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Paxton Automotive Automobile Parts 1200 User's Manual

1. 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 This Page Left Intentionally Blank P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 14 WATER PUMP WIRING ection WATER PUMP WIRING 14 WATER PUMP WIRING A Using a supplied sheet metal screw attach water mix If the water is not flowing the supplied relay to the driver s side radia remove the charge cooler supply hose and tor core support per Fig 14 a lower until water flows out of the hose If necessary provide light suction to the hose to help prime the pump Verify water flow Do not let the pump run for extended peri ods 30 seconds or more without water flow Fill the charge cooler tank until the level stabilizes Fig 14 a B Attach a supplied ring terminal to the ground wire black on terminal 86 of the supplied relay attach a supplied ring termi nal to the relay mounting screw C Route the red wire on terminal 87 down and along the backside of the front bumper and connect to the green wire using the supplied butt connector at the previously installed water pump Use the supplied wire ties to secure as necessary D Route the yellow wire from terminal 85 and the 22 E Route the red wire from terminal 30 on the relay into the engine compartment and attach a supplied ring terminal to the wire end The ring terminal must be connected to a constant battery
2. 5W001 009 16 14GA MALE SLIDE INSULATED 2 5W001 010 16 14GA FEMALE INSULATED 2 5W001 019 10 12GA BUTT CON INSUL 1 5W001 042 12 10GA x 3 16 RING TERMINAL 1 5W001 017 3 8 RING TERMINAL 12GA 1 5W001 030 14GA STRD WIRE BLACK 3 5W001 014 FUSE HOLDER 10GA WIRE 1 5W001 011 16 14GA EYELET 25 HOLE 2 5W001 015 FUSE BLADE TYPE 20AMP 1 5WO01 009 16 14GA MALE SLIDE INSULATED 1 7A250 050 1 4 20 x 50 SHCS ZINC PLTD 1 7J006 093 6mm WASHER PLTD 1 5W001 022 T TAP CONN 14 16AWG 1 8F101 510 H20 PUMP WIRING ASSY 1 8PN106 010 WATER CLR MTG ASSY 03 HEMI 8N006 010 WATER COOLER 1 7P500 026 1 2 NPT TO 3 4 HOSE BARB 90 2 7A250 074 1 4 20 HHD 3 4 LONG 8 7F250 021 1 4 20 NYLOCK NUT 8 7J250 001 1 4 FLAT WASHER 16 1016419 P SUPERCHARGER ASSY 2A047 119 ACCESSORY DRIVE BELT 4PCH114 018 COOLANT RESV ASSY 7R002 016 16 HOSE CLAMPS 3 2A017 876 01 875 x 328 x 952 LONG SPACERS 3 7C060 050 6mm x 1 0 x 50mm LONG BOLTS 3 7J006 093 6mm LARGE OD FLAT WASHERS 3 4PCH014 010 FORMED COOLANT TUBE 1 7U038 012 3 4 90 HOSE 4 x 12 1 7P375 045 45 STREET ELBOW 2 7R002 012 12 HOSE CLAMP 2 7U133 065 J SHAPED HOSE 7P500 001 1 2 HOSE UNION 1 5A001 110 ENGINE CONTROL UNIT 5A001 111 PROGRAMMED ENGINE CONTROL UNIT P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured e 11NOV04 v1 0 03DodgeHemi 4809650v1 0 VIII 1 COMPONENT REMOVAL ection COMPONENT REMOVAL 1 COMPONENT REMOVAL A Using a su
3. Install the supplied 5 8 hose mender into the open end of the J shaped hose and secure with a supplied hose clamp C Trim the factory coolant hose for best fit ment and connect to the open end of the supplied 5 8 hose mender Secure using a supplied hose clamp P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 1 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 This Page Left Intentionally Blank P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 3 COOLANT RESERVOIR RELOCATION Section 5 COOLANT RESERVOIR RELOCATION 5 COOLANT RESERVOIR RELOCATION A Locate the lower radiator hose Locate the TEE fitting in the lower radiator hose that the 1 hose attaches measure up approxi mately 2 1 2 from the TEE fitting and cut the upper portion of the hose B Locate the three spacers screws and wash ers in the coolant relocation assembly Raise the coolant reservoir using the spacers and secure with the supplied 6mm screws and washers See Fig 5 a TO MODIFIED LOWER COOLANT HOSE po i Fig 5 b D Attach the L shaped hose to the outlet of the coolant reservoir Measure and trim to the appropriate length and secure with the supplied hose clamps See Fig 5 c Fig 5 a C Locate the supplied 1 L shaped hose hose clamps and the polished formed cool ant tu
4. Report any shortages or damaged parts immediately PART NO DESCRIPTION QTY 8PN104 010 ASSY SURGE TANK 03 HEMI 8N056 060 SURGE TANK 1 7E010 075 12 SHEET METAL SCREWS 2 7P500 078 1 2 x 3 4 STR HOSE BARB 2 8N055 050 PLASTIC CAP SURGE TANK 1 7J006 093 6mm WASHER PLATED 4 7C060 016 M6 x 1 00 x 16 HXHD 2 7U100 055 6 TIE WRAP 10 7P500 078 1 2 x 3 4 STR HOSE BARB 3 7P500 026 1 2 x 3 4 90 HOSE BARB 1 7U100 044 4 TIE WRAP 5 7A250 050 1 4 20 SHCS 1 2 LONG 2 8N010 130 MTG TAB 1 8PN107 010 WATER PUMP MTG ASSY 03 HEMI 8F001 402 PUMP HELLA WATER 1 7R003 027 ADEL CLAMP 1 5W001 009 16 14GA MALE SLIDE INSULATED 2 5W001 010 16 14GA FEMALE INSULATED 2 5W001 019 10 12GA BUTT CON INSUL 1 5W001 042 12 10GA x 3 16 RING TERMINAL 1 5W001 017 3 8 RING TERMINAL 12GA 1 5W001 030 14GA STRD WIRE BLACK 3 5W001 014 FUSE HOLDER 10GA WIRE 1 5W001 011 16 14GA EYELET 25 HOLE 2 5W001 015 FUSE BLADE TYPE 20AMP 1 5WO01 009 16 14GA MALE SLIDE INSULATED 1 7A250 050 1 4 20 x 50 SHCS ZINC PLTD 1 7J006 093 6mm WASHER PLTD 1 5W001 022 T TAP CONN 14 16AWG 1 8F101 510 H20 PUMP WIRING ASSY 1 8PN106 010 WATER CLR MTG ASSY 03 HEMI 8N006 010 WATER COOLER 1 7P500 026 1 2 NPT TO 3 4 HOSE BARB 90 2 7A250 074 1 4 20 HHD 3 4 LONG 8 7F250 021 1 4 20 NYLOCK NUT 8 7J250 001 1 4 FLAT WASHER 16 1016419 SUPERCHARGER ASSY 2A047 119 ACCESSORY DRIVE BELT 4PCH114 018 COOLANT RESV ASSY 7R002 016 16 HOSE CLAMPS 3 2A017 876 01 875 x 328 x 952 LONG SPACER
5. from the plastic throttle body enclosure See Fig 1 d Fig 1 d P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 G Unclip the 4 clips that retain the top portion of the factory air filter housing and set the housing and rubber duct aside it will not be reused Remove the air filter and lift up on the lower portion of the factory air filter housing and remove it from the air filter support bracket set the lower portion of the housing aside it will not be reused See Fig 7 e Fig 1 e Locate the intake air temperature sensor on the passenger side of the large plastic throt tle body enclosure Disconnect the wire har ness plug remove the sensor using a twist ing motion and set the sensor aside to be reinstalled in a later step of the installation Remove the two 10mm headed bolts secur ing the plastic throttle body enclosure Remove the rubber hose going to the oil fill neck and remove the enclosure and set aside it will not be reused See Fig 7 f 10mm HEADED BOLTS K Remove the factory orange silicone ring from the throttle body and set aside Remove the accessory drive belt See Fig g L Using a 8mm socket remove the eight fac tory screws securing the underside of the passenger side inner fender well cover Remove the four 13mm head screws secur ing the air filter enclosure bracket to the fen
