owner’s installation guide for the paxton automotive novi ... · we suggest that you obtain a...

DP/N: 4809629 - V2.0 10/22/02

Owner’s Installation Guide for the

Paxton AutomotiveNovi 1000 Supercharger

WITH PAXTON HEADERSfor the

2000/2001Plymouth ProwlerPaxton Automotive . 1300 Beacon Place . Oxnard CA 93033

(805 604-1336 . FAX (805) 604-1337

P/N: 4809629©2003 Paxton AutomotiveAll Rights Reserved, Intl. Copr. Secured22OCT02 v2.0 PlymProwler(4809629v2.0)

ii

FOREWORD

Proper installation of this supercharger kit requires general auto-motive mechanic knowledge and experience. Please browsethrough each step of this instruction manual prior to beginningthe installation to determine if you should refer the job to a pro-fessional installer/technician. Please call Paxton Automotive forinstallers in your area.

© 2003 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: 4809629©2003 Paxton Automotive

All Rights Reserved, Intl. Copr. Secured22OCT02 v2.0 PlymProwler(4809629v2.0)

iii

TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iiTABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iiiIMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv1.1 PROWLER HEADER INSTALLATION INSTRUCTIONS 1-12.1 DISASSEMBLY 2-13.1 NOVI 1000 3-14.1 INSTALLING OIL FEED FITTINGS 4-15.1 THE POWER STEERING SYSTEMMODIFICATION 5-16.1 MODIFY AND RELOCATE THE ALTERNATOR/ INSTALL BELT TENSIONERS 6-17.1 INSTALL THE MOUNTING BRACKET ASSEMBLY AND SUPERCHARGER 7-18.1 FAN MODIFICATION 8-19.1 FUEL LINE MODIFICATION 9-110.1 INSTALLING THE BOOST GAUGE (APPENDIX 1018105) 10-111.1. FUEL SYSTEM MODIFICATION 11-112.1 INSTALLING THE AIR INTAKE ASSEMBLY (APPENDIX 1016043) 12-113-1 FINAL CHECK-OUT PROCEDURES 13-1APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Drawing No. 1201711 Kit, Parts List 1997-2000 Prowler . . . . . . . . . . . . . . . . . . . . . . . . .A-2Drawing No. 1011811 Asy, Novi 1000 Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Drawing No. 1016034 Asy, S/C Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Drawing No. 1016032 Asy, A/C Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5Drawing No. 1016033 Asy, Tensioner Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6Drawing No. 1016043 Asy, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7Drawing No. 1016046 Asy, Power Steering Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8Drawing No. 1016049 Asy, Air Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9Drawing No. 1016055 Asy, Radiator Tube Modification . . . . . . . . . . . . . . . . . . . . . . . . .A-10Drawing No. 1019347 Asy, Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-11Drawing No. 1019346 Asy, Oil Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12Drawing No. 1015513 Asy, Compressor Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-13Drawing No. 1016069 Asy, Alternator Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-14Drawing No. 7000180 Diag, Power Steering Line Mod . . . . . . . . . . . . . . . . . . . . . . . . . .A-15Drawing No. 1017717 Asy, Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-16Drawing No. 1018105 Asy, Gauge Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-17Drawing No. 7000100 Asy, Diag, Power Steering Line Mod . . . . . . . . . . . . . . . . . . . . . .A-18Drawing No. 7000105 Asy, Diag, Thermostat Housing Mod . . . . . . . . . . . . . . . . . . . . . .A-19Drawing No. 7000110 Asy, Belt Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-20Drawing No. 7000110 Diag, Wiring Fuel Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-21Drawing No. 7000145 Diag, Relay Witing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-22


iv

2000-2001 Plymouth Prowler

IMPORTANT NOTESCongratulations! You have purchased the finest street supercharger available for the 2000-2001 PlymouthProwler. The centerpiece of this kit is the High Efficiency Paxton NOVI 1000 Supercharger, a mechanical-ly driven centrifugal blower.

This kit comes with all of the parts you will need to install the supercharger. This instruction manual hasbeen grouped in order of sequence, with photographs and drawings to illustrate the text. This will allowyou quick part identification and orientation.

The installation will require metric and SAE wrenches and sockets, Phillips and standard head screw-drivers, pliers, wire cutters and a wire crimping tool, a selection of pails or buckets for the collection andstorage of motor fluids, an air impact gun (and air compressor), and a 3/8” NPT tap.

We suggest that you obtain a Prowler shop manual and become familiar with the details of your car’s sys-tem. Manuals may be obtained from your local Plymouth dealer, or you can order one from HelmPublications at (800) 782-4356. If your vehicle is not within the normal operating parameters, we do notrecommend the use of a supercharger.

