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Owner’s Installation Guide for the
Paxton Automotive
Novi 1000 Supercharger
for the
2000/2001 Dodge Durango
Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033
888 9-PAXTON . FAX (805) 604-1337
DP/N: 4809632 - V1.0 09/25/02
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FOREWORD his manual provides information on the installation, maintenance and service of the Paxton supercharger kit expressly designed for the 2000-2001 4.7L Dodge Durango. TContact 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 ben
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TABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv RECOMMENDED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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RECOMMENDED TOOLS FOR INSTALLATION: 1. Metric and Standard sockets sets 2. Metric and Standard combination wrenches 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 P/N: 4809632 iv ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0)
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Section 1 INTRODUCTION installation will result in a charge for any missing parts. Before starting the installation, we suggest ongratulations! You have purchased the your engine compartment be clean. You can finest street Supercharger available for clean the engine and compartment with a pres- Cthe 2000-2001 4.7L Dodge Durango. sure washer (such as those used at self serve The centerpiece of this kit is the highly effi- car washes) and a safe-for-aluminum cient and reliable Paxton Automotive Co
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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 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 in neutral and the parking brake is set. • Never remove the
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Section 2 INITIAL PREPARATION AND DISASSEMBLY d. Remove the fan using a 36mm or a large egin the initial preparation and disassembly crescent wrench. Hitting the wrench with a process by disconnecting the battery cables. brass hammer will break it loose. The fan B unscrews counter-clockwise as viewed from 2.1 FAN AND FAN SHROUD REMOVAL the front of the engine. (See Fig. 2-3.) a. Remove the plastic panel under the front of the vehicle by prying out the seven plastic clips. Drain the radiator. b.
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i. Attach the supplied coolant hoses being careful to get the orientation correct. If nec- essary, hold the original metal lines in place to see which hose goes with what fitting. Re-use the factory spring type clamps removed from both ends of the original metal lines at the splice point. (See Fig. 2-8.) Fig. 2-5 f. Remove both metal coolant lines and their mounts that run across the top of the engine. g. On the passenger side of the engine, remove the uppermost hose fitting that was connect- e
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Fig. 2-12 Fig. 2-10 p. Detach the cruise control cable at the throttle body. (See Fig. 2-13.) Using a 10mm socket, m. Remove the three bolts securing the A/C unbolt the cruise control actuator and seper- compressor using a 13mm and 15mm sock- ate it from its mounting bracket. et. Lift compressor up and let it rest on top of the valve cover. n. Using a 1-1/8” wrench or socket, remove the large bolt on the front of the cylinder head. (See Fig. 2-11.) Fig. 2-13 q. Once you have removed the two 10m
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r. Re-route the cruise control cable behind the A/C lines at the firewall. Unbolt the comput- er from the inner fender panel using an 8mm socket and route the cruise control cable behind it. (See Fig. 2-15.) Fig. 2-17 v. Bolt the oil filler neck to the plate using the supplied hardware. (See Fig. 2-18.) Re- attach the PCV hose. Fig. 2-15 s. Re-assemble the actuator onto the new bracket. (See Fig. 2-16.) Fig. 2-18 w. Bolt the A/C Compressor back in place using the original hardware. You may need
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x. Bolt the front plate to the rear plate using a z. From under the vehicle mark and drill the 9/16”, 3/4” and a 17mm socket (See Fig. oil pan in preparation for the oil drain. (See 2-20.) Check the tightness of the small idler Fig. 2-23.) On the front of the pan, measure attached to the plate with a 9/16” socket. and mark the center. Now find the center- point between the pan rail. Coat a 3/16” drill bit with grease and drill the hole. Coat the supplied punch with anti-seize or heavy grease and
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This Page Left Intentionaly Blank. P/N: 4809632 2-6 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0)
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Section 3 SUPERCHARGER INSTALLATION AND ASSEMBLY d. Fasten supercharger with 6 bolts and attach 3.1 SUPERCHARGER INSTALLATION: drain hose to fitting on pan. (See Figs. 3-3, a. Test fit the supercharger in the mounting 3-4.) bracket. You may need to bend the A/C lines for a perfect fit. b. Measure and cut the supplied oil drain hose to 22-1/2” long. Secure hose to drain fitting on supercharger using supplied clamp. (See Fig. 3-1.) Fig. 3-3 Fig. 3-1 c. Lower the supercharger into place making sure
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e. Bolt the belt tensioner assembly to the front of the supercharger using a 7/32” allen wrench or socket (See Fig. 3-5.) Fig. 3-7 h. Under the vehicle, near the oil filter, you will find the oil pressure sender. Unplug and Fig. 3-5 remove using an oil pressure sender socket available at most auto parts stores. Install f. Install the supercharger drive belt and ten- the brass TEE fitting using Teflon sealant on sion by turning the leadscrew clockwise the threads. (See Fig. 3-8.) The sender is us
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Fig. 3-11 Fig. 3-9 n. Attach the discharge tube so the injectors are k. Attach the oil line, again supporting the oil situated under the throttle linkage. (See Fig. jet at the top. (See Fig. 3-10.) 3-12.) Fig. 3-12 Fig. 3-10 o. Attach the straight end of the fuel line to the l. Re-install the plastic undertray reusing the fuel rail and the 90 deg. end to the injector seven plastic fasteners. block. Tighten using a 9/16” wrench. (See m. Locate the fuel pressure test port directly Fig. 3-13.) und
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q. Route the red and black wires along with the small four wire harness back and along the firewall, but do not secure. The relay will be mounted to the stud just above and to the side of the brake booster. (See Figure 3-14.) Fig. 3-16 *****DURANGO ONLY***** Engine Management installation, please refer to assembly drawing #1017718. This shows the pin locations and correct connector on the factory ECM. Mount Paxton’s Engine Control Unit to the cover of the power distribution box in the engine co
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Section 4 FINAL CHECK OUT AND START UP his section covers pre-start checks and inspec- Ttions, as well as initial start-up. *****CAUTION***** 4.1 INSPECT THE FOLLOWING: See the supercharger service manual included in your kit a. Wires, harnesses and electrical connections. for information on supercharger servicing and mainte- Are all items properly dressed, connected nance, belt tightening, troubleshooting, special tuning, and secured? If any electrical connections and warranty information. have
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This Page Left Intentionaly Blank. P/N: 4809632 3-6 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0)
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Appendix P/N: 4809632 A-1 ©2002 Paxton Automotive All Rights Reserved, Intl. Copr. Secured 25SEP02 v1.0 Dodge Durango(4809632v1.0)
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APPENDIX INDEX APPENDIX NO. Pg. PART NO. DESCRIPTION 1 A-3 1201216 KIT CONTENTS 2 A-4 1016416 ASY, S/C NOVI 1000 FORWARD ROTATION 3 A-5 1016623 ASY, S/C MTG BRKT 4 A-6 1015934 ASY, AIR INTAKE 5 A-71017416 ASY, BELTTENSIONER 6 A-8 1019342 ASY, S/C OIL FEED HOSE 7A-91019343 ASY, S/C OILDRAIN HOSE 8 A-10 1020116 ASY, AIR DISCHARGE WITH FUEL INJECTION 9 A-111020217ASY, HEATER HOSE RELOCATION 10 A-12 1015511 ASY, COMPRESSION BYPASS 11 A-13 1020216 ASY, CRUISE CONTROL RELOCATION 12 A-