6. 1 5 COOLANT RESERVOIR RELOCATION LL Y FFF FFF Yu 5 1 6 SUPERCHARGER MOUNTING BRACKET LL LY YY ee 6 1 Te AIR INTAKE ASSEMBLY a ogee pean UR eta Ru FI E T YR WA EAR 7 1 8 FUEL SYSTEM ASSEMBLY L2 eee YSG Bowe Mos dean be Meee eh YDY 8 1 9 ENGINE CONTROL UNIT INSTALLATION LL LL FFF FF YY Y Y a 9 1 10 CHARGE COOLER INSTALLATION ui po eR Rp RR ee dare ed WG ea 10 1 11 HEAT EXCHANGER INSTALLATION 2 0 0 0 FFF FFF II 11 1 12 SURGE AND RESERVOIR TANK INSTALLATION LLY Y Y Y uu 12 1 13 WATER HOSE ROUTING cde 3b dices GR y EDERN GR AGO LOU 13 1 14 WATER PUMP WIRING iu RA RUG AG DDR ROY FA kuto 14 1 15 FINAL ASSEMBLY AND CHECK i WET YDAN Rex SERERE HER DES 15 1 P N 4809650 2004 Paxton Automotive iii 1 1NOVO4 V1 0 03DodgeHemi 4809650V1 0 RECOMMENDED TOOLS FOR INSTALLATION 2002 Dodge Hemi through this entire instruction booklet and the Street Supercharger System Owner s Manual which includes the Automotive Limited aes Program and the Warranty Registration orm Paxton supercharger systems are performance improving devices In most cases increases in torque of 30 3596 and horsepower of 35 4596 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 Auto
7. ASSY 03 HEMI x 2 A 2 TANGLES rir 8N003 070 COOLER DUCT LT1 GROUND 8H040 050 AIR FILTER 3 5 FLG x 7 L 1 8N101 001 WELDED CORE ASSY W ENDS ONLY 7R002 056 56 HOSE CLAMPS 4 RD AS HO ECH AMP 8N003 011 INLET DUCT MACH 8H040 050 FILTER 3 50 x 7 0 LONG 1 8PN105 010 WATER TANK MTG ASSY 03 HEMI 7U035 001 FLEX HOSE 3 5 x 12 T 8N055 030 RESERVOIR 1 APCH112 010 INLET DUCT ASSY 1 4PCHO010 110 BRKT RESERVOIR 1 7P100 103 BUNG WELD ON 7A250 050 1 4 20 SHD 1 2 LONG 3 7P500 112 BUNG WELD ON 1 2 NPT 1 7A250 074 1 4 20 HHD 3 4 LONG PLTD 3 7P100 578 AIR TEMP SENSOR BUNG 1 7J006 093 1 4 WASHER 8 7PS275 200 SLEEVE 2 75 x 2 00 2 7U038 000 3 4 HEATER HOSE CUT TO FIT 14 7PS350 200 SLEEVE 3 5 x 2 00 1 7U038 012 3 4 90 HOSE 4 x 12 5 7P500 026 1 2 NPT x 3 4 HOSE BARB 1 7U030 065 3 4 HOSE TANK PUMP 1 7U038 012 3 4 x 90 HOSE 4 x 12 LONG 2 7R007 001 NYLON CLAMP 1 1 8 16 7P375 075 3 4 HOSE MENDER 1 7P500 026 1 2 TO 3 4 90 HOSE BARB 2 7A250 126 1 4 x 20 x 1 HXHD BOLT 4 7U038 150 3 4 x 150 HOSE 2 7F250 021 1 4 NYLOC 4 7P375 075 3 4 HOSE MENDER 1 7K250 001 1 4 AN WASHERS 8 7F250 021 1 4 NYLOCK NUTS 3 7J250 150 1 4 FENDER WASHERS 3 P N 4809650 2004 Paxton Automotive v All Rights Reserved Intl Copr Secured 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 SUPERCHARGERS 2003 Dodge Hemi Part No 1201220 P PARTS LIST IMPORTANT Before beginning installation verify that all parts are included in the kit
8. plied 3 4 brass hose mender into the long end of the hose Using a supplied 3 4 90 molded hose trim 2 off of the short end install the short end onto the 3 4 90 brass fitting previously installed in the aftercooler core Install a supplied 3 4 brass hose mender into the long end of the molded hose Cut a 55 section of 3 4 hose connect one end onto the 3 4 hose mender previously installed in the molded hose attached to the aftercooler Route the hose along the passen ger side inner fender under the radiator and connect to the open end of the 3 4 brass hose mender elbow hose connected to the heat exchanger Using another 3 4 90 molded hose trim 2 1 2 off of the short end of the hose install the short end onto the outlet of the previously installed water pump Install a 3 4 brass hose mender into the open end of the hose Cut a 27 long section of the supplied 3 4 hose attach an end to the open end of the previously installed brass hose mender Attach the open end of the hose to the open fitting on the supplied heat exchanger trim the hose for best fitment Cut a 14 long section of the supplied 3 4 hose attach one end to the straight fitting on the aftercooler core connect the open hose end to the fitting on the side of the surge tank trim the hose length for best fitment Cut a 60 long section of the supplied 3 4 hose attach one end to the 3 4 x 1 2 NPT brass fitting previously installed i
9. the cover and drill a 9 16 hole that will allow the PECU harness and the 5 32 vacuum line to pass through Reinstall the cover and route the PECU wire harnesses and vacuum hose through the 9 16 opening See Fig 9 a Fig 9 a Run the PCEU harness across the firewall thru the factory wire harness cover to the Factory engine control unit Locate the C2 plug at the factory ECU pin 35 cut the gray black wire crank sensor Using the connectors provided connect the gray wire from the PECU to the gray black wire leading to the crank sensor Connect the gray black wire from the PECU to the gray black wire going to factory ECU plug that it is recommended that these and all other con nections be soldered y P N 34 P N ECU PLUG BLAC P N 35 CRANK IN CAM IN MAP GREEN RED Locate pin 34 at the C2 plug on the Factory ECU Cut the tan yellow wire Cam Sensor Connect the tan wire from the PECU to the tan yellow wire leading to the cam sensor on the factory ECU Connect the tan yellow wire from the PECU to the tan yellow wire leading to the factory ECU plug Locate pin 23 at the C2 plug on the factory ECU Cut the green red wire Map Sensor Connect the green wire from the PECU to the green red wire leading to the map sensor Connect the green red wire from the PECU to the wire leading to the factory ECU plug Tape up the violet wire as it will not be used Tap the small red wire coming from the PECU to
10. the open mount ing location on the bracket See Fig 12 b Fig 12 c P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 1 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 H Attach the supplied 3 4 short 90 hose to the inlet of the water pump and connect to the previously installed brass fitting at the bottom of the reservoir Secure the hose using the supplied nylon ratchet clamps Mark two mounting locations using the water pump reservoir assembly bracket as a template on the passenger side inner frame rail Drill and secure the water pump reser voir assembly to the frame rail using the supplied sheet metal screws Fig 12 d Fig 12 e Cut the harness for the water pump leaving as much of the wires intact from the pump Install a supplied ring terminal onto the brown negative wire and secure to one of the water pump reservoir assembly mount ing screws P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 13 WATER HOSE ROUTING ection WATER HOSE ROUTING 13 WATER HOSE ROUTING Make sure to leave the hose slightly long to allow for engine movement A Using a 3 4 90 molded hose trim 2 off from the short hose leg attach the cut end onto the 3 4 x 1 2 NPT 90 brass fitting on the passenger side of the supplied heat exchanger previously installed Install a sup