For best results, we suggest that you read this entire manual before beginning. Be familiar with the processand identify the areas of the car that you will be working on. The average installation time is 14-16 hours.Your actual install time will depend on your personal skill level, experience installing superchargers, work-ing conditions, and preparedness for the job at hand. This estimate does not include time for the initialvehicle inspection, cleaning, fine tuning, or troubleshooting. Once again, before picking up a wrench, readthis entire manual. We are available for technical assistance at (805) 604-1336 between the hours of 7am-3PM Monday through Friday PST.

After reading this manual, verify that all major assembly groups are present in the main kit box. Youshould have ample space to lay out the components. As you remove a box or bag from the main kit, notethe identification label and compare it with the parts list.

Paxton Automotive makes every effort to insure that allparts are included in the box, but mistakes do occur. If

you discover that you are missing any part, orthat a part is damaged in transit, please call

Paxton Automotive for service. DO NOT attempt installationif any part(s) are missing from this kit. Failure to contact

Paxton prior to beginning installation willresult in a charge for any missing parts.

Before starting the installation, we suggest that the engine and engine compartment be clean. You canclean the engine with a pressure washer, such as those used at self-serve car washes. Use a safe-for-alu-minum cleaner/degreaser, and cover the distributor with a plastic bag to prevent water from entering.

P/N: 4809629©2003 Paxton Automotive


v

You are undoubtedly eager to get started with your project, but take a little more time to insure that yoursafety is not in jeopardy. A moment’s lack of attention can result in an accident, as can failure to observesome simple safety precautions. The possibility of an accident always exists, and the following pointsshould not be considered a comprehensive list of all of the dangers. They are only intended to make youaware of the risks and to encourage you to take a safety conscious approach to all of the work that you willbe doing on your vehicle.

• 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.These can 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 comments or suggestionsregarding this manual.


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1-1 P/N: 4809629©2003 Paxton Automotive


Section 1HEADER INSTALLATION

1.1 PROWLER HEADER INSTALLATIONINSTRUCTIONSA. Raise vehicle approximately 2 feet off the

ground, preferably using a lift. The only wayto install the headers is to work from thebottom, so use either ramps or heavy-dutyjack stands to get the vehicle to a workableheight. You will need basic metric andAmerican tools for disassembly.

B. Remove the stock manifolds and catalyticconverters. Clean out any carbon buildupfrom the heads. Install the studs provided inthe kit using a torx socket to tighten. Afterthe studs are tightened, place the gasketsover the studs and install the headers.

*****NOTE*****You may need to enlarge the holes in the head-ers with a file to ease assembly. Use the lockwashers provided in the kit and tighten equally.

After the headers are tightened, refer toattached diagram to see where to cut thestock head pipe away from the cats. Oncethe stock head pipes are removed, insert thecats back into the factory slip fits.

C. Fasten the 3-bolt flanges and gaskets fingertight to the headers. Position the cats toindex into the blank flanges bolted to thenew headers.

*****Note*****The tube size on the stock cat is 2-1⁄4" and theheader collector is 2-1/2" We recommend takingthe cats to a muffler shop and having themexpanded to better fit the flange. Once this isdone, position both cats in their factory slip fitsand index into the new headers. Using a migwelder tack the cat to the flanges in at leastthree places. Remove the cats and finish weld.Re-install the cats using the lock washersincluded in the kit. Tighten the 3 bolt flangejoints first then the factory slip fits last.

*****IMPORTANT*****Once the headers and cats are finish welded andinstalled, pay close attention to any hoses, wiresetc., that may be touching the headers. Moveany of these objects out of the way. If you wishto use any conforming heat shields, wrap thepart but NOT THE HEADERS. The headers needto "breathe". Wrapping it with a shield will dam-age it in time.

D. When everything is done and inspected startthe vehicle and check for leaks. If every-thing looks good, let it idle for appoximately15 minutes. Shut it off and re-tighten theheader bolts. New bolts and or studs willstretch once when hot. You will notice a nor-mal rate of approximately 1/2 turn to tight-en. Once this is completed you are ready togo.

1-2P/N: 4809629©2003 Paxton AutomotiveAll Rights Reserved, Intl. Copr. Secured22OCT02 v2.0 PlymProwler(4809629v2.0)

*****NOTE*****:You may notice a “burning rubber” smell whenthe vehicle is first fired up and immediately afterthe first long hard full throttle pulls you do. Thisis caused by the special composition headergaskets “burning in” and takiing a set. However,please feel free to check and double-check thatno hoses or rubber components are beinngincinerated.

PROWLER DIAGRAMFor removing stock head pipe for header installation

STOCK HEAD PIPE 2-1/4”

MEASURE 1/4” ABOVE WELD, CUT AND REMOVE USING A BASIC MUFFLERSHOP EXPANDER OR HAND HELD. EXPAND THIS UP TO 2-1/2” O.D.

