2010 Overrunning Alternator Pulleys

2010 Overrunning Pulleys

THE CASE FOR INA OVERRUNNING ALTERNATOR PULLEYS Ignition and compression within an engine results in acceleration and deceleration of the crankshaft. These rotational variances are then transferred to the engine s auxiliary components via the belt drive system. Unacceptable noise, strong belt vibration and early belt wear are the result. Individual accessories affect the drive system to varying degrees. The alternator has the greatest moment of inertia and therefore the biggest infl uence on noise, vibration and harshness. To disengage the alternator and remove it s effects on the drive system, INA has developed the overrunning clutch belt pulley. This belt pulley is assembled on the alternator shaft and is integrated within the belt drive. These units are mainly used: in diesel engines in direct injection gas engines in V-engines with cylinder row shut-down at reduced idle speed in automatic transmissions with high shifting impulse with increased noise requirements at idle speed (use of a Dual-Mass Flywheel) for alternators with high moment of inertia INA overrunning clutch belt pulleys: disengage the alternator from the rotational irregularities of the crankshaft. reduce the noise of belt vibrations. reduce the force levels in the belt drive at idle speeds, during engine startup and shut-down. improve the noise behavior in the belt drive. increase the durability of the belt. reduce the tensioner forces and shorten the tensioner paths, resulting in increased durability of the belt tensioner. increase the average alternator speed in the idle speed range. are economically manufactured in a modular construction system, which includes the standard disengagement unit. prevent possible whistling noises (slipping) of the belt during up-shifting under full load. cannot come free from the alternator shaft during operation, unlike rigid belt pulleys. are designed so that no changes in the alternator shaft are necessary. are supplied with a protective cover which protects it against dirt and spray. The visible surface of the belt pulley has an anti-corrosion layer.

Overrunning Pulleys Table of Contents Interchange... 2 Interchange... 2 OAP Interchange... 5 Buyers Guide... 7 Design... 41 Functional Test... 42 Damage Symptoms... 43 Notes... 44 2010 Schaeffl er Group USA Inc. All rights reserved. Printed in U.S.A.

ALTERNATOR INTERCHANGE ALTERNATOR INTERCHANGE INA INA BMW (Bosch) 12 31 7 521 488 535007510 12 31 7 521 489 535007510 BMW (Valeo) 12 31 751 6721 535012710 12 31 751 6722 535012710 12 31 751 6723 535012710 12 31 751 6724 535012710 12 31 752 1488 535012710 12 31 752 1489 535012710 12 31 752 1490 535012710 12 31 752 1491 535012710 12 31 753 2968 535012710 12 31 753 3272 535012710 Bosch 0 120 468 145 535006810 0 120 469 115 535007810 0 123 310 035 535001010 0 123 310 038 535000910 0 123 310 049 535000110 0 123 320 032 535001010 0 123 320 033 535000910 0 123 320 038 535000110 0 123 320 041 535000310 0 123 320 046 535000310 0 123 320 047 535007710 0 123 320 051 535001510 0 123 320 054 535001410 0 123 320 055 535000410 0 123 320 065 535001510 0 123 325 006 535000910 0 123 325 048 535000910 0 123 510 038 535000310 0 123 510 045 535000710 0 123 510 047 535001010 0 123 510 049 535000310 0 123 510 058 535007710 0 123 510 075 535007710 0 123 510 080 535000310 0 123 510 082 535001510 0 123 510 091 535001410 0 123 510 099 535001010 0 123 510 101 535000310 0 123 510 102 535007710 0 123 510 107 535001510 0 123 510 108 535001510 0 123 510 109 535002610 0 123 515 003 535000410 0 123 515 017 535000110 0 123 515 020 535000110 0 123 515 021 535001010 Bosch 0 123 520 010 535007710 0 123 520 014 535005210 0 123 520 023 535001510 0 124 315 001 535001210 0 124 315 013 535001210 0 124 325 001 535001210 0 124 325 012 535001210 0 124 325 018 535000510 0 124 325 020 535001410 0 124 325 039 535005010 0 124 325 046 535005010 0 124 325 049 535000510 0 124 325 072 535007510 0 124 325 073 535001210 0 124 325 087 535007510 0 124 325 088 535005210 0 124 325 105 535001510 0 124 515 010 535001210 0 124 515 019 535007210 0 124 515 022 535001210 0 124 515 024 535001410 0 124 515 025 535000810 0 124 515 026 535000510 0 124 515 042 535002510 0 124 515 054 535007210 0 124 515 059 535004110 0 124 515 061 535005010 0 124 515 062 535004210 0 124 515 064 535005010 0 124 515 073 535002510 0 124 515 083 535000510 0 124 515 084 535005010 0 124 515 088 535004210 0 124 515 091 535005010 0 124 515 101 535001210 0 124 515 110 535005210 0 124 515 117 535001210 0 124 525 009 535004110 0 124 525 014 535007210 0 124 525 019 535003810 0 124 525 027 535001210 0 124 525 029 535007210 0 124 525 039 535001210 0 124 525 050 535001210 0 124 615 009 535004110 0 124 615 015 535005010 0 124 615 017 535001210 0 124 615 018 535005010 2

