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Paxton Automotive Novi 1200 Supercharger Owner's Installation Manual

Supercharger for the 2001, 2003 8.1l gm truck
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Owner's Installation Guide for the
Paxton Automotive
Novi 1200 Supercharger
for the
2001, 2003 8.1L GM Truck
Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033
805 604-1336 . FAX (805) 604-1337
DP/N: 4809642 - v1.2
09/28/04

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Summary of Contents for Paxton Automotive Novi 1200 Supercharger

  • Page 1 Owner’s Installation Guide for the Paxton Automotive Novi 1200 Supercharger for the 2001, 2003 8.1L GM Truck Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033 805 604-1336 . FAX (805) 604-1337 DP/N: 4809642 - v1.2 09/28/04...

  • Page 2: Foreword

    Automotive for installers in your area. © 2004 PAXTON AUTOMOTIVE All rights reserved. No part of this publication may be reproduced, transmitted, transcrived, or translated into another language in any form, by any means without written permission of Paxton Automotive. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl.

  • Page 3: Table Of Contents

    FINAL ASSEMBLY AND CHECK......... 20-1 20.1 P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 4: Important Notes

    19 Wire Strippers & Crimpers label and compare it to the parts list. PAXTON AUTOMOTIVE makes every effort to insure that all parts are included in the box. If you discover that you are missing any part, or that a part was damaged in shipping, call PAXTON immediately.
  • Page 5 A/C line and compressor assembly that is NOT compatible with the Vortech kit. (GM 15708738) A/C LINE AND COMPRESSOR ASSEMBLY THAT IS COMPATIBLE WITH VORTECH KIT (GM 15187285) DENSO COMPRESSOR P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 6 Clean up any spills immediately, and dispose of waste materials properly. Pets, wild animals, and children may die if they ingest the liquid. PAXTON Automotive thanks you for your pur- chase. We welcome your comments and sugges- tions to help us improve our product.

  • Page 7: Parts List

    SURGE TANK BRKT 7P375-017 3/8" NPT x 1/2 BARB 8N106-060 WATER COOLER ASSEMBLY 7U030-036 1/2” OIL DRAIN HOSE 1.83’ 8N006-010 WATER COOLER (SETRAB) 7R001-008 #6 HOSE CLAMP P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 8 1" I.D. x 90° MOLDED TUBE 7P100-010 1" PLASTIC CONNECTING BARB 7R002-020 #20 HOSE CLAMPS 7R003-024 ADEL CLAMP 4PGE010-011 Brkt, Airbox Mounting 7E010-075 #12 x 3/4" SHTMETAL SCREWS P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured viii 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 9: Initial Preparation And Removal

    K. Remove the MAF from the factory air box, then remove the air box. L. Remove the plate from underneath the origi- nal air box location. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 10 This Page Left Intentionally Blank. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 11: Intake Manifold Removal

    Remove all fasteners securing the intake manifold to the engine. Slowly lift up on the manifold breaking the gasket seal and remove it from the engine compartment. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...
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  • Page 13: Intake Manifold Breather/Pcv/Throttle Body Gasket

    With a pair of pliers, pull out the metal piece leaving an open hole. Use a 7/16" drill to enlarge the hole. Fig. 3-b P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 14: Installation

    PCV valve. Secure both ends of the hose with the supplied #8 hose clamps. (See Fig. 3-e.) Fig. 3-e P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 15: Fuel Injector Replacement

    Check to see that each injector has been seated properly into the manifold. Tighten down the fuel rail assembly with the original bolts. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...
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  • Page 17: Intake Manifold/Breather Installation

    Install the baffle/barb assembly onto the previously installed 3/8" street elbow/nipple assembly on the rear of the manifold. Orient the baffle and barb as shown in Fig. 3-c. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...
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  • Page 19: A/C Line Modification

    (See Figs. 6-b, 6-c,) Refer to Fig. 8-a for a photo of the bent section mounted to the A/C compressor P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 20 Fig. 6-b ORIGINAL END CONNECTING TO A/C PORT LOCATED NEAR THE FIREWALL, NOW LOCATED IN THE A/C COMPRESSOR RUBBER SECTION CURLED NEAR THE INNER FENDER Fig. 6-c P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 21: Coolant Hose Modifications

    C. Using the supplied 1" hose union, connect the supplied 90° molded hose to the trimmed radiator hose. Cut the long end of the supplied hose for best fit. Attach the 90° Fig. 7-c P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...
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  • Page 23: Mounting Plate/Supercharger Installation