2-1/2” 3-BOLT FLANGE

BOLT FLANGE TO COLLECTOR INDEXCAT INTO FLANGE TACK WELD OUTSIDEREMOVE AND FINISH WELD INSIDE



Section 2SUPERCHARGER INSTALLATION

A. Disconnect the batteryB. Using a 10mm socket, remove the 3 bolts

securing the body panel immediately in frontof the driver’s door. Pull it out at the topthen lift up to remove. Disconnect the sidemarker light. (See Fig. 2-1.)

C. Using a 13mm socket, disconnect the sup-port rods (that go over the top of the engine)at the rear of the engine compartment.Leave them connected to the radiator sup-port plate. (See Fig. 2-2.)

D. Using a 13mm and a 10mm socket, discon-nect the upper radiator support and removethe upper radiator support and the supportrods covering the engine. If your car has thehood support as part of this assembly, youwill need a prop rod to support the hoodduring the rest of the installation. (SeeFig. 2-2.) Place the front end of the car onjackstands as near to the engine supports aspossible. (See Fig. 2-3.)

2.1 DISASSEMBLY

E. Disconnect the plug at the top of the fanshroud (see Fig. 2-4). From under the vehi-cle, loosen the petcock on the passenger sideof the radiator and completely drain thecoolant into a bucket. If coolant is notreusable, please dispose of it properly.Disconnect both upper and lower and radia-tor hoses and remove the lower radiatorhose. Disconnect the wiring harness fromthe fan shroud. Using a 10mm socket,remove the two bolts that secure the radiatorto the A/C condenser, and remove the radia-tor by lifting it straight up.

REMOVE

DISCONNECT

SUPPORT RODS

REMOVE

WIRINGHARNESS

Fig. 2-1

Fig. 2-2

Fig. 2-3

Fig. 2-4


F. Using masking tape, mark the edges of thesupport brace that the body side panel wasbolted to. This will help you in the re-assembly. (See Fig. 2-5.)

G. Disconnect the plug to the hood switch, and,if needed, disconnect the driver’s side hoodpiston. Unbolt the power steering reservoirbracket. Remove the six 13mm head boltssecuring the support brace (that was markedin step 6). Use a 60º offset wrench toremove the two bolts closest to the driver’sside headlight. Disconnect the wiring har-ness from the support brace and remove thebrace.

H. Ease the tension on the 6 rib belt by loosen-ing the 15mm nut on the tensioner pulley,then loosen the 13mm head lead screw.Remove the belt.

I. Drain the power steering fluid by discon-necting the large hose at the pump and thesmaller hose near the steering rack. Removethe reservoir, hood switch assembly, andlines. Remove the two plastic clips thatsecure the metal lines from the rack and pin-ion. Disconnect the metal line that runs fromthe pump to the rack and pinion and remove.

J. Disconnect the electrical connections to thealternator and use a 15mm socket to removethe alternator, alternator bracket, and brace.(See Fig. 2-6.)

K. Remove the three 13mm head bolts securingthe Drive Belt tensioner to the front of theengine. Remove the tensioner.

L. From underneath the vehicle, remove theA/C belt using the same procedure as in step8. Remove the two 15mm bolts that securethe tensioner assembly and remove theassembly.

M. If required, remove the belt guard near theA/C compressor using a 13mm socket.

N. Remove the passenger side body side panelas you did the driver’s side panel in step 2 togain access to the air filter box, and removethe box assembly from the vehicle.Disconnect and remove the plastic pipegoing into the throttle body. You will have toloosen the coolant overflow bottle from theframe in order to create enough space toremove the air box. Disassembling the airbox and removing the filter and box inpieces simplifies the removal.

O. Disconnect the heater hose from the thermo-stat. (Make sure that you have a drain pandirectly underneath it.) Remove the thermo-stat housing using a 10mm socket. Modifythe thermostat housing, as shown inAppendix 7000105. Pry the heater pipeslightly away from the neck so that the radi-ator hose will slide back on. (See Fig. 2-7.)Be careful not to cave in the neck.Reconnect the heater hose and reinstall thethermostat housing using the original gasket

Fig. 2-6

Fig. 2-5

Fig. 2-7



***NOTE:***For this step you will need a drill motor, 3/16”and 37/64 drill bits, 3/8 x 16 NPT tap, anti-seizelubricant and heavy grease.

3.1 NOVI 1000A. The Paxton Automotive Novi 1000 super-

charger relies on pressurized engine oil forits lubrication. The oil must then be returnedto the oil pan, via a drain back fitting thatmust be installed into the pan. This involvesmaking a hole in the driver’s side of the oilpan. To do this, first drain 1 quart of oilfrom the pan, then scribe an X into the oilpan 1-1/2” forward of the rib and 3/4-inchbelow the pan rail. After the X is scribed,drill a 3/16-inch pilot hole into the center ofthe X. See Fig 8 for the general placementof the Oil Drain fitting.

