E46 M3 Underdrive Pulley Install (Power steering & Water pump pulley)

BY: 4getR34/m3forum

All tools used:

Flat head screw driver 8,10,13,16mm socket Torx 25,30,50 ½ drive torque wrench 1/4 ,3/8 wrench, extensions 32mm long wrench 1703 water pump pulley tool Loctite blue Safety goggles Trim removal tools or Needle nose pliers

Underside Splash Guard Access

Tools 8mm socket

Step 1: Put front of the on jack stands and ensure all proper safety for working under the car.

Step 2: Remove 7x 8mm screws from underside splash guard. It should slide out from front to back end direction.

Notes: When re-installing the splash guard, its easier if you slide it into place and secure it by starting with screws on the back (towards the rear of the car).

Remove Oil Cooler

Tools: T25

Step 1: Remove 2x T25 on either side of the oil cooler plastic housing. See Figure 1.

Step 2: There are two clips on the oil cooler housing that helps to hold it in place. Take the driver side of the oil cooler and slide it towards the rear of the car and it will come off. The oil cooler will hang from the driver's side. There is no need to disconnect the hoses- just move it to the side (See picture)

Looking up from bottom of the car, passenger side.

Oil cooler dangling. Source: evannever from m3fourm.

Air Intake Components Removal

Tools: Pliers Trim removal tool Flat head screw driver 8mm socket

Step 1: Remove 4x expanding rivets on suction hood using pliers. Pull the pin up with flat head, then remove body of the rivets with pliers. Remove suction hood (13) and air intake duct (12).

Step 2: Disconnect 2x xenon wires. Remove xenon box cover to access 2x 10mm hex bolt which secure top cover of intake cover.

Step 3: Remove top cover to intake air filter housing by unlatching 2x clips. Loosen intake clamps with flat head, you do not need to take the clamps off.

Step 4: Remove 8mm hex screws securing the xenon housing to the chassis. Remove air filter. Wiggle and pull up the intake cover towards fender. Cover up intake opening with tape.

Location of 8mm hex screws.

Fan Shroud Removal

Tools: T25 torx flat head screw driver pliers

Step 1: Disconnect wiring connector plugged into the shroud on the passenger side. There is another wire relay under the one on the top, you do not need to unplug this, just unlatch it from clips which retain it to the shroud.

Step 2: Remove 4x amount of expanding rivets on the fan shroud. There are two each on the passenger/driver side of fan shroud. They can be accessed from the top of the car.

Pulling out one of the rivets using trim removal tool.

Step 3: Remove 2x T25 from fan shroud from the top (One on each driver/passenger side).

Passenger side view.

Driver side view.

Step 4: Remove 2x T25 from the bottom of the shroud, they are located on the bottom corners where the plastic shroud is mounted to the radiator.

From under the car, passenger side view.

From under the car, driver side view.

Step 5: Remove passenger side shroud(4) and top shroud (5).

Step 6: Move the driver side shroud (6) towards the fender. There is no need to disconnect the radiator hose.

Driver side shroud moved.

Fan Removal

Tools: 32mm long wrench 1703 water pump pulley tool

Note: Ensure the fan is being held on while loosening 32mm nut and not dropped.

Step 1: Loosen by placing 32mm wrench on the nut and smacking from left to right (clockwise because it’s reverse threaded.) with a hammer.

Step 1: (Alternative). Using 1703 tool to seat the water pump pulley bolts loosen nut with 32mm wrench by torquing it clockwise.

Notes: The screws are staggered and you have to align them by turning the 32mm wrench clockwise in order for the 1703 tool to lock into place. There’s been discussions on the boards which mention that if you turn it counter clockwise you will likely put strain on the timing chain. If you want to turn it clockwise, make sure you have the car in neutral otherwise the car will move. I did not know this during my install and turn it counter clockwise, I have not experienced any issues as a result of this. Obviously if you decide to use this method to remove the fan, take the necessary precautions to ensure safety as your car will be on jack stands. I used stops at the rear wheels and backup jack stands under the car to ensure safety.

