 991519395 3SIMH3HIO 9537131 N m 0 00G G vd HLOOWS AH9 9 OLLSW1d 4310 091 91 0747 g L H3HSVM 100 008 LAN 6 06 86 90 00944 91001 X 1 06 6 0 574 M389S 001 084 H3NOISN3L 002 0089 50 31 B3NIVILSH 160 010 44 91821 X 91 8 8 514 MIHIS 91008 q 1 06 X Q O 9487 56 90 628 2 1072 uvTIOO 4315 8 7 MHL 18 31V1d DLW H3NOISN3 L 7 0
25. elocation assembly Using the bracket as a template Drill two 3 16 holes in the bar just under the radiator You may have to bend the washer bottle bracket a little to get a perfect fit Install sheet metal screws and extend the wires and the hose P N 480964 1a 2006 Paxton Automotive 25 All Rights Reserved Intl Copr Secured 01MAY06 v1 1 Dodge Ram 1500 4809641av1 1 2 3 AIR FILTER REMOVAL A Remove the small vent hose and hard plastic lines and set aside This item will not be reused B Remove the crankcase breaker hose from the air filter cover See Fig 2 3 a C Remove the air filter assembly See Fig 2 3 b by first loosening the clamp at the throttle body Remove the nut securing rear of air box using a 10mm socket Lift assem bly up and off the rubber mounts There are a number of different styles of air cleaner assemblies Yours may differ from what 15 shown Fig 2 2 a Fig 2 2 b P N 4809641 2006 Paxton Automotive All Rights Reserved Intl Copr Secured ee 01 06 v1 1 Dodge Ram 1500 4809641a v1 1 DECON SUPERCHARGER INSTALLATION AND ASSEMBLY 3 1 SUPERCHARGER MOUNTING E Detach wiring harness from the front of the BRACKET PREPARATION engine This allows space for the super charger mounting plate See Fig 3 1 b A Remove the factory accessory drive belt by rotating the tensioner using a 15mm wrench or socket B Remove
26. heir proper levels Are there any fluid leaks Belt s Is the serpentine drive belt or accessory drive and supercharger drive belts depending on the requirement of your vehi cle properly installed aligned and ten sioned Perform the following A D Cycle the ignition key from off to on position three 3 times at fifteen 15 sec ond intervals Afterwards check the entire fuel system for any leaks Start the car Verify that the oil pressure is within the normal operating range Listen closely The engine should idle and sound the same as it did before you began the installation Shutdown the engine disconnect the oil feed line from the blower Remove the oil jet from the blower Blow through the oil jet to ensure there is no blockage or foreign matter plugging it Re install oil jet and oil feed line and proceed Allow the engine to come to normal operat ing temperatures Bleed the cooling system and top off as necessary Check for the following Fuel leaks Fluid leaks Belt slippage Throttle response 7 1 CAUTION See the supercharger service manual included in your kit for information on supercharger servicing and mainte nance belt tightening troubleshooting special tuning and warranty information Now that the work 15 done it s time to enjoy your labor of love Take the car out on the road and let it flex it s muscles but remember the response and pe
27. le E Fig 4 1 a B Onthe front of the pan measure and mark the center between the two oil pan retaining bolts Find the centerpoint between the pan rail Coat a 3 16 drill bit with grease and drill the hole C Coat the supplied punch with anti seize or heavy grease and drive it in only halfway using an air chisel with a blunt tip Do not use a hammer Do not go in all the way or you will damage internal engine compo nents D Cut off the front portion of the hardened steel punch with either a grinder or a cut off wheel Continue driving the punch in stop ping 9 16 before the punch makes contact Fig 4 2 a with the flat portion of the punch Go slow m with this It will affect your tapped hole if C Using teflon sealant install the straight fit you go too far See Fig 4 1 b ting into the remaining port and attach one end of the line using 9 16 wrench Route the line up and across the top of PUNCH the engine toward supercharger Fig 4 1 b P N 4809641a 2006 Paxton Automotive 4 1 All Rights Reserved Intl Copr Secured 01MAY06 v1 1 Dodge Ram 1500 4809641av1 1 D Install the 90 fitting in the supercharger oil jet using teflon sealant Support the jet with a 1 2 wrench as you tighten the fitting Route the oil line See Fig 4 2 b Fig 4 2 b E Attach the oil line again supporting the oil jet at the top See Fig 4 2
