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      06-09-2009, 10:01 PM   #1
tom @ eas
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▀▄ eas | Rogue Engineering S65 Underdrive Pulley installation DIY

As most know, the heart of every BMW is its engine. When you blip the throttle to ask for power, the engine responds with the power that BMW designed into it. Well, almost all of the power.



The engine is also asked to drive specific accessories in the vehicle such as the A/C compressor, alternator, power steering pump and water pump. All of these crank pulley driven accessories inherently affect the engine's efficiency.

Underdriving the Overachievers
Rogue Engineering has developed a power pulley kit that reduces the drag on specific pulleys while allowing others to remain at their same efficiency. This allows for perfect operation in daily driven vehicles without a hiccup or stutter. However, when the demand of power is requested, the power pulley kit allows for the freed power to become apparent. To show the specifics of the Rogue Engineering Power Pulley Kits on a BMW engine, we show their effect and cause.

Rogue Engineering Power Pullies are machined from 6061-T6 heat treated aluminum and specially coated with a MIL-A-8625 Type III hardcoat anodize finish. This kind of anodizing is not to be confused with a Type II cosmetic anodize finish (typical colors such as red, black, blue, silver, green, etc.). The hardcoat anodize finish actually builds a small surface layer on top of the aluminum, preventing wear.

Until now, MIL-A-8625 Type III hardcoat anodize was not available in a deep, rich, black color. By working with our anodizing vendors, we have been able to implement a hardcoat anodize finish that we are proud to phase into our product line. This unique gloss, jet black anodize finish is unlike the "dark greyish-brown" of other dark hardcoat finishes. This unique finish is now standard on all Rogue Engineering pulleys.

Its all in the R&D

Rogue Engineering is proud of its motorsport association with its racing team partner ships which allow us to offer products used in professional racing. This association allows us to offer the BMW enthusiast the same parts being used in motorsport endurance racing. For example, our E46 M3 RACE pulley kit is a direct result of our involvement with Automatic Racing since 2005. Similar associations with Bimmerworld Racing continue to allow Rogue Engineering to develop parts that work in racing environments, not just bullet points on an internet based website.

Rogue Engineering Power Pulleys benefit all types of BMW models, not just manual transmission cars. BMWs including those equipped with Steptronic, SMG or All Wheel Drive can also benefit from the freed power of the pulleys.

Each Rogue Engineering Power Pulley kit comes complete with installation manual and high quality replacement serpentine belt.
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      06-09-2009, 10:01 PM   #2
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2008-5/08 6SPD models (non DCT) belts included, not shown


6/08+ and all DCT models belts included, not shown
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      06-09-2009, 10:02 PM   #3
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Lets begin:

Subject is a MY09 DCT-equipped M3, ready for new pulley installation:



1. Remove screws holding upper intake snorkel



2. Remove upper intake snorkel





Supper snorkel removed, ready for electric fan removal



3. Remove PCV valve



4. Remove intake duct





5. Remove airbox

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      06-09-2009, 10:02 PM   #4
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Downward view of pulley system, OEM crank pulley is silver in color



Downward view of pulley system, OEM power steering pulley is black in color

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      06-09-2009, 10:03 PM   #5
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6. Remove electric fan mounting (1 bolt, 1 clip), making clear of coolant overflow tube





Slide electric fan out of channel in an upward position



7. With accessory belt still attached, break loose mounting bolts



8. Retract tensioner and remove power steering/AC belt



9. Remove idler pulley



10. With accessory belt still attached, break loose crank pulley mounting bolts. Similar to step 8, retract tensioner pulley and remove crankshaft pulley belt.



You're complete. Install new Rogue Pulleys and reverse previous steps for installation.

Enjoy your newfound power!
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      06-09-2009, 10:03 PM   #6
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Belt routing:

2008-5/08 6SPD models (non DCT) belt routing


6/08+ and all DCT belt routing
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      06-09-2009, 10:45 PM   #7
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Thanks... EAS!

