SEAT Workshop Service and Repair Manuals

Renewing pulley set „I“   Note

t  If pulley set „I“ is renewed, the following steps are necessary: t  Bearings „D“ and „E“ for pulley set „I“ must be renewed → Chapter. t  Bearing „C“ must be checked for wear and renewed if necessary → Chapter. t  Shim -2- and circlip -1- must be measured again to fit → Anchor. t  The existing shim -3- should always be refitted.

t  If a spacer -2- was fitted on the existing pulley set „I“, the spacer should not be refitted. The spacer is only required for bearing „D“ with inner race; this is always replaced by bearing „D“ without inner race. Operation process –  Remove chain and pulley set „I“ → Chapter. –  Check wear on bearing „C“ for pulley set „I“ → Chapter; if necessary, renew bearing „C“ → Chapter. –  Renew bearings „D“ and „E“ for pulley set „I“ → Chapter.

Determining thickness of shim and circlip –  Insert the existing circlip -1- for for the pulley set „I“ in the groove of the old pulley set „I“-item 2- used until now. l  Note the fitting position: The boreholes in the eyes of the circlip are tapered. The smaller side faces upwards. l  The circlip must be properly seated in the base of the groove. –  Determine and note „dimension -a- (old)“ as shown in illustration.   Note „Dimension -a- (old)“ is measured from the top side of the circlip to the contact surface.

–  Insert existing (old) circlip for pulley set „I“ in groove on new pulley set „I“. l  Note the fitting position: The boreholes in the eyes of the circlip are tapered. The smaller side faces upwards. l  The circlip must be properly seated in the base of the groove. –  Determine and note „dimension -a- (new)“ as shown in illustration. If difference between „dimension -a- (old)“ and „dimension -a- (new)“ is less than 0.2 mm: l  Reinstall new circlip (of same thickness as old circlip) and existing shim with new pulley set „I“. If difference between „dimension -a- (old)“ and „dimension -a- (new)“ is greater than 0.2 mm: l  Determine dimension of new shim as follows:

Example 1: „dimension -a- (new)“ is greater than „dimension -a- (old)“
„Dimension -a- (new)“	34.90 mm
„Dimension -a- (old)“	– 34.55 mm
Difference -a-	= + 0.35 mm

Note

t  Dimension -b- is the total thickness of circlip -1- and shim -2-. t  „Dimension -b- (old)“ is the previous total thickness; „dimension -b- (new)“ is the new total thickness.

Determining „dimension -b- (old)“:
Existing circlip	1.90 mm
Existing shim	1.60 mm
„Dimension -b- (old)“	= 3.50 mm

Determining „dimension -b- (new)“:
Formula: „dimension -b- (new)“ = „dimension -b- (old)“ + difference -a-
„Dimension -b- (old)“	3.50 mm
Difference -a-	+ 0.35 mm
„Dimension -b- (new)“	= 3.85 mm

–  From the available shims and circlips, choose the combination that comes nearest to „dimension -b- (new)“.

Available shims and circlips [thickness in mm]
Shims	Securing rings
1,40	1,80
1,60	1,85
1,80	1,90
2,00	1,95
2,20

Determining thickness of shim/circlip combination
New circlip	1.85 mm
New shim	+ 2.00 mm
„Dimension -b- (new)“	= 3.85 mm

Note The total thickness of the new shim and the new circlip must not exceed „dimension -b- (new)“.

Example 2: „dimension -a- (new)“ less than „dimension -a- (old)“
„Dimension -a- (new)“	34.40 mm
„Dimension -a- (old)“	– 34.85 mm
Difference -a-	= – 0.45 mm

Note

t  Dimension -b- is the total thickness of circlip -1- and shim -2-. t  „Dimension -b- (old)“ is the previous total thickness; „dimension -b- (new)“ is the new total thickness.

Determining „dimension -b- (old)“:
Existing circlip	1.90 mm
Existing shim	2.00 mm
„Dimension -b- (old)“	= 3.90 mm

Determining „dimension -b- (new)“:
Formula: „dimension -b- (new)“ = „dimension -b- (old)“ + difference -a-
„Dimension -b- (old)“	3.90 mm
Difference -a-	– 0.45 mm
„Dimension -b- (new)“	= 3.45 mm

–  From the available shims and circlips, choose the combination that comes nearest to „dimension -b- (new)“.

Available shims and circlips [thickness in mm]
Shims	Securing rings
1,40	1,80
1,60	1,85
1,80	1,90
2,00	1,95
2,20

Determining thickness of shim/circlip combination
New circlip	1.85 mm
New shim	+ 1.60 mm
Dimension -b-„new“	= 3.45 mm

Note The total thickness of the new shim and the new circlip must not exceed „dimension -b- (new)“. Assembling –  Install new chain and new pulley set „I“ → Chapter.