B. Enlarge the pilot hole with the 37/64-inchdrill.

C. Apply a liberal amount of grease to thethreads of a 3/8-inch X16 NPT tap, andslowly insert into the hole. The grease willmake tapping the hole easier, and will alsokeep metal chips from falling into the pan.Tap the hole until the fitting tightens 3/4 ofthe way into the hole.

*****NOTE*****:This fitting has tapered threads and is intendednot to seal flush against the drain pan.

D. Clean the finished threads with a clean rag.Apply a sparing amount of sealer such assilicon RTV to the threads of the supplieddrain back fitting, and install.

*****NOTE*****:Do not over-tighten.The finished Oil Drain is inFig. 3-1. Please note that the hose is shown inthis picture, but it is not to be connected at thistime.

Fig. 3-1

Section 3INSTALLING SUPERCHARGER DRAINBACK

E. Drain the rest of the oil and fill withfactory recommended oil.



Section 4INSTALLING THE OIL FEED FITTINGS

A. Using a 13mm socket, remove the threemounting bolts that secure the power steer-ing pump. (You can get to the bolts throughthe openings in the pulley.) Let the pumphang by the lines. Remove the oil pressuresender using a special 1-1/16” oil pressuresender socket. This can be found at mostauto parts stores. Install the supplied largehex fitting using either liquid teflon or RTVsealant. Tighten the fitting using 1-1/8”socket or wrench. It is correctly positionedwhen the large tapped hole points straightdown. Install the factory oil pressure senderinto the hex fitting using sealant. Now,install the supplied 90º fitting into theremaining hole. It should aim up and back,over the oil filter. Reattach the power steer-ing pump and attach the electrical plug tothe sender. (To get more slack in the senderwire, carefully remove the tape securing itnear the intake manifold. This will free upthe two or three inches bundled up inside).Attach one end of the oil feed line to the 90ºfitting and tighten. See Appendix Number1016059.

4.1 INSTALLING OIL FEED FITTINGS



Route the 5/8”power steering hose tothe new reservoir through the samenotch as the battery cables go through.It may be helpful to flatten a section ofthe fins on the bottom of the A/C con-denser to ease the routing. Route the3/8” hose around the end of the A/Ccondenser on the driver’s side.

B. The line from the Power Steering Pumpto the Rack and Pinion is modified, per7000100. Reinstall the line and checkfor the correct orientation. If it is notcorrect, loosen the fitting and rotate.Reinstall the plastic clip to hold the linein place, as shown in Fig 5-2. Fig. 5-3

Fig. 5-1

Fig. 5-2New power steering reservoir, mounted on

frame rail. Showing hoses going through the frame.

C. Cut the existing metal tube and flarethe ends with a pair of pliers. (See Fig. 5-3.)

5.1 THE POWER STEERING SYSTEM-MODIFICATION

A. Mount the supplied power steeringreservoir to the frame rail in front ofthe hood release and next to the driver’sside headlight. Drill two 11/64” holesand secure the reservoir using the sup-plied hardware. (See Fig. 5-1.)

Section 5MODIFICATION OF THE POWER STEERING SYSTEM

Install the existing rubber hose andhose clamps. The metal line is reversed,so that the same end remains attachedto the curved rubber tube. Attach themetal line to the new reservoir with theprovided 5/8” rubber hose.


Fig. 12The new 3/8” line from the reservoir.

Fig. 11Shows both the new reservoir-pump line (A), therack-and-pinion pump line (B) and the clip (C).The rack-reservoir line (A) remains the same.

A

B

C

D. The line from the Rack and Pinion tothe reservoir is left the same, except forthe new rubber line from the reservoir.Secure the Power Steering hoses andtrim as needed for best fit. Shown arethe various parts of the system.

***NOTE:***Refill with factory recommended power steeringfluid only.



Section 6MODIFY AND RELOCATE THE ALTERNATOR

AND INSTALL THE BELT TENSIONER6.1 MODIFY AND RELOCATE THE

ALTERNATOR/ INSTALL BELT TEN-SIONERSA. Extend the alternator wiring harness using

the supplied wires. Cut the eyelet off of thelarge power wire (this may be either red orblack) and connect to the supplied large redwire.

*****NOTE:*****The butt connectors supplied in the kit are theheat-shrink type. After crimping, use a heat gunor lighter to shrink the ends for a water tight fit.The connector is water tight when glue bubblesout of the ends.

Next, cut the wires leading to the two wireplug about 6 inches from the plug and attachthe supplied extension wires. Cover thewires with the supplied split loom and routealong the bottom of the radiator, and thelower frame rail on the passenger side to thealternator. DO NOT attach the plug yet. Youwill first mount the alternator then cut thewires to length.

B. Remove the factory alternator pulley capand using an impact gun with a 17mm allenhead socket remove the stock pulley. (SeeFig. 6-1.) Install the supplied pulley in itsplace securing with supplied 17mm nut.Heating the pulley will make the installationeasier.

