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Paxton Automotive Novi 1200 Supercharger Owner's Installation Manual

Supercharger for the 2005 mustang gt
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Owner's Installation Guide for the
Paxton Automotive
Novi 1200 Supercharger
for the
2005 Mustang GT
Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033
805 487-3796 • FAX 805 247-0669
DP/N: 4809654 v2.1
12/01/05

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  • Page 1 Owner’s Installation Guide for the Paxton Automotive Novi 1200 Supercharger for the 2005 Mustang GT Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033 805 487-3796 • FAX 805 247-0669 DP/N: 4809654 v2.1 12/01/05...

  • Page 2: Foreword

    Please browse through each step of this instruction manual prior to beginning the installation to determine if you should refer the job to a profes- sional installer/technician. Please call Paxton Automotive for installers in your area. © 2005 PAXTON AUTOMOTIVE All rights reserved.

  • Page 3: Table Of Contents

    FINAL CHECK ............15-1 P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured...

  • Page 4: Important Notes

    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 whole or part, abstractly or fundamentally, intentionally or fortuitously, nor shall any design, dimension, or other information be incorporated into any product or apparatus without prior written consent of Paxton Automotive.

  • Page 5: Recommended Tools For Installation

    Factory Repair Manual be expected with the boost levels specified by 3/8" Socket and Drive Set: SAE & Metric Paxton Automotive. This product is intended for use on healthy, well maintained engines. 1/2" Socket and Drive Set: SAE & Metric Installation on a worn-out or damaged engine is 3/8"...

  • Page 6: Parts List (2005 Mustang Gt, Standard)

    #20 SAE TYPE “F” SS HOSE CLAMP 7ROO2-024 #24 SAE TYPE “F” SS HOSE CLAMP 7P125-002 FREEZE PLUG, Ø1.25, .25 TAL 7R002-010 #10 SAE TYPE “F” SS HOSE CLAMP 7P125-016 1/8"NPT PLUG P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 7: Parts List (2005 Mustang Gt, H.o.)

    1/4-20 x 75 SHCS PLTD 7J250-001 1/4" WASHER, SAE, PLTD 7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 4FU010-010 P/S RELOC BRKT, '05 GT MUST 7U100-055 TIE-WRAP, 7.5" NYLON P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 8 Y-UNION, 3/8" BARBED TEFLON 7U032-025 HOSE, 5/16"ID, 3/8"OD, 1/32"W 6.25' 7U032-030 HOSE, SPIRAL 3/8" CUFF ID, 1'L 5A003-035 DIABLO PREDATOR, '05 MUST GT 5A001-025 DIABLO MAFia, '05 MUST P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured viii 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 9: Preparation/Removal

    D. Remove the six plastic push pins securing the radiator cover. Remove the cover and set aside to be reinstalled later. (See Fig. 1-e.) NYLON CLIPS THROTTLE BODY CLAMP Fig. 1-b Fig. 1-e P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 10 Remove the rails and injectors as a com- plete unit and set aside. New injectors will HOSE TO THERMOSTAT be installed in a later step.(See Figs. 1-i, 1-j.) Fig. 1-g P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 11 Locate and remove the stud that secures the alternator in place as well as the stud-bolts located to the right of the alternator. (See Fig. 1-j.) P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 12 Move the harness out of the way. This harness will have to be relocated to gain clearance for the super- charger. P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 13: Oil Feed Installation

    Reinstall the factory sensor in the branch of the TEE as shown. (See Fig. 2-a.) FACTORY PRESSURE SENSOR 1/4"NPT x -4 90° Fig. 2-a P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 14 This Page Left Intentionally Blank P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 15: Oil Drain Assembly Installation

    *** NOTE *** This method of rolling over the lip of the hole and tapping it works very well if carefully done and should cause no problems. P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 16 This Page Left Intentionally Blank P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 17: Power Steering Relocation

