Paxton Automotive 1300001 User manual

Installation Manual for the PAXTON Automotive Intercooler
P/N 4809638 v2.0 11/10/03
Installation Manual for the
for the
PAXTON Automotive
Intercooler Kit #1300001
1999-2003 Ford Mustang GT
Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033
805 604-1336 . FAX [phone]

P/N: 4809638
©2003 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
10NOV03 v2.0 99-01 MusGT(4809638 v2.0) ii
© 2003 PAXTON AUTOMOTIVE
All 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: 4809638
©2003 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
10NOV03 v2.0 99-01 MusGT(4809638 v2.0)
iii
TABLE OF CONTENTS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
1.1 INITIAL PREPARATION AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
2.1 AFTERCOOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
3.1 FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
List of Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Appendix A 7000185 ASY, S/C NOVI 1000 . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Appendix B 1300001 Kit, Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

P/N: 4809638
©2003 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
10NOV03 v2.0 99-01 MusGT(4809638 v2.0) iv
IMPORTANT NOTES
Congratulations! You have purchased the
finest street charge cooler available for
the Mustang GT. The centerpiece of this
kit is the Highly Efficiency PAXTON charge
cooler.
This kit comes with all the parts you will need to
install the charge cooler. The instruction manual
has been edited in order of sequence, and photo-
graphs and drawings have been included to illus-
trate the text. This will allow you quick part
identification and orientation.
The installation will require metric and SAE
sockets and wrenches, a hand drill and bits.
Become familiar with the details of your car’s
system. If it is not operating within normal
parameters, we do not recommend the installa-
tion or use of the charge cooler.
For the quickest installation time, we suggest
that you read this manual thoroughly before
beginning. Make sure that you understand the
process, have identified the areas of the car that
you will be working on, and have the tools that
you will need on hand. The average installation
time is 6 to 8 hours, but your time will depend
on your working conditions, experience
installing superchargers, charge cooler, personal
skill level, and preparedness for the job. This
estimate does not include time for the initial
vehicle inspection, cleaning, fine tuning, or trou-
ble-shooting. Once again, we recommend read-
ing the manual before beginning the process. We
are available for tech support at [phone],
Monday through Friday, 7AM - 3 PM PST.
After reading the manual, verify that all major
assembly groups are present in the main kit box.
As you remove a box or bag, note the identifica-
tion 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. DO NOT begin installation if a part
is missing. Failure to contact PAXTON prior to
beginning installation will result in a charge for
the missing part.
We suggest that the engine compartment be
cleaned before the installation. You can clean
the engine with a pressure washer that is found
at self-serve car washes. Use a safe-for-alu-
minum cleaner/degreaser, and cover the distribu-
tor and any electronics with a plastic bag to pre-
vent water from entering.

P/N: 4809638
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10NOV03 v2.0 99-01 MusGT(4809638 v2.0)
v
You are undoubtedly eager to get started,
but please take a little more time to
insure that your safety is not in jeopardy.
Amoment’s lack of attention may cause a seri-
ous injury to you, or to someone else who hap-
pens to be standing around. By following some
PAXTON Automotive thanks you for your pur-
chase. We welcome your comments and sugges-
simple safety precautions, you can avoid many
potential dangers. The following list is not meant
to be a comprehensive list, but rather it is meant
to make you aware of some of the risks, and
encourage you to take a safety minded approach
to your work area.
•Never rely solely on a floor jack when working
underneath a vehicle. Always use jack stands that
are rated for the weight of your vehicle, use them at
the recommended lift points, and place your vehicle
in ‘PARK’ or ‘FIRST’ gear with the parking brake set.
•Always use eye protection when using power tools,
such as drills, saws, and grinders, or when working
underneath a vehicle.
•Never smoke, use an open flame, or have spark
producing items around gasoline or flammable
objects. Always have a fire extinguisher that is rated
for chemical and electrical fires handy when work-
ing on motor vehicles. Also, make sure that the
extinguisher is fully charged.
•Operate engines only in a well ventilated area.
Carbon Monoxide, gasoline, and solvent vapors are
colorless and sometimes odorless, and may
asphyxiate and explode without warning.
•Always disconnect the battery from your engine
before doing work on the electrical or fuel systems,
or doing underdash work.
•The chemicals used in the vehicle systems, such
as oils and coolants, are poisonous. Clean up any
spills immediately, and dispose of waste materials
properly. Pets, wild animals, and children may die if
they ingest the liquid.
tions to help us improve our product.

