Undersized Crankshaft Pulley
The undersized pulley is available through unorthodoxracing.com and can be found on the web by using the link provided. Group buys through Volvospeed are possible. This pulley is undersized by 15% instead of 20% normally done to undersized pulleys, this makes it a bit conservitive and better suited to the daily driver. With a 15% reduction you will have less output out of your alternator, so if you are running a big intertainment rig in your car you need to consider this. The stock Volvo pulley weighs 4 pounds 9 oz., the UR pulley weighs in at 11.6 oz. Undocumented claims include; a reduction in turbo lag, 8 to 10 HP gain at the wheels. There is a serpintine belt change required when installing the pulley, Gates K060630 which can be purchased at NAPA. This Gates belt requires the old serpentine belt routing.
Tools Needed:
Serpentine belt tool, I used a 3/4 drive for the belt
13mm socket to remove the pulley bolts, and a puller to break the pulley free from the shaft,
30mm socket and drive to rotate the crank pulley.
Start by putting the car up on jack stands and removing the right front wheel. Then pull back the plastic fender cover and secure it out of the way. Take the serpentine belt off. Remove the 4 13mm bolts that hold the pulley on the crankshaft. You can use the 30mm socket and drive to rotate the pulley so you can get to all the pulley bolts. Once the 4 bolts are off, remove the 30mm nut that holds the pulley to the crank, then you can use a puller to start/break the pulley loose from the crank.
Once the pulley breaks loose, you can move it out of the way. When you are pulling the pulley off with the puller, you may find that the sprocket gear on the crank might have moved out a bit, just tap it back towards the engine.
Install the new UR pulley, start the 13mm bolts to hold it in place, hand tighten them. Tighten the center crankshaft nut to 133 LbFt., then go back and tighten the 13mm nut to 18 LbFT. and 30 degrees. Install the serpentine belt and you are good to go.