Well, I'm finally done installing my new 3.5 pulley and the tensioner pulley with it as well. I took it for a spin and let me tell ya...I can FEEL the difference.

I ran into a problem while installing the pulley, though. I and my friend Scott work together on it. I found that the M90 pulley puller was a *$%#@& to get all three screws started. I actually filed down the edge(read:rims) on my stock pulley just enough so we could get it secured on the pulley. For those of you who have the older Bonnies this probably wasn't an issue. Perhaps my puller (the horseshoe part) was a bit too small?

Anyway, I had no other choice. I either had to file a groove so the last screw could get into the hole, or pack it up. I just wanted you to know what I went through so you can be informed as to what happened. The stock pulley is a 3.8" The pulley is still fine to reuse if needed. It just has a groove around 1/8 maybe a bit more in the rims so the screw could line up with the hole.

Anyone else out there had this problem?

Also, you may want to unbolt the radiator overflow tank. You don't need to undo the hose connection, just the bolts. It will give you more room to manouver. Also be careful of the red box next to the fuses there on your left side....it'* right about where you will have your rachet or breakerbar. There is live voltage there and you may arc out on it even through the plastic cover if you push on it too hard with your metal tools! Trust me on this one!

Lastly, there is a piece of pipe, I believe it'* to the ac and it is always in the way. Since my friend was over it wasn't too bad cause one of us could hold it down. Just FYI

As a footnote, I want to say that zzp'* tensioner pulley went on fairly well and gave me a nice tight(not too tight) fit.

My next project will be the Ac Delco 41-932 spark plugs and the 180 stat. I'll probably wait 'till spring for the stat since winter is comming and the Cleveland area is one cold mother during the winter.

Question to all you northerners(both Americans and our Canadian neighbors) Those of you who have a 180 stat, do you change your'* out back to stock for winter? Is your heater warm enough for those of you who don't take your'* out?

Its pretty funny that people don't think a pulley could do so much until they drive the car with the smaller pulley. It definately is a difference you can feel. It completely transforms the car.

The plugs and T-stat are both very good mods to do, and if I were you I wouldn't worry about putting the t-stat in now. It isn't going to make any difference at all. You aren't going to notice 15 degree cooler heat, and since your stock t-stat is already drilled, that won't make a difference either. Our GTP has a drilled 160 t-stat that we leave in year round, our SSEi has a drilled 180 t-stat that we leave in year round (it would be a 160 but the PCM doesn't like those), and our '90 Turbo Grand Prix has a drilled 160 t-stat and they all have very warm heat in the winter. Can't tell the difference between the heat now, and with the stock t-stats.


As for your little summary of the pulley swap, it is very well written, and I would also like to add that you are very lucky that yours went that easy. They usually do, it is just that I didn't have a very good experience with the last one I did. And as for the part where you had to file down the old pulley, I think your "horseshoe" part as you call it is too small or something, because that shouldn't be an issue.

I didn't realize that the stock stat was drilled. :o Is the 180 undrilled better than the 195 drilled? Where do you drill it at and how big a hole? I know I remember someone talking about it earlier. Do I really need to drill the 180?

Also, It took a solid three hours and a half, maybe a bit more to do the pulley and the tensioner. I chaulk it up to inexperience, but also the fact that we tried like crazy to make the puller fit on. It was with reluctance that I filed the grooves in it. Still, it is still a good part just not so pretty anymore.

All said, I'm real pleased overall.