P/N: 4809638
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10NOV03 v2.0 99-01 MusGT(4809638 v2.0) vi
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P/N: 4809638
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10NOV03 v2.0 99-01 MusGT(4809638 v2.0)
1-1
Section 1
INITIAL PREPARATION AND REMOVAL
1.1 INITIAL PREPARATION AND REMOVAL
A. Remove the plastic clips(4) that hold the
grill cover in place. (See Fig. 1-a.)
Fig. 1-a
CLIPS
B. Remove the hood latch support screw using
a T-30 torx bit. (See Fig. 1-b.)
Fig. 1-b
SCREW
C. Place car on lift or jackstands.
D. Remove the screw at the bottom of the sup-
port bar. (See Fig. 1-c.)
Fig. 1-c
Fig. 1-d
E. Remove the power steering cooler line sup-
port screw. (See Fig. 1-d.)

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10NOV03 v2.0 99-01 MusGT(4809638 v2.0) 1-2
Fig. 1-e
Fig. 1-f
Fig. 1-h
Fig. 1-g
E. Remove the plastic clips (4) that hold the air
deflector in place. (See Fig. 1-e)
F. Remove the plastic clips(2) that attach the
front bumper to the frame. (See Fig. 1-f.)
G. Remove the screw that holds the power
steering cooler bracket in place. Set the line
aside to be installed in a later step of the
installation. (See Fig. 1-g.)
H. Pop loose the clips on the air deflector to the
left and right sides of the radiator. (See
Fig. 1-h.)
Fig. 1-i
I. Disconnect the rear radiator reservoir sup-
port brace from the bottom of the frame.
(See Fig. 1-i.)

P/N: 4809638
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10NOV03 v2.0 99-01 MusGT(4809638 v2.0)
2-1
Fig. 2-a
Fig. 2-c
Fig. 2-b
Section 2
INTERCOOLER INSTALLATION
2.1 INTERCOOLER INSTALLATION
A. Install the intercooler and support with jack-
stands or wood blocks. (See Fig. 2-a.)
C. Drill one more 1/8" hole and re-attach the
rear radiator overflow reservoir support in
its new location with a 1/4" sheetmetal
screw. (See Fig. 2-c.)
B. Drill two 1/8” holes as shown in Fig. 2-b.
Install two 1/4" sheetmetal screws. D. Re-attach the powersteering cooler line to
the intercooler.
E. Re-attach the front bumper to the frame re-
using the stock plastic clips.

P/N: 4809638
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10NOV03 v2.0 99-01 MusGT(4809638 v2.0) 2-2
Fig. 2-g
Fig. 2-h
Fig. 2-i
F. Attach the supplied intercooler mounting
bracket with the bolts supplied in the kit.
(See Fig. 2-g.)
G. Remove the discharge tube, bypass valve
and air intake tube. (See Fig. 2-h.)
H. Disconnect the oil lines. Disconnect the oil
return at the pan and the oil feed at the
supercharger.
I. Remove the accessory drive belt by relaxing
the tensioner.
J. Disconnect the supercharger. You will need
to loosen the two bolts on the coolant reser-
voir and move the reservoir to the side to
gain access to the supercharger. (See
Fig. 2-i.)

P/N: 4809638
©2003 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
10NOV03 v2.0 99-01 MusGT(4809638 v2.0)
3-1
Fig. 3-a
Fig. 3-b
Fig. 3-d
Fig. 3-c
Section 3
FINAL ASSEMBLY
3.1 FINAL ASSEMBLY
A. Re-clock the supercharger scroll. Refer to
the supercharger assembly drawing in the
back of the installation manual for position-
ing.
B. Re-attach the oil lines.
C. Connect the discharge tube between the
intercooler and the supercharger. (See.Fig.
3-a.)
D. Attach the discharge tube assembly between
the intercooler and the throttle body. (See
Fig. 3-b.)
E. Re-install the air intake tube between the air
filter/mass air meter and the supercharger.
(See Fig. 3-c.)
F. Re-install the bypass valve from air intake
to discharge tube. (See Fig. 3-d.)

