Underdrive pulley installation on a Porsche 987.1 Cayman: How to do it DIY

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Do you want a fairly cheap 10-15 horsepower? Did you replace your dual-mass flyhweel with a lightweight single-mass flywheel? Then you might consider installing a harmonically dampened underdrive pulley on your Porsche 987.1 Cayman or Boxster. In this video, Damon does just that, swapping out his stock pulley with a Road Sport Supply (RSS) harmonically dampened underdrive pulley. Here's how to do it.
This guide was filmed with a 987.1 Cayman, but the process is almost exactly the same for a 986 and 987.1 Boxster. The process is similar on the 996 and 997.1 911 Carrera line, which the RSS kit was actually designed for, but accessing the pulley from the rear of the car is different and, frankly, easier.
RSS Harmonically Damped Underdrive Pulley Kit (986, 987, 996, 997): roadsportsuppl...
IMPORTANT NOTE ON FITMENT of RSS 608: Fits on all Porsche 986, 996, 987, 997 models EXCEPT 2.9L (multi hole crank pulley pattern), DFI engines, GT2, GT3 and Turbo.
This video may be used for guidance if you're reinstalling your original pulley or are installing the 997 Carrera S original equipment harmonically dampened pulley (which is the stock diameter). Here's the part number: 997.102.241.01
Watch our 2 quart oil sump extension installation video, performed on this very same 2007 Cayman: • How cool is your Porsc...
#Porsche #PorscheCayman #Porsche987 #DIY
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[@M_IkeLeBlanc]

Major props Damon! No way I would attempt this. 😮
I’d be more inclined to attempt open heart surgery than disassemble my Cayman.

[@damonlowney]

Thanks! Knowing you have the right tools goes a long way to boost confidence in a job.

[@flatsixracer]

Great job Damon, I enjoy watching your videos! Brings back memories from when I've made the same mod on my 987.1S

[@damonlowney]

Thanks Martin! Been a long time, hope you’re doing well.

[@Asaleiro14]

Nice job Damon!

[@damonlowney]

Thanks!

[@user-lt7xe2gt2k]

Greatly enjoyed the video, thanks.

[@craigs3166]

Great video Damon! Very informative and helpful. Would love to see more of these common mods videos for 911's too.

[@goody5582]

Great job Damon. Where did you get the ft/lb - angle torque wrench?

[@damonlowney]

Harbor freight. Icon 12.5-250 ft-lb

[@goody5582]

@@damonlowney Thx Damon. Always enjoy your videos.

[@craigurciuoli6994]

When you ground down the timing boss I saw there was still a shorter hole for the pin/bolt to fit. Will that pin/bolt still function in the lowered timing boss if you want to go back to the stock pully?

[@damonlowney]

If I go back to stock or install the Carrera S dampened pulley, I would plan to use the timing boss to tighten it back up. I'm pretty sure, but not certain, that there's plenty of material left if you grind it down only to get the space you need to install the underdrive. My recommendation is to not grind the boss down too much.

[@timothyerrington8877]

Excellent video Damon. Would it have been easier with the engine out? Especially considering the difficulty you had with removing the crank seal.

[@damonlowney]

Removing the engine for the pulley would be more work than necessary. This is definitely an engine-in job. Same with the crank seal. I was given direction to drill holes in the crank seal, but I tried every Avenue but that before biting the bullet. In retrospect, I should have started by drilling the holes with a flex right angle drill attachment and self tapping screws. Took maybe an hour or two when I used the correct technique.

[@hughmann1908]

I didn’t add one specifically as I didn’t want to take out that timing tower.

[@damonlowney]

Yes, can’t reverse that…

[@Aiken47]

I’m not very mechanically savvy, thanks Damon I’ll leave it to you and the pros. 😅

[@starlightsims9229]

It's not entirely clear how you kept the new pulley/crank from rotating while you torqued it. It seems you were holding it steady with your left hand?
You mentioned putting the car in 5th gear, wouldn't that allow the engine to turn easier against force than a lower gear?

[@briansturgill5905]

Does the pulley have to be at TDC when tightening it to keep timing or that doesn’t matter? Thanks.

[@ahmadmuzakkialfahmi8182]

Is that using new vanbelt (lower) or stock vanbelt

[@RobertWelchman]

so was the dampened pulley noticably smoother?