*****NOTE:*****Do not use the washer supplied with the alterna-tor pulley nut.

Fig. 6-1

C. LOOSELY bolt the alternator mountingbracket to the engine block where the A/Ctensioner was bolted (see Fig. 6-2).

Fig. 6-2

Install the supplied drive belt tensioner platewith the spacer (see Fig. 6-3). Align thecrank and drive belt pulleys, and tighten thebolts on the drive belt tensioner plate andthe alternator mounting plate using a 17mmsocket

Fig. 6-3


D. Bolt the alternator support arm to the ear onthe alternator. Leave it slightly loose so itcan be adjusted. Next, mount the alternatorto the bracket. You will have to bend the OilDipstick tube up and away from the bracketto make room for the alternator. (See Fig. 6-4.)

Fig. 6-4

Fig. 6-5 / Complete installed Drive Belt Tensioner.

Fig. 6-6

H. Complete the alternator wiring. Install thedrive belt tensioner. (See Fig. 6-5.)

I. Refer to Fig. 6-6. Replace the factory boltswith two 6mm Buttonhead screws from theA/C Tensioner Assembly (p/n 1016032).

E. Loop the supplied V-belt around the crankpulley, then around the A/C compressor.

F. Remove the two 10mm head nut and brack-et, the 15mm head bolt/stud and the 15mmhead bolt.

G. To install the A/C tensioner, place the beltover the lower pulley, then under the topadjuster pulley.

*****NOTE:*****The tensioner pulley will push down on the belt,so make sure the pulley is at the uppermostposition. Now bolt the bracket to the engine.

Tighten the bolt by turning the screw count-er-clockwise. When the bolt is sufficientlytight, tighten the lock nut on the front of theA/C tensioner assembly.



Section 7INSTALL THE MOUNTING BRACKET ASSEMBLY

AND SUPERCHARGER

7.1 INSTALL THE MOUNTING BRACKETASSEMBLY AND SUPERCHARGERA. Remove the two 10mm Head Bolts and

replace them with the Buttonhead allen boltssupplied with the mounting bracket assem-bly (P/N: 1016034). (See Fig. 7-1.)

Fig. 7-1

B. Bolt the supercharger mounting bracket tothe front of the engine using the four 8mmbolts and one 10mm bolt (See Appendix1016034 for the proper bolt placement.) Thebracket fits behind the power steering pul-ley. You must put the 3/8-16 x 3-1/4” longbolts (item #8) in the lowermost outer holesin the bracket before installation. (See Figs.7-2, 7-3.) shows the installed MountingBracket.

Fig. 7-2S/C mounting bracket from front of engine (pulleys attached).

10mm HEAD BOLTS

PUT THESEBOLTS IN

FIRST

POWER STEERINGPULLEY

Fig. 7-3S/C Mounting bracket from rear of engine

C. Test fit the supercharger by laying it into themounting bracket. You will need to trim thebody panel for clearance. Do not permanent-ly attach the supercharger yet. (See Fig. 7-4.)

Fig. 7-4


D. Install the oil drain fitting on the supercharg-er. Install a 2” long turbo hose (from the dis-charge tube assembly p/n 1016049) onto thedischarge of the supercharger using a #48hose clamp (place the screw of the clamp intowards the supercharger). (See Fig. 6-4.)

Fig. 6-4

TURBO SLEEVE

OIL DRAIN

E. Install the supplied Lower Radiator hose(P/N: 1016055) to the engine.

F. Relocate the wiring harness that runs under-neath the supercharger by drilling a newhole and attaching the harness with a ZipTie.(See Fig. 6-5.)

Fig. 6-5

NEW HOLEDRILLED

Attach the oil feed and oil drain hoses to thesupercharger, making sure they won’t comein contact with the exhaust manifold, hotengine surfaces, or hit anything when theengine rocks. The oil drain fitting can beturned to make adjustments in the line place-ment.

H. Affix the remaining smooth idler pulley tothe last open hole in the mounting bracket.Install the accessory/supercharger drive belt.(See diagram 7000110.)

G. Mount the supercharger to the bracket, butleave the four 3/8” bolts slightly loose.

*****NOTE***** The discharge tube points straight down. Startthe three countersink allen bolts and tightenusing a 7/32 allen wrench. Go back and tightenthe 3/8” bolts, using a 9/16 socket.



Section 8FAN MODIFICATION

A. Install spacers between the fan and theshroud. Detach the fan from the supportbrace by removing the two mounting screwsand popping the spring clips (see Fig 8-1).

8.1 FAN MODIFICATION

Fig. 8-1

Remove the spring clip that retains the fan(see Fig. 8-2) and remove the three screwsusing an internal Y-27 torx socket (This is ahard to find size. If you do not have one, apair of pliers will do the job.)

