The Supercharger System
| Item |
Part # |
Description |
|---|---|---|
| 1 | 12B637 | Wiring harness |
| 2 | 9C986 | Fuel pulse damper |
| 3 | 9F792 | Fuel injection supply manifold |
| 4 | 9F593 | Fuel injector |
| 5 | - | Stud |
| 6 | 9D475 | Exhaust gas recirculation valve |
| 7 | W701232 | Bolt |
| 8 | N806979 | Stud |
| 9 | - | EGR vacuum hoses |
| 10 | 6F089 | Vacuum actuator valve |
| 11 | N605892 | Bolts (2 req'd) |
| 12 | - | Bolts (10 req'd) |
| 13 | 9J447 | Lower intake manifold |
| 14 | 9L438 | Coolant intake manifold gasket |
| 15 | - | Coolant tubes |
| 16 | 9N491 | Coolant intake manifold |
| 17 | W701592 | Bolt |
| 18 | NL443 | Inter cooler hose |
| 19 | NL443 | Inter cooler hose |
| 20 | W506404 | Bolts (10 req'd) |
| 21 | 6K755 | Charge air cooler |
| 22 | 6F066 | Supercharger assembly |
| 23 | N605892 | Bolt |
| 24 | 9726 | Accelerator cable bracket |
Intake Air Distribution and Filtering - Supercharger, Charge Air Cooler
The supercharger (SC) is a positive displacement pump. Its purpose is to supply an excess volume of intake air to the engine by increasing air pressure and density in the intake manifold. The supercharger is matched to the engine by its displacement and belt ratio, and can provide excess airflow at any engine speed.
NOTE: The supercharger is repaired only as an assembly. Disassembly of the supercharger unit may void the warranty.
NOTE:The supercharger is not a bolt-on option. It is part of an integrated engine system. Many components of the supercharged engine are not interchangeable with similar parts from a non-supercharged engine.
The supercharger contains two three-lobed rotors. The helical shape and specialized porting provide a smooth discharge flow and low level of noise during operation. The rotors are supported by ball bearings in front and needle bearings at the rear. The drive gears are pressed into place, therefore the supercharger is installed new as a unit, and is not repairable.The supercharger system is a blow-through type with the fuel injected directly into the intake ports. The supercharger is belt driven off the crankshaft through an idler pulley. The throttle body controls the amount of intake air to the supercharger through the intake plenum. Air from the supercharger is routed through the charge air cooler (CAC), then to the intake manifold. The resulting denser air charge in the combustion chamber provides for a higher power output of the engine over a non-supercharged engine of the same displacement.
NOTE: It is not possible to increase manifold pressure or engine power output by altering the bypass valve or the actuator.
At partial-throttle opening or when vacuum is present in the intake system, a vacuum-controlled bypass valve reroutes some discharged air from the supercharger back through the intake plenum. This prevents the supercharger from cavitating, causing reduced performance, increased temperatures, and poor fuel economy.
The supercharger has a self-contained oiling system that does not require a fluid change for the life of the vehicle. However, at every 30,000 mile interval, the supercharger fluid level should be checked. The vehicle should be parked on a level surface, the engine cool, and not running. To check the oil, remove the Allen head plug located at the front of the supercharger. The oil level should be at the bottom of the fill plug threads when cold. If the fluid level is low, add Synthetic Supercharger Fluid E9SZ-19577-A or equivalent meeting Ford specification ESE-M99C115–A Supercharged vehicles are equipped with a charge air cooler (CAC). The CAC cools the pressurized air from the supercharger, increasing the air density, which improves combustion efficiency, engine horsepower and torque.
Torque Specifications
| Description |
Nm |
lb-ft |
lb-in |
|---|---|---|---|
| Air cleaner and duct assembly bolt | 7 | 62 | - |
| Coolant supply and return manifold | - | - | - |
| Charge air cooler bolts | - | - | - |
| Supercharger mounting bolts | - | - | - |
| Air intake scoop bolts | 25 | 18 | - |
| Air intake scoop bracket bolt | 25 | 18 | - |
| Air intake scoop bracket nuts | 25 | 18 | - |
| Air intake scoop bracket throttle body nut | 9 | - | 80 |
| Exhaust gas recirculation (EGR) vacuum regulator solenoid bolts | 10 | - | 89 |
The Supercharger Assembly
The most obvious part on the whole Engine, is,.... yes you guessed it.... the Supercharger. Just the look of it sends chills down the performance minded guy’s spine. This is the main difference between the 03-04 Cobra and the rest of the Cobra family. Of-coarse, by now you have learned that there are many differences that make the 03-04 Cobra special, it’s just this one piece tells the world who it is and what it can do!
