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Sylvania 1000 manual

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  • Page 1

    DP/N: 4809628 - V2.1 06/05/03 Owner ’ s Installation Guide for the Paxton Automotive Novi 1000 Supercharger for the 2001-2003 4.6L SOHC Mustang GT Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033 805 604-1336 . F AX (805) 604-1337[...]

  • Page 2

    P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) ii FOREWORD Before you start the installation of your supercharger Paxton superchar ger kit, you will have to find the Paxton Computer Chip V oucher located in your information packet. The 2001-2003 Mustang GT Supercharger Kit requires[...]

  • Page 3

    P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) iii T ABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii T ABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 4

    P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) iv IMPOR T ANT NOTES C ongratulations! Y ou have purchased the finest street supercharger available for the Mustang GT . The centerpiece of this kit is the High Efficiency P AXTON Superchar ger , a mechanically driven centrifugal blowe[...]

  • Page 5

    P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) 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 serious injury to you, or to someone else who happens to be sta[...]

  • Page 6

    P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) vi This Page Left Intentionally Blank.[...]

  • Page 7

    1-1 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Section 1 INITIAL PREPARATION AND REMOVAL B. Before the air intake assembly can be removed, you must first disconnect the plas- tic crankcase breather hose (A) and air idle bypass hose (B). Unplug the air temperature sensor (C) and[...]

  • Page 8

    1-2 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Fig. 1-b Fig. 1-c E. Once the assembly is out of the car , use a 10mm socket to remove the mass air flow sensor and screen from the air filter housing (see Fig 1-d ). Place the mass air flow sensor aside to be re-installed in a lat[...]

  • Page 9

    2-1 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Section 2 SUPERCHARGER MOUNTING BRACKET ATTACHMENT 2.1 SUPERCHARGER MOUNTING BRACKET A TT ACHMENT Fig. 2-a A. Loosen (but do not remove) the four 10 mm head bolts securing the water pump pulley . Next, remove the accessory drive be[...]

  • Page 10

    2-2 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) D. Remove both nuts using a 10mm and 13mm socket. Then remove both studs using a 13mm and 18mm socket. Enlarge the hole in the tab that held the wiring harness to the outermost stud. Using a round file, enlarge the hole so that it [...]

  • Page 11

    2-3 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) G. Install the supercharger rear support bracket as shown in Fig 2-h . T emporarily install the long 10mm bolt to line up the bracket. Leave the bolts finger tight, as it will be necessary to move the bracket when you install the m[...]

  • Page 12

    2-4 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) This Page Left Intentionally Blank.[...]

  • Page 13

    3-1 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Section 3 FAN RESISTOR RELOCATION 3.1 F AN RESISTOR RELOCA TION A. Disconnect the wiring harness from the fan resistor . (See Fig. 3-a .) Remove clips hold- ing the fan resistor to the fan shroud. Attach the fan resistor to the sup[...]

  • Page 14

    3-2 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) This Page Left Intentionally Blank.[...]

  • Page 15

    4-1 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Section 4 PREPARING TO MOUNT THE SUPERCHARGER A. Mount the main supercharger bracket, installing the two 3/8 bolts and spacers in the upper portion of the bracket. Install the long 6mm bolt and spacer in the lower mid- dle portion [...]

  • Page 16

    4-2 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) D. Remove the drive belt from the alternator pulley . Install the supercharger into the main bracket, while looping the drive belt around the supercharger pulley . (See Fig. 4-d. ) Fig. 4-d E. T ighten the supercharger mounting bol[...]

  • Page 17

    5-1 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Section 5 OIL FEED AND DRAIN LINES 5.1 OIL FEED AND DRAIN LINES A. Y our Paxton Automotive NOVI 1000 super- charger uses pressurized engine oil for lubri- cation. Use an oil sending unit socket (Snap- On tools; part number 6152 or [...]