Step 2: Remove the fan and center shroud together. Hang it with clutch standing up (to prevent damage to blades).

Notes: I wiggled the fan out from the bottom first before sliding out the shroud from the top

Remove belts and tension from pulleys.

Tools: 8mm socket or 16mm Torx 50 flat head screw driver

Note: Mark down direction of spin on the belts incase it needs to be reinstalled.

Source: Bently Manual

Step 1: Relive tension from ac mechanical tensioner using a 16mm socket. This socket (4) is an attachment site and is used for leverage. Pull it clockwise to detension. There are two rings on the pulley tensioner casing which will line up when you detension it - stick a thick allen key through to hold it in the de-tensioned state. Remove belt.

Source: ECS Tunning

Step 2: Remove cap (17) on tension pulley using a flat head screw driver by twisting along the edge.

Step 3: Pull clockwise using a T50 on screw #7 to compress the hydraulic tensioner.

De-tension Idler pulley. Source: evannever from m3fourm.

Step 3a (if you have a mechanical tensioner like the one used for the AC Condenser): Use the same method as ac tensioner which comes with earlier e46 models. You can confirm the type of tensioner you have upon inspection.

Step 4: Remove serpentine belt

Remove pulleys

Tools: 10mm socket 13mm socket

Step 1: Loosen 4x 10mm bolts on water pump pulley.

Step 2: Remove power steering pulley

Step 3: Loosen 3x 13mm bolts on power steering pulley.

Step 4: Remove water pump pump pulley

Step 4a: Check for corrosion on bolts (use wire brush to remove rust if any).

Note: if any bolts are seized, use small amount of wd-40. Be careful not to get any onto the belt.

Pulley Install Tools: 10mm socket 13mm socket

Step 1: Put small amounts of Locktite Blue on bolts. Mount new pulleys and keep the bolts loosen. (logo faces out or shallow bevel face out for PS pulley).

Step 2: Install new underdrive belt (this should be included in your kit, do not use the original belt since the underdrive pulley requires a longer, 1538mm E46 non M belt with OEM part #11281706545).

Step 3: Install ac belt. Remove Allen Key used to hold it in the de-tensioned state.

Step 4: Install and cross tighten water pump pulley bolts based on the following recommended settings:

TMS/EVOSport ft*lb TMS/EVOSport in*lb Rogue ft*lb Rogue in*lb water pump 7.4 89 7-8 84-96 power steering 16 192 7-8 84-96

Verify install Before installing the cap cover for the idler tension pulley, start the car and let it run to make sure the belt is properly seated and does not fall off. Turn on ac to verify aux belt is also working. Turn off car.

References:

BMP Design talking about pulleys on m54 http://www.youtube.com/watch?v=3jJgZgCJhvQ&feature=PlayList&p=EA75724F8A05B465&playnext_fro m=PL&index=1

Why is the underdrive pulley heavier than stock? http://www.uucmotorwerks.com/udp/udp_info/about.htm

After market underdrive pulleys http://www.evosport.com/product/proddetail.aspx?partnum=EVO.PER.B46.P05 http://www.bavhypersports.com/products/driventrain/dtp5.htm (closed?) http://www.rogueengineering.com/Merchant2/merchant.mvc?Screen=PROD&Product_Code=POWERPULLE Y&Category_Code=PP http://www.turnermotorsport.com/html/detail.asp?PRODUCT_ID=PPK-S54 http://www.modbargains.com/_e/E46_Performance/product/UUC_UnderDrive_Pulleys_E46_MW/UUC_Und er_Drive_Pulley_Kit_99_03_E46.htm http://www.koperformance.com/BMW/engine/underdrive_pulleys/victory_product_design/victory_product _design_bmw_e46_m3_underdrive_pulleys.htm

After market DIY guides (Missing some details) http://www.turnermotorsport.com/pages/tms_ppk_detail.pdf http://www.rogueengineering.com/pdf/re_e46m3_pulleys.pdf

