POWER PULLEY KIT FOR E90/E92/E93 M3 S65 V (After 05/2008+) 6 SPEED MANUAL AND DCT TRANS Part # PPK-S65-L

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1 Turner Motorsport Inc, 16 Hunt Road South, Amesbury, MA / DBM 4/08/13 POWER PULLEY KIT FOR E90/E92/E93 M3 S65 V (After 05/2008+) 6 SPEED MANUAL AND DCT TRANS Part # PPK-S65-L Get MORE HORSEPOWER and TORQUE on your M3 by replacing the stock crank pulley with this specially designed performance version. The Power Pulley reduces rotational mass and safely underdrives your belt driven auxiliaries for reduced parasitic power loss. The end result: More power to the rear wheels on your M3! These have been designed to give the best performance benefit with no sacrifices or compromises to your BMW's reliability. They have been tested on hundreds of cars before public release and there are simply NO DOWNSIDES to this upgrade. We manufacture these pulleys using aircraft grade 6061 aluminum billet, CNC machined to better-than factory tolerances, and anodized with a stealthy black coating. Other brands may advertise "their" crank pulley boasting higher numbers (using a smaller pulley profile), but we have concluded that for street or track driven M3, this is the best size and design to ensure proper engine temp and auxiliary function. As the S65 V8 engine doesn't use a traditional harmonic balancer, all factory harmonics and dampening are fully and properly retained. We've found this pulley alone adds 10 to 14 HP and 7 to 9 Ft/lbs torque on a stock M3 with no other changes! Fits the following BMWs: 2008 E90/E92/E93 M3 6 Speed Manual Transmission (After 05/2008) E90/E92/E93 M3 6 Speed Transmission E90/E92/E93 M3 DCT Double Clutch Transmission When would it be a good time to perform this work on my car? When servicing main dive belts or any front of engine maintenance. Install time: Approximately hours depending on mechanical abilities and condition of automobile. Parts list for kit: 1 - TEN Crank Pulley 6 - M8 Flat Washers 6 - Female Torx M8 x bolt with washer 1-6PK1440 Belt 1-6PK1100DS Belt

2 Directions start on next page Directions: 1. Remove rear intake duct. Hardware two - Torx bolt T20 2. Loosen two hose clamps on intake tube and place intake tube off to one side. No need to remove small hose from intake tube. Tip: place a rag over the plenum with the hose clamp to prevent debris from entering engine. 3. Remove air box. Hardware two 6mm bolts. 2

3 4. Remove fan shroud - Unclip small upper and lower hoses from fan shroud, Do not disconnect any lines or fittings. Unplug fan wiring and set aside. Remove torx bolt on right side of fan shroud. Undo clip on left side of fan shroud. Carefully lift out fan and shroud starting with the left side. This will take some negotiating. 5. Note the routing of the A/C / Power Steering belt (front belt, blue in diagram ) and the main serpentine belt (rear belt red in diagram ). Re-installation follows the same routing so be precise! BMW equipped the M3 with two different belt configurations, but failed to accurately distinguish which cars came with which. The belt diagram below refers to the LATER style. If your car is different than shown, contact Turner Motorsport right away. You have one of the few cars built during the changeover. Do not continue with the installation as the belts and pulley are different. 3

4 6. To remove the A/C / Power Steering belt, pry the black plastic covers from the center of the tensioner pulley. Rotate the tensioner pulley clockwise with a 14mm socket and free the belt. 7. Remove the 16mm bolt for the A/C / Power Steering idler pulley and set pulley aside. 8. To remove the Alternator / Water Pump Belt, pry the black plastic covers from the center of the tensioner and idler pulleys. Rotate the tensioner pulley clockwise with a 14mm socket and free the belt. 4

5 9. Remove the 6 female (T45) Torx bolts holding the crank pulley and crank rotator stud to the harmonicbalancer. Do not remove the four Torx bolts located at the center of the crank pulley! 10. Remove the stock crank pulley and crank rotator stud. Note: the stock crank pulley, crank rotator stud, and 6 M8 female Torx bolts will not be reused. 11. Remove rust from the crank pulley mounting surface on the harmonic-balancer with scuff pad by hand. 12. Install the new crank pulley with the, the new 6 female Torx bolts and second M8 flat washers supplied in kit and Blue Loctite. Torque to 24ft-lbs in a crisscross pattern. 13. Install new 6PK1440 Alternator / Water Pump belt following the routing that you noted earlier. 14. Reinstall stock A/C / Power Steering idler pulley with the original bolt. 15. Install A/C / Power Steering belt following the routing that you noted earlier. 5

6 16. Reinstall each of the 3 black plastic pulley covers (they just snap into place). 17. Reinstall fan shroud in the reverse of removal. Note you may want to remove the front undertray to make sure you clip lower hoses into fan shroud correctly. 18. Reinstall front undertray if removed. 19. Reinstall airbox air ducts in the reverse of removal. 20. Start the engine and observe belt routing and the new crank pulley and stock A/C idler pulley. Make sure both are running true (no wobbles). Safety glasses are strongly recommended for this step. 21. With engine off ensure the belts are properly seated on all pulleys. 22. Drive and enjoy! 6