11. x 2 00 2 7U038 000 3 4 HEATER HOSE CUT TO FIT 14 7PS350 200 SLEEVE 3 5 x 2 00 1 7U038 012 3 4 90 HOSE 4 x 12 5 7P500 026 1 2 NPT x 3 4 HOSE BARB 1 7030 065 3 4 HOSE TANK PUMP 1 7U038 012 3 4 x 90 HOSE 4 x 12 LONG 2 7R007 001 NYLON CLAMP 1 1 8 16 7P375 075 3 4 HOSE MENDER 1 7P500 026 1 2 TO 3 4 90 HOSE BARB 2 7A250 126 1 4 x 20 x 1 HXHD BOLT 4 70038 150 3 4 x 150 HOSE 2 7F250 021 1 4 NYLOC 4 7P375 075 3 4 HOSE MENDER 1 7K250 001 1 4 AN WASHERS 8 7F250 021 1 4 NYLOCK NUTS 3 7J250 150 1 4 FENDER WASHERS 3 P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured VII 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 2003 Dodge Hemi Part No 1201220 SUPERCHARGERS PARTS LIST IMPORTANT Before beginning installation verify that all parts are included in the kit Report any shortages or damaged parts immediately PART NO DESCRIPTION QTY PART NO DESCRIPTION QTY 8PN104 010 ASSY SURGE TANK 03 HEMI 8N056 060 SURGE TANK 1 7E010 075 12 SHEET METAL SCREWS 2 7P500 078 1 2 x 3 4 STR HOSE BARB 2 8N055 050 PLASTIC CAP SURGE TANK 1 7J006 093 6mm WASHER PLATED 4 7C060 016 M6 x 1 00 x 16 HXHD 2 7U100 055 6 TIE WRAP 10 7P500 078 1 2 x 3 4 STR HOSE BARB 3 7P500 026 1 2 x 3 4 90 HOSE BARB 1 7U100 044 4 TIE WRAP 5 7A250 050 1 4 20 SHCS 1 2 LONG 2 8N010 130 MTG TAB 1 8PN107 010 WATER PUMP MTG ASSY 03 HEMI 8F001 402 PUMP HELLA WATER 1 7R003 027 ADEL CLAMP 1
12. 0 044 SUPERCHARGER MTG PLT 1 7U031 018 5 16 EFI FUEL HOSE 24 4PCH010 010 SUPPORT S C MOUNTING PLT 1 7U031 018 5 16 EFI FUEL HOSE 9 4PCH010 020 SUPPORT S C MTG PLT 1 7U031 018 5 16 EFI FUEL HOSE 1 8 4PCH010 030 ALTERNATOR BRACE 1 7U031 018 5 16 EFI FUEL HOSE 1 8 APCHO17 011 COLLAR IDLER PULLEY 1 7U031 018 5 16 EFl FUEL HOSE 65 7A312 125 5 16 x 18 x 1 25 HXHD GR5 BOLT 2 7U033 010 FUEL PWR STEERING HOSE 5 8 2 0 7K312 001 WASHER AN 6 7P312 017 FUEL PUMP FITTING 1 7A312 100 5 16 x 18 x 1 00 HXHD GR5 BOLT 4 7P312 020 FUEL LINE FITTING 90 1 7C080 120 8mm x 120mm x 1 25 1 7P312 016 5 16 x 5 16 FORD FITTING 1 7C010 130 10mm x 130 x 1 5 BOLT 1 8F001 500 FUEL PUMP PURBURG 1 7J010 002 10mm WASHER 1 7R003 028 ADEL CLAMP 2 3 8 26 HOLE 2 7J012 092 12mm WASHER 2 7P312 082 TEE HOSE BARB 2 7C012 100 12mm x 1 00 x 1 75 BOLT 1 7R004 003 14 5 STEPLESS CLAMP 14 7G010 175 12mm x 1 75 NUT 1 7E010 075 SHEET METAL SCREW 2 4FRO16 150 SMOOTH IDLER PULLEY 1 7A250 101 1 4 x 20 x 1 0 BOLT 2 7437 325 7 16 x 3 25 x 14 BOLT 1 7F250 021 NYLOC NUT 2 7K437 001 WASHER AN 2 7J006 094 6mm SS WASHER 4 7J438 072 7 16 WASHER 94 OD x 109 THICK 1 7F010 024 NYLOC NUT 2 7F437 000 7 16 x 14 NYLOC NUT 1 7C010 075 BOLT 2 i 7J010 001 10 WASHER 4 S Red ar ME 1 4PCH010 070 FUEL PUMP FMU MTG BRKT 1 7P125 104 1 8 NPT FEMALE TEE 1 APCH238 068 FMU ASSY 03 HEMI 7P125 004 1 8 NPT TO 4 x 90 JIC FITTING 1 6PZ001 001 DECAL PAXTON FMU 1 7U250 090 240 OIL FEED HOSE 4 x 2
13. 6 LONG 1 6Z010 101 FMU HOUSING BLUE ANODIZED 1 7P125 005 1 4 x 4 JIC FITTING 1 62010 111 FMU VALVE COVER 1 APCH130 036 OIL DRAIN ASSY 03 HEMI 6Z010 132 COVER FMU w SPRING NO LZR 1 7P375 053 3 8 NPT x 8 FTG 1 6Z020 130 SML DIAPHRAM 1 7P500 500 8 x 90 ALUM FITTING 1 seo eae 1 7U030 036 1 2 OIL DRAIN HOSE 48 62030 150 BRACKET FMU 1 7R004 002 STEPLESS CLAMP 17 0 70 2 6Z040 160 PISTON FMU 1 7R001 006 6 STNL HOSE CLAMP NARROW 2 6Z050 161 FMU WASHER 6 1 30LB PLATED 1 7R004 687 CLAMP 13 16 ONE EAR 2 6Z060 181 SHIM FMU 1 7P375 055 3 8 NPT x 1 2 HOSE BARB 1 62070 010 FMU RING SPCER 6 1 1 6Z080 011 RETAINER FMU SPRING 4 3 GM 2 4PCH112 020 DISCHARGE ASSY 03 HEMI 6Z090 010 SPRING FMU 1 4PCHO012 020 DISCHARGE DUCT 03 DODGE HEMI 1 7C010 050 10 24 x 50 SHCS GR8 PLT 6 7P156 082 5 32 TEE 2 7C010 075 10 24 x 3 4 SHCS GR5 ZINC 4 7PS350 275 SLEEVE REDUCER 3 5 2 75 1 7C024 025 10 24 x 1 4 PHIL HEAD 3 7R002 016 16 HOSE CLAMP 5 7P125 025 1 8 NPT x 5 32 HOSE 90 1 7R002 056 56 HOSE CLAMPS 1 7P125 031 1 8 NPT x 90 5 16 HOSE BARB 1 7U030 046 5 32 VAC HOSE 3 7P125 032 1 8 NPT x 5 16 STR HOSE BARB 1 7U034 016 1 GS HOSE 2 7u030 218 7 32 VAC HOSE 12 8D001 001 STANDARD COMPRESSOR BYPASS 1 7P157 219 5 32 x 7 32 UNION 1 7P100 103 1 WELD ON BUNG 1 7P 156 082 5 32 TEE 1 7PS275 200 SLEEVE 2 75 x 2 2 7U030 046 5 32 VACUUM HOSE 10 7R002 044 44 HOSE CLAMP 4 7U100 030 O RING FMU 1 4PCH212 010 AIR INTAKE ASSY 8PN101 180 POWER CHARGE COOLER
14. 80 011 RETAINER FMU SPRING 4 3 GM 2 4PCH112 028 DISCHARGE ASSY 03 HEMI 6Z090 010 SPRING FMU 1 4PCHO12 020 DISCHARGE DUCT 03 DODGE HEMI 1 7C010 050 10 24 x 50 SHCS GR8 PLT 6 7P156 082 5 32 TEE 2 7C010 075 10 24 x 3 4 SHCS GR5 ZINC 4 7PS350 275 SLEEVE REDUCER 3 5 2 75 1 7C024 025 10 24 x 1 4 PHIL HEAD 3 7R002 016 16 HOSE CLAMP 5 7P125 025 1 8 NPT x 5 32 HOSE 90 1 7R002 056 56 HOSE CLAMPS 1 7P125 031 1 8 NPT x 90 5 16 HOSE BARB 1 7U030 046 5 32 VAC HOSE 3 7P125 032 1 8 NPT x 5 16 STR HOSE BARB 1 7U034 016 1 GS HOSE 2 7u030 218 7 32 VAC HOSE 12 8D001 001 STANDARD COMPRESSOR BYPASS 1 7P157 219 5 32 x 7 32 UNION 1 7P100 103 1 WELD ON BUNG 1 7P156 082 5 32 TEE 1 7PS275 200 SLEEVE 2 75 x 2 2 7U030 046 5 32 VAC HOSE 10 7R002 044 44 HOSE CLAMP 4 7U 100 030 O RING FMU 1 4PCH212 010 AIR INTAKE ASSY 8PN101 188 POWER CHARGE COOLER ASSY 03 HEMI a o is Me m 8N003 078 COOLER DUCT LT1 GROUND 8H040 050 AIR FILTER 3 5 FLG x 7L 1 8N101 001 WELDED CORE ASSY W ENDS ONLY 7R002 056 56 HOSE CLAMPS 4 RODG OOE CLAUD 8N003 018 INLET DUCT MACH 8H040 050 FILTER 3 50 x 7 0 LONG 1 8PN105 010 WATER TANK MTG ASSY 03 HEMI 7U035 001 FLEX HOSE 3 5 x 12 T 8N055 030 RESERVOIR 1 4PCH112 010 INLET DUCT ASSY 1 4PCH010 110 BRKT RESERVOIR 1 7P100 103 BUNG WELD ON 7A250 050 1 4 20 SHD 1 2 LONG 3 7P500 112 BUNG WELD ON 1 2 NPT 1 7A250 074 1 4 20 HHD 3 4 LONG PLTD 3 7P100 578 AIR TEMP SENSOR BUNG 1 7J006 093 1 4 WASHER 8 7PS275 200 SLEEVE 2 75
