Owner’s Installation Guide for the Paxton Automotive Novi ...2)1.pdfhave any comments or suggestions regarding this manu-al at (805) 604-1336 Paxton Automotive Corporation 1300 Beacon

DP/N: 4809632 - V1.0 09/25/02

Owner’s Installation Guide for the

Paxton AutomotiveNovi 1000 Supercharger

for the

2000/2001 Dodge DurangoPaxton Automotive . 1300 Beacon Place . Oxnard CA 93033

888 9-PAXTON . FAX (805) 604-1337

P/N: 4809632©2002 Paxton AutomotiveAll Rights Reserved, Intl. Copr. Secured25SEP02 v1.0 Dodge Durango(4809632v1.0)

ii

FOREWORD

This manual provides information on the installation, maintenance and service of thePaxton supercharger kit expressly designed for the 2000-2001 4.7L Dodge Durango.Contact Paxton Automotive Corporation for any additional information regarding

this kit and any of these modifications at (805) 604-1336 7:00am-3:30pm PST.An understanding of the information contained herein will help novices, as well as experi-enced technicians, to correctly install and receive the greatest possible benefit from theirPaxton supercharger. When reference is made in this manual to a brand name, number, spe-cific tool or technique, an equivalent product may be used in place of the item mentioned.All information, illustrations and specifications contained herein are based on the latestproduct information available at the time of this publication. All rights reserved to makechanges at any time without notice.

© 2002 PAXTON AUTOMOTIVEAll rights recerved. No parts 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: 4809632©2002 Paxton Automotive

All Rights Reserved, Intl. Copr. Secured25SEP02 v1.0 Dodge Durango(4809632v1.0)

iii

TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

RECOMMENDED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

2.0 INITIAL PREPARATION AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

3.0 SUPERCHARGER INSTALLATION AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .3-1

4.0 FINAL CHECK-OUT AND START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

APPENDIX:

#1201216 KIT, PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

#1016416 ASY, S/C NOVI 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

#1016623 ASY, S/C MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

#1015934 ASY, AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

#1017416 ASY, BELT TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

#1019342 ASY, OIL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

#1019343 ASY, OIL DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

#1020116 KIT, AIR DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

#1020217 KIT, HEATER HOSE RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9

#1015511 ASY, COMPRESSOR BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10

#1020216 ASY, CRUISE CONTROL RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . .A-11

#1017718 ASY, FUEL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12

#1020218 ASY, WASHER HOSE MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . .A-13

P/N: 4809632©2002 Paxton AutomotiveAll Rights Reserved, Intl. Copr. Secured25SEP02 v1.0 Dodge Durango(4809632v1.0)

iv

RECOMMENDED TOOLSFOR

INSTALLATION:

1. Metric and Standard sockets sets

2. Metric and Standard combinationwrenches

3. Phillips and common screw drivers

4. 12” crescent wrench or 36mm open end wrenches

5. Pliers

6. Wire cutters and wire crimping Tool

7. Hose cutters

8. 1/8” drill bit and hand drill

9. Allen wrenches

10. Small heat source

11. 3/8 Tap NPT

1-1 P/N: 4809632©2002 Paxton Automotive


Section 1INTRODUCTION

Congratulations! You have purchased thefinest street Supercharger available forthe 2000-2001 4.7L Dodge Durango.

The centerpiece of this kit is the highly effi-cient and reliable Paxton Automotive Corp.NOVI-1000 supercharger. A mechanicallydriven (by belt) centrifugal blower (super-charger).This kit comes with all of the parts you’ll needfor a successful installation. The operationsrequired have been grouped in order ofsequence. Photos and drawings accompany thetext, allowing quick orientation and parts iden-tification.Installation requires a selection of tools whichare listed in a table at the end of this section.We also suggest that you obtain a Dodge shopmanual and become familiar with the details ofyour cars systems. Manuals may be obtainedfrom your local Dodge dealer or you can orderone from Helm publications at (800)782-4356.For best results follow the instructions closelyand in sequence. The average installation timefor this kit is 8-10 hours. Your actual installa-tion time will depend on skill level and work-ing conditions. The estimate does not includetime for initial vehicle inspection, cleaning,fine tuning or troubleshooting. Before evenpicking up a wrench, read this entire manual.We are available for technical assistance at(805) 604-1336, 7am-3:30pm pacific time.After reading the manual, verify that all majorassembly groups are present in the main kitbox. You should have ample space to layoutthe components. As you remove a box or bagfrom the main kit, note the identification labeland compare it with the parts list. Please checkthe box for small parts.Paxton makes every effort to insure that allparts are included in the box. However, if youdiscover any missing or mislabeled parts,please contact Paxton by phone for service.