Other Related DIY

(S54) http://www.myonlinegalleries.com/LoadGallery.aspx?g=9000641680640901 http://www.m3forum.net/m3forum/showthread.php?p=4941092&posted=1#post4941092 http://www.m3forum.net/m3forum/showthread.php?t=124068&highlight=changing+belts&page=2

(M54/M52) http://forums.bimmerforums.com/forum/showthread.php?t=1473825&highlight=pulley (mech adjusting pulley) http://forum.e46fanatics.com/showthread.php?t=483472&highlight=pulley http://home.comcast.net/~jns-johnson/pulleyinstall.htm http://www.bmw330ci.net/maintenance/completecoolant.php http://forum.e46fanatics.com/showthread.php?t=634490&highlight=oil+cooler http://forum.e46fanatics.com/showthread.php?t=634490

Intake http://www.m3forum.net/m3forum/showthread.php?t=249779 http://www.youtube.com/watch?v=WDsGAYwNb7M (M54)

AC tensioner pulley http://www.youtube.com/watch?v=zaXmp7sFVj4 http://www.argyrides.eu/bmw/mods/wp_exp_ten/images/07B.jpg

Alternator pulley (Did not do) http://www.m3forum.net/m3forum/showthread.php?t=227995&highlight=water+pump+pulley&page=3 http://forums.m3cutters.co.uk/showthread.php?t=10943&highlight=pulley

Fan http://www.m3forum.net/m3forum/showthread.php?t=168780&highlight=water+pump+pulley&page=3 http://www.youtube.com/watch?v=GuKguZBW_MA&feature=PlayList&p=338E4EAF7E102DBC&playnext_fr om=PL&index=12 http://www.m3forum.net/m3forum/showthread.php?t=221529&highlight=fan http://forum.e46fanatics.com/showthread.php?t=696330&highlight= http://www.m3forum.net/m3forum/showthread.php?t=221529 http://www.m3forum.net/m3forum/showthread.php?t=295244 (m3)

Releasing belt http://www.youtube.com/watch?v=ENg25sIjNh0 http://www.pelicanparts.com/bmw/techarticles/E36-Belt-Replacement/E36-Belt-Replacement.htm http://www.m3forum.net/m3forum/showthread.php?t=124068&highlight=changing+belts&page=2 http://forum.e46fanatics.com/showthread.php?p=5440016#post5440016 http://www.m3forum.net/m3forum/showthread.php?t=124068&highlight=changing+belts&page=2

Alternator http://forums.m3cutters.co.uk/showthread.php?t=10943&highlight=pulley

How to loosen hydraulic (not mechanical) http://forum.e46fanatics.com/showthread.php?t=463302&highlight=pulley

Hydraulic tensioner composition http://forum.e46fanatics.com/showthread.php?t=410372&highlight=belt+tensioner

Hydraulic tensioner removal http://www.youtube.com/watch?v=lrNz6zZiA_U http://www.m3forum.net/m3forum/showthread.php?t=323671 (discussion about just the pulley removal) http://forums.bimmerforums.com/forum/showthread.php?t=1284446&highlight=pulley (mechanical and hydrolic tension unit) Mechanical Belt Tensioner Assembly.jpg (ac?) Hydraulic Accessory Belt Tensioner Assembly.jpg (accessories?)

Idler pulley (torx 50 to 40nm) http://www.youtube.com/watch?v=asu3FRyf7Ww&feature=player_embedded http://forum.e46fanatics.com/showthread.php?t=725088&highlight=pulley http://www.argyrides.eu/bmw/mods/wp_exp_ten/images/08.jpg

Torque Converter http://www.pitt.edu/~rsup/touqueconv.html

New belt http://www.pelicanparts.com/cgi-bin/smart/more_info.cgi?pn=11-28-1-706-545- M21&catalog_description=Belt%20for%20Alternator,%20Water%20Pump%20and%20Power%20Steering, %20BMW%20E46%203%20Series,%20All%20Except%20M3%20(1999-05),%20Each%20%20%20%20

RE and Stock Pulley Measurements: http://www.m3forum.net/m3forum/showthread.php?t=247242&highlight=pulley+weight&page=4