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Owner’s Installation Guide for the
Paxton Automotive
Novi 1000 Supercharger
for the
2002 Dodge Ram 1500
Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033
888 9-PAXTON . FAX (805) 604-1337
DP/N: 4809641a - Ram 1500 v1.1 05/01/06
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FOREWORD his manual provides information on the installation, maintenance and service of the Paxton supercharger kit expressly designed for the 2002 4.7L Dodge Ram. Contact TPaxton 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
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TABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii TOOL & SUPPLY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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S U P E R C H A R G E R S 2002 4.7L DODGE RAM Installation Instructions 50 State Smog Legal, as per CARB EO #D-195-19 / #D-213-20 Congratulations on selecting the best performing and best backed automotive supercharger available today! Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner's Manual which includes the Automotive Limited Warranties Program and the Warranty Registration form. Paxton supercharge
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Section 1 INTRODUCTION 1.1 INTRODUCTION *** WARNING *** DO NOT attempt installation if any part(s) are missing ongratulations! You have purchased the from this kit. Failure to contact Paxton prior to beginning finest street Supercharger available for installation will result in a charge for any missing parts. Cthe 2002 4.7L Dodge Ram 1500. The Before starting the installation, we suggest centerpiece of this kit is the highly efficient your engine compartment be clean. You can and reliable Paxton
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• Never rely solely on a jack when working under a vehicle. Always use an approved set of jackstands to support the vehicle and place them under the recommended lift points. • When raising 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 in neutral and the parking brake is set. • Never remove the
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Section 2 FAN, COOLANT OVERFLOW, WASHER BOTTLE REMOVAL egin the initial preparation and disassembly C. Next, remove the windshield washer bottle and disconnect the plugs from the washer process by disconnecting the battery cables. pump and the warning sensor along with the B hoses and set it aside. You will replace this with a Paxton supplied washer bottle in a 2.1 FAN AND COOLANT OVERFLOW later stage of the installation. AND WINDSHIELD WASHER BOTTLE REMOVAL D. Remove the fan using a 36mm or a
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2.3 AIR FILTER REMOVAL A. Remove the small vent hose and hard plastic lines and set aside. This item will not be reused.. B. Remove the crankcase breaker hose from the air filter cover. (See Fig. 2.3-a.) C. Remove the air filter assembly (See Fig. 2.3-b) by first loosening the clamp at the throttle body. Remove the nut securing rear of air box using a 10mm socket. Lift assem- bly up and off the rubber mounts. (There are a number of different styles of air cleaner assemblies. Yours may differ fr
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Section 3 SUPERCHARGER INSTALLATION AND ASSEMBLY E. Detach wiring harness from the front of the 3.1 SUPERCHARGER MOUNTING engine. This allows space for the super- BRACKET PREPARATION charger mounting plate. (See Fig. 3.1-b.) A. Remove the factory accessory drive belt by rotating the tensioner using a 15mm wrench or socket. B. Remove the four bolts securing the oil filler neck using a 10mm deep socket, to be rein- stalled in a later step. (See Fig. 3.1-a.) Fig. 3.1-b F. Remove the three bolts sec
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3.2 SUPERCHARGER MOUNTING D. Bolt the A/C compressor back in place using BRACKET INSTALLATION the original hardware. You may need to bend the A/C line slightly to fit in corner of plate. A. Attach the rear support plate to the cylinder (See Fig. 3.2-c.) head using the supplied large bolt. (See Fig. 3.2-a.) Use at least two of the supplied 6mm bolts to align the bracket with the other mounting holes before tightening. Make sure the supplied O-ring is in place on the rear of the plate. A/C LINE F
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P/N: 4809641a ©2006 Paxton Automotive 3-3 All Rights Reserved, Intl. Copr. Secured 01MAY06 v1.1 Dodge Ram 1500(4809641av1.1)
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3.3 SUPERCHARGER INSTALLATION D. Fasten supercharger with six bolts. (See Figs. 3.3-c.) A. Test fit the supercharger in the mounting bracket. You may need to bend the A/C lines for a perfect fit. B. Measure and cut the supplied oil drain hose. Secure hose to drain fitting on supercharger using supplied clamp. (See Fig. 3.3-a.) Fig. 3.3-c E. Bolt the belt tensioner assembly to the front of the supercharger using a 7/32" allen wrench or socket (See Fig. 3.3-d.) Fig. 3.3-a C. Lower the supercharg
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H. Tighten the nut on the tensioner pulley using a 3/4" wrench. You will have to bend the upper- most a/c line up slightly to clear the belt. (See Fig. 3.3-g.) Also, bend it up slightly at the radi- ator end until it clears. (Your air conditioner lines may differ from the picture and some steps may not be needed.) TENSIONER NUT Fig. 3.3-e F. Install the supplied longer accessory drive belt. Use the factory belt routing with the exception of going around the supplied idler and S/C drive pulley.