15. E fitting into the bypass valve vacuum line previously installed and attach the vacuum line from the FMU to the supplied TEE Install another supplied 5 32 brass TEE into the bypass valve vacuum line attach the vacuum hose from the PECU to the previ ously installed TEE P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 This Page Left Intentionally Blank P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 11 HEAT EXCHANGER INSTALLATION Section 11 HEAT EXCHANGER INSTALLATION 11 HEAT EXCHANGER INSTALLATION A Install the two supplied 90 brass fittings into the supplied heat exchanger both must be pointing in the same direction to the side See Fig 11 a Fig 11 a B Using the supplied heat exchanger as a tem plate mark two mounting locations on the radiator core support the heat exchanger should be mounted towards the passenger side C Mount the supplied heat exchanger with the previously installed x 90 brass fittings pointing toward the passenger side of the vehicle use the supplied 1 4 20 nuts bolts and washers to secure to the radiator core support See Fig 11 b P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 1 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 Thi
16. ING 1 7C010 130 10mm x 130mm x 1 5 BOLT 1 8F001 500 FUEL PUMP PURBURG 1 7010 002 10mm WASHER 1 7R003 028 ADEL CLAMP 2 3 8 26 HOLE 2 7012 092 12mm WASHER 2 7P312 082 TEE HOSE BARB 2 7C012 100 12mm x 100 x 1 75 BOLT 1 7R004 003 14 5 STEPLESS CLAMP 14 7G010 175 12mm x 175 NUT 1 7E010 075 SHEET METAL SCREW 2 4FR016 150 SMOOTH IDLER PULLEY 1 7A250 101 1 4 x 20 x 1 0 BOLT 2 7437 325 7 16 x 3 25 x 14 BOLT 1 7F250 021 NYLOC NUT 2 7K437 001 WASHER AN 2 73006 094 6mm SS WASHER 4 7J438 072 7 16 WASHER 94 OD x 109 THICK 1 7F010 024 NYLOC NUT 2 7F437 000 7 16 x 14 NYLOC NUT 1 7C010 075 BOLT 2 i 7J010 001 10 WASHER 4 T s SS NETUS 1 4PCH010 070 FUEL PUMP FMU MTG BRKT 1 7P125 104 1 8 NPT FEMALE TEE 1 4PCH238 068 FMU ASSY 03 HEMI 7P125 004 1 8 NPT TO 4 x 90 JIC FITTING 1 6PZ001 001 DECAL PAXTON FMU 1 7U250 090 240 OIL FEED HOSE 4 x 26 LONG 1 62010 101 FMU HOUSING BLUE ANODIZED 1 7P125 005 1 4 x 4 JIC FITTING 1 6Z010 111 FMU VALVE COVER 1 4PCH130 036 OIL DRAIN ASSY 03 HEMI 6Z010 132 COVER FMU w SPRING NO LZR 1 7P375 053 3 8 NPT x 8 FTG 1 6Z020 130 SML DIAPHRAM L 7P500 500 8 x 90 ALUM FITTING 1 6Z020 140 LRG DIAPHRAM 1 7030 036 1 2 OIL DRAIN HOSE 48 6Z030 150 BRACKET FMU 1 7R004 002 STEPLESS CLAMP 17 0 70 2 6Z040 160 PISTON FMU 1 7R001 006 6 STNL HOSE CLAMP NARROW 5 6Z050 161 FMU WASHER 6 1 30LB PLATED 1 7R004 687 CLAMP 13 16 ONE EAR 2 6Z060 181 SHIM FMU 1 7P375 055 3 8 NPT x 1 2 HOSE BARB 1 62070 010 FMU RING SPACER 6 1 1 6Z0
17. Owner 5 Installation Guide for the Paxton Automotive Novi 1200 Supercharger Dodge Hemi Paxton Automotive 1300 Beacon Place Oxnard CA 93033 805 604 1336 FAX 805 604 1337 11 09 04 ____ __ FOREWORD gt gt automotive mechanic knowledge and experience Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job toaprofessionalinstaller technician Pleasecall Paxton Automotive for installers in your area pau installation of this supercharger kit reguires general O 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 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured ii 11NOV04 v1 0 03DodgeHemi 4809650v1 0 FOREWORD 586025 RUG RY GOR he en CREDE DY REX FER ERAN ii TABLE OF CONTENTS esee ee iii RECOMMENDED TOOLS FOR INSTALLATION e Y Y Ya iv PARTS LIST Loeb Rx sehen Ce daw eto RM be aw eae A y 1 COMPONENT REMOVAL 3 dead hed Rainer Gute DER Keen dope rdc edes d heed 1 1 2 OIL FEED ASSEMBLY een Eiu du sete icine ter Rb iR Ee d Rh Re doy dane 2 3 OIL DRAIN ASSEMBLY rune sei nites rmt REC a RE we RR Ww EE Ra 3 1 4 HEATER HOSE RELOCATION eges eR meer ey p REO gea 4
18. S 3 7C060 050 6mm x 1 0 x 50mm LONG BOLTS 3 7J006 093 6mm LARGE OD FLAT WASHERS 3 4PCHO14 010 FORMED COOLANT TUBE 1 7U038 012 3 4 x 90 HOSE 4 x 12 1 7P375 045 45 STREET ELBOW 2 7R002 012 12 HOSE CLAMP 2 7U133 065 J SHAPED HOSE 7P500 001 1 2 HOSE UNION 1 5A001 110 ENGINE CONTROL UNIT 5A001 111 PROGRAMMED ENGINE CONTROL UNIT P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 vi 2003 Dodge Hemi Part No 1201220 P SUPERCHARGERS PARTS LIST IMPORTANT Before beginning installation verify that all parts are included in the kit Report any shortages or damaged parts immediately PART NO DESCRIPTION QTY PART NO DESCRIPTION QTY 4PCH110 044 S C MNTG BRKT ASSY 03 HEMI 1 4PCH101 001 FUEL PUMP ASSY 03 HEMI 4PCH 010 044 SUPERCHARGER MTG PLT 1 7U031 018 5 16 EFI Fuel hose 24 4PCH010 010 SUPPORT S C MOUNTING PLT 1 7U031 018 5 16 EFI Fuel hose 9 4PCH010 020 SUPPORT S C MTG PLT 1 7U031 018 5 16 EFI Fuel hose 1 8 4PCH010 030 ALTERNATOR BRACE 1 7U031 018 5 16 EFI Fuel hose 1 8 4PCH017 011 COLLAR IDLER PULLEY 1 7U031 018 5 16 EFI Fuel hose 6 5 7A312 125 5 16 x 18 x 1 25 HXHD GR5 BOLT 2 7U033 010 FUEL PWR STEERING HOSE 5 8 2 0 7K312 001 WASHER AN 6 7P312 017 FUEL PUMP FITTING 1 7A312 100 5 16 x 18 x 1 00 HXHD GR5 BOLT 4 7P312 020 FUEL LINE FITTING 90 1 7C080 120 8mm x 120mm x 1 25 1 7P312 016 5 16 x 5 16 FORD FITT
19. and allow to idle for a few minutes F Recheck to be sure no hoses wires etc are near exhaust headers or moving parts and check for any signs of fluid leakage Recheck all fluid levels G PLEASE TAKE SPECIAL NOTE Operating the vehicle without ALL subas semblies completely and properly installed may cause FAILURE OF MAJOR COMPONENTS H Test drive the vehicle Read the Street Supercharger System Owner s Manual and RETURN THE Warranty REGISTRATION FORM within thirty 30 days of purchasing your super charger system to gualify for the 3 year lim ited warranty P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 1 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 This Page Left Intentionally Blank P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 This Page Left Intentionally Blank P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 3 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 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 DP N 4809650 v1 0 11 09 04