*****WARNING*****DO NOT attempt installation if any part(s) are missingfrom this kit. Failure to contact Paxton prior to beginning

installation will result in a charge for any missing parts.

Before starting the installation, we suggestyour engine compartment be clean. You canclean the engine and compartment with a pres-sure washer (such as those used at self servecar washes) and a safe-for-aluminumcleaner/degreaser. Cover the distributor with aplastic bag to prevent water from entering.

*****CAUTION*****We do not recommend proceeding with the kit installa-tion unless your vehicle is within normal operatingparameters.

You are undoubtedly enthusiastic about gettingstarted on your project, but take just a littlemore time to insure that your safety is notjeopardized. A moment’s lack of attention canresult in an accident, as can failure to observecertain simple safety precautions. The possibil-ity of an accident will always exist, and thefollowing points should not be considered acomprehensive list of all dangers. Rather, theyare intended to make you aware of the risk andto encourage a safety conscious approach to allwork you do on your vehicle.

We look forward to hearing from you, particularly if youhave any comments or suggestions regarding this manu-al at (805) 604-1336

Paxton Automotive Corporation1300 Beacon PlaceOxnard, CA 93033E-mail Address [email protected].

***** NOTE *****Throughout these procedures the word “discard” is usedperiodically in relationship to items that will no longer beutilized in conjunction with the supercharger installation.It is recommended that these items be saved for futureuse should it become necessary.

1-2P/N: 4809632©2002 Paxton AutomotiveAll Rights Reserved, Intl. Copr. Secured25SEP02 v1.0 Dodge Durango(4809632v1.0)

• Never rely solely on a jack when working under a vehicle. Alwaysuse an approved set of jackstands to support the vehicle and placethem under the recommended lift points.

• When jacking a vehicle, make sure it is on a level surface, prefer-ably concrete or asphalt. The transmission should be in “PARK” or“FIRST”, the parking brake engaged and the wheels blocked.

• Never start the car without first verifying that the transmission is inneutral and the parking brake is set.

• Never remove the radiator cap while the engine is hot.

• Always wear eye protection when using power tools such as drills,saws, grinders, etc., or when working under a vehicle.

• Never smoke, use an open flame, or have spark-producing itemsaround gasoline or flammable solvents. Always have a fire extin-guisher rated for chemical and electrical fires handy when workingon motor vehicles.

• Run engines only in well ventilated areas. Carbon monoxide, gaso-line, and solvent vapors are colorless and sometimes odorless. Thesecan asphyxiate or explode without warning.

• Always disconnect at least the negative (-) or ground terminal of thebattery when doing any electrical, fuel system, or underdash work.

We look forward to hearing from you, particularly if you have any commentsor suggestions regarding this manual.

Paxton Automotive makes every effort to insure that all parts areincluded in the box, but mistakes do occur. If you discover that you are

missing any part, or that a part is damaged in transit, please callPaxton Automotive for service. DO NOT attempt installation if anypart(s) are missing from this kit. Failure to contact Paxton prior tobeginning installation will result in a charge for any missing parts.



Section 2INITIAL PREPARATION AND DISASSEMBLY

Begin the initial preparation and disassemblyprocess by disconnecting the battery cables.

2.1 FAN AND FAN SHROUD REMOVALa. Remove the plastic panel under the front of

the vehicle by prying out the seven plasticclips. Drain the radiator.

b. Remove the upper fan shroud/reservoir byfirst disconnecting the three elctrical plugsand two small hoses on the passenger side.(See Fig 2.1.)

Fig. 2-1

c. Disconnect the coolant overflow hose at thefiller cap. (See Fig. 2-2.) Make sure toclamp or plug this hose to avoid coollantloss. Remove the two bolts securing theshroud using a 10mm socket. Lift up andremove shroud.

Fig. 2-2

d. Remove the fan using a 36mm or a largecrescent wrench. Hitting the wrench with abrass hammer will break it loose. The fanunscrews counter-clockwise as viewed fromthe front of the engine. (See Fig. 2-3.)

Fig. 2-3

2.2 AIR FILTER REMOVAL

Fig. 2-4

e. Remove the air filter assembly (See Fig. 2-4). by first loosening the clamp at the throt-tle body, then disconnect the “S” shaped pcvhose. (See Fig. 2-5.) Remove the nut secur-ing rear of air box using a 10mm socket.Lift assembly up and off the rubber mounts.


f. Remove both metal coolant lines and theirmounts that run across the top of the engine.

g. On the passenger side of the engine, removethe uppermost hose fitting that was connect-ed to the coolant hose using a 3/4” wrench.

h. Using Teflon sealant, install the supplied 45deg. brass fitting so it points back and upslightly. Thread the straight hose fitting intothis using Teflon sealant. (See Figs. 2-6, 2-7.)

