(How-To)Installing lightened crank pulley

[HFSDevil]

Since there is not one of these posted anywhere I decided to make one while I installed mine :D

I just got my Mr. Josh lightened (non-underdriven) crankshaft pulley the other day, and installed it last night.

There is a little bit of engine noise increase due to the fact that on the stock pulley it has sound dampening stuff on it and the new one doesnt. There is just a little bit of a whine, nothing annoying or bothersome, but enough to let you know something has been changed. The engine revs much faster due to the less rotating mass.

The installation was a bit hairy, but nothing too bad....

:THINGS NEEDED:

- New pulley
- 1/2 inch drive breaker bar with 7/8 inch socket
- 1/2 inch socket driver
- 3/8 socket driver with 10mm and 12mm socket
- Breaker bar extension pipe (You can improvise. Just something to put over the end of the 1/2 inch socket wrench so you can hold it)
https://sl-i.net/FORUM/images/imported/2005/08/h-1.jpg
- Torque wrench
- Pry bar
- 2-2X4
- 2 friends
- 1 Case of beer

:INSTALLATION:

- First remove the intake inlet by removing the 2 10mm bolts that hold it onto the radiator shroud. (If you have a CAI (Cold-Air Intake) you do not have to do this since it is already gone.)
https://sl-i.net/FORUM/images/imported/2005/08/a-1.jpg
- Remove the belt covers by removing the 2-10mm bolts and just LOOSEN the 12mm bolt so the cover can come off, and also remove the 1 nut (10mm).
https://sl-i.net/FORUM/images/imported/2005/08/b-1.jpg
- Loosen and remove the serpentine belt that connects the water pump, alternator, and crankshaft by loosening the two tensioner bolts.
https://sl-i.net/FORUM/images/imported/2005/08/c-1.jpg
- Loosen and remove the A/C-crankshaft (Air conditioner) belt by loosening the other two tensioner bolts.
https://sl-i.net/FORUM/images/imported/2005/08/d-1.jpg
- Use the 1/2 inch drive breaker bar with a 7/8 inch socket on the bolt for the pulley. Make sure you have an extension for the bar (some form of pipe to fit over it.)
https://sl-i.net/FORUM/images/imported/2005/08/f-1.jpg

https://sl-i.net/FORUM/images/imported/2005/08/g-1.jpg

https://sl-i.net/FORUM/images/imported/2005/08/g2-1.jpg
- Place the 2X4s ontop of the battery in such a way that the breaker bar/extension can rest on it.
- Have 2 people hold onto the breaker bar/extension so it doesnt fly away while the 3rd person slighty turns the motor over (Turn the key JUST A TINY BIT! DO NOT START THE CAR!!!!!) This will break loose the bolt since it is torqued on well over 120 pounds.
- Use 1/2 inch socket driver with 7/8 inch socket to take the bolt off the rest of the way. Once off the pulley WILL NOT fall.
- Use the pry bar on the stock pulley to take it off the crankshaft. *NOTE* Be VERY careful doing this because behind this pulley is plastic that covers the camshaft belt and you DO NOT want to mess it up.
- The pulley is idiot-proof since there is a notch for alignment and it will only go on one way.
- Put the crankshaft bolt back on and tighten it until the engine starts to turn.
- Remove the cap that covers the torque-converter (automatic) or flywheel (manual) and you will see the top of a disk with rectangular holes in it. (It is on top of the bellhousing, below the intake manifold)
https://sl-i.net/FORUM/images/imported/2005/08/e-1.jpg

https://sl-i.net/FORUM/images/imported/2005/08/e2-1.jpg
- Place the pry bar into one of these holes and have somebody hold it. It will spin clock-wise.
- Set the torque wrench to 115 pounds and while somebody is holding the pry bar on the torque-converter/flywheel, torque the bolt.
- Reinstall cap to the hole for the torque-converter/flywheel.
- Reinstall the A/C-crankshaft belt and tighten the tensioner bolts.
- Reinstall the serpentine belt that connects the water pump, alternator, and crankshaft and tighten the tensioner bolts.
- Reinstall the belt covers
- Reinstall the intake inlet
- DRINK BEER!!!!!

[pdawg]

Great write up. 2 friend and only one case of beer and you make them finish before they can drink it. you are the devil.

[Reason]

Great write up, but more than half that case of beer should be gone before you are done.

