Difficulty level from 1 to 10 is 7
Price: $190
this mod freed up max 8HP and 10LBS/FT to the wheels. very impressive
Remove the bolts holding up the luggage bar

there is also an additional carpet pressure screw you have to pry out.


there are also little torx screws holding down the edge of the panels that I found easier to slide the carpet in and out when removing these.

I used the pulley removal tool...

before realizing that you can just use a screw as well...

I have an audi, on the audi it also has this place to screw in a bolt to hold down the pulley. The Cayman has the same thing here. Just turn the pulley so that one of the holes are between 10-11 o'clock and thread the bolt in.

This allows one person to remove the pulley with ease.

once removed I use a cut off wheel to cut down the removal bolt sleeve...

30seconds later... yes my engine is clean and yes I vacuumed the tiny micro aluminum dust particles.

The new pulley is smaller but heavier.

11.3oz for the stock one.

13oz for the new one pulley (2.8oz heavier)

The advantage is not in the weight but the smaller size. I matched the stock notch on the new pulley.


made a notch in it to match the stock one

 

put the pulley in place, it can only go on one way

now use the installation tool provided

tighten to 50nm plus a 1/4 turn

use your torque socket wrench to measure the tightness and your done!

actually put it back together and your done!
I dynoed the car... I will post it when I find it. This was a while back, 3 pulls the average was an increase of 5-8HP and 7-10LBS/TQ to the wheels. (Dynapack Dyno)

 

Great article!!!
1.What is the Notch you made in the Pully for ? and how did you make it
2.did you use the same belt? or is a smaller one needed
3.did they supply you with the pulley removal tool ?
Thanks

 

Great thread. Thanks for sharing it.

 

I know this thread is years old, but I just came across it, great pictures, thanks. The notch is used to line up with a mark on the engine case which indicates that the #1 cylinder is at top dead center, TDC.

 

Another bump of an old thread, but the best I've seen so far on the topic...

 

Throw back thread! Great write up though, nice write up and illustrations to help further explain the process.

 

Just did the install tonight....

Not much to add, went pretty smoothly. Hardest part is just climbing in or reaching behind the seats to work.

Test drive tomorrow!