Paxton Automotive Automobile Parts 1300001 User's Manual
Contents
1. A 1 List of Appendices A 2 Appendix A 7000185 ASY S C NOVI 1000 A 3 Appendix B 1300001 Kit Parts List A 4 P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 iv IMPORTANT NOTES C ongratulations You have purchased the finest street charge cooler available for the Mustang GT The centerpiece of this kit is the Highly Efficiency PAXTON charge cooler This kit comes with all the parts you will need to install the charge cooler The instruction manual has been edited in order of sequence and photo graphs and drawings have been included to illus trate 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 Become familiar with the details of your car s system If it is not operating within normal parameters we do not recommend the installa tion or use of the charge cooler For the quickest 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 to2. e G Install inlet air control to discharge tube at the throttle body See Fig 3 e P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 A 1 APPENDIX P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 A 2 Please understand that PAXTON Automotive is constantly improving the performance and appearance of its various components The parts in your kit may appear differently than what is pictured in this manual This may be due to photographs being taken in pre production changes in mate rials or improvements in performance Rest assured that you have purchased the best quality kit that PAXTON Automotive manufactures at this time The instal lation of the materials will remain the same LIST OF APPENDICES Appendix Number DWG Number Rev DWG Title A 1300001 NC Kit Parts List B 7000185 NC Asy S C NOVI 1000 P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 A 3 1300001 FORD 4 6L MUST A A COOLER ASSEMBLY Part Number Description Qty Parent 8PN101 001 COOLR CORE W CAPS DUCTS A A 1 8PN012 010 DISCH TUBE A COOLR TO TB 4 6 A 1 8PN012 020 DISCH TUBE B S C TO COOLR INL 1 8PN012 030 DISCH TUBE C FROM COOLR DI
3. Installation Manual for the PAXTON Automotive Intercooler P N 4809638 v2 0 11 10 03 Installation Manual for the for the PAXTON Automotive Intercooler Kit 1300001 1999 2003 Ford Mustang GT Paxton Automotive 1300 Beacon Place Oxnard CA 93033 805 604 1336 FAX 805 604 1337 P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 ii 2003 PAXTON AUTOMOTIVE All rights recerved No parts of this publication may be reproduced transmitted transcrived or translated into another language in any form by any means without written permission of Paxton Automotive P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 iii TABLE OF CONTENTS TABLE OF CONTENTS iii IMPORTANT NOTES iv 1 1 INITIAL PREPARATION AND REMOVAL 1 1 2 1 AFTERCOOLER INSTALLATION 2 1 3 1 FINAL ASSEMBLY 3 1 APPENDIX
4. OV03 v2 0 99 01 MusGT 4809638 v2 0 v Y ou 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 seri ous injury to you or to someone else who hap pens to be standing around By following some PAXTON Automotive thanks you for your pur chase We welcome your comments and sugges simple safety precautions you can avoid many potential dangers The following list is not meant to be a comprehensive 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 work ing on motor vehicles Also make sure that the extinguisher is fully charged Operate engines only in a well ventilated area Carbon Monoxide gasoline and solvent vapors are colorless and some
5. R IN LINE WITH EDGE RE CLOCK SCROLL AS SHOWN S C ROTATION Appendix B Asy S C NOVI 1000 P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 A 5 This Page Left Intentionally Blank P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 A 6 Paxton Automotive 1300 Beacon Place Oxnard CA 93033 805 604 1336 FAX 805 604 1337
6. SCH 1 7PS300 400 BUMP HOSE 3 00D x 4 00L 2 7PS300 401 SLEEVE BLACK 3 00D x 4 00 3 7R002 048 48 SAE TYPE F SS HOSE CLAMP 10 7A250 400 1 4 20 x 4 HXHD GR5 1 7J250 022 1 4 WASHER SAE STAINLESS 3 7A312 075 5 16 18 x 3 4 HXCS GR5 ZINC 4 7F312 017 5 16 18 NYLOCK NUT 4 7J312 000 5 16 FLAT WASHER SAE 8 7E014 075 14 x 75 SHEETMETAL SCREW 3 4809638 INST MAN CHARGE COOLER 4 6 1 2A017 876 09 SPACER 875 OD x 3 210 LONG 1 7A250 051 1 4 20 x 50 HHCS ZINC PLTD 2 7U133 100 HOSE ELBOW 90 1 ID MOLDED 1 7C060 050 M6 x 1 0 x 50 HXHD ZINC PLATE 1 7J006 093 6MM WASHER PLATED 1 2A017 876 07 SPACER 875 OD x 1 490 LONG 1 P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 A 4 SCALE SIZE DWG NO D SHEET 1 OF 1 REV DATE APPROVALS DRAWN ENGINEERING R amp D UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE DECIMALS XX 01 XXX 005 MATERIAL FINISH NONE SEE PARTS LIST DO NOT SCALE DRAWING WEIGHT 20 7 LBS 2 1 7000185 NC FRACTIONS ANGLES 1 16 1 2 ASY S C NOVI 1000 REVERSE ROTATION w INTERCOOLER APPR PAXTON AUTOMOTIVE INTERCOOLER 1999 2003 MUSTANG GT 1300 BEACON PLACE OXNARD CA 93033 TEL 805 604 1336 FAX 805 604 1337 CAD GENERATED DRAWING DO NOT MANUALLY UPDATE NUT CORNE
