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Upgraded Supercharger Pulley

Jaguar XKR XJR - Range Rover sport

Please read through instructions thoroughly before starting.

Remove bonnet.

Remove pulley belt and check its condition, if it looks like fig 1, with lots of cracks in the grooves then it needs replacing!!

Mark a line around the rear of the pulley onto the supercharger. This will be used later for a reference when filing.

Now grind away the front section of the old pulley nose cone to a flat as in the fig 2,3 and 4 until you grind down to the shaft. It is important to grind this all the way down until a hairline crack appears in the nose of the pulley. Then cut down through the side of the pulley to meet the first cut. Use the second groove in as a guide. See fig 3.

It should then knock off very easily

If you have a pulley puller available this is better than trying to knock the old one off as it avoids the possibility of damage to the bearing.. Note there is a hairpin style clip in front of the bearing holding the bearing cover in place. Be careful not to loose this!

THIS IS VERY IMPORTANT!!!
Once the pulley is off you need to file down the nose cone of the supercharger as far back as the line that was marked earlier. Obviously this is to allow the smaller pulley to fit over the nose of the supercharger. You will be supplied with a Nylon dummy pulley to ensure correct fitment. the Nylon pulley has a "window" cut into it so you can see where more filing is needed. The nylon dummy should push all the way on and move freely. This needs to be done in a precise manner, so that the nose cone is 54mm diameter or less. The best tool for the job is an air file or belt sander if machining is not an option. Once the nose cone is filed down and the dummy pulley fits ok we are ready to fit the new pulley.

Have the pulley near to the vehicle when heating it as time is critical here. Within a few feet is good! Heat the pulley using oxyacetylene or a good blow torch. As the pulley heats up it will change colour.

This is important
It will first turn BLUE.. Keep the heat on… Next it will turn dark GREY… Once grey, keep the heat on For a further 30 sec or so. DO NOT LET IT GLOW ORANGE!!! Once it has turned grey, pick up the pulley using welding gloves or similar and place on the shaft, it should slide on easily with no interference. TIME IS OF THE ESSENCE… BE QUICK you have about 30-40 sec before it will cool enough to start gripping the shaft.

This is important
The nose of the new pulley should line up with the end of the shaft to within 0.5mm to ensure the belt runs true. It should look like fig 7 & 8. If it does not, remove the pulley quickly and find out why!! Ensure the pulley can rotate freely and does not bind anywhere, if it does, remove it! And re-assess the situation

Allow the pulley to cool naturally.

Refit belt and bonnet

Job Done!!