Fig. 2-5

Fig. 2-6

Fig. 2-7

i. Attach the supplied coolant hoses beingcareful to get the orientation correct. If nec-essary, hold the original metal lines in placeto see which hose goes with what fitting.Re-use the factory spring type clampsremoved from both ends of the originalmetal lines at the splice point. (See Fig. 2-8.)

Fig. 2-8

j. Detach wiring harness from the front of theengine. (See Fig. 2-9.)

Fig. 2-9

k. Remove the fan belt by rotating the tension-er using a 15mm wrench or socket.

l. Remove the four bolts securing the oil fillerneck using a 10mm deep socket. (See Fig. 2-10.)



Fig. 2-10

m. Remove the three bolts securing the A/Ccompressor using a 13mm and 15mm sock-et. Lift compressor up and let it rest on topof the valve cover.

n. Using a 1-1/8” wrench or socket, remove thelarge bolt on the front of the cylinder head.(See Fig. 2-11.)

Fig. 2-11

o. Trim the plastic hose that connects to the oilfiller by cutting it off just before the secondbarb (approx 3/4”). Do not remove the sec-ond barb as this keeps the hose from comingoff under boost. (See Fig. 2-12.) Install thesupplied longer hose.

Fig. 2-12

p. Detach the cruise control cable at the throttlebody. (See Fig. 2-13.) Using a 10mm socket,unbolt the cruise control actuator and seper-ate it from its mounting bracket.

Fig. 2-13

Fig. 2-14

q. Once you have removed the two 10mm nutssecuring the cable to the actuator, pull outthe small pin using a pair of pliers. (See Fig.2-14.)


r. Re-route the cruise control cable behind theA/C lines at the firewall. Unbolt the comput-er from the inner fender panel using an 8mmsocket and route the cruise control cablebehind it. (See Fig. 2-15.)

Fig. 2-15

s. Re-assemble the actuator onto the new bracket.(See Fig. 2-16.)

Fig. 2-16

t. Bolt the bracket to the fender panel usingthe two existing holes next to the largeopening. The plug portion should pointstraight down. Re-attach the cable at thethrottle body. Re-attach the computer.

u. Attach the rear support plate to the cylinderhead using the supplied large bolt. (See Figure2-17) Use at least two of the supplied 6mmbolts to align the bracket with the othermounting holes before tightening. Make surethe supplied O-ring is in place on the rear ofthe plate.

Fig. 2-17

v. Bolt the oil filler neck to the plate using thesupplied hardware. (See Fig. 2-18.) Re-attach the PCV hose.

Fig. 2-18

w. Bolt the A/C Compressor back in placeusing the original hardware. You may needto bend the A/C line slightly to fit in cornerof plate. (See Fig. 2-19.)

Fig. 2-19

A/C COMPRESSOR

A/C LINE



x. Bolt the front plate to the rear plate using a9/16”, 3/4” and a 17mm socket (See Fig. 2-20.) Check the tightness of the small idlerattached to the plate with a 9/16” socket.

Fig. 2-20

y. Install the new Accessory drive belt. (SeeFig. 2-21.) Re-install the fan. (See Fig. 2-22.)

Fig. 2-21

Fig. 2-22

z. From under the vehicle mark and drill theoil pan in preparation for the oil drain. (SeeFig. 2-23.) On the front of the pan, measureand mark the center. Now find the center-point between the pan rail. Coat a 3/16” drillbit with grease and drill the hole. Coat thesupplied punch with anti-seize or heavygrease and drive it in only halfway using anair chisel with a blunt tip. Do not use a ham-mer. Do not go in all the way or you willdamage internal engine components. Nowyou must cut off the front portion of thehardened steel punch with either a grinder ora cut off wheel. Continue driving the punchin, and expand the hole until it measuresØ9/16". Go slow with this. It will affectyour tapped hole if you go too far. Now tapthe hole using a greased 3/8 NPT tap. Goslowly and make sure the tap goes instraight. Stop periodically to clean and re-grease the tap. Run the tap in only 2/3 of theway and check to see that the fitting willscrew in leaving at least three threadsexposed. Clean threads thoroughly, coat fit-ting with Teflon sealant and install.

