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Installing upper pulley by heating it?

12K views 9 replies 6 participants last post by  Liqidvenom  
We did a pulley swap on my wife's Audi with the supercharged 3.0 TFSI engine and it worked fine. We used a toaster oven and had to heat the pulley for about an hour at 400-450F.

A few thoughts:


1)I would not use a torch or heat gun - the temps are too high and heating won't be uniform and can warp things. You need a super tight fit...

2) Have some really good heat proof gloves to handle the pulley with once it's hot. Tongs or pliers can work too, but it's really awkward to handle and manipulate the hot pulley with anything other than gloves, and you need to slip it on the cold shaft very quickly and uniformly.

3) Have one of those "air in a can" spray dusters handy. Once you slip the hot pulley over the shaft, invert the can and spray the liquid over the entire pulley to cool it quickly. Spray the whole pulley as uniformly as possible to ensure it cools evenly. This should lock in on securely.

All of this assumes that the fit is just right. The swap we did used a pulley designed to be heated and slipped on (we still had to use a jaw puller to remove the stock pulley...)

Also worth noting that on a V, the supercharger uses quite a bit of HP, so the torque on the input shaft can be pretty high. On the Audi the overdrive ratio is much lower and the engine smaller. The SC is a 1.7L on a 3.0 liter engine so you don't have to spin the hell out of it. The heat-and-slide method may be better suited for lower supercharger input loads, but it could definitely work fine on this as well.