20. be in the coolant reservoir assembly Se Install the straight section of the tube into a WASHER the modified 1 lower radiator hose and ee ae secure with a supplied hose clamp See Fig 5 b P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 1 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 This Page Left Intentionally Blank P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 6 SUPERCHARGER MOUNTING BRACKET Section 6 SUPERCHARGER MOUNTING BRACKET 6 SUPERCHARGER MOUNTING BRACKET A Locate the supplied two small supercharger E Loosen the remaining alternator retaining mounting plate support brackets bolts and bolt and rotate the alternator up leaving it washers Assemble the two brackets using attached to the front cover See Fig 6 c the four 5 16 x 18 x 1 0 bolts and washers that are provided B Using the supplied support bracket and the supplied 8mm x 120 bolts and 10mm x 130 bolts confirm that the heater hose fittings and hose previously installed clear the sup port bracket C Remove the 15mm headed bolt closest to the passenger side on the alternator that secures the alternator to the front cover See Fig 6 a This bolt will be reused to secure the alternator in a later step F Remove the 13mm headed bolt just to the left of the upper Idler pulley Set it aside as it w
21. cle s firewall secure all connections using the supplied hose clamps It may be necessary to gently bend the air condition ing line to gain clearance between it and the super charger discharge C Install the supplied 3 4 NPT x 90 brass fit ting into the lower threaded opening of the aftercooler core the fitting must face towards the firewall of the vehicle Install the supplied 1 2 x 3 4 straight brass fitting into the upper threaded opening in the after cooler core Install the short end of the supplied 1 90 elbow hose onto the bung on the 180 air inlet duct Attach a 6 section of 1 hose onto the bung on the supercharger discharge duct Install the supplied bypass valve into the hose lines per Fig 0 c Attach an end of the supplied 5 32 vacuum hose onto the vacuum nipple on the previ ously installed bypass valve Route the length of supplied vacuum hose to the brake booster mounted on the driver s side firewall and secure the hose as necessary using the supplied wire ties Remove the small vacuum cap from the fac tory fitting on the vehicle s brake booster Attach the supplied vacuum hose onto the open port on the brake booster install a sup plied 5 32 brass reducer into the vacuum line previously installed Trim the supplied 5 32 vacuum line connected to the bypass valve for the best fitment and install onto the open port of the previously installed reducer Install a supplied 5 32 brass vacuum TE
22. der and remove the bracket it will not be reused Reinstall the inner fender well cover using the factory hardware See Fig 1 h P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 OIL FEED ASSEMBLY Section 2 OIL FEED ASSEMBLY 2 OIL FEED ASSEMBLY A Disconnect the factory oil pressure sending unit wire harness from the sending unit Remove and set aside the factory oil pres sure sender located on the passenger of the engine Using the supplied fitting install the short 1 nipple into the side of the supplied TEE fitting Do not use Teflon paste or Teflon tape on this fitting as it may clog the supercharger oil jet and lead to premature supercharger failure B Install the supplied TEE fitting into the location were the factory sending unit was originally located With the supplied TEE fitting installed and the outlets facing up and down install the factory sending unit into the outlet of the tee that is facing up Install the supplied 1 8 NPT x 4 x 90 fitting into the outlet that is facing down and orientate the supplied 90 fitting to face to the passen ger side of the vehicle See Fig 2 a D t U En Gw Fig 2 a C Install the straight portion of the supplied steel braided 4 hose to the 90 fitting The 90 end will attach to the supercharger oil jet in a later step D Reattach the oil pre
23. e pro vided adel clamps and 1 4 20 bolts nuts washers as shown in Fig 8 a li FUEL OUTLET Verify that the fuel pump outlet fitting is a 5 16 brass barbed fitting and that a copper washer is installed and the fitting is tight if the fitting 5 16 brass barbed fitting has not been installed it will be necessary to remove the existing fitting from the fuel pump and install the supplied 5 16 brass barbed fitting with a copper washer B Mount the supplied FMU to the fuel pump FMU mounting bracket using supplied 10 24 bolts nuts and washers Assemble per Fig 8 a Fig 8 a From beneath the vehicle mark two mount ing locations on the inner driver s side frame rail near the factory fuel lines for the fuel pump FMU bracket assembly to mount Use the bracket as a template and mount the bracket using the supplied self tapping sheet metal screws to mount the bracket to the inner frame rail See Fig 8 b Fig 8 b Using a 5 16 spring lock disconnect tool disconnect the flexible fuel line from the hard line Attach a length of 5 16 fuel hose to the outlet of the fuel pump and secure with a supplied clamp route the hose to the open end of the fuel line leading to the engine Trim the hose for best fit install the supplied male 5 16 fuel line adapter fitting into the open end of the hose and secure with a supplied clamp Attach the male adapter fitting to the factory fuel line Attach a 2 1 2
24. e to 9 16 of an inch It is recommended to use anti seize or grease on the punch which will allow the punch to role the pan correctly Fig 3 b Using a hammer can damage the oil pan extra care F h Drain the engine oil install a new oil filter is required and refill the engine with fresh oil D When you have the hole enlarged to 9 16 pack the flutes of a 3 8 NPT tap not sup plied Tap the hole until the fitting can be started P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 1 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 This Page Left Intentionally Blank P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 4 HEATER HOSE RELOCATION Section 4 HEATER HOSE RELOCATION 4 HEATER HOSE RELOCATION A Install a supplied 3 8 x 45 street elbow into the front cover of the engine install the second supplied 3 8 x 45 street elbow into the previously installed elbow Install the factory hose barb fitting that was removed in Step 1 e and install into the open end of the street elbow Assemble the fittings using Teflon paste to aid in sealing Attach the J shaped hose to the hose barb and secure with a supplied hose clamp Orientate the fittings and hose as seen in Fig 4 a These fittings may need to be re oriented to clear the supercharger support bracket Fig 4 a B