28. r technical assistance at 805 604 1336 7am 3 30pm Pacific time After reading the manual verify that all major assembly groups are present in the main kit box You should have ample space to layout the components As you remove a box or bag from the main kit note the identification label and compare it with the parts list Please check the box for small parts Paxton makes every effort to insure that all parts are included the box However if you discover any missing or mislabeled parts please contact Paxton by phone for service streets You have purchased the WARNING 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 Before starting the installation we suggest your engine compartment be clean You can clean the engine and compartment with a pres sure washer such as those used at self serve car washes and a safe for aluminum cleaner degreaser Cover the distributor with a plastic bag to prevent water from entering CAUTION We do not recommend proceeding with the kit installa tion unless your vehicle is within normal operating parameters You are undoubtedly enthusiastic about getting started on your project but take just a little more time to insure that your safety 1s not Jeopardized A moment s lack of attention can result 1n an accident as can failure to observe cer
29. rade SF rated engine oil or a high quality synthetic and change the oil and filter every 3 000 miles or less Never attempt to extend the oil change interval beyond 3 000 miles regardless of oil manufacturer s claims as potential damage to the supercharger may result 6 Before beginning installation replace all spark plugs that are older than 1 year or 10 000 miles with origi nal heat range plugs as specified by the manufacturer and reset timing to factory specifications follow the procedures indicated within the factory repair manual and or as indicated on the factory underhood emissions tag Do not use platinum spark plugs unless they are original equipment Change spark plugs every 15 000 miles and spark plug wires at least every 50 000 miles TOOL amp SUPPLY REQUIREMENTS Factory Repair Manual 3 8 Socket and Drive Set SAE amp Metric 1 2 Socket and Drive Set SAE 8 Metric 3 8 NPT Tap and Handle e Adjustable Wrench Open End Wrenches 3 8 7 16 1 2 9 16 Center Punch and a 5 8 Tapered Punch 5 Quarts SH CF Rated Quality Engine Oil Filter and Wrench Flat 2 Screwdriver O1 gt Phillips 2 Screwdriver Heavy Grease Silicone Sealer Drill Motor 1 8 3 16 27 64 Drill Bits 3 16 Allen Wrench Wire Strippers and Crimpers Utility Knife If your vehicle has in excess of 10 000 miles since its last spark plug change then you will also need Spark Plug Socket
30. ration and disassembly C Next remove the windshield washer bottle process by disconnecting the battery cables and disconnect the plugs from the washer pump and the warning sensor along with the hoses and set it aside You will replace this 2 1 FAN AND COOLANT OVERFLOW with a Paxton supplied washer bottle in a AND WINDSHIELD WASHER later stage of the installation BOTTLE REMOVAL D Remove the fan using a 36mm or a large crescent wrench Hitting the wrench with a brass hammer will break it loose The fan unscrews counter clockwise as viewed from the front of the engine See Fig 2 1 To aid in the installation of your new Paxton Supercharger System remove the coolant overflow bottle See Fig 2 1 a 1 Fig 2 1 a B Remove the two 12mm bolts on top of the Fig 2 1 c fan shroud and remove the small hose con ing from the coolant fill neck You will also 2 2 WASHER BOTTLE RELOCATION need to remove the large hose from the back INSTALLATION of the overflow Next lift up and set aside 4 You will re install this at a later stage of the installation See Fig 2 1 The factory window washer bottle will have to be discarded and the Paxton supplied washer bottle installed in the area just behind the front bumper See Figs 2 2 a 42mm BOLTS 2 2 b 2 1 c You will have to cut and f extend the pump sensor wires along with the hose This is supplied in the washer bottle r