Place the three spacers between the motorand the fan shroud (see Fig. 8-3). This willspace the back of the fan motor away fromthe engine slightly. Reassemble the fan.

Fig. 8-2

Fig. 8-3

REMOVE SPRING CLIPS

3 SPACERS



Section 9FUEL LINE MODIFICATION

9.1 FUEL LINE MODIFICATIONA. Please refer to Appendix 1016049 for the

attachment of the S/C discharge tube. It willtravel from the supercharger, underneath thecar, up between the engine and the firewall,and connects to the throttle body. Begin byattaching item number 4 to the throttle bodyat the rear of the engine and tighten bothclamps on the factory elbow. Install themounting hardware from the stock plasticpart that is attached to the throttle body (seeFig. 9-1)

Fig. 9-1

You will have to remove a plastic cover andthe Schraeder Valve to make the connection.At this time, it is also recommended that thespark plugs be changed to AUTOLITE5224, or equivalent, gapped to .035. Do notuse Platinum Spark Plugs with the super-charger.

C. Attach the Compressor Bypass Assembly tothe discharge tube. (See Appendix 1016066).Notice that the “T” fitting (item 5) goesbetween the Vacuum Reservoir and theVacuum Branch next to the Brake Booster.Connect the vacuum line going to the BoostGauge to the other “T’ fitting. The BoostGauge Vacuum line goes through the bodypanel through the grommet and comes outunder the steering column. (See Fig. 9-3.)

Fig. 9-2

Fig. 9-3

STOCK HARDWARE

Then, from underneath the vehicle, attachitem 1, the cast discharge tube, to the turbohose that you previously attached to thesupercharger. Attach item 6 to the throttlebody side, and finally attach item 5 to con-nect both ends. Make sure all of the clampsare tightened properly. Make sure that theDischarge Tube is level as it passes under thevehicle, and that it will clear the ground.Adjustments can be made at either end at theTurbo Sleeve connectors.

B. The fuel line from the discharge tube assem-bly will need to be routed at this point. Thefuel line needs to be routed along the fire-wall (being careful to avoid any exhaust orpotentially hot surfaces), under the back ofthe manifold, and to connect with the fittingon the side of the fuel rail (see Fig. 9-2).


D. Modify upper radiator support as shown (seeFig. 9-4).

Fig. 9-4

E. Reinstall the radiator into the vehicle. Plugin the fan harness. Connect the upper andlower radiator hoses. Reattach the condensorto the radiator with the two 6mm factorybolts.



10.1 INSTALLING THE BOOST GAUGE(APPENDIX 1018105)A. The studs on the back of the Boost Gauge

will have to be cut off to make it fit into themounting cup.

B. Splice the wires that are supplied in theassembly to the Boost Gauge. Disconnectthe socket and bulb from the gauge to easethe wiring.

C. Remove the panel from under the steeringcolumn (two bolts, see Fig. 10-1).

Fig. 10-1

D. Disconnect the wiring harness to the RPMGauge and route to the bottom of the steer-ing column.

E. Trim the sleeving on the wiring harness toaccess the wires to the RPM Gauge.Connect the Boost Gauge wires to the RPMGauge wires (Black to Black and White toOrange). (See Fig. 10-2.)

Fig. 10-2

Section 10INSTALLING THE BOOST GAUGE

F. Take the Vacuum Line (from step 38) andfeed it up the steering column and the BoostGauge Sheath. Attach the vacuum line to theBoost Gauge using the supplied fitting, perthe installation instruction that are providedwith the gauge. Route the wiring harnessback to the top of the steering column.Check the placement of the line, to makesure that it will not kink when the steeringcolumn is tilted.

G. Reinstall the socket and bulb into the BoostGauge.

H. Reinstall the steering column panel, onceagain watching for kinks in the vacuum line.

I. Attach the RPM and Boost gauges to themounting brackets and the steering columnas shown in Appendix 1018105.



RED WIRE, FROM RELAY TOFUSE BOX (POWER)



Section 11FUEL SYSTEM MODIFICATIONS

11.1. FUEL SYSTEM MODIFICATION

*****NOTE:*****Refer to Appendices 1017717 (Asy, FuelControl), 7000125 and 7000145 (WiringDiagrams) and the photo (next page) for thissection. The Controller (4PCA016-011) will con-nect to the Factory Stock ECU, the FuelInjectors, and the Boost Retardant Device. Allwill be accessed from the passenger side, wherethe side body panel was removed. (See Fig. 11-1.)

Fig. 11-1

A. Before working on the vehicle’s electricalsystem, make sure that the battery has beendisconnected.

B. Disconnect the plugs from the ECU andremove the ECU using a 7mm socket on the3 mounting bolts and then open up the wireharness (split loom) that leads out of theECU unit. (Refer to the wiring diagram inthe Appendix page A-23 for wire color andpin location.)