You guys are great!
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      06-09-2009, 10:56 PM   #8
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So the new additional pulley is larger than the OEM one. Should that help or hurt horsepower compared to the Active Autowerke setup?
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      06-09-2009, 11:08 PM   #9
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Quote:
Originally Posted by King Tut View Post
So the new additional pulley is larger than the OEM one. Should that help or hurt horsepower compared to the Active Autowerke setup?


Velocity = omega x radius (V = ωr)., so its just the opposite when referring to the driving pulley.
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      06-10-2009, 11:21 AM   #10
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So by using a new larger additional pulley you are overdriving that pulley and thus underdriving the crank more freeing up more horsepower.
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      06-10-2009, 11:25 AM   #11
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Quote:
Originally Posted by King Tut View Post
So by using a new larger additional pulley you are overdriving that pulley and thus underdriving the crank more freeing up more horsepower.
The RE crank pulley (and all other brands) are smaller than OEM, effectively allowing the accessories to spin at a slightly slower rate freeing up additional hp.
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      06-10-2009, 03:25 PM   #12
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Im not talking about the crank pulley Im talking about the included additional pulley being larger than the OEM one it replaces.
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      06-10-2009, 03:30 PM   #13
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Quote:
Originally Posted by King Tut View Post
Im not talking about the crank pulley Im talking about the included additional pulley being larger than the OEM one it replaces.
No, the replacement power steering pulley is the same diameter as stock.

Since the crank is already smaller on the RE side (referring to 6/08+ and DCT models only), there's no need to change the diameter.
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      06-10-2009, 06:27 PM   #14
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I guess it is the photos. It looked bigger to me. Oh well.
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      06-11-2009, 10:14 AM   #15
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a few questions Tom

1. Remove electric fan mounting (1 bolt, 1 clip) - can you show where is that bolt and clip? is it on each side ?
2. How do you retract tensioner pulley ?
3. What are the torque specs for crank pulley when you put it back ?
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      06-11-2009, 03:37 PM   #16
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Quote:
Originally Posted by doba_s View Post
a few questions Tom

1. Remove electric fan mounting (1 bolt, 1 clip) - can you show where is that bolt and clip? is it on each side ?
Here's a picture of the bolt, the clip is in the same position on the opposite side. There is only 1 bolt and 1 clip holding the radiator in place.



Quote:
Originally Posted by doba_s View Post
2. How do you retract tensioner pulley ?
Tensioner is hydraulic, you will need a 14mm socket with pressure in the clockwise direction.

Quote:
Originally Posted by doba_s View Post
3. What are the torque specs for crank pulley when you put it back ?
Torque specs are between 12-15ft lb.
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      06-11-2009, 09:43 PM   #17
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I will add that be very careful with the clip when reinstalling the fan. I broke mine during my install. Second I will say that you need ALOT of force to move the tensioner. You will probably want another set of hands so one can do the tensioner and one can take the belt off or put it back on.
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      06-18-2009, 05:36 PM   #18
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Quote:
Originally Posted by King Tut View Post
I will add that be very careful with the clip when reinstalling the fan. I broke mine during my install. Second I will say that you need ALOT of force to move the tensioner. You will probably want another set of hands so one can do the tensioner and one can take the belt off or put it back on.

o really ? sorry but which one is the tensioner for the crank pulley ?
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      06-26-2009, 01:23 PM   #19
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Tom can you show where is the tensioner for the crank pulley on this picture ?





thanks
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      06-26-2009, 06:33 PM   #20
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Quote:
Originally Posted by doba_s View Post
Tom can you show where is the tensioner for the crank pulley on this picture ?





thanks
Actually, they both are. What specific question do you have?
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      07-06-2009, 06:40 AM   #21
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Tom,

Correct me if I'm wrong, but based off what I recently learned, if I purchase a pulley set for a pre 06/08 build, I will only be changing out one pulley? Thanks!
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      07-06-2009, 11:15 AM   #22
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Quote:
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Tom,

Correct me if I'm wrong, but based off what I recently learned, if I purchase a pulley set for a pre 06/08 build, I will only be changing out one pulley? Thanks!
Correct, you will be changing only the crankshaft pulley as you have a single-sided belt system.
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