So I have a 06 JCW w 225K miles, supercharger finally gave up. I got a replacement supercharger, but need to swap the JCW pulley on to it. I have the removal tool, but not sure if I'll be able to install it. All I see regarding pulley installations are using the aftermarket 2 piece pulleys. Anybody done it before.

Also, I know, just buy an aftermarket pulley, but those are all 15 or 17, the JCW is 11. At this mileage I don't want any extra boost..

 

If it were me, I'd put the JCW pulley in the oven at 450 (I'd do a bit more to research this number) and see if enough heat would allow the pulley to be installed without effort.

Otherwise you're probably looking at taking the snout off so you can use a back stop on the pulley shaft with a hydraulic press to install. (and probably still some heat)

***This is based on my experience with the supercharger and not actually performing this operation. This is where I would start if I were looking to perform the same operation.***

 

Honestly if I were you I would just install a 15% pulley, the only thing you would need to change is belt size. Your R53 already has 380’s injectors in it, and the 15% isn’t that much of a change.

 

Not sure on how much extra it would cost due to exchange rates, customs, etc., but Kavs in the UK sells 2 piece replacements in 11% and 13%, along with the usual sizes available in the US.

 

I would say a 15% wouldn't cause much more wear and a 2wo piece aftermarket would be easier to install.
Afterall - it's all in the manner of how you drive it and regular (preventative) maintenance that matter....IMO

EDIT:
Now ontheotherhand - wanting to keep it as original as possible ...I can understand. Which is whole different conundrum.

 

Thanks all! Looking at the Kavs options, they sell a factory one piece and instructions say 400 degrees and a press might be the method. Or 2 piece, but closing in on $200 with shipping..

Will look into how to remove the snout.

 

the snout is easily reloveable , you can buy upgraded coupler gears for it too. If theres play in the sc , thats usually where it is..
you could stick the snout in the freezer and the stock pulley in the over and attempt to see if it would be able to be tapped on with a rubber mallet and socket.
imo , 200k sc would have NO ISSUE running a 15% pulley.
There's too much misinformation on the net about these superchargers being over spun into diminished returns ( I've run a 20% on a manual car shifting at 7k).
also it's false that the waterpump too will cause air bubbles in the coolant from being spun too fast..
imo go for a 15% , change the sc oil on both ends , upgrade the coupler gears and remove the waterpump and clean the pto gear ends and around it.. after that , imo you'll be juuuuuuuuust fine.
I've personally seen higher mileage cars have lower reduction pulley put on and had 0 issue doing so.