    G. It will be necessary to trim the corner of the radiator core support cover to clear the relocat- ed P/S reservoir. (See Fig. 4-d.) TRIMMED AREA Fig. 4-d Fig. 4-b P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
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  • Page 19: Coolant Tube Relocation

    10mm HEADED BOLTS Fig. 5-b D. Remove the factory coolant bleed plug and set the plug aside. It will not be reused. (See Fig. 5-c.) Fig. 5-d P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 20 Leave these loose as they are there only as a pilot for the cross-over tube. P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 21 X. Locate the breather hose removed from the dri- ver’s side valve cover and the intake manifold. Remove and retain the 90° plastic hose-end connector. Discard the plastic tube. P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 22 This Page Left Intentionally Blank P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 23: Supercharger Mounting Plate Installation

    16 x 1.0" bolts and washers and install through the plate into the two stud bolt spacers retaining the factory idlers. (See Figs. 6-a, 6-b.) Fig. 7-b P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 24 SUPERCHARGER MOUNTING PLATE INSTALLATION, cont’d P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 25 R. Using a 1/2" ratchet, rotate the factory spring tensioner clockwise and install the accessory drive belt. Refer to Fig. 6-e for proper belt rout- ing. Fig. 6-g P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
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  • Page 27 Fig. 7-b D. Trim approximately 5" off of the 9" end of the hose and 5-1/4" of the 13" end. P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 28: Thermostat Housing Relocation

    Install the end with the 90° bend onto the thermostat housing. Install the opposite end to the previouusly modified coolant cross-over tube. Secure using the #20 hose clamps provided. (See Fig. 7-c.) Fig. 7-d P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 29: Charge Air Cooler Installation (H.o. Kits Only)

    Remove the six Phillips-head screws (3 BOLTS each side) on the lower portions of the plastic inner fender liners. (See Fig. 8A-b.) Fig. 8A-d PHILLIPS- HEAD SCREWS Fig. 8A-b P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 30 12. Remove the bumper cover and set aside. (See Fig. 8A-i.) Fig. 8A-f Remove the two 10mm headed bolts (1 each side upper portion of grill). (See Fig. 8A-g.) P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 31 17. Replace the styrofoam bumper support using the factory retainers. Fig. 8A-j 14. Remove four inner bolts of eight 13mm headed bolts retaining the metal bumper support. (See Fig. 8A-k.) P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 32: Charge Air Cooler Assembly

    Loosely install the short ends of the two 90° rubber elbows onto each end of the Fig. 8B-d charge cooler using the supplied #48 hose clamps. (See Fig. 8B-c.) P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 33 (See Fig. 8B-f.) TUBE “E” DISCHARGE DUCT Fig. 8B-h TUBE “D” 13. Secure all hose connections at this time, adjust- ing for best fit and clearance. Fig. 8B-f P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 34: Compressor Bypass Valve Assembly Installation

    3" x Ø1" HOSE (TRIM TO FIT) TO DISCHARGE TUBE “A” BY-PASS VALVE (TRIM TO APPROX. 5.75") 7U133-100 MOLDED 90° HOSE TRIM TO FIT (TRIM TO APPROX. 4") Fig. 8C-a P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 35 TO DISCHARGE TUBE AT THE THROTTLE BODY BYPASS VALVE 15" x Ø1" HOSE (TRIM TO FIT) TO INLET DUCT #16 HOSE CLAMPS TO MANIFOLD PRESSURE/VACUUM Fig. 8C-b P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 36 #2 using the TEE provided. (See Fig. 8C-d.) VACUUM TEE VACUUM HOSE Fig. 8C-c P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 37 8C. CHARGE AIR COOLER INSTALLA- TION (H.O. Kits Only), cont’d P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 38: Wiring Harness Relocation

