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I decided to experiment with installing a larger crank pulley on the B8.5 S5 but this will also work the same for the Audi B8.5 S4. I wanted to see just how simple I could make it. I am documenting this method as the quickest way I see to get an overdrive/lightweight/aftermarket crank pulley on the car.
This turned out to be much more simple than the supercharger pulley installation. I hope all the tuners will stop requiring the purchase of their proprietary supercharger pulley because this appears to be a much more hassle free way to go.
First, the thing that took half the amount of time...getting together all the right tools. I had no idea what ones I would need so having these ready to go ahead of time is going to really save you.
TOOLS:
1. M10 12 point metric bit (aka, triple square). If you use the seat puller bits you may want a 13mm socket to use with a socket wrench to turn it.
2. Low profile 3/8 Drive socket wrench
3. T30 Torx Bit with 1/4 Drive Socket Wrench
4. Generic surpentine belt wrench (for tensioners) with 16mm socket
5. Dremel or metal file
6. Whatever bit is required for fastening your new crank pulley bolts
7. Torque wrench
8. A medium sized nail you have sitting around or something like it. (for locking the tensioner in place)
9. A big screwdriver for the belly pan bolts.
STEPS:
1. Raise the car using a safe method such as Race Ramps. Engage parking brake. Chock rear wheels. Double secure your lift using jack stands, blocks, a spare tire, whatever you usually use. Remove your belly pan using a screwdriver.
2.
Using the generic serpentine belt wrench and a 16mm socket, rotate the supercharger belt tensioner clockwise and lock it in place with a nail. Remove the supercharger belt. It slides right out.
3.
Using the T30 Torx Bit and 1/4 drive socket wrench unfasten the bolt on the bracket of the dual lower hard metal coolant lines. This allows you to move the coolant lines out of the way as you access the 16mm bolt on the main serpentine belt tensioner.
4.
Again using the generic serpentine belt wrench and a 16mm socket, rotate the main serpentine belt tensioner and remove the belt from the crank pulley pushing it to the rear of the crank pulley. Dont remove the entire belt. Just push it off the crank pulley.
5.
Mark the bottom of the stock crank pulley with something sharp or some white-out or whatever you normally use to mark up parts. This is going to save you a tremendous amount of time when you go to install your new crank pulley due to the crank pulley having a single (1) offset hole out of the eight (8) total holes.
6.
Using a low profile 3/8 drive socket wrench with your 12 point M10 metric bit, remove the eight (8) crank pulley bolts from your stock crank pulley. Once removed the crank pulley is sitting on about 3mm worth of hub in the center. Wiggle the crank pulley back and forth a bit and it will slide right off. You could bang it slightly with a rubber mallet but this wasnt necessary on mine that is 3 years old.
7.
Now line up your old stock crank pulley with your new crank pulley. Line them up so the offset hole is in the same place (orientation) on both pulleys. Now mark a reference point on your new crank pulley just like you did on your stock one.
8.
Slide on your new crank pulley and put in each of the eight (8) new bolts torquing them to 20 ft/lbs or whatever the aftermarket manufacturer specs.
Make sure you have the main serpentine belt sitting behind the new crank pulley so that all you have to do is pull it back forward over the pulley once you have the new pulley on. Keep it wrapped around and to the rear of the pulley. Do this by just releasing it off the tensioner.
Make sure you cross torque and go back and check a second time since the first ones may be a bit loose again.
9.
Grind/file down the metal thing that sticks out off of the block. Take 3mm off of it.
10.
Put the belts back on.
Pull the main serpentine belt back up over the new crank pulley. It should be resting behind it if you oriented it behind it before you installed the new pulley.
Thread your new supercharger belt onto the new crank pulley and supercharger pulley. Using the tensioner, slide it back on and then release the tensioner.
11.
Dont forget to fasten the hard coolant pipe bracket back into place with that T30 Torx bit.
That's it. You're done. Put the belly pan back on and have some fun.
Mike
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Originally Posted by S4'ed
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