  • Page 18

    5-2 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) D. Next, apply a small amount of anti-seize lubricant to the tip of the punch, and insert it into the pilot hole. Hit the punch with an air hammer carefully using small bursts, until the punch is inserted up to its shoulder . The h[...]

  • Page 19

    6-1 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Section 6 INTAKE TRACT MODIFICATIONS 6.1 INT AKE TRACT MODIFICA TIONS A. Install the discharge tube assembly as shown, using the supplied rubber sleeves and stainless steel clamps. (See Fig. 6-a .) Fig. 6-a B. Install the supplied [...]

  • Page 20

    6-2 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) E. Remove the screen from the MAF , which was removed in step 4.(See Fig. 6-e .) Fig. 6-e F. Assemble the MAF , mounting bracket, MAF/air filter adapter and air filter . The MAF bracket assembly may look different from what you rec[...]

  • Page 21

    6-3 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Fig. 6-h L. Place the MAF/air filter bracket over the existing studs, then secure with the original nuts. (See Fig. 6-h .) M. Carefully open the main wiring harness (runs from the passenger side inner fender into the engine compart[...]

  • Page 22

    6-4 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Fig. 6-l T. Place the secondary intake tube/bypass valve assembly on the supercharger inlet, and attach it to the flex hose. Attach the other end of the bypass valve to the dis- charge tube. Connect the hose that was pre- viously i[...]

  • Page 23

    7-1 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Fig. 7-a Section 7 ENGINE CONTROL COMPUTER REMOVAL AND MODIFICATION 7.1 ENGINE CONTROL COMPUTER REMOV AL AND MODIFICA TION B. Pull the harnesses down and out of the way , creating unobstructed access to the comput- er . Remove the [...]

  • Page 24

    7-2 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) D. Remove the 10mm bolt that secures the main harness to the computer , and remove the harness. (See Fig. 7-d .) E. Once the computer is removed from the car , you will need to send your computer and the chip voucher to Paxton Auto[...]

  • Page 25

    8-1 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Section 8 IN-TANK FUEL PUMP INSTALLATION 8.1 IN-T ANK FUEL PUMP INST ALLA TION (2001-2002 Models Only) A. Raise the rear of the car and support it with jack stands. B. Open the fuel door and remove the fuel cap and the three filler[...]

  • Page 26

    8-2 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) BYP ASS TUBE PLASTIC FUEL PUMP OUTLET MANIFOLD FUEL OUTLET HOSE FUEL PUMP OUTLET PUMP CANISTER Fig. 8.2-a M. Remove the screen from the bottom of the canister assembly being careful not to punc- ture flapper valve. (See Fig. 8.2-b [...]

  • Page 27

    8-3 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Fig. 8-c / Completed Installation[...]

  • Page 28

    8-4 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) This Page Left Intentionally Blank.[...]

  • Page 29

    9-1 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Section 9 FINAL ASSEMBLY AND CHECK W e know that you are anxious to get out and drive your new vehicle, but please take a little bit more time to perform these simple check-out steps. A Inspect all wiring harnesses and electrical c[...]

  • Page 30

    9-2 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) This Page Left Intentionally Blank.[...]

  • Page 31

    A-1 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) APPENDIX[...]

  • Page 32

    A-2 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Please realize that P AXTON Automotive is con- stantly improving the performance and look of the NOVI 1000 supercharger . Parts in your kit may appear dif ferently than what is pictured in this manu- al. This is due to photographs [...]

  • Page 33

    A-3 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) SCALE: SIZE DWG. NO. D SHEET 1 OF 1 REV . DA TE APPROVALS DRAWN ENGINEERING R&D UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: DECIMALS: .XX ± .01 .XXX ± .005 MA TERIAL FINISH NONE SEE PAR TS LIST DO NOT [...]

  • Page 34

    A-4 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) ITEM NO. QTY . P AR T NO. DESCRIPTION 23 7R002-024 CLAMP , HOSE #24 31 4PFH014-011 REDUCER, RADIATOR HOSE 41 4PFH014-020-1 SCALE: SIZE DWG. NO. D SHEET 1 OF 1 REV . DA TE APPROVALS DRAWN ENGINEERING R&D UNLESS OTHERWISE SPECIFI[...]

