Essential Parts for EVO Supercharger Kit for Porsche: A Complete Guide

The EVO supercharger kit is a popular power adder for Porsche models, notably the 911 (996 and 997) and Cayman/Boxster platforms. While many enthusiasts focus on the overall horsepower gains, understanding the individual parts that make up the kit is crucial for installation, maintenance, and future upgrades. This guide breaks down every component you'll find in a typical EVO supercharger kit for Porsche, explaining its function and what to look for when sourcing replacements or aftermarket upgrades.

Main Components of the EVO Supercharger Kit

Supercharger Head Unit

The heart of the kit is the positive displacement supercharger, usually a Lysholm twin-screw or an Eaton TVS unit. EVO kits commonly use a Lysholm-type compressor for its efficiency and linear power delivery. The head unit has a specific part number for each Porsche application (e.g., for 996 Turbo or 987 Cayman S). When replacing, ensure you get the correct displacement and pulley ratio designed for your engine. Rebuild kits are available if the bearings or seals wear out.

Intake Plenum and Throttle Body Adapter

The supercharger bolts onto a custom intake plenum that distributes compressed air into the intake manifold. The plenum often incorporates a larger throttle body opening (e.g., 82mm to 90mm) and requires a matching throttle body adapter. Stock throttle bodies may not flow enough; EVO kits usually include an upgraded unit or a spacer. If you need a replacement, verify the bore size and bolt pattern.

Intercooler System

Most EVO supercharger kits include a liquid-to-air intercooler system. This consists of:

• Intercooler core: A heat exchanger mounted in the plenum or charge pipe.
• Coolant pump: Circulates coolant through the intercooler and a front heat exchanger.
• Reservoir tank: Holds the coolant mixture.
• Front heat exchanger: Mounted in the front bumper area to dissipate heat.

The intercooler core is a common upgrade point. Mishimoto and CSF offer high-performance cores that provide better heat rejection. The coolant pump, often a Bosch unit, can be replaced with an uprated pump from EMP Stewart if thermal issues arise.

Pulley System and Belt Drive

The supercharger is driven by a belt from the crankshaft. The kit includes:

• Crank pulley: Often an overdrive pulley to spin the supercharger faster.
• Supercharger pulley: Sized to achieve desired boost (typically 6-12 psi).
• Tensioner and idler pulleys: Maintain belt tension and routing.
• Drive belt: Kevlar-reinforced belt for durability.

Stock belts may slip at higher boost. Gates Green Stripe or Dayco belts are good replacements. Upgraded pulley sets allow boost adjustment; a 2-4 psi increase can often be done with a smaller supercharger pulley and proper tuning.

Fuel System Upgrades

To support the increased airflow, the kit includes:

• Fuel injectors: Usually high-impedance injectors sized from 440cc to 750cc depending on power level.
• Fuel pressure regulator: An adjustable regulator (e.g., Aeromotive A1000) to raise base pressure.
• Fuel rails: Some kits replace the stock rails to handle higher flow.
• High-flow fuel pump: In-tank pump upgrade (e.g., Walbro 255 or 450 lph) or an external booster pump.

Matching injectors to your specific tuning is critical. Commonly, Bosch 0280158117 or ID725 injectors work well. Always verify injector flow rates and impedance with your ECU tune.

Engine Management and Tuning

The kit usually comes with a reflash or piggyback ECU (e.g., Cobb Accessport, HP Tuners). This modifies fuel maps, timing, and boost control. Some kits include a separate boost controller. For trouble-free operation, use the supplied tune or have a professional tuner calibrate your ECU. If the ECU fails, replacement can be done via EVO directly or an authorized tuner.

Mounting Brackets and Hardware

Custom CNC-machined brackets mount the supercharger to the engine and the intercooler pump to the chassis. These are specific to each Porsche model (e.g., 996 vs. 997). Do not lose these bolts; they are often grade 10.9 or 12.9. If missing, source from EVO or a metric fastener supplier.

Intake and Charge Pipes

• Intake pipe: Connects the air filter to the supercharger inlet, usually 3” or 4” diameter.
• Charge pipes: Carry compressed air from supercharger to intercooler, then to the plenum. Silicone hoses and T-bolt clamps are typical.

Silicone hoses can be replaced with higher temperature-rated silicone (e.g., 4-ply) if heat soak is an issue. HPS or Vibrant Performance offer compatible couplers.

Bypass Valve (Blow-Off Valve)

To prevent compressor surge on throttle lift, the kit includes a bypass valve. Common choices are Tial Q or HKS SSQV. They are often recirculated (plumbed back into intake) or vented to atmosphere. For emissions compliance, keep recirculated. Springs can be swapped to adjust boost threshold.

Heat Management Components

Supercharger kits generate extra heat. EVO kits often include:

• Coolant expansion tank relocation: To make room for the intercooler system.
• Radiator shroud mods: To improve airflow.
• Heat shielding: Around the supercharger to protect intake air and components.

Ceramic coating or turbo blankets can be added for further heat reduction.

Common Replacement and Upgrade Parts

Supercharger Rebuild Kit

After 60,000-100,000 miles, the supercharger may need rebuild. A rebuild kit includes bearings, seals, and rotor coating. EVO offers rebuild services, but an authorized rebuilder like Supercharger Rebuilders can also do it.

Intercooler Pump Upgrade

The stock coolant pump is adequate for moderate boost but can be upgraded to a Bosch motorsport pump or EMP Stewart pump for higher flow and reliability. Use AN fittings and silicone hoses for best results.

Larger Throttle Body

If you are chasing high horsepower (>500 whp), consider a Billet Dynamics or Tial 90mm throttle body. Requires a plenum adapter and tune adjustment.

Boost Control Upgrades

For precise boost management, add an external wastegate (e.g., Turbosmart) and boost controller. This allows running higher boost without overshoot.

Oil System Modifications

High G-forces can starve supercharger bearings of oil. An inline oil filter or a separate oil cooler for the supercharger can extend life.

Installation Tips and Common Issues

• Hardware torque: Use exact torque values from the manual. Loose bolts cause boost leaks.
• Belt tension: Too tight wears bearings; too loose slips. Use a Gates belt tension gauge.
• Coolant bleeding: Intercooler system must be burped to avoid hot spots. Run the pump on high speed before driving.
• Tuning data logging: After install, run a few pulls and log fuel trims, knock, and boost pressure. Adjust as needed.
• Crush washer on oil feed: Always use a new crush washer to avoid leaks.

Where to Source Parts

When you need a specific component, contact EVO Performance directly. They provide individual parts, not just full kits. For aftermarket upgrades, reach out to specialists like BBI Autosport, Auto Federation, or Sharkwerks. Be ready with your chassis number and kit serial number to get correct fitment.

Final Recommendation

If you are assembling or maintaining an EVO supercharger kit for your Porsche, focus on the quality of the head unit, intercooler, and fuel system. These three areas determine reliability and power. Never cut corners on injectors or belt tension. Keep a log of part numbers and maintenance intervals. For a standard street build (500-550 whp), the kit components are excellent out of the box. For track use, upgrade the intercooler pump and consider a larger heat exchanger. Always have a professional tuner verify your setup after any parts change. By understanding each component, you can keep your supercharged Porsche running strong for years.