SX3 pulley rubbing?

[Cardnim]

I've completely broken down my SX3 into the tiniest pieces it will go to in order to completely rebuild for the oOple race.

...and wouldnt you know, like a plonker Im already stuck on Step 2 in the instructions!

Can anyone offer any help as to what Im doing wrong?

Here's the problem:
In the instruction manual it shows just sliding on the bearing and then placing the whole layshaft into the metal housing...


Then, I complete the Steps and place on all the pulleys, the slipper, spur, housing etc and then screw on the steel idlers with the lock nuts.

But now this pulley (the one in the pic above) fouls on the metal housing and drags.

I can see it has actually been happening to the car previously, as the black paint on the housing metal has been scoured off.

Here's where it is happening:


What am I doing wrong?

It feels like in the instruction manual in Step 2B (see pic above) that there should be a little washer/spacer between the pulley and the bearing just to space it out, but there isnt.

Is this a known problem? I've heard about people putting spacers on this layshaft, but thought that was just before the lock nut went on to eliminate the "click".

Any thoughts?

[mark christopher]

what if you turn the pulley round on the shaft, is it offset?

[bigred5765]

what mark said may be you have the pulley on back wards ares clears the metal buy 2-3 mm

[DCM]

Mine has at least 1mm gap, so I would suggest that there is a difference if you turn it around.

[Cardnim]

Originally Posted by DCM

Mine has at least 1mm gap, so I would suggest that there is a difference if you turn it around.

Sorry chum, didnt mean to leave you out of the thanks.
You posted as I was typing my reply.
Thanks!

So it sounds like you are all saying the same thing.
That the first pulley, shown in Step2B needs turned round. ie. this one:


correct?

[MikePimlott]

Youve not missed off the little crush spacer have you ?

Just another check.

[Cardnim]

Originally Posted by mark christopher

what if you turn the pulley round on the shaft, is it offset?

Originally Posted by bigred5765

what mark said may be you have the pulley on back wards ares clears the metal buy 2-3 mm

Thanks so much for the replies guys. Really helpful.

Interesting point about which way round the pulleys go, but Im fairly confident they are both correct.

In the next step:


you can see that the central pulley has an obvious "squared" part to one side, this is definately correct on mine.

The first pulley (the one thats rubbing) I cant be jsut so sure about, and unfortuantely cant check cause Im in work now.
But Im 99% sure that its right too, as the face of the pulley and the end of the layshaft are completely flush and level for the little M3 washer & locking screw to go on (see Step 2B on first post above)

?

[Cardnim]

Got it sorted last night.

You guys were spot on; it was indeed the very first pulley, it was round the wrong way and the tiny collar on one side of it was enough to make all the difference.

Its this pulley shown in Step 2B that was the culprit.


A massive (MASSIVE) thanks to everyone who helped me.
It was invaluable guys, and it is very much appreciated.

I just couldnt see thw wood for the trees and was getting lost looking for some werid problem, when it was the simplest thing.
IBut I couldnt have reasoned it out without your advice.

Thanks again.

[MikePimlott]

[bigred5765]

easy done i suppose, at least you have it right now