[HFSDevil]

Drunk people can't work, and if you are drinking, u are not working.

The beer at the end is an incentive.... :lol:

[InSaNe AzN KiD]

ur welcome for some of those instructions HFSDevil 8)

[Plays_with_Toys]

So the engine revs quicker and there's some sound, any thing else? Quicker throttle response/acceleration, anything?

BTW I have your sound clip, but it doesn't sound any better than the one you already posted.

[HFSDevil]

Yes Insane thank you for your help :)

Plays: Yes, that is about all the pulley adds to. I notice I am quicker off the line, and going through the gears, which was definetely needed.

[Perdue]

A lightened pulley (more so a pulley set) has been named as one of the best modifications for the automatic subies. I plan on doing and whole set before long (Alternator, Power Steering, and Crankshaft)

[HFSDevil]

Well the only sets I found are underdriven. I have not found non-underiven alternator or power steering pulleys.

Also looking at the power steering and laternator pulleys, they look pretty lightweight to begin with. I could be wrong though.

Anybody eklse find any non-underdriven alternator and power steering pulleys???

[Plays_with_Toys]

Does the mod have as dramatic an effect on manuals too? I just checked ebay and they have aluminum ones for $25, how much was yours?

[HFSDevil]

I did mine in a group .buy from Mr. Josh for $80. Normally from him they are $90.

[InSaNe AzN KiD]

Does the mod have as dramatic an effect on manuals too? I just checked ebay and they have aluminum ones for $25, how much was yours?

For a MT, these are good if u alredy got a lightened flywheel.
it's either 1 or the other, usually ppl pick the fly.

[scottzg]

http://www.spdusa.com/pulley_kit.htm

[importtund]

Anybody eklse find any non-underdriven alternator and power steering pulleys???

www.boxer4racing.com (http://www.boxer4racing.com)

[Plays_with_Toys]

Wow old thread. I actually installed my lightweight pulley last week.

I LOVE IT! Give's the little 2.2 liter a good initial punch and makes first gear starts super smooth. Feels just a little more powerful in the 2000-3500rpm range.

[ryankenn]

http://www.spdusa.com/pulley_kit.htm

As much as I like his dialogue, its hard to take advice from a website setup from the default Frontpage 2000 template with checkplate background. NICE SETUP. That shit right there is worth 2HP in bandwidth savings.

[Wiscon_Mark]

As much as I like his dialogue, its hard to take advice from a website setup from the default Frontpage 2000 template with checkplate background. NICE SETUP. That shit right there is worth 2HP in bandwidth savings.

Would all sorts of advertisments and lots of hi-res WRX pictures make it more credible? :roll:

There is very good information in there.

[Huffer]

I might be swapping the GFB to a new vehicle in the spring. Something with a 5spd. ;)

[Khanhfucious]

I LOL'd at the breaker bar extension

[jewbaru]

whats the difference between underdriven and non underdriven ?

[jewbaru]

and whats up with HFSdevils radiator? is that an STI radiator or is that juat a sticker he put on there?

[harrymaneuvers]

Under driven is a pulley that has a diameter less than stock.

Taken directly from Wikipedia:

Definition

An Underdrive pulley refers to an aftermarket crankshaft or accessory pulley (such as an alternator pulley) that is designed to drive a vehicle's accessories at a slower rate than stock. Underdrive in general means the input rate of rotation in a system is greater than the output rate of rotation. However, an underdrive pulley is considered to be an accessory pulley that is larger than the stock pulley or a crankshaft pulley that is smaller than the stock crankshaft pulley, even though the accessory may not necessarily be underdriven with respect to the crankshaft pulley.
[edit] Typical Usage Scenario

Underdrive pulleys usually are marketed as a performance enhancing item that increases the torque and horsepower output of an engine by reducing parasitic drag caused by belt-driven accessories, but more importantly by reducing the moment of inertia. Horsepower gains from underdrive pulleys alone are usually minimal, 1-3 wheel horsepower depending on the engine.[citation needed]

[jewbaru]

Shit man lol thanks. Shoulda done a little offsite research

[ESSYMOND]

a whole kit is worth $250 on boxer4racing... really?

[jewbaru]

yea, i just say that lol. 250 is a tad steap. i read someone found one on ebay for 20 bucks?

im thinkin like 150 would be my max if i could find a kit around that price