P/N: 4809638
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All Rights Reserved, Intl. Copr. Secured
10NOV03 v2.0 99-01 MusGT(4809638 v2.0) 3-2
Here is your completed installation.
Fig. 3-e
G. Install inlet air control to discharge tube at
the throttle body. (See Fig. 3-e)

P/N: 4809638
©2003 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
10NOV03 v2.0 99-01 MusGT(4809638 v2.0)
A-1
APPENDIX

P/N: 4809638
©2003 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
10NOV03 v2.0 99-01 MusGT(4809638 v2.0) A-2
Please understand that PAXTON Automotive is constantly
improving the performance and appearance of its various
components. The parts in your kit may appear differently
than what is pictured in this manual. This may be due to
photographs being taken in pre-production, changes in mate-
rials, or improvements in performance.
Rest assured that you have purchased the best quality kit that
PAXTON Automotive manufactures at this time. The instal-
lation of the materials will remain the same.
LIST OF APPENDICES
Appendix Number DWG Number Rev DWG Title
A1300001 NC Kit, Parts List
B7000185 NC Asy, S/C NOVI 1000

P/N: 4809638
©2003 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
10NOV03 v2.0 99-01 MusGT(4809638 v2.0)
A-3
1300001 FORD, 4.6L MUST A/A COOLER ASSEMBLY
Part Number Description Qty/Parent
-------------------------------------------------------------------------------------------------
.8PN101-001 COOLR CORE,W/CAPS/DUCTS,A/A 1
.8PN012-010 DISCH TUBE A,COOLR TO TB 4.6 A 1
.8PN012-020 DISCH TUBE B, S/C TO COOLR INL 1
.8PN012-030 DISCH TUBE C, FROM COOLR DISCH 1
.7PS300-400 BUMP HOSE, 3.00D x 4.00L 2
.7PS300-401 SLEEVE, BLACK 3.00D x 4.00 3
.7R002-048 #48 SAE TYPE F SS HOSE CLAMP 10
.7A250-400 1/4-20 x 4 HXHD GR5 1
.7J250-022 1/4" WASHER SAE STAINLESS 3
.7A312-075 5/16-18 x 3/4 HXCS GR5 ZINC 4
.7F312-017 5/16-18 NYLOCK NUT 4
.7J312-000 5/16 FLAT WASHER-SAE 8
.7E014-075 #14 x .75 SHEETMETAL SCREW 3
.4809638 INST MAN, CHARGE COOLER 4.6 1
.2A017-876-09 SPACER, .875 OD x 3.210 LONG 1
.7A250-051 1/4-20 x .50 HHCS ZINC PLTD 2
.7U133-100 HOSE,ELBOW,90^,1"ID, MOLDED 1
.7C060-050 M6 x 1.0 x 50 HXHD ZINC PLATE 1
.7J006-093 6MM WASHER, PLATED 1
.2A017-876-07 SPACER, .875 OD x 1.490 LONG 1

P/N: 4809638
©2003 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
10NOV03 v2.0 99-01 MusGT(4809638 v2.0) A-4
SCALE:
SIZE DWG. NO.
DSHEET 1 OF 1
REV.
DATE
APPROVALS
DRAWN ENGINEERING R&D
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE:
DECIMALS: .XX±.01
.XXX±.005
MATERIAL FINISH NONE
SEE PARTS LIST
DO NOT SCALE DRAWING
WEIGHT 20.7 LBS 2:1 7000185 NC
FRACTIONS:
ANGLES: ±1/16
±1/2•
ASY, S/C NOVI 1000 REVERSE ROTATION
w/ INTERCOOLER
APPR.
----- ----- PAXTON AUTOMOTIVE INTERCOOLER-1999-2003 MUSTANG GT
-----
-----
----- -----
1300 BEACON PLACE OXNARD, CA 93033 TEL: [phone] FAX: [phone]
CAD GENERATED DRAWING, DO NOT MANUALLY UPDATE
----- -----
NUT CORNER IN LINE WITH EDGE
RE- CLOCK SCROLL AS SHOWN
S/C ROTATION
Appendix B - Asy, S/C NOVI 1000

P/N: 4809638
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All Rights Reserved, Intl. Copr. Secured
10NOV03 v2.0 99-01 MusGT(4809638 v2.0)
A-5
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P/N: 4809638
©2003 Paxton Automotive
All Rights Reserved, Intl. Copr. Secured
10NOV03 v2.0 99-01 MusGT(4809638 v2.0) A-6
Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033
805 604-1336 . FAX [phone]