25. from any sharp edges sources of heat or moving parts using the supplied wire ties See Fig 6 g Fig 6 g P Install the supercharger accessory drive belt using the belt routing diagram provided O Install the supplied 1 8 NPT x fitting into the supercharger oil jet attach the open end of the supplied braided oil feed line to the 4 fitting previously installed See Fig 6 h 90 4 OIL SUPPLY HOSE AND 1 8 NPT FITTING Fig 6 h R Reinstall the factory heater hose onto the factory fitting on the side of the front cover using the factory hose clamp This hose was removed in an earlier step of the installation MAIN BELT FACTORY IDLER PULLEY ALTERNATOR PULLEY PULLEY IDLER PULLEY FACTORY IDLER gt TENSIONER WATER PUMP PULLEY POWER STEERING FACTORY IDLER PULL PULLEY 8 CRANK SHAFT PULLEY P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 This Page Left Intentionally Blank P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 4 7 ds AIR INTAKE ASSEMBLY Section AIR INTAKE ASSEMBLY AIR INTAKE ASSEMBLY A Locate the supplied air filter formed enclo sure mounting flange and 1 4 20 mount ing hardware Attach the flange to the air filter enclosure using
26. ill be reused in a later step See Fig 6 d Fig 6 a D Remove and set aside the factory plate that secures the alternator A C compressor and front cover together See Fig 6 b P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 1 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 G Remove the casting flash from the lower mounting location using a file or small disc sander INSTALL THE 12mm x 100 x 1 75 BOLT THROUGH THE ORIGINAL MOUNTING ca 9 HOLE IN THE FRONT COVER E KKK NOTE xx F Care must be taken to not damage the machined NY t surface as this surface is critical to proper mounting 13mm HEADED BOLT REMOVED IN AN EARLIER STEP gt p s CASTING FLASH TO BE REMOVED Fig 6 e J Install the supplied supercharger mounting plate as an assembly using the cylinder head and the engine block mounting locations Leaving the 8mm and the 10mm bolts loose at this time K Install the supplied 12mm x 100mm x 1 75 bolt through the supercharger mounting plate and into the alternator mounting boss Reattach the ground strap sandwiching it between the nut and the alternator boss secure the bolt with the nut provided leaving the nut loose at this time L Install the factory 13mm headed bolt removed in a previous step See Fig 6 e M Locate the supplied supercharger idler pul ley idler pulley stand off and the supplied 7 16 x 3 25 bolt washer
27. itable container drain the engine coolant On the driver s side of the vehicle at the lower corner of the radiator locate the drain petcock using a 16mm open end wrench rotate the petcock and drain the coolant Locate the coolant over flow reservoir locat ed on the top of the radiator loosen the hose clamp securing the large 1 coolant hose and remove the hose from the reservoir Disconnect the smaller coolant hose from the over flow reservoir that connects to the radiator See Figs 1 a 1 b Fig 1 a Remove the three 10mm headed screws that retain the reservoir to the top of the radiator fan shroud and set the reservoir aside to be reinstalled at a later stage of the installation See Fig 1 b COOLANT OVERFLOW HOSE 10mm BOLTS Using a pair of needle nose pliers or a spring hose clamp tool remove the spring clamps that retain the two heater hoses that are located on the passenger side of the front cover Remove the hoses Set the hoses aside in the engine compartment to be modified in a later step of the installation Fig 1 c Using a 19mm deep socket or wrench remove the heater hose barbed fitting at the front cover Set the fitting aside to be installed in a later step of the installation Locate the hose clamp securing the factory air ducting attached to the large plastic throt tle body enclosure to the air filter cover Using a 8mm socket or flat blade screw driver loosen the clamp and remove the duct
28. l Copr Secured 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 Fig 7 c Locate the air intake temperature sensor pre viously removed install into the unthreaded bung on the 180 inlet elbow Locate the air temperature sensor factory plug strip back the tape to expose the wires and cut the wires approximately 3 from the connector plug Using the supplied 12 length of wires extend the connector plug to reach the relo cated air temperature sensor It is recommended that these wire connections be soldered and heat shrink used to insulate the con nections to ensure the best contact J Cut 2 off the short end of a supplied 3 4 90 elbow hose Attach the cut end onto the oil fill neck breather barb Install a supplied 3 4 hose mender into the open end of the installed elbow hose Cut a 13 long section of the supplied straight 3 4 hose and connect one end onto the hose mender previously installed con nect the opposite end onto the 3 4 90 hose barb previously installed into the supplied 180 air inlet duct Tighten all hose clamps P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 8 FUEL SYSTEM ASSEMBLY Section 8 FUEL SYSTEM ASSEMBLY 8 FUEL SYSTEM ASSEMBLY A Locate the supplied supplemental fuel sup ply assembly 4PCH101 001 Assemble the supplied fuel pump to the supplied fuel pump FMU mounting bracket using th
29. length of supplied 5 8 fuel line onto the inlet of the fuel pump two of the supplied clamps must be used to secure this hose onto the fuel pump Install the sup plied 5 8 to 5 16 barbed reducer into the open end of the previously installed 5 8 hose secure using the supplied clamp Install a section of 5 16 fuel hose onto the previously installed barb and secure the end with a supplied clamp Route the open end of the hose to the open end of the fuel line leading to the vehicle s gas tank trim the hose for best fitment and install a provided 5 16 plastic female fitting into the hose and secure with a supplied hose clamp Attach the supplied female adapter fitting to the factory fuel line Cut the 5 16 fuel hose previously installed from the supplied fuel pump inlet to the fac tory fuel line install the supplied TEE fitting at this connection and secure it using two supplied hose clamps Attach a length of P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 5 16 fuel hose to the inlet of the FMU and secure using a supplied clamp Route the open end of the 5 16 fuel hose to the open barb of the TEE fitting trim the hose for best fitment and secure using a supplied hose clamp Cut the 5 16 fuel hose previously installed from the supplied fuel pump outlet to the factory fuel line install the supplied TEE fit ting at this connection and
