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Paxton Automotive Viper Owner's Installation Manual

For the 2003-2005 dodge viper
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KIT # 1201810
Owner's Installation Guide for the
Paxton Automotive
Novi 2000 Supercharger
for the
2003-2005 Dodge Viper
Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033
805 604-1336 . FAX • 805 604-1337
DP/N: 4809644 - v2.0
12/13/04

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  • Page 1 KIT # 1201810 Owner’s Installation Guide for the Paxton Automotive Novi 2000 Supercharger for the 2003-2005 Dodge Viper Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033 805 604-1336 . FAX • 805 604-1337 DP/N: 4809644 - v2.0 12/13/04...

  • Page 2: Foreword

    FOREWORD roper installation of this supercharger kit requires general 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 to a professional installer/technician. Please call Paxton Automotive for installers in your area.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS FOREWORD ..............ii TABLE OF CONTENTS .

  • Page 4: Important Notes

    Dodge Viper IMPORTANT NOTES his product is protected by state common law, copyright and/or patent. All legal rights therein are reserved. The design, layout, dimensions, geome- try and engineering features shown in this product are the exclusive prop- erty of Paxton Automotive. This product may not be copied or duplicated in...

  • Page 5: Recommended Tools

    Dodge Viper efore beginning this installation, please read through this entire instruction book- let and the Street Supercharger System RECOMMENDED TOOLS Owner's Manual which includes the Automotive FOR INSTALLATION: Limited Warranties Program and the Warranty Registration form. Factory Repair Manual Paxton supercharger systems are performance improving devices.

  • Page 6: Goldseal Hose Clamp

    2003-2005 Dodge Viper Part No. 1201840 PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any short- ages or damaged parts immediately. PART NO. DESCRIPTION PART NO. DESCRIPTION 1011840 VIPER SUPERCHARGER ASSY 4PCW112-010 AIR INTAKE ASSY.
  • Page 7 2003-2005 Dodge Viper Part No. 1201840 PARTS LIST IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any short- ages or damaged parts immediately. PART NO. DESCRIPTION PART NO. DESCRIPTION 8PN301-040 POWER COOLER ASSY. ' VIPER 8PN201-040 DISCHARGE ASSY.
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  • Page 9: Preparation/Removal

    Section 1 COMPONENT REMOVAL PREPARATION/REMOVAL A. Disconnect the Idle Air Control (IAC) motor hose and the valve cover breather hose from the air box (air filter housing). B. Remove the air box and all of the inlet duct- ing up to but not including the throttle body. C.
  • Page 10 This Page Left Intentionally Blank. P/N: 4809644 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 13DEC04 v2.0 03-05Viper(4809644v2.0)

  • Page 11: Oil Feed

    Section 2 OIL FEED 2. OIL FEED A. Remove the oil dipstick by removing the retaining screw from the passenger side valve cover. B. Drain the engine oil and remove the oil filter. C. Remove the oil pan. D. Remove the oil pressure sender (1 1/8") from the passenger side of the engine in front of the engine mount.
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  • Page 13: Oil Drain

    Section 3 OIL DRAIN 3. OIL DRAIN A. To provide an oil drain for the supercharger, it is necessary to make a hole in the oil pan. B. The hole should be located per Fig. 3-a on the passenger side of the oil pan. Use the supplied 9/16"...
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  • Page 15: Crank Pulley Installation

    Section 4 CRANK PULLEY INSTALLATION CRANK PULLEY INSTALLATION Make sure to make small cuts and cool with *** NOTE *** cutting fluid to prevent the drill from over- Dowel pins must be installed throught the damper and into the crankshaft to assure that the damper does not heating and breaking.
  • Page 16 M. Install the supplied 7-rib crank pulley onto the harmonic damper using the supplied 5/16 x 1" hex head bolts, washers and thread locker. Torque the six mounting bolts in a rotating pattern to 20 Ft-lbs. N. From underneath the vehicle, install the supercharger 8 rib crank pulley onto the pilot on the 7 rib crank pulley.

  • Page 17: Supercharger Mounting Bracket Installation

    Section 5 SUPERCHARGER MOUNTING BRACKET INSTALLATION SUPERCHARGER MOUNTING BRACKET INSTALLATION G. Route the supplied 8-rib belt around the A. Disconnect the emissions line from the bot- crank pulley and the upper alternator spacer tom of the throttle body and re-route it on block (See Fig.
  • Page 18 Install the primary mounting plate onto the previously installed studs making sure that the 8 rib belt is routed around the 8 rib idler. Install the supplied 5/16" nut and washer onto the A/C stud. K. Insert 3/8 x 1-1/4" bolts through the mount- ing plate and into the threaded holes in the upper spacer block and tighten.