31. rformance will now be different from that to which you have been accustomed Have fun P N 4809641a 2006 Paxton Automotive All Rights Reserved Intl Copr Secured 01 06 v1 1 Dodge Ram 1500 4809641av1 1 This Page Left Intentionally Blank P N 4809641a 2006 Paxton Automotive 7 5 All Rights Reserved Intl Copr Secured 01 06 v1 1 Dodge Ram 1500 4809641a v1 1 APPENDIR P N 4809641a 1 2006 Paxton Automotive All Rights Reserved Intl Copr Secured 01 06 v1 1 Dodge Ram 1500 4809641av1 1 ONIMVHQ 31V9S LON Od 9121021 ON LAVH XIONAddV 581712 LHOIAM ANON HSINH 008 9000 1Z 2002 LIM 494 1511 51800 335 0081 39000 1 7 2000 ONIYSANIONA 1VI431VN 5 8 E 1221 709 908 Xv4 9221 709 908 HL 0 91 10 NOLdWOO 9 9 5310 SNOLLOVEH 66066 VO NOOV38 0061 ALVddN ATIVANVIW LON OG ONIMVHYC Q31VH3N39 QVO S00TXXX SIVWIO3Q 107 XX 3uv S3ONVHH TOL S3HONI NI 38V SNOISNAWIG 9315193995 3SIMH3HIO SS3 INR 91400431 NOTAN 0041287 3NION3 5 TANVd 0006197 6 ANVLOO 66 1905 006187 NOILONHLSNI 13140084 0696087 NOILVOO 114 412108 H3HSVM 0200001 IN3IN39VNV IN 8122
32. t connectors Although with care the butt connectors will work We recommend that you solder the connections H Route the injector harness across to the supercharger discharge tube and connect to the supplemental injector I Re install the coolant overflow and hoses On some models this step may differ from the photo and Fig 6 1 f procedure shown here L Install the air intake assembly Connect the compressor bypass to the larger hose barb and secure Attach the air filter housing using the supplied sheet metal screws to the frame rail next to the radiator Install the air filter assembly and attach with the screws supplied See Fig 6 1 2 P N 480964 1a 2006 Paxton Automotive All Rights Reserved Intl Copr Secured 6 2 01 06 v1 1 Dodge Ram 1500 4809641a v1 1 JeCLION FINAL CHECK OUT AND START UP his section covers pre start checks and inspec tions as well as initial start up 7 1 FINAL CHECK OUT AND START UP Inspect the following Wires harnesses and electrical connections Are all items properly dressed connected and secured If any electrical connections have been dis connected re connect them before you start your vehicle Hoses lines and fittings Are all items prop erly dressed connected and secured Fasteners brackets and clamps Are all items properly installed and tightened Fluid levels Is the radiator coolant and the engine oil at t
33. tain simple safety precautions The possibil ity of an accident will always exist and the following points should not be considered a comprehensive list of all dangers Rather they are intended to make you aware of the risk and to encourage a safety conscious approach to all work you do on your vehicle We look forward to hearing from you particularly if you have any comments or suggestions regarding this manu al at 805 604 1336 Paxton Automotive Corporation 1300 Beacon Place Oxnard CA 93033 E mail Address info paxtonauto com Throughout these procedures the word discard is used periodically in relationship to items that will no longer be utilized in conjunction with the supercharger installation It is recommended that these items be saved for future use should it become necessary P N 480964 1a 2006 Paxton Automotive All Rights Reserved Intl Copr Secured 01MAY06 v1 1 Dodge Ram 1500 4809641av1 1 Never rely solely 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 raising a vehicle make sure it is on a level surface prefer ably concrete or asphalt The transmission should be in PARK or FIRST the parking brake engaged and the wheels blocked e Never start the car without first verifying that the transmission is in neutral and the parking brake is set
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