30. motive is not responsible for engine damage Installation on new vehicles will not harm or adversely affect the break in period so long as fac tory break in procedures are followed For best performance and continued durability please take note of the following key points 1 Use only premium grade fuel 91 octane or higher R M 2 2 The engine must have stock compression ratio 3 If the engine has been modified in any way check with Paxton prior to using this prod uct 4 Always listen for any sign of detonation pinging and discontinue hard use no boost until problem is resolved 5 Perform an oil and filter change upon com pletion of this installation and prior to test driving your vehicle Thereafter always use a high grade SF rated engine oil or a high quality synthetic and change the oil and fil ter 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 super charger may result 6 Before beginning installation replace all spark plugs that are older than 1 year or 10 000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications follow the procedures indicated within the Fate 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 at least e
31. n the bot tom of the supplied surge tank Route the hose along the passenger side inner fender and connect the open end of the hose to the 3 4 x 1 2 NPT 90 brass fitting on the top of the water reservoir trim the hose for best fitment Secure all hose connections using the sup plied nylon hose clamps Check to ensure all hose lines are free of kinks secure hose lines as needed away from sharp hot or moving objects using the supplied wire ties 7EO10 075 SHEET METAL SCREWS 1 4 x 20 x 1 2 BOLTS 7A250 ufpam WASHER 7J006 093 SURGE TANK BRACKET TO FIEWALL 3 4 HOSE UNION BARDED 7P375 075 0 4 D AIR CHARGE COOLER SURGE TANK 90 1 2NPTT GNIS6030 4 HOSE BA 3 4 HOSE 7P500 026 UO38 0 1 CUT TO FI 90 HOSE BA a NN _ 7P500 026 SN 1 NPT HOLE NOT USED HOLE SHOULD N BE BLIND OR N PLUGGED WATER PUMP CLAMP 8NO ies 8PN101 180 N LI 7f d i 2l N lt 3 4 HOSE 7U038 000 2 CUT TO F Tl z WATERCOOLER 8N006 010 Je Mm m WATERCOOLER 8N006 010 1 2 SOCKET HEAD CAP SCREW 7A2 26 05 050 INSTALL THROUGH ADEL CLAMP A Gwa ATER PUMP WATER TANK TO HOLD WATER PUMP 8F00 1 402 90 MOLDED HOSE ELBOW PM M 989 CONNECTS FITTING ON BOTTOM TANK TO INLET OF WATER PUMP Fig 13 a P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured
32. power source Remove the cover from the remote battery lug next to the engine compartment s fuse relay center Secure the ring terminal to this lug using factory hardware and use wire ties to secure the wire as needed away from sharp or hot objects F With the key on make sure the charge cool er water pump is operating and that water is flowing through the surge tank Fill the surge tank if necessary with a 50 50 coolant P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 1 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 This Page Left Intentionally Blank P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 15 FINAL ASSEMBLY AND CHECK Section 15 FINAL ASSEMBLY AND CHECK 15 FINAL ASSEMBLY AND CHECK A If your battery was disconnected reconnect it B If your vehicle has gone over 10 000 miles since its last spark plug change you will need to change the spark plugs now before test driving the vehicle C Check all fittings nuts bolts and clamps for tightness Pay particular attention to oil and fuel lines around moving parts sharp edges and exhaust system parts Make sure all wires and lines are properly secured with clamps or wire ties D Check all fluid levels making sure that your tank s is are filled with 91 octane or higher fuel before commencing test drive E Start the engine
33. s and nut Install the idler pulley and standoff in the location noted using the supplied hardware See Fig Fig 6 d 6 f H With the supplied support brackets assem bled using the 5 16 x 18 x 1 bolts and washers confirm that the support bracket sits flush with the cylinder head and engine block I Remove the support bracket after confirming that it sits flush with the head and block Using the three 5 16 18 x 1 bolts and washers provided attach the support bracket to the supercharger mounting plate leave these bolts loose Align the supplied support bracket using the supplied 8mmx120 x 1 25 bolt and 10mm x 130 x 1 5 bolt See Fig 6 e P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 Fig 6 f Attach the supplied 1 2 supercharger oil drain line and supplied hose clamp to the 3 8 NPT barbed fitting on the supercharger tighten the hose clamp Lower the super charger into place and secure using the five supplied 3 8 x 24 x 1 25 long bolts and washers Tighten all mounting hardware Route the oil drain line down towards the fitting previ ously installed in the oil pan Trim the hose for best fitment and install the supplied 90 push lock fitting into the open end of the supplied oil drain hose Attach the 90 fit ting and drain hose to the fitting previously installed into the oil pan Secure the hose away
34. s Page Left Intentionally Blank P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 12 SURGE AND RESERVOIR TANK INSTALLATION Section 12 SURGE AND RESERVOIR TANK INSTALLATION 12 SURGE AND RESERVOIR TANK INSTALLATION A Screw two supplied 3 4 x 1 2 NPT straight brass fittings into the plastic surge tank B Using the supplied 1 4 20 x 50 SHCS screw and washers attach the supplied surge tank to the supplied surge tank mounting bracket See Fig 12 a Fig 12 b F Mount the supplied water pump to the side of the supplied triangle water reservoir using the supplied 1 4 20 hardware and adel clamp G Install the supplied 3 4 x 1 2 NPT 90 brass fittings into the water reservoir Mount Fig 12 a the supplied triangle water reservoir to the supplied reservoir mounting bracket using C The factory ground wire located on the pas the 1 4 20 hardware provided See Fig senger side of the firewall will need to be 12 c relocated Using a 10mm socket remove the nut securing the ground strap to the stud as well as the nut secured on the stud to the right of it Secure the ground strap to the second stud using the factory hardware D Attach the surge tank to the stud the ground strap had been originally secured to using the factory 10mm headed nut E Mark and drill a hole using the supplied sheet metal screw to secure
