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Metco Lower Install
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<blockquote data-quote="2F2F" data-source="post: 454424" data-attributes="member: 6314"><p><em>I plan to edit this as I go along...</em></p><p></p><p><strong>A Numerical Recap:</strong></p><p></p><p>1. Note stock locations of brackets, wire sets and hoses bolted to the lower cage.</p><p>2. Secure the vehicle on jack stands and use wheel blocks if required.</p><p>3. Have a friend apply the brakes when torquing the 14mm lower crank pulley.</p><p>4. Loosen the power steering fluid reservoir (three 10mm hex screws)</p><p>5. Remove the nuts and bolts of the lower cage prior to torquing the 14mm crank pulley</p><p>6. Light sanding may be required to fit the new pulley hub onto the stock dampener.</p><p>7. Insure that wire sets and hoses are clear of the A/C compressor.</p><p>8. There is a good amount of wrenching to be done in and around tight spaces. </p><p></p><p><strong>Additional Notes:</strong></p><p></p><p>1. There is a considerable amount of play when attempting to free the 14mm crank pulley. Be patient and above all, be strong. Removal of the lower crank pulley requires greater torque than does the removal of the supercharger pulley. Be sure to keep the supplied 14mm hex aligned with the crank pulley, else run the risk of bending the stock pulley assembly.</p><p>2. Clearance is tight when fitting the 14mm hex key and 1/2" drive between the engine fan and lower crank pulley. Come in at an angle and wiggle the hex key in.</p><p>3. Setting the vehicle into 4th, 5th or 6th gear before torquing the 14mm lower crank pulley is recommended.</p><p></p><p><strong>Personal Notes:</strong></p><p></p><p>1. Installed unresized 2 lb. lower ring. Revised 2 lb. pulley ring to be installed when production run commences. Would have gone with the revised 4 lb. ring, but wanted to avoid CA summer heatsoak. Will consider a 4 lb. ring when FLUIDYNE releases their '03-specific heat exchanger for general consumption.</p><p></p><p><strong>Recommended Tools & Accessories:</strong></p><p></p><p>1. 1/4" ratchet drive (for tight spaces)</p><p>2. 3/8" ratchet drive (for general use)</p><p>3. 1/2" ratchet drive (for belt tensioner and crank pulley cage removal)</p><p>4. 18.0" SCH 40 steel pipe (for use over 1/2" ratchet drive as a breaker bar)</p><p>5. 5mm Allen wrench (for idler bracket assembly)</p><p>6. 6mm Allen wrench (for idler bracket assembly)</p><p>7. 8mm hex key to 3/8" hex socket (for pulley hub and ring installation)</p><p>8. WD-40 or comparable product (for nut removal and thread cleaning)</p><p>9. Loctite Tite’N for Bolts (for threadlocking)</p><p></p><p><strong>Nuts & Bolts - Installation Instructions: Picture #1</strong></p><p></p><p>A = 10mm hex socket </p><p>B = 13mm hex socket </p><p>C = 13mm hex socket </p><p>D = 13mm hex socket </p><p>E = 13mm hex socket </p><p>F = 14mm hex key (supplied by manufacturer)</p><p>G = 10mm hex socket </p><p></p><p><strong>Nuts & Bolts - Installation Instructions: Picture #2</strong></p><p></p><p>A-1 = 5mm hex key or Allen</p><p>A-2 = 5mm hex key or Allen</p><p>B = 18mm hex socket</p><p>C = 6mm hex key or Allen</p><p>D = 10mm hex socket</p><p>E = 8mm hex socket</p><p></p><p><strong>Recommended belt size:</strong></p><p></p><p>1. Pulley Boys 3.10" upper</p><p>2. Metco 2 lb. lower (unresized)</p><p>3. Metco idler in top position</p><p>----------------------------------------</p><p>Use a 78-5/8" NAPA/Gates #080780</p><p></p><p>1. Pulley Boys 3.10" upper</p><p>2. Metco 4 lb. lower (resized)</p><p>3. Metco idler in top position</p><p>4. Metco 3.20" alternator pulley</p><p>----------------------------------------</p><p>Use a 79-3/4" Gatorback #4080797</p><p></p><p>Much thanks and appreciation to Dana for starting this thread...</p><p>And to others for helping me through my initial installation =>) !</p></blockquote><p></p>