    Secure the harness to the A/C line with wire ties. (See Fig. 8D-b.) Fig. 8D-c SECURE HARNESS WITH WIRE-TIES BENT A/C LINE Fig. 8D-b P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 8-10 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 39 (See Fig. 8E-c.) 3/8" BARBED FITTING Fig. 8E-a Attach bracket 4FU010-061 to the front of the reservoir with the hardware provided. (See Fig. 8E-b.) Fig. 8E-c P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 8-11 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 40 (See Fig. 8E-g.) 3/4" HOSE ATTACHED TO THERMOSTAT HOUSING Fig. 8E-e Fig. 8E-g *** NOTE *** Leave this bolt loose for final adjustment in a later step. P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 8-12 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 41 16. Reinstall the front bumper assembly including the foam inner bumper, all plas- tic splash panels and light connections in the reverse order removed. Fig. 8E-i P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 8-13 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 42 This Page Left Intentionally Blank P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 8-14 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 43: Air Discharge Assembly Installation (Non-Cooled Kits Only)

    Secure with a #16 hose clamp. The open end of the 15" long hose will be connected to the air inlet in a future step. P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 44 BYPASS VALVE 15" x Ø1" HOSE (TRIM TO FIT) TO INLET DUCT #16 HOSE CLAMPS TO MANIFOLD PRESSURE/VACUUM Fig. 9-b FUEL REGULATOR SUPPLIED VACUUM Fig. 9-c P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 45: Coolant Reservoir Re-Installation (Non-Cooled Kits Only)

    Once the cooling system is filled and all trapped air expelled, install the 1/8"NPT plug provided in the previously installed cross-over tube. Thread sealant should be used. P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 10-1 01DEC05 v2.1 05MusGT(4809654v2.1)
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  • Page 47: Crank Case Breather And Pcv Installation

    Route the open end of the 3/8" hose behind the alternator and across to where the air inlet duct will be located. Fig. 11-b CONNECTION ON PASSENGER’S SIDE FACTORY 90° HOSE CONNECTOR Fig. 11-c P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 11-1 01DEC05 v2.1 05MusGT(4809654v2.1)
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  • Page 49: Air Inlet Assembly

    1/4"NPT x 3/8" x 90° BARBED FITTING HOSE BARBED FITTING Fig. 12-b D. Install the 1/4"NPT x 3/8" hose barb fitting in the location noted. (See Fig. 12-b.) P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 12-1 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 50 FACING AIR FILTER N. Install the element reusing the factory hardware to the supplied MAF tube that is provided. (See Figs. 12-f, 12-g.) Fig. 12-g P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 12-2 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 51 N. Secure the rear clamp at the inlet duct union to the previously installed support bracket. (See Fig. 12-i.) P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 12-3 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 52 Any change to the MAF Interface Adapter box by setting it to a higher or lower number could cause damage to the engine. P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 12-4 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 53: Fuel Pump Upgrade

    D. Using a small screwdriver or chisel and ham- mer, tap the retaining ring in a counter clock- wise direction. Remove the retaining ring and set aside. (See Fig. 13-b.) P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 13-1 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 54 (See Fig. 13-f.) SUPPLIED .75" LONG TEFLON SLEEVES Fig. 13-g P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 13-2 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 55 N. Use the supplied T-splice and slide connectors to connect the black and red wires from the supplied pump to the corresponding power and ground on the factory pump. (See Fig. 13-h.) P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 13-3 01DEC05 v2.1 05MusGT(4809654v2.1)
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  • Page 57: Reflash Computer

    If you have any questions, either refer to the manual that is provided with the reflash tool or contact our service depart- ment for further assistance. Fig. 14-b P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 14-1 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 58 Do not disturb the cable, or turn the ignition off during this time. If the programming is disrupted, the computer will not start or run your vehicle! P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 14-2 01DEC05 v2.1 05MusGT(4809654v2.1)

  • Page 59: Final Check

    Read the STREET SUPERCHARGER SYSTEM OWNER'S MANUAL AND RETURN THE WARRANTY REGISTRA- TION FORM within thirty (30) days of pur- chasing your supercharger system to qualify. P/N: 4809654 ©2005 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 15-1 01DEC05 v2.1 05MusGT(4809654v2.1)
  • Page 60 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: 4809654 v2.1 12/01/05...

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