I have a 2000 XJR with 89,000 miles. I have installed a 3.5" intake all the way from the throttle body to the K&N filter that is positioned directly behind the passenger-side headlight. Temperatures are currently cold/cool, but I plan to add a divider to isolate the filter from hot engine air.

This past weekend I installed a 3# steel upper pulley purchased from Powerhouse in the U.K. I went with the upper pulley due to cost and, from all that I read, it was a definite DIY. Nothing new to add to the many excellent installation write-ups, but I did want to throw in my $.02 that may help someone considering this mod for their car:

Removing/installing the belt: I went with a new Gatorback belt. To remove/install, there is a square slot just above the bolt on the tensioner. Slip the square end of a breaker bar in the slot and rotate the tensioner counter clockwise to remove tension. Slip the belt off/on. As others have said in other posts on the subject, a 5 minute job.

Hood removal: Not too difficult. I removed the hood and electric fans for easier access from the front. This also allowed me to sit on an upside down 5 gallon bucket and work on the snout.

Grinding: I used the combination of a Dremel and a hand file. It is a little unnerving when you start grinding/filing, but after the first hour you'll settle in.

Time: I took approximately 14 hours from start to finish. I tried to be careful in all that I was doing.

Thermostat housing: This piece has 4 or 5 hoses attached to it. After looking at it, I marveled at the engineers that design stuff like this. "Okay, so we need to have a common place for 5 coolant passage ways to come together. I know, something like an octopus." The tricky one is a smaller hose on the back side that goes under the SC. To put that back on I positioned the clamp so that I could grasp it from the top, lubed the inside of the hose with a little coolant, the wriggled the hose onto the pipe. I used my file (approximately 1" wide) against the back of the clamp to help walk it on the rest of the way. I reached down from the top with long needle nose pliers to grasp the clamp and put it into position.

Impressions: Noticeably stronger in the low to mid rpm range. SC whine was pronounced from the intake, and was made even more so from the pulley. In a nice way.

Future plans: I have a higher flow rate Bosch intercooler pump to install (model #010, I believe). Also, I bought Waterdragon's nameless cats and look forward to installing them.

I am happy with the modification and would recommend it. The air intake, too!

Many thanks to the many posters before me who shared their experiences and from whom I learned a lot. Also, Waterdragon, for offering some timely tips as I went through this project.

 

Nice one Dan and a really cool write up too, but no pics??

Seriously though, thanks for sharing

 

Sorry, I'm a little photo illiterate

 

I think I finally got this figured out

Below are pics of during the filing process and after the pulley was installed. I saw 14 psi on the boost gauge yesterday, so I know the R is putting down a little more power!