Toyota GR86, 86, FR-S and Subaru BRZ Forum & Owners Community - FT86CLUB

I just received my Light Weight Crank Pulley in the mail today. Decided to make a DIY tutorial for those who need a visual walkthrough. The most I've ever done to an engine was change a fuel filter and alternator on an integra years ago. This was a bit of a scary endeavor that worried me but I felt brave enough after carefully reading through the 2 page installation guide provided.

Tools needed:

Flat head screwdriver
Phillips head screwdriver
10mm socket wrench
Breaker Bar **
1/2" Torque Wrench**
14mm socket 1/2" Drive
22mm sock 1/2" Drive

** I didn't own my own breaker bar or torque wrench but for a $125 dollar refundable deposit you can borrow one from Autozone!

http://www.lastonehere.com/misc2012/.../perrin-1s.jpg
http://www.lastonehere.com/misc2012/.../perrin-2s.jpg

We will start by loosening the screws circled in blue that holds the intake and resonator tube together. Uncouple the oxygen sensor from the intake as denoted by the green arrow. Then use the 10mm socket to remove screws circled in red the resonator box and air intake (the third screw is to the right and is a bit of a squeeze to reach).
http://www.lastonehere.com/misc2012/.../perrin-7s.jpg
Remove the air intake and then move the tubing off to the right side.

http://www.lastonehere.com/misc2012/.../perrin-5s.jpg
With the intake out of the way you can see the tensioner pulley in blue and the crank pulley in red. We'll have to loosen the belt first by moving the tensioner pulley (note: not removing or loosening the bolt holding the tensioner pulley)

http://www.lastonehere.com/misc2012/.../perrin-8s.jpg
Using the breaker bar and the 14mm socket, turn it clockwise. When you apply leverage with the breaker bar it will move the whole tensioner pulley to the left giving slack to the belt. Slide out the belt from tensioner pulley and let go of the break bar gently. The tensioner pulley will slide back into it's normal spot.

http://www.lastonehere.com/misc2012/.../perrin-9s.jpg
Here is how the belt will look when loosened.

http://www.lastonehere.com/misc2012/...perrin-10s.jpg
Now make sure the car is in 6th so the crank will not turn when you loosen the bolt. With the breaker arm and the 22mm socket, you will need a good tug counter-clockwise to loosen the bolt. It will feel spongy because of the crank slightly turning but with the car in 6th gear it will not spin freely. Give a good yank.

Word of warning: It will require a bit of force so much so that tennis shoes are required to give you grip. And don't wear a belt or jeans! you'll risk scratching your bumper!

Once it's loosened you can remove and set aside the bolt and crank pulley shown below. Be careful as they will be hot to the touch if you have recently driven your FRS/BRZ!
http://www.lastonehere.com/misc2012/...perrin-11s.jpg
Admire the differences in weight and finish between the OEM and new crank pulleys!

http://www.lastonehere.com/misc2012/...perrin-12s.jpg
http://www.lastonehere.com/misc2012/...perrin-13s.jpg
To install the crank pulley you will have to line up the key hole show above. Make sure the crank pulley is facing the right away with the threading inwards.

http://www.lastonehere.com/misc2012/...perrin-14s.jpg

In the case of the crank pulley lettering logos should be facing towards the front. With the crank pulley aligned with the keyhold correctly it should not be able to turn freely at all.

http://www.lastonehere.com/misc2012/...perrin-15s.jpg
Get some motor oil and grease up the threads and flat surface of the bolt head before inserting back into the pulley.

http://www.lastonehere.com/misc2012/...perrin-16s.jpg
You will need to torque the bolt to 94lbs. Those of you not familiar with torque wrenchs you will turn the black grip until the zero "0" lines up with the 85 marking shown above. You then turn the grip until the 9 is lined up center. 85+9 = 94lbs

I must of forgotten to take a pic of this step but it is pretty straight forward. Using the torque wrench and 22mm socket you tighten it until you feel and hear a distinctive click.

http://www.lastonehere.com/misc2012/...perrin-17s.jpg
Now you will have to use the breaker bar and 14mm socket and move the tensioner pulley just enough so the belt can reseat onto all the pulleys. It will be a little tough as you seat the belt on one pulley and it comes loose off another pulley. Quite Annoying but use the reference picture below of how the belt should line up.
http://www.lastonehere.com/misc2012/.../perrin-6s.jpg

Inspect the belt and make sure it is seated properly on all the pulleys before reassembling the air intake and resonators in reverse order. Remember to reattach the oxygen sensor or you will get CEL. Start the engine up and watch the crank pulley and belt. If all goes well you have installed an awesome and very affordable upgrade to your FRS/BRZ!

Return breaker bar and torque wrench to autozone and get your money back! Drive back home the long way and laugh maniacally as you wide open throttle every chance you get with your new crank pulley!

Enjoy!

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