Fig. 2-23


This Page Left Intentionaly Blank.



Section 3SUPERCHARGER INSTALLATION AND ASSEMBLY

3.1 SUPERCHARGER INSTALLATION:a. Test fit the supercharger in the mounting

bracket. You may need to bend the A/C linesfor a perfect fit.

b. Measure and cut the supplied oil drain hoseto 22-1/2” long. Secure hose to drain fittingon supercharger using supplied clamp. (SeeFig. 3-1.)

Fig. 3-1

c. Lower the supercharger into place makingsure that the oil drain hose goes over theA/C line. (See Fig. 3-2.)

Fig. 3-2

d. Fasten supercharger with 6 bolts and attachdrain hose to fitting on pan. (See Figs. 3-3,3-4.)

Fig. 3-3

Fig. 3-4

Make sure the drain hose is routed smoothly downhill without dips or kinks. Drain restriction maycause supercharger failure.


e. Bolt the belt tensioner assembly to the frontof the supercharger using a 7/32” allenwrench or socket (See Fig. 3-5.)

Fig. 3-5

f. Install the supercharger drive belt and ten-sion by turning the leadscrew clockwiseusing a 10mm socket. The belt should bevery tight as it will stretch after being runand loosen up. (See Fig. 3-6)

Fig. 3-6

g. Tighten the nut on the tensioner pulley using a3/4” wrench. You will have to bend the upper-most a/c line up slightly to clear the belt. (SeeFig. 3-7.) Also, bend it up slightly at the radia-tor end until it clears.

Fig. 3-7

h. Under the vehicle, near the oil filter, youwill find the oil pressure sender. Unplug andremove using an oil pressure sender socketavailable at most auto parts stores. Installthe brass TEE fitting using Teflon sealant onthe threads. (See Fig. 3-8.) The sender isnow re-installed pointing toward the front ofthe vehicle.

Fig. 3-8

i. Using Teflon sealant, install the straight fit-ting into the remaining port and attach oneend of the oil line using a 9/16” wrench.Route the oil line up and across the top ofthe engine toward the supercharger.

j. Install the 90 deg. fitting in the superchargeroil jet using Teflon sealant. Support the jetwith a 1/2” wrench as you tighten the fitting.Next, route the oil line. (See Fig. 3-9.)



Fig. 3-9

k. Attach the oil line, again supporting the oiljet at the top. (See Fig. 3-10.)

Fig. 3-10

l. Re-install the plastic undertray reusing theseven plastic fasteners.

m. Locate the fuel pressure test port directlyunder the dipstick on the passenger side fuelrail. (See Fig. 3-11.) Remove the plastic capand place a rag over the port. Hold the ragwith one hand and depress the valve with asmall screwdriver to relieve fuel systempressure. Use caution when prforming thisstep to avoid getting fuel in your eyes.Remove the valve core using a small screw-driver or valve core removal tool.

Fig. 3-11

n. Attach the discharge tube so the injectors aresituated under the throttle linkage. (See Fig.3-12.)

Fig. 3-12

o. Attach the straight end of the fuel line to thefuel rail and the 90 deg. end to the injectorblock. Tighten using a 9/16” wrench. (SeeFig. 3-13.)

Fig. 3-13


q. Route the red and black wires along with thesmall four wire harness back and along thefirewall, but do not secure. The relay will bemounted to the stud just above and to theside of the brake booster. (See Figure 3-14.)

Fig. 3-14

r.) Attach the ground from the relay and thePaxton engine management unit to the samestud. Connect the red wire from the fueler toterminal 87 on the relay. Route the wiresfrom the relay back toward the fuse box.Using the supplied blue shrink type buttconnector, splice the green wire into thegreen wire with the black stripe. (See Fig. 3-15.) This will be the trigger for the relay.

Fig. 3-15

s. Using a heat gun or lighter, apply heat untilthe connector shrinks. Attach the red to themain power terminal in the fuse box (largeblack wire). (See Fig. 3-16.) Cover the wireswith the black splitloom.

t. Route the small four wire harness across thefirewall to the factory computer.