  • Page 19: Supercharger Installation

    Section 6 SUPERCHARGER INSTALLATION SUPERCHARGER INSTALLATION A. Install the supplied 1/2" oil drain hose on *** NOTE *** the barb fitting on the bottom of the super- Bending the factory hard line that runs to the radiator charger and secure with the supplied #8 hose fan will provide supercharger clearance.
  • Page 20 Install the 3/8 x 2-3/4" bolt through the K. Route the free end of the oil feed hose to the mounting plate assembly and into the open supercharger oil feed fitting hole in the supercharger gear case. Install *** NOTE *** the 3/8 x 2-1/4"...

  • Page 21: Timing Controller Installation

    Section 7 TIMING CONTROLLER INSTALLATION 7. TIMING CONTROLLER INSTALLATION E. Connect the thin 20GA RED wire to battery *** NOTE *** positive switched by the ignition (Black The VIOLET (and green and yellow if equipped) wire is PCM C1 connector, Pin # 2, Pink with gray not used.
  • Page 22 L. Connect the TAN/YELLOW wire to the wire leading to the PCM cam sensor input. (See Fig. 7-c.) M. Connect the large 12 GAGE RED wire to the battery (+) positive terminal located at the front of the fuse box. N.

  • Page 23: Charge Air Cooler Installation

    Section 8 CHARGE AIR COOLER INSTALLATION CHARGE AIR COOLER INSTALLATION 10. Install the supplied 90º hose (trimmed A. CHARGE AIR COOLER (CAC) CORE as necessary) onto the 3/4" barb on the INSTALLATION passenger side of the discharge duct. Using sealant, install 1/2" NPT to 3/4" Secure with the factory clamps.

  • Page 24: Nylock Nut

    Using one of the supplied hose menders, connect the long leg to the hose attached to the top of the water tank (trim as necessary). Horn “A” a. Using the factory 90° horn bracket with the 2.75" short leg as a tem- plate, mark and drill a 5/32"...

  • Page 25: Plastic Wire Loom

    Connect the fuse holder using a yellow Drill a hole and use the supplied sheet slide connector to terminal #30 on the metal screw to mount the water pump CAC pump relay and to the fuse box relay and the ground wire in the loca- tion shown in Fig.
  • Page 26 Drill the radiator air inlet duct using a 1 10. Route 90º 3/4" hose between the radia- 1/8" hole saw so that the hose can be tor and the passenger side frame rail. routed smoothly from the water cooler Install a 90º hose on the top fitting on to the water pump outlet.

  • Page 27: Auxiliary Fuel Pump Assembly Installation

    Section 9 AUXILIARY FUEL PUMP ASSEMBLY INSTALLATION AUXILIARY FUEL PUMP ASSEMBLY INSTALLATION A. Plumb the supplied fuel pumps in parallel by now configured so that one TEE feeds both connecting the pump inlets to a TEE fitting. pump inlets and another TEE draws from Do the same with the outlets.
  • Page 28 H. Install the FCU in the location shown in Fig. B. Connect the ground terminals to the ground- 9-d using the supplied sheet metal screws. ing location under the windshield using the supplied wire and ring terminal connectors. Cut the auxiliary fuel pump supply (inlet) (See Fig.

  • Page 29: Air Inlet Duct Installation

    Section 10 AIR INLET DUCT INSTALLATION 10. AIR INLET DUCT INSTALLATION A. Install the supplied 4" bump sleeve onto the 1. (2003-2004 vehicles) Using the supplied supercharger inlet. 5/8" hose menders and hose, connect the fac- tory crankcase vent hose to the grommet B.
  • Page 30 2. (2005 vehicles) Disconnect the rubber G. Slide the supplied air filter into the air box elbow from the front of the driver’s side and use the supplied retainer to hold it in. valve cover. Install a short length of 3/8" Install the four fasteners through the retainer hose onto the inlet of the supplied PCV and air inlet and into the radiator shroud.

  • Page 31: Final Check

    Section 11 FINAL CHECK FINAL CHECK A. Reconnect battery. engine, usually at full throttle. It can quickly destroy an engine. If detonation is detected, B. Make sure that all oil feed and oil drain fit- discontinue hard use until the problem is tings are connected and tight and that the fixed.
  • Page 32 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: 4809644 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 11-2 13DEC04 v2.0 03-05Viper(4809644v2.0)

This manual is also suitable for:

Novi 2000 supercharger

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