1.7 intercooler...same as 03-04 cobra?

[2000 4.6]

Quick question...is the intercooler that comes on the 1.7L kits the same OE intercooler that is on a stock 03-04 cobra?

Thanks!

[bikewiz]

TTT!

I need to know what it takes to make a 03-04 intercooler work in a KB 1.7L also.

[tooblue02]

are you refering to the heat exchanger on the outside or the one inside the blower?

[bikewiz]

The intercooler is mounted below the supercharger, in the intake plenumn. The heat exchanger is mounted behind the front bumper. I am talking about the intercooler. Kenne Bell refuses to sell it separately. I would rather make my own intercooler setup for the KB than drop $1100 on their upgrade kit.

[tooblue02]

Just wanted to make sure I got the right one, your best bet would be to see if someone has one that got destroyed and has the intercooler as a piece they are willing to sell. You can try to speak with Mike at KB, he is usually very helpful when it comes to this stuff. If you have a KB and have the 03-04 intercooler, why not just try it out, I have never heard of it being done before. I would imagine the mounting points are slightly different but there is probably a way to make it all work.

[bikewiz]

with the right amount of time and money, anything is possible. i do have a KB'd car, but I don't have a '03-04 intercooler. This is my girlfriends summer DD so I'm not gonna pull it apart just to find out whats up. If its not straightforward, I'll just spend the $1100 with KB and buy their upgrade because I know it will work and not have the headaches of custom fabbing an intercooler.

[tooblue02]

Sometimes a little extra money is worth not having the migrain!

[bikewiz]

So, I have done a TON of research into this. First I e-mailed TJ @ Kenne Bell to see if they would sell the intercooler separately because I have everything else off of an 03 cobra. He said no, but suggested that I try modifying an '03 Cobra intercooler. After seeing pictures of an '03 cobra intercooler I didn't see how it would work because the cobra has fittings off the front of the intake manifold for the intercooler hoses, while the KB uses fittings on the back of the intake However, the lightning intercooler looks like it could be modified to fit because the hose barbs are in the right place for the KB intake. Then I read on google (after 6 hours of searching) that the rumor is that KB has a hand in Roush superchargers. So I look up pics of the roush intercooler and .... HAHA! It appears to be a direct drop in for the Kenne Bell. Looks like Kenne Bell sold their setup to Roush. Here are the pics I have scrounged up:

Kenne Bell intake/intercooler pics:





Heres a pic of the lightning intercooler:



And heres the pics of the Roush intercooler setup:




Straight out of the 2005+ Mustang Roushcharger install manual:




The "intercooler tubes" as Roush calls them are part # G1ZE-9L442-AA. The same tubes from a '03 Cobra are 2R3Z-9L442-AA and cost about $20 each. I don't know if the Roush tubes are the exact same as the 03 Cobra's, but the part #s are sure close.

The intercooler itself is part # G1ZE-6K775-AA.

I'm gonna call my local Ford dealer monday and see if they can get these parts and for how much.

So far I have a '03 Cobra heat exchanger that I got for $50 and looks brand new and came with the OEM piping. I can pick up a Bosch pump for about $80. All I need is:

• the intercooler and tubes
• some hose barbs to go into the back of the intake
• bulk heater hose
• a bracket to mount the heat exchanger
• a reservoir
• a smaller pulley

I plan on getting the bracket and reservoir from a parted out '03 cobra. Either way, it should be less money than the $1100 that Kenne Bell wants for the upgrade kit.