35. secure it using two supplied hose clamps Attach a length of 5 16 fuel hose to the outlet of the FMU and secure using a supplied clamp Route the open end of the 5 16 fuel hose to the open barb of the TEE fitting trim the hose for best fitment and secure using a supplied hose clamp Route the hoses away from sharp or hot objects and secure using the supplied wire ties Attach an open end of the supplied 5 32 vacuum line onto the vacuum port of the previously installed FMU Route the vacu um line along the frame rail and into the engine compartment near the factory brake booster mounted on the vehicle s firewall Secure the hose line away from any sharp hot or moving objects using the supplied wire ties The vacuum line with be attached to a vacuum source at a later step P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 9 9 ENGINE CONTROL UNIT INSTALLATION Section 9 ENGINE CONTROL UNIT INSTALLATION ENGINE CONTROL UNIT INSTALLATION A Using a T 15 torx bit remove the two factory screws securing the panel below the steering column on the driver s side of the vehicle and remove the panel In a suitable location in the driver s compartment under the dash secure the PECU with the Velcro hook latch that 1s provided Locate the two 15mm headed bolts that retain the cover that the clutch actuating cable would pass through remove
36. ssure sending unit wire harness See Fig 2 b P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 1 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 This Page Left Intentionally Blank P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 3 OIL DRAIN ASSEMBLY Section 3 OIL DRAIN ASSEMBLY 3 OIL DRAIN ASSEMBLY A On the passenger side of the oil pan locate E Thoroughly clean the threaded area Reach the large hump in the oil pan measure inside the oil pan and retrieve any stray down 1 3 4 from the lip of the oil pan and chips Apply a small amount of sealer to the make a mark Center the mark between the new threads Apply more sealer to the sup two oil pan retaining bolts See Fig 3 a plied 3 8 x 16 x 8 fitting and secure in the hole using a 13 16 open end wrench Make NOTE sure a seal is formed all around the fitting It may be necessary to slightly bend the transmis See Fig 3 b sion cooler lines to gain access to the oil drain loca tion Fig 3 a B Using a 3 16 drill bit drill a pilot hole at the designated mark use grease on the drill bit to catch any metal shavings from falling into the oil pan With a small piece of wire con firm that there is nothing to interfere with the punch that is provided C Using an air hammer and the supplied punch start to enlarge the hol
37. the 1 4 20 nuts bolts and washers provided See Fig 7 a Fig 7 a Attach the supplied air filter to the air filter mounting flange and secure with the hose clamp provided Remove the aluminum A C line from its plastic clip on the passenger side inner fend er Remove the plastic clip from the vehicle it will not be reused Gently bend the A C line up for clearance for the air filter enclo sure Mount the supplied air filter enclosure to the passenger side inner fender using the sup plied sheet metal fasteners provided in the assembly The upper mounting tab should be about 1 8 down from the top of the fender See Fig 7 x Place the supplied 3 1 2 sleeve and the sup plied 56 hose clamps onto the inlet of the supercharger Leave the hose clamps loose at this time Locate the supplied 180 inlet duct Install the supplied 90 x 3 8 NPT x 1 2 hose barb into the tapped bung on the 180 inlet duct using Teflon paste to seal the threads This fitting should face straight up See Fig 7 b Fig 7 b Install the supplied 180 inlet duct to the supplied 3 1 2 sleeve previously attached to the supercharger Attach a 6 length of sup plied flex hose to the open end of the inlet duct and connect the opposite end to the pre viously mounted air filter enclosure Secure all connections using the hose clamps pro vided See Fig 7 h P N 4809650 2004 Paxton Automotive All Rights Reserved Int
38. the C1 plug pin 11 Tap the small black wire coming from the PECU to the C1 plug pin 18 Route the supplied 5 32 vacuum line into the engine compartment near the brake booster it will be connected at a later step GREEN RED MAP SENSOR TAN YELLOW GREY BLACK TAN YELLOWC AM SENSO CREY BLAP CRANK SENSOI OU CAM OUITAN YELLOW CAM IN TAN CRANK OUTGREY BLACK CRANK INGREY TO MANIFOLD 9 VACUUM BOOS1 MAP SENSOFGREEN RED MAP SENSOFGREEN IN RED PAXTON ENGINE CONTROL UNIT ra BLAC Fig 9 b P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOVO04 v1 0 03DodgeHemi 4809650v1 0 This Page Left Intentionally Blank P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2 10 CHARGE COOLER INSTALLATION Section TO CHARGE COOLER INSTALLATION 10 CHARGE COOLER INSTALLATION A Install a supplied reducer sleeve onto the throttle body install the aftercooler core into the reducer sleeve and secure with the sup plied hose clamps Install the supplied 2 75 x 2 sleeve onto the discharge of the super charger and another on the open end of the aftercooler core previously installed Install the supplied discharge duct between the supercharger and the aftercooler core with the welded bung facing the vehi
39. very 15 000 miles and spark plug wires at least every 50 000 miles Bs beginning this installation please read RECOMMENDED TOOLS FOR INSTALLATION o gv ur A wow S 9 10 11 125 13 14 15 16 17 18 19 20 Factory Repair Manual 3 8 Socket and Drive Set SAE amp Metric 1 2 Socket and Drive Set SAE amp Metric 3 8 NPT Tap and Handle Adjustable Wrench Open End Wrenches Metric and Standard Center Punch and a 5 8 Tapered Punch Springlock 3 8 and 5 8 Fuel Fitting Disconnect Tool 5 Quarts SH CF Rated Quality Engine Oil Cil Filter and Wrench Flat 2 Screwdriver Phillips 2 Screwdriver Heavy Grease Silicone Sealer Drill Motor 1 8 3 16 27 64 Drill Bits Wire Strippers and Crimpers Utility Knife Power Steering Pulley Puller amp Installer Pliers If your vehicle has in excess of 10 000 miles since its last spark plug change then you will also need 21 Spark Plug Socket 22 NEW Spark Plugs P N 4809650 2004 Paxton Automotive All Rights Reserved Intl Copr Secured 11NOV04 v1 0 03DodgeHemi 4809650v1 0 2003 Dodge Hemi Part No 1201220 SUPERCHARGERS PARTS LIST IMPORTANT Before beginning installation verify that all parts are included in the kit Report any shortages or damaged parts immediately PART NO DESCRIPTION QTY PART NO DESCRIPTION QTY 4PCH110 044 S C MNTG BRKT ASSY 03 HEMI 1 4PCH101 001 FUEL PUMP ASSY 03 HEMI APCH 01

Paxton Automotive Automobile Parts 1200 User's Manual

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