C. Open up the ECU harness on the Prowler.Locate the wire connected to the CrankSensor (it will be connected to the #32 lead,and should be Gray and Black).

D. Cut the wire. It should be cut in the area ofthe wiring harness. The end that comes fromthe ECU will be connected to theGray/Black wire on the Controller. Theother end will be connected to the Graywire. Use the heat shrink Butt Connectors toinsure a water tight seal.

E. The CAM sensor wires will be connected tothe #33 connection, and will be Tan and

Yellow. Cut the wire in the same area, andconnect the ECU side to the Tan and Yellowwire in the controller, and the other side tothe Tan wire.

F. Next locate the Gray and black connector onthe ECU harness find the Yellow/Black wirethis should be Pin #73 in this connector.

G. The Paxton fueler and Ignition box needs anRPM signal to operate you just have to TEEinto this wire for the correct signal.

H. Close the ECU harness. Make sure that yourButt Connectors have a good seal, and placethem into the wiring harness.

I. Connect the Vacuum Tube from the con-troller to the Intake Manifold Vacuum. Thisis done with the included adapter and line.You will have to remove a factory cap onthe manifold to make the connection. (SeeFig. 11-2.)

Fig. 11-2

J. The controller is now ready to be connectedto a power source. The RED (Power) wire isconnected to terminal 87 on the relay with afemale disconnect (crimp and shrink type.The Relay will be installed on the uppermounting bolt behind the controller.

K. The black (ground) wire from the controllerwill be connected to the ground on the sideof the ECU with a crimp type of ring termi-nal.

ECU AND HARNESS


TO INJECTORS

RED WIRE, FROM RELAY TOFUSE BOX (POWER)

TO MANIFOLD VACUUM/BOOST

BLACK WIRE, FROM RELAYTO FUSE BOX (GROUND)

SPLIT LOOM, FOR THERED, GRAY AND BLACK

WIRES FROM TE RELAY TOTHE FUSE BOX

RED WIRE, FROM CONTROLLER TO RELAY

GRAY WIRE, FROM THE RELAYTO THE FUSE BOX (TRIGGER)

RELAY PLUG, TO BE MOUNTED ON THEFRAME BEHIND THE CONTROLLER

Fig. 11-3

BLACK WIRE, FROM RELAYTO FUSE BOX (POWER)

TO CAM, CRANK ANDRPM SENSORS



Fig. 11-4

M. Ground to the relay is supplied by the blackwire running from a screw in the frame railunder the fuse box on the driver’s side. (SeeFig. 11-5.) This wire is attached to the screwon the frame rail with a ring connector andto the relay with a female disconnect on the85 terminal (relay).

Fig. 11-5

L. Power to the relay is supplied by a red wire,running from the positive (red) terminal on thefuse box. (See Fig. 11-4.) This wire is attachedto the fuse box with the 3/8” ring connectorand to the relay with a female disconnect onthe 30 terminal relay.

N. Open the Fuse box and find connection #16.Take the time to number the other connec-tors for identification to help in the reassem-bly. (See Fig. 11-6.)

Fig. 11-6

O. Remove the plugs, and remove the red plas-tic relay port by pressing on the tabs in thecorners. (See Fig. 11-7.)

Fig. 11-7

RELAY POWER

P. Detach the wire to the connector by pressingon it from the top side with a small screw-driver. (See Fig. 11-8.)

Fig. 11-8


Q. Here is the trigger wire for the controller.(See Fig. 11-9.) Use a provided QuickConnector to attach the gray wire. The otherend of the trigger wire is connected to therelay with a female disconnect on the 86 ter-minal (relay). Reassemble the fuse box.

Fig. 11-9

R. The red, black, and gray wires from the fusebox are routed along the firewall wiringloom in the supplied split loom.

S. Before reinstalling the ECU there is an A/Cline that runs close to the header. When yourelocated the Altenator there was a bracketthat you removed from the back of theAlternator.This will be used to relocate theA/C line using the supplied hardware. (SeeFigs. 11-10, 11-11.)

Fig. 11-12

Next reinstall the ECU. Being sure that thebolt head is not contacting the ECU. Youmay have to space the ECU out using wash-ers. (See Fig. 11-12.)

Fig. 11-10

Fig. 11-11



12.1 INSTALLING THE AIR INTAKEASSEMBLY (APPENDIX 1016043)A. Install the supplied 45° fitting and position

to provide the maximum clearance betweenthe headers and the vent line. (See Fig. 12-1.)

Fig. 12-1

B. Attach the adapter hose (item #7) to thesupercharger, using the #48 hose clamp.Leave clamp loose at this point.

C. Attach the Nipple Fitting (item #12) to theCompressor Bypass, and then to the Air Box(item #1). Attach the box to the supercharg-er.

D. Secure the box to the engine using thebracket (item #13). You may have to trimthe turbo hose between the supercharger andair box to clear the headers and fit themounting bracket.