The Supercharger is relatively a easy piece to get, there are many on E-Bay to purchase, every time I visit the site. The main problem, is trying to purchase a good, useable, and complete piece....that’s the difficult part. These Superchargers are still available from Ford, and while they are very expensive, listing in the $12-1300.00 range, they are useable from the get go. The units on E-bay, at least the majority, have to be rebuilt before they can be re-used. Yes, the adds might say different, but any Supercharger with that many miles will need rebuilding.....Period....so make sure you budget for it. Yes you could bolt the used piece onto your new Engine and it will work, meaning it will turn and might even produce some boost, But it will not produce the right amount of boost or power a new unit, or re-built unit will. You will be less then impressed with your new Engine, to say the least. The rebuild process is not that complicated, at least not if the core is still useable. A good company like Stegmieers, will rebuilt the front drive and re-coat the rotor tips to bring the Supercharger back to like new performance. They can also Port the Blower for even better performance, as well as Polish the blower for out standing looks. I have used there services and whole heartedly endorse them.
The Blower sit on top of the Lower Intake Manifold, and is held there by 10 bolts. Between the Manifold and the Blower is a special gasket, who’s purpose is to seal the two piece against leaks. This gasket is always replaced when the blower is separated....no exceptions. It is a very thin metal gasket that has a raised bead all the way around the gasket and this bead gets flattened when the two are tightened down against one another.
The bottom line is you can buy new and bolt it on, or you can buy used and send it out for a re-build, then bolt it on. The choice is yours to make, just be sure to know the options and budget accordingly.
| Supercharger Assembly | 2R3V-6F066 |
Accelerator Cable Bracket
This small bracket sits on the passenger side of the Supercharger assembly, and is used to secure the end of the accelerator cable. I have never seen one of these for sale on E-bay and would advise to just purchase it from Ford, they are not expensive.
| Accelerator Cable Bracket | 2R3V-9726 |
Lower Intake Manifold
The Lower Intake Manifold is the part the Blower sits on and is bolted to. This part is very large and is made form Cast Aluminum. While very protected, you have to make sure the sealing surfaces are OK, and that the bottom of the Intake Manifold is not damaged. While it is rare, I have seen several Engines where a Rod has let go, taking the block and Intake Manifold with it. This is just something to check. These are also on the rare parts watch list, and when found always bring top dollar. It’s a good ideal to buy one anytime you find one at a reasonable price, regardless of weather you plan to build your own "Terminator" Engine or not, they are money in the bank. The Intake Manifold requires 2-gaskets that seal the passage from the Heads to the Intake Manifold, and always start with new gaskets. There are 10-Mounting Bolts that secure the supercharger to the Manifold and another 10-Mounting Bolts that secure the Intake Manifold to the Heads.
| Lower Intake Manifold | 2R3Z-9J447 |
| Manifold Mounting Bolts (10 Req'd) | - |
Supercharger Charged Air Cooling System
This is a Sub-System of the Supercharger system, and we will examine this system at a higher degree. The Sub-System is made up of the following parts:
- The Inter-Cooler or Charge Air Cooler
- The Inter-Cooler Tube Assembly
- The De-Gas Bottle
- Water Pump
- System Plumbing
- Front Mounted Cooler
We have already talked about the Charge Air Cooler or Inter-Cooler as it is known by most. This assembly also includes the Coolant Intake Manifold and it's gasket. This group of parts consist of the Manifold, 2-small tubes, each with O-Rings attached to them, and a Gasket. This group of parts has the duty of allowing coolant to pass into and from the Inter-Cooler without allowing a leak of coolant or air. The Coolant Intake Manifold, it's gasket and Twin-Tube assembly are very hard items to find used. If you do find these, make sure the unit is complete, as they are also expensive and hard to get from Ford.
De-Gas Bottle
The De-Gas Bottle has the responsibility of allowing traped system air to escape and allowing the owner to re-fill the system with clean freash coolant. The original system uses a plastic De-Gas Bottle which can be replaced by a Canton Aluminum unit pictured. I have seen this item on E-Bay cheap, but not many of them. The Canton unit is readialy available and can be polish to a rich luster. Make sure the De-Gas Bottle is locate at the highhest point in the system, and remember, you have to be abile to access it for system replinishment.