    Figs. 8-c, 8-d 8-e for cover, washer and 3/8" hardware to the large proper hardware and spacer locations. mounting plate. (See Fig. 8-b.) Make sure SMALL Fig. 8-c P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 24 3.5" PAXTON SUPPLIED IDLER - LOOSEN IDLER WHEN INSTALLING BELT ALTERNATOR PULLEY 3.33" SUPERCHARGER PULLEY WATER PUMP TENSIONER PULLEY POWER STEERING PUMP PULLEY CRANK PULLEY Fig. 8-e P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 25 (See Fig. 8-e.) Once you have the belt installed, re- tighten the bolt holding the idler in place. Fig. 8-f P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 26 This Page Left Intentionally Blank. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 27: Oil Drain Line

    Fig. 9-a ***NOTE*** When drilling and tapping the hole, be carefull not to damage the windage tray. The tray will be close when performing the following steps: P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 28 This Page Left Intentionally Blank. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 29: Oil Feed Line

    (See Fig. 10-b.) E. Drain the engine oil, install a new filter and refill the engine with fresh oil. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 10-1 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 30 This Page Left Intentionally Blank. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 10-2 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 31: Fuel Pump Wiring

    (-) terminal on the fuel Fig. 11-b pump. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 11-1 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 32 NECESSARY SO THAT THE FUEL PUMP WILL MOUNT EASILY ON THE FRAME RAIL Fig. 11-c BEND UP 90° BEND UP 90° 90° 90° SIDE VIEW IGNITION RELAY FUSE TAP MODIFICATIONS FINISHED MODIFIED FUSE Fig. 11-d P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 11-2 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 33: Inlet Duct/Air Box Installation

    #60 hose clamp. ***NOTE*** Be sure to install the MAF meter with the flow arrow pointing away from the air filter. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 12-1 28SEP04(4809642 v1.2)8.1GMTruck...
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  • Page 35: Charge Cooler Installation

    D. Trim the Ø3.88" end of the 90° silicone #44 HOSE CLAMPS elbow (see Fig. 13-b) to allow for hood clearance when the discharge duct is installed. Fig. 13-c TRIM .750 Fig. 13-b P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 13-1 28SEP04(4809642 v1.2)8.1GMTruck...
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  • Page 37: Supercharger Bypass Valve Installation

    E. Run a 5/8" hose from the previously installed breather assembly to the 5/8" barb installed into the 180° cast inlet duct. (See Fig. 3-c on page 3-1 and Fig. 14-a. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 14-1 28SEP04(4809642 v1.2)8.1GMTruck...
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  • Page 39: Surge And Reservoir Tank Installation

    (See Fig. 15-b.) Screw the 3/4" x 90° brass fittings into the top and bottom of the water reser- voir. Fig. 15-c P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 15-1 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 40 Mount the water pump/reservoir assem- bly to the previously installed bracket in the fender well using two 1/4-20 x .50 screws and washers. (See Fig. 15-d.) Fig. 15-d P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 15-2 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 41: Heat Exchanger Installation

    Center punch and drill a 9/32" hole. Use a P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 16-1 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 42 KEEP CLOSE TO TRANS- MISSION COOLER BUT WITHOUT CONTACT Fig. 16-d POSSIBLE SPACER LOCATION Fig. 16-c / Heat Exchanger Bracket Mounted Without Heat Exchanger Fig. 16-e P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 16-2 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 43: Charge Air Cooler Hose Routing

    Pull th hose up and through, then connect it to the driver’s side 90° fitting. E. Secure all hose ends with the supplied nylon clamps. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 17-1 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 44 Verify water flow. Do not let the pump run for extended periods (30 seconds or more) without water flow. Fill the charge air cooler tank until the level stabilizes. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 17-2 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 45: Water Pump Wiring

    Secure as necessary to avoid heat and sharp edges. Run the negative brown wire from the water pump to a clean ground. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 18-1 28SEP04(4809642 v1.2)8.1GMTruck...
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  • Page 47: Reflash Computer

    You only need to press the YES button once to start the programming cycle. The pro- gramming process takes 1 minute and 15 seconds to complete. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 19-1 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 48: Superchips Notice (Vehicles With On-Star)

    On GMC trucks, the exterior fuse panel should be located under the hood on the right hand side of the vehicle. It will be labeled Fuse Panel or similar. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 19-2 28SEP04(4809642 v1.2)8.1GMTruck...

  • Page 49: Final Assembly And Check

    Owner's Manual and RETURN THE Warranty REGISTRATION FORM within thirty (30) days of purchasing your super- charger system to qualify for the 3 year lim- ited warranty. P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 20-1 28SEP04(4809642 v1.2)8.1GMTruck...
  • Page 50 Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033 805 604-1336 . FAX (805) 604-1337 P/N: 4809642 ©2004 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 20-2 28SEP04(4809642 v1.2)8.1GMTruck...

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