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This Page Left Intentionally Blank. P/N: 4809641a ©2006 Paxton Automotive 3-6 All Rights Reserved, Intl. Copr. Secured 01MAY06 v1.1 Dodge Ram 1500(4809641a v1.1)
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Section 4 OIL DRAIN & FEED INSTALLATION E. Tap the hole using a greased 3/8"NPT tap. 4.1 OIL DRAIN INSTALLATION Go slowly and make sure the tap goes in A. From under the vehicle, mark and drill the straight. Stop periodically to clean and re- oil pan in preparation for the oil drain. (See grease the tap. Fig. 4.1-a.) F. Run the tap in only 2/3 of the way and check to see that the fitting will screw in leaving at least three threads exposed. G. Clean threads thoroughly and coat the fitting with
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D. Install the 90° fitting in the supercharger oil jet using teflon sealant. Support the jet with a 1/2" wrench as you tighten the fitting. Route the oil line. (See Fig. 4.2-b.) Fig. 4.2-b E. Attach the oil line, again supporting the oil jet at the top. (See Fig. 4.2-c.) Fig. 4.2-c P/N: 4809641a ©2006 Paxton Automotive 4-2 All Rights Reserved, Intl. Copr. Secured 01MAY06 v1.1 Dodge Ram 1500(4809641a v1.1)
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Section 5 AIR INLET & DISCHARGE INSTALLATION 5.1 AIR DISCHARGE INSTALLATION C. Attach the straight end of the fuel line to the fuel rail and the 90° end to the injector A. Locate the fuel pressure test port directly block. Tighten using a 9/16" wrench. (See under the dipstick on the passenger side fuel Fig. 5.1-c.) rail. (See Fig. 5.1-a.) Fig. 5.1-c Fig. 5.1-a 5.2 AIR INLET INSTALLATION B. Remove the plastic cap and place a rag over A. Attach the air filter housing using the sup- the port. Hol
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B. Attach the 180° plastic duct to the inlet of the supercharger using the sleeve and clamps provided. Fig. 5.2-b Fig. 5.2-c B. Next, route the flex hose to the 180° elbow attached to the supercharger, and tighten the clamps. (See Figs. 5.2-b, 5.2-c.) P/N: 4809641a ©2006 Paxton Automotive 5-2 All Rights Reserved, Intl. Copr. Secured 01MAY06 v1.1 Dodge Ram 1500(4809641a v1.1)
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Section 6 ENGINE MANAGEMENT UNIT INSTALLATION 6.1 ENGINE MANAGEMENT UNIT INSTALLATION A. Locate the factory ECM. It is located on the passenger side of the engine compartment at the back of the engine compartment. There are two.silver boxes. The one that is attached to the firewall is where you will attach the Paxton Engine Controller. There are three plugs on it. You want the one with the black plug. Look in the assembly draw- ings and find drawing #1017718. This draw- ing gives the pin locatio
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J Locate the crank case breather hose that was originally attached to the factory air filter assembly. Towards the back of the engine, there is a tube that runs across from the dri- ver’s side to the passenger’s side. On the driver’s side, there is a TEE coupler. This was originally connected to the factory air box. K. Connect the supplied length of hose to the 1/2" nipple that is installed in the air intake assembly, and it would be located on most vehicles next to the compressor bypass fit- t