Front Mounted Cooler
The Ford unit mounts in the front fashia, behind the bumper cover. There are stock replacement pieces and several high capacity units out there for sale. I would consider a higher capacity unit way before I purchased stock unit from the factory. For those installing this unit in a Hot Rod or Street Rod, you may ellect to not use the De-Gas Bottle or Front Mounted Cooler from Ford, and instead use a small Radiator. I have used small Motorcycle Radiators or even small Car Radiators from Honda to serve as both Cooler and Filler piece. The main thing is, you have to get the Cooler into the air flow, in crowded locatuion you might think about using a Electric Fan mounted to the Cooler to draw additional air flow. If placed right, a small radiator can serve as cooler, de-gas bottle and filler.
Electric Water Pump
The Water Or Coolant Pump is a seperate and dedicated part that only serves the Intake Charge Cooling System. This Pump is manufactured by Bosch and opperates on standard 12 Volts Electric. It is controlled by a Coolant Temp Sensor that senses Inter-Cooler Coolant temps and switches on or off independently of other vehicle functions. This is a very popular item on E-Bay and generally sell for $90-100.00. Again there is no need to use a old Pump.
Twin Tube Assembly and other Cooling System Hoses
The Twin-Tube Assembly is located in the passenger side front of the Engine. It takes both incomming and out going coolant down the side of the engine to where it will connect with the System Hoses. The Assembly keeps the coolant protected and well dressed. I have many times abandoned this assembly and simply attached my Performance Hoses right at the Coolant Manifold. This elliminates a lot of engine cluter and keeps the hose connections to a minimum. You will have one hose that runs from the outlet side of the Manifold to the De-Gas Bottle, or Radiator (depends on your arangemnt) then one hose from the De-Gas Bottle to the Front Mounted Cooler. Another hose from the Front Mounted Cooler to the Coolant Pump, then another hose from the Coolant Pump to the Inlet side of the Manifold. While the Twin-Tube Assembly has it place, especially on a stock vehicle, it also adds many un-neccessary connections.
Fuel Injectors
The Twin-Tube Assembly is located in the passenger side front of the Engine. It takes both incomming and out going coolant down the side of the engine to where it will connect with the System Hoses. The Assembly keeps the coolant protected and well dressed. I have many times abandoned this assembly and simply attached my Performance Hoses right at the Coolant Manifold. This elliminates a lot of engine cluter and keeps the hose connections to a minimum. You will have one hose that runs from the outlet side of the Manifold to the De-Gas Bottle, or Radiator (depends on your arangemnt) then one hose from the De-Gas Bottle to the Front Mounted Cooler. Another hose from the Front Mounted Cooler to the Coolant Pump, then another hose from the Coolant Pump to the Inlet side of the Manifold. While the Twin-Tube Assembly has it place, especially on a stock vehicle, it also adds many un-neccessary connections.
AC Compressor
The AC Compressor is located on the passengers side down low. It is held in place by three long bolts, and the pulley comes with the Compressor. I like to always use a new AC Compressor, like the Water Pump on a new engine, it just keeps thing on a even scale, and completes the Engine. The 03-04 AC Compressor uses a special manifold adapter, this adapter bolts to the back of the Compressor and allows the AC hoses to attach. These don't come with the new Compressors, so make sure you find one used or new, cause you have to have it. Also, most new compressors NO NOT come with OIL in the Compressor, so make sure you add the correct amount and type befor you use it.
| AC Compressor | 2R3V-19D269 |
| Compressor Bolts (3 Req'd) | 2R3V-N806184 |
Front Engine Cover or Timing Cover
While all Modular Front Covers are demensionally the same, it's the lay-out on the front of the cover that is different. The 03-04 Cobra Timming Cover is a uniqe one and is the only Timming Cover that will work with the Supercharged Engine. These Covers are very hard to find used, and bring a pretty penny when they are for sale on web sites like E-Bay. Generally there isn't to much to worry about, but I would stay away from cars that were involved in front end collissions or other simular accidents. I have seen other Aluminum Timming Covers wear in the front seal area, they developed small cracks all around the circumforance of the seal. These Front Engine Covers are still available form Ford, I have bought several and they generally list for around $700.00. When purchased new, the Front Cover comes with a new Belt Tensioner, all three pieces of the Front Cover Gasket and a new Idler Pulley, three items that are never there on a used one, so watch out and don't end up paying to much for a used Front Engine Cover..