  • Page 35

    A-5 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) SCALE: SIZE DWG. NO. D SHEET 1 OF 1 REV . DA TE APPROVALS DRAWN ENGINEERING R&D UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: DECIMALS: .XX ± .01 .XXX ± .005 MA TERIAL FINISH NONE SEE PAR TS LIST DO NOT [...]

  • Page 36

    A-6 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) SCALE: SIZE DWG. NO. D SHEET 1 OF 1 REV . DA TE APPROVALS DRAWN ENGINEERING R&D UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: DECIMALS: .XX ± .01 .XXX ± .005 MA TERIAL FINISH NONE SEE PAR TS LIST DO NOT [...]

  • Page 37

    A-7 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) L. KECK 10/30/00 SCALE: SIZE DWG. NO. D SHEET 1 OF 1 REV . DA TE APPROVALS DRAWN ENGINEERING R&D UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: DECIMALS: .XX ± .01 .XXX ± .005 MA TERIAL FINISH NONE SEE PA[...]

  • Page 38

    A-8 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) 1300 BEACON PLACE OXNARD, CA 93033 TEL: (805) 604-1336 FAX: (805) 604-1337 CAD GENERA TED DRAWING, DO NOT MANUALL Y UPDA TE SCALE: SIZE DWG. NO. C SHEET 1 OF 1 REV . DA TE APPROVALS DRAWN ENGINEERING R&D UNLESS OTHERWISE SPECIF[...]

  • Page 39

    A-9 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) SCALE: SIZE DWG. NO. C SHEET 1 OF 1 REV . DA TE APPROVALS DRAWN ENGINEERING R&D UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: DECIMALS: .XX ± .01 .XXX ± .005 MA TERIAL FINISH NONE SEE PAR TS LIST DO NOT [...]

  • Page 40

    A-10 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) SCALE: SIZE DWG. NO. D SHEET 1 OF 1 REV . DA TE APPROVALS DRAWN ENGINEERING R&D UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: DECIMALS: .XX ± .01 .XXX ± .005 MA TERIAL FINISH NONE SEE PAR TS LIST DO NOT[...]

  • Page 41

    A-11 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) ITEM NO. QTY . PAR T NO. DESCRIPTION 1 2 3 4 5 1 2 4 2 2 4PFL010-041 7E014-075 7J010-001 7F010-024 7C010-075 BRKT , F AN RESISTOR RELOCATION SCREW , #14 X .75 LG, SELF T APPING W ASHER, FLA T , #10 NUT , HEX, 10-24UNC-2B, STEEL WI[...]

  • Page 42

    A-12 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) ITEM NO. QTY . PAR T NO. DESCRIPTION PIGT AIL CONNCTR, FUEL PUMP SPACER, .312 OD/.14 ID 14-16AWG SOLDERLESS CONNECTOR SCREW , SHTMTL, HXHD, #6 x .75 LG. 2 3 4 5 1 2 2 2 5W001-052 2A017-048 5W001-013 7E006-075 SCALE: SIZE DWG. NO. [...]

  • Page 43

    A-13 P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) WA TER PUMP POWER STEERING AL TERN SUPERCHARG A/C CRANK 1300 BEACON PLACE OXNARD, CA 93033 TEL: (805) 604-1336 FAX: (805) 604-1337 CAD GENERA TED DRAWING, DO NOT MANUALL Y UPDA TE SCALE: SIZE DWG. NO. B SHEET 1 OF 1 REV . DA TE AP[...]

  • Page 44

    P/N: 4809628 ©2003 P axton Automotiv e All Rights Reserved, Intl. Copr . Secured 05JUN03 v2.1 MusGT(4809628 v2.1) Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033 805 604-1336 . F AX (805) 604-1337[...]