E. Tighten all of the clamps at this time.F. Attach the Vent Tube to the box. The tube is

brought along the firewall splitloom, andattached to the passenger intake manifold.(See Fig. 12-2.)

G. Assemble the Air Filter and attach it to theAir Box. Thread the steel rod (item #11)through the box, and thread a nut and wash-er on the end. Place the restrictor, plate, fil-ter element, tube, and plate onto the rod.Finally, secure the assembly with the knob.(See Fig. 12-3.)

Fig. 12-2

Fig. 12-3

H. Reattach the oxygen sensor to the manifoldand plug back into the electrical connection.

I. Reattach the driver side support rail and thesupport rods. Finally, reattach the outer bodypanels on the passenger and driver’s side.

Section 12INSTALLING THE AIR INTAKE ASSEMBLY

AIR BOX VENT TUBE

ECU VACUUM


Congratulations! Your NOVI 1000 Supercharger is now installed.

Fig. 12-4

J. Reinstall the upper radiator support and sup-port arm assembly using supplied washers(see Fig. 12-4). While reinstalling, be sureto push the radiator toward the front of thevehicle. Refill the radiator with cleancoolant.

Fig. 12-5



Section 13FINAL CHECK

13-1 FINAL CHECK-OUT PROCEDURES

We know that you are anxious to get out and drive yournew vehicle, but please take a little bit more time toperform these simple check-out steps.

A. Inspect all wiring harnesses and electricalconnections. Make sure that all items areproperly routed, connected and secured.

B. Check all hoses, lines, and fittings for prop-erly secured connections.

C. Make certain all fasteners, brackets, andclamps are installed and properly tightened.

D. Check serpentine accessory belt and super-charger drive belts for proper tension andalignment.

E. Cycle ignition key from “off” to the “on”position.

F. Check the entire fuel system for possibleleaks.

G. Start engine and verify that the oil pressureis within normal range.

H. Allow the engine to come up to normaloperating temperature.

I. Check the coolant level in the coolant recov-ery bottle and top off as needed.

J. Check the following:Fluid LeaksFluid LevelsBelt SlippageThrottle Response

Now that the work is done, it’s time to enjoy. PAXTONAutomotive wants to thank you for choosing our prod-uct, and wants to remind you that the performance andresponse of your vehicle is now different that what youare used to. Please drive cautiously until you havegrown accustomed to the feel of your vehicle.

Please see the service manual included in your kit forinformation on the service and maintenance of yourPAXTON Supercharger. Belt tightening, troubleshoot-ing, special tuning requirements, and warranty informa-tion is also included in the Service Manual.

A-1 P/N: 4809629©2003 Paxton Automotive


AppendicesThank you for purchasing this Paxton Supercharger. Please under-stand that because we are constantly improving and upgrading ourproduct, there may be pictures in this manual showing parts thatappear to be different than the parts in your kit. This may be due topictures taken in pre-production, a change in material, or a differ-ent model year. Rest assured that the parts will install in the samefashion, and that you have purchased the most up-to-date kit thatPaxton is selling at this time.

Drawing No. 1201711 Kit, Parts List 1997-2000 Prowler . . . . . . . . . . . . . . . . . . . . . . . . .A-2Drawing No. 1011811 Asy, Novi 1000 Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Drawing No. 1016034 Asy, S/C Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Drawing No. 1016032 Asy, A/C Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5Drawing No. 1016033 Asy, Tensioner Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6Drawing No. 1016043 Asy, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7Drawing No. 1016046 Asy, Power Steering Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8Drawing No. 1016049 Asy, Air Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9Drawing No. 1016055 Asy, Radiator Tube Modification . . . . . . . . . . . . . . . . . . . . . . . . .A-10Drawing No. 1019347 Asy, Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-11Drawing No. 1019346 Asy, Oil Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12Drawing No. 1015513 Asy, Compressor Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-13Drawing No. 1016069 Asy, Alternator Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-14Drawing No. 7000180 Diag, Power Steering Line Mod . . . . . . . . . . . . . . . . . . . . . . . . . .A-15Drawing No. 1017717 Asy, Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-16Drawing No. 1018105 Asy, Gauge Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-17Drawing No. 7000100 Asy, Diag, Power Steering Line Mod . . . . . . . . . . . . . . . . . . . . . .A-18Drawing No. 7000105 Asy, Diag, Thermostat Housing Mod . . . . . . . . . . . . . . . . . . . . . .A-19Drawing No. 7000110 Asy, Belt Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-20Drawing No. 7000110 Diag, Wiring Fuel Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-21Drawing No. 7000145 Diag, Relay Witing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-22

Drawing Title Page

A-2P/N: 4809629©2003 Paxton AutomotiveAll Rights Reserved, Intl. Copr. Secured22OCT02 v2.0 PlymProwler(4809629v2.0)

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