[QUOTE="2F2F, post: 454424, member: 6314"] [i]I plan to edit this as I go along...[/i] [b]A Numerical Recap:[/b] 1. Note stock locations of brackets, wire sets and hoses bolted to the lower cage. 2. Secure the vehicle on jack stands and use wheel blocks if required. 3. Have a friend apply the brakes when torquing the 14mm lower crank pulley. 4. Loosen the power steering fluid reservoir (three 10mm hex screws) 5. Remove the nuts and bolts of the lower cage prior to torquing the 14mm crank pulley 6. Light sanding may be required to fit the new pulley hub onto the stock dampener. 7. Insure that wire sets and hoses are clear of the A/C compressor. 8. There is a good amount of wrenching to be done in and around tight spaces. [b]Additional Notes:[/b] 1. There is a considerable amount of play when attempting to free the 14mm crank pulley. Be patient and above all, be strong. Removal of the lower crank pulley requires greater torque than does the removal of the supercharger pulley. Be sure to keep the supplied 14mm hex aligned with the crank pulley, else run the risk of bending the stock pulley assembly. 2. Clearance is tight when fitting the 14mm hex key and 1/2" drive between the engine fan and lower crank pulley. Come in at an angle and wiggle the hex key in. 3. Setting the vehicle into 4th, 5th or 6th gear before torquing the 14mm lower crank pulley is recommended. [b]Personal Notes:[/b] 1. Installed unresized 2 lb. lower ring. Revised 2 lb. pulley ring to be installed when production run commences. Would have gone with the revised 4 lb. ring, but wanted to avoid CA summer heatsoak. Will consider a 4 lb. ring when FLUIDYNE releases their '03-specific heat exchanger for general consumption. [b]Recommended Tools & Accessories:[/b] 1. 1/4" ratchet drive (for tight spaces) 2. 3/8" ratchet drive (for general use) 3. 1/2" ratchet drive (for belt tensioner and crank pulley cage removal) 4. 18.0" SCH 40 steel pipe (for use over 1/2" ratchet drive as a breaker bar) 5. 5mm Allen wrench (for idler bracket assembly) 6. 6mm Allen wrench (for idler bracket assembly) 7. 8mm hex key to 3/8" hex socket (for pulley hub and ring installation) 8. WD-40 or comparable product (for nut removal and thread cleaning) 9. Loctite Tite’N for Bolts (for threadlocking) [b]Nuts & Bolts - Installation Instructions: Picture #1[/b] A = 10mm hex socket B = 13mm hex socket C = 13mm hex socket D = 13mm hex socket E = 13mm hex socket F = 14mm hex key (supplied by manufacturer) G = 10mm hex socket [b]Nuts & Bolts - Installation Instructions: Picture #2[/b] A-1 = 5mm hex key or Allen A-2 = 5mm hex key or Allen B = 18mm hex socket C = 6mm hex key or Allen D = 10mm hex socket E = 8mm hex socket [b]Recommended belt size:[/b] 1. Pulley Boys 3.10" upper 2. Metco 2 lb. lower (unresized) 3. Metco idler in top position ---------------------------------------- Use a 78-5/8" NAPA/Gates #080780 1. Pulley Boys 3.10" upper 2. Metco 4 lb. lower (resized) 3. Metco idler in top position 4. Metco 3.20" alternator pulley ---------------------------------------- Use a 79-3/4" Gatorback #4080797 Much thanks and appreciation to Dana for starting this thread... And to others for helping me through my initial installation =>) ! [/QUOTE]
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