Fig. 3-16

*****DURANGO ONLY*****Engine Management installation, please refer to assemblydrawing #1017718. This shows the pin locations andcorrect connector on the factory ECM. Mount Paxton’sEngine Control Unit to the cover of the power distributionbox in the engine compartment. Route the 8-wire har-ness across the firewall of the engine compartment tothe factory ECM. Locate the black connector on the ECMand strip back enough of the factory tape and split loomto allow locating the pins and colored wires in the factoryharness. Make your cuts in the harmess approximately2” to 3” from the plug to the ECM. This allows workingroom to make the connection from the Paxton suppliedEngine Management Unit to the factory ECM. (AlthoughPaxton supplies 8 butt connectors in the kit to make theconnections between the Engine Control Unit and theECM we recommend you solder the connection in placeof the supplied connectors, assuring a good connection.)If you use the connectors, be sure to carefully crimpthem to make a good connection.

u. Route the injector harness straight acrossand over the engine. Connect to the twoinjectors in the discharge tube.

v. Re-install the fan shroud and re-connect allelectrical connections. Install the supplied90°. rubber elbow on the washer pump dis-charge port nearest the dual idler pulley. Re-connect the remaining pump as stock. (SeeFig. 3-17.)

Fig. 3-17y. Install the air intake assembly. Connect the

“S” shaped hose to the small hose barb.Connect the compressor bypass to the largerhose barb and secure.

z. Refill the radiator with coolant.Congratulations - you are done.



Section 4FINAL CHECK OUT AND START UP

This section covers pre-start checks and inspec-tions, as well as initial start-up.

4.1 INSPECT THE FOLLOWING:a. Wires, harnesses and electrical connections.

Are all items properly dressed, connectedand secured? If any electrical connectionshave been dis-connected, re-connect thembefore you start your vehicle.

b. Hoses, lines and fittings. Are all items prop-erly dressed, connected and secured?

c. Fasteners, brackets, and clamps. Are allitems properly installed and tightened?

d. Fluid levels. Is the radiator coolant and theengine oil at their proper levels? Are thereany fluid leaks?

e. Belt(s). Is the serpentine drive belt (oraccessory drive and supercharger drive belts,depending on the requirement of your vehi-cle) properly installed, aligned and ten-sioned?

4.2 Perform the following:a. Cycle the ignition key from “off “ to “on”

position three (3) times at fifteen (15) sec-ond intervals. Afterwards, check the entirefuel system for any leaks.

b. Start the car. Verify that the oil pressure iswithin the normal operating range. Listenclosely. The engine should idle and soundthe same as it did before you began theinstallation. Shutdown the engine, discon-nect the oil feed line from the blower.Remove the oil jet from the blower. Blowthrough the oil jet to ensure there is noblockage or foreign matter plugging it. Re-install oil jet and oil feed line and proceed.

c. Allow the engine to come to normal operat-ing temperatures. Bleed the cooling systemand top off as necessary.

4.2 Check for the following:a. Fuel leaksb. Fluid leaksc. Belt slippaged. Throttle response

*****CAUTION*****See the supercharger service manual included in your kitfor information on supercharger servicing and mainte-nance, belt tightening, troubleshooting, special tuning,and warranty information.

Now that the work is done, it’s time to enjoy yourlabor of love. Take the car out on the roadand let it flex it’s muscles, but remember, theresponse and performance will now be differentfrom that to which you have been accustomed.Have fun!


This Page Left Intentionaly Blank.

A-1 P/N: 4809632©2002 Paxton Automotive


Appendix

A-2P/N: 4809632©2002 Paxton AutomotiveAll Rights Reserved, Intl. Copr. Secured25SEP02 v1.0 Dodge Durango(4809632v1.0)

APPENDIX INDEX

APPENDIX NO. Pg. PART NO. DESCRIPTION

1 A-3 1201216 KIT CONTENTS2 A-4 1016416 ASY, S/C NOVI 1000 FORWARD ROTATION3 A-5 1016623 ASY, S/C MTG BRKT4 A-6 1015934 ASY, AIR INTAKE5 A-7 1017416 ASY, BELT TENSIONER6 A-8 1019342 ASY, S/C OIL FEED HOSE7 A-9 1019343 ASY, S/C OIL DRAIN HOSE8 A-10 1020116 ASY, AIR DISCHARGE WITH FUEL INJECTION9 A-11 1020217 ASY, HEATER HOSE RELOCATION10 A-12 1015511 ASY, COMPRESSION BYPASS11 A-13 1020216 ASY, CRUISE CONTROL RELOCATION12 A-14 1017718 ENGINE MANAGEMENT WIRING DIAGRAM13 A-15 1020218 ASY, WASHER HOSE MODIFICATION



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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 20

1016

416

1016

623

1015

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1017

416

1019

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1019

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116

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217

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616

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x 13


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Documents

Owner’s Installation Guide for the Paxton Automotive Novi ...2)1.pdfhave any comments or suggestions regarding this manu-al at (805) 604-1336 Paxton Automotive Corporation 1300 Beacon