7. ols that you will need on hand The average installation time is 6 to 8 hours but your time will depend on your working conditions experience installing superchargers charge cooler personal skill level and preparedness for the job This estimate does not include time for the initial vehicle inspection cleaning fine tuning or trou ble shooting Once again we recommend read ing the manual before beginning the process We are available for tech support at 805 604 1336 Monday through Friday 7AM 3 PM PST After reading the manual verify that all major assembly groups are present in the main kit box As you remove a box or bag note the identifica tion 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 and cover the distribu tor and any electronics with a plastic bag to pre vent water from entering P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10N
8. racket with the bolts supplied in the kit See Fig 2 g G Remove the discharge tube bypass valve and air intake tube See Fig 2 h H Disconnect the oil lines Disconnect the oil return at the pan and the oil feed at the supercharger I Remove the accessory drive belt by relaxing the tensioner J Disconnect the supercharger You will need to loosen the two bolts on the coolant reser voir and move the reservoir to the side to gain access to the supercharger See Fig 2 i P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 3 1 Fig 3 a Fig 3 b Fig 3 d Fig 3 c Section 3 FINAL ASSEMBLY 3 1 FINAL ASSEMBLY A Re clock the supercharger scroll Refer to the supercharger assembly drawing in the back of the installation manual for position ing B Re attach the oil lines C Connect the discharge tube between the intercooler and the supercharger See Fig 3 a D Attach the discharge tube assembly between the intercooler and the throttle body See Fig 3 b E Re install the air intake tube between the air filter mass air meter and the supercharger See Fig 3 c F Re install the bypass valve from air intake to discharge tube See Fig 3 d P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 3 2 Here is your completed installation Fig 3
9. s 4 that hold the air deflector in place See Fig 1 e F Remove the plastic clips 2 that attach the front bumper to the frame See Fig 1 f G Remove the screw that holds the power steering cooler bracket in place Set the line aside to be installed in a later step of the installation See Fig 1 g H Pop loose the clips on the air deflector to the left and right sides of the radiator See Fig 1 h Fig 1 i I Disconnect the rear radiator reservoir sup port brace from the bottom of the frame See Fig 1 i P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 2 1 Fig 2 a Fig 2 c Fig 2 b Section 2 INTERCOOLER INSTALLATION 2 1 INTERCOOLER INSTALLATION A Install the intercooler and support with jack stands or wood blocks See Fig 2 a C Drill one more 1 8 hole and re attach the rear radiator overflow reservoir support in its new location with a 1 4 sheetmetal screw See Fig 2 c B Drill two 1 8 holes as shown in Fig 2 b Install two 1 4 sheetmetal screws D Re attach the powersteering cooler line to the intercooler E Re attach the front bumper to the frame re using the stock plastic clips P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 2 2 Fig 2 g Fig 2 h Fig 2 i F Attach the supplied intercooler mounting b
10. times odorless and may asphyxiate and 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 tions to help us improve our product P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 vi This Page Left Intentionally Blank P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 1 1 Section 1 INITIAL PREPARATION AND REMOVAL 1 1 INITIAL PREPARATION AND REMOVAL A Remove the plastic clips 4 that hold the grill cover in place See Fig 1 a Fig 1 a CLIPS B Remove the hood latch support screw using a T 30 torx bit See Fig 1 b Fig 1 b SCREW C Place car on lift or jackstands D Remove the screw at the bottom of the sup port bar See Fig 1 c Fig 1 c Fig 1 d E Remove the power steering cooler line sup port screw See Fig 1 d P N 4809638 2003 Paxton Automotive All Rights Reserved Intl Copr Secured 10NOV03 v2 0 99 01 MusGT 4809638 v2 0 1 2 Fig 1 e Fig 1 f Fig 1 h Fig 1 g E Remove the plastic clip
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