There are several bolts and studs that hold the Front Cover in place, but also are made to secure other item that mount in front of the Engine Cover. These are very specific in both length and design, and have to be purchased from Ford.
| Engine Front Cover | 2R3Z-6019-BF |
| Bolts (8 Req'd) | 2R3V-N806177 |
| Studs (5 Req'd) | 2R3V-N806300 |
Front Cover Bolt Diagram
| Item | Part # | Description |
|---|---|---|
| 1 | N806177 | Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 |
| 2 | N806177 | Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 |
| 3 | N806177 | Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 |
| 4 | N806177 | Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 |
| 5 | N806177 | Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 |
| 6 | N806300 | Stud, Hex Shldr Pilot, M8 x 1.25 x 1.25 x 91.1 |
| 7 | N806300 | Stud, Hex Shldr Pilot, M8 x 1.25 x 1.25 x 91.1 |
| 8 | N806177 | Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 |
| 9 | N806177 | Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 |
| 10 | N806177 | Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 |
| 11 | N806177 | Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 |
| 12 | W706560 | Stud, Hex Head Pilot, M8 x 1.25 x 65 — M8 x 1.25 x 16 |
| 13 | N806300 | Stud, Hex Shldr Pilot, M8 x 1.25 x 1.25 x 91.1 |
| 14 | N806300 | Stud, Hex Shldr Pilot, M8 x 1.25 x 1.25 x 91.1 |
| 15 | N806300 | Stud, Hex Shldr Pilot, M8 x 1.25 x 1.25 x 91.1 |
Idler Pulley Support
The Idler Pulley Support Assembly is a large and very nesseccary piece for the 03-04 Cobra Engine. It is the only modular Engine that uses this important piece, and that makes them scarce and expensive. But be carefull not to confusse the issue, Ford still sells these pieces, and they often sell for more used then you can purchase a new part with all the additional pieces. This is simply a case where the purchaser does not know his subject or the current prices very well, and gets taken because of it. I always purchase this part new, and in my opinion you would be fullish not to.
Belt Tensioner
If you used my advise you already have this item, it came with the new Front Engine Cover, but if not you will need a new one. Don't even think about going used with this one, it serves a very important role in keeping the Accessory Belt tight. These are very popular on E-Bay and generally sell for around $50.00. The Engine requires two of them, and they are both the same part number,
| Belt Tensioner | 2R3Z |
Idler Pulley
There are three Idler Pulleys on the Accessory Drive System. They are all the same part number and are all made from stamped steel and have one, centrally located bearing, supporting them. I would like to see you use all new Pulleys, but if you have to purchase them, I would go with an aftermarket brand and not the factory Pulley. The Aftermarket has several vendors that sell very nice Aluminum Billet Idler Pulleys. These are supported by Double-Sealed Ball Bearings and are much stronger then factory pieces. They are also available in different diameters and styles, which realy dress-up the front of the Engine. While E-Bay sells the stock Factory Pulleys for $34.00, you could have a much stronger and better looking Pulley for just $10.00 more.
| Idler Pulley | 2R3Z-19A216 |
Drive Belt
The Accessory Drive System uses one Drive Belt, part number 8620. This Belt is the same as the Supercharger Drive Belt and should be bought new. New Belts are not expensive nor hard to get. I have used both Goodyear and Ford belts with success, and would think that as long as you stay with a known brand name, you would do fine.
| Drive Belt | 2R3Z-8620 |
Crankshaft Pully
The Crankshaft Pulley is the heart of the Accessory Drive System. This one piece supplies the power to turn all the other parts in the Accessory Drive System. This part is often refeered to as the Balancer or Harmonic Balancer, but Ford never calls it that, only the Crankshaft Pulley, so I'll call it that also. This is a very hard part to find used, and the few I have seen went for what a new Pulley would go for or more! I would say to just purchase this part from the Ford dealer, yes it's expensive, but at least you know what you have. You will also need the center bolt and washer, these I would get from a very well respected manufacturer, ARP. They make quality fasteners for some of the industries most discriminating users. I use them in as many places as I can, youu can never have to much of a Quality Product.
| Crankshaft Pulley | 2R3Z-6312-BAA |
| Washer | 2R3Z-N806165 |
| Bolt | 2R3Z-W701512 |
Accessory Drive Layout
| Item | Part # | Description |
|---|---|---|
| 1 | 8678 | Belt idler pulley |
| 2 | 8678 | Belt idler pulley |
| 3 | 8678 | Belt idler pulley |
| 4 | 3A733 | Power steering pulley |
| 5 | 10344 | Coolant pump pulley |
| 6 | 6C254 | Crankshaft pulley |
| 7 | 6B209 | Belt tensioner |
| 8 | 19D784 | A/C clutch pulley |
| 9 | 8620 | Drive belt |