ALTERNATOR INTERCHANGE INA INA Bosch 0 124 615 019 535005010 0 124 615 021 535000510 0 124 615 022 535004210 0 124 615 026 535008310 0 124 615 028 535004210 0 124 625 003 535007210 0 124 625 014 535008610 0 124 625 033 535008610 1 123 325 036 535000910 6 033 GB3 030 535001310 6 033 GB3 031 535001310 6 033 GB3 040 535001310 Denso TN 102211-0500 535002410 Fiat (Valeo) 9621791480 535003910 9640878780 535007310 Ford 98VW 10300 EA 535001210 YM21 10300 CA 535001210 Ford (Bosch) 1076005 535000110 95VW 10300 ABA 535000510 97VW10300EA 535000110 98VW 10300 BA 535001010 98VW 10300 CA 535001210 GM 5 350 087 535003810 GM (Valeo) 4403540 535003010 9111540 535003010 9112331 535004810 Hyundai 37300-27011 535004610 (Nippon Denso) Kia (Melco) 0K29T-18-300 535003510 Kia (Poong Sung) 0K552-18-300 535003410 0K552-18-300A 535003410 0K552-18-300B 535003410 Mazda K801-18 300AT 535001710 K801-18 300B 535001710 K801-18 300C 535001710 K801-18 300D 535001710 Mazda (Melco) BPE8-18-300 535003510 BPE9-18-300 535003510 FS05-18-300 535003510 Mercedes (Bosch) 009 154 98 02 535007810 010 154 00 02 535006810 010 154 03 02 535007710 010 154 08 02 535000310 010 154 16 02 535007710 010 154 48 02 535000310 010 154 49 02 535007710 010 154 59 02 535001510 010 154 74 02 535007710 010 154 77 02 535007710 010 154 94 02 535000310 Mercedes (Bosch) 010 154 95 02 535001510 010 154 96 02 535001510 011 154 06 02 535001510 011 154 09 02 535001510 011 154 54 02 535001310 011 154 66 02 535005010 011 154 70 02 535001510 011 154 78 02 535001510 012 154 17 02 535005010 012 154 22 02 535001510 012 154 24 02 535005010 012 154 46 02 535005010 012 154 54 02 535001510 012 154 63 02 535005010 012 154 98 02 535008610 013 154 36 02 535001510 013 154 59 02 535008610 271 154 02 02 535004210 271 154 08 02 535004210 Mercedes (Delphi) 000 150 05 50 535001610 000 150 17 50 535001610 000 150 25 50 535001610 Mitsubishi (Valeo) A004TF0091 535003910 A4TF0091 535003910 S30638577 535003010 S620870 535004810 Nissan (Bosch) 23100 00QBB 535011710 Nissan (Hitachi) 23100-2W201 535005310 23100-VC201 535005310 Nissan (Valeo 23100-00QAL 535004810 Porsche (Bosch) 021 903 026 B 535008310 916 603 012 00 535002510 927 603 012 01 535002510 955 603 017 00 535008310 997 603 022 00 535009910 998 603 022 01 535009910 PSA (Valeo) 57054F 535003910 57055H 535003910 57055J 535003910 5705A1 535007310 5705ER 535007310 5705GC 535003910 Renault (Bosch) 0 124 525 028 535011710 77 01 474 326 535011710 82 00 122 976 535011710 82 00 323 137 535011710 Renault (Valeo) 77 00 426 849 535003010 82 00 162 474 535003010 Saab 5350087 535003810 Steyr 011 154 54 02 535001310 3

ALTERNATOR INTERCHANGE INA INA VAG (Bosch) 021 903 026 A 535001210 021 903 026 B 535008310 028 903 026 A 535000910 028 903 026 B 535000910 028 903 026 H 535001210 028 903 026G 535000110 028 903 027 S 535000410 028 903 028 535000410 028 903 028 E 535001210 028 903 028 F 535000410 028 903 028 P 535000910 028 903 028J 535000110 028 903 029 B 535000510 028 903 029 N 535000510 028 903 029 Q 535000510 028 903 029 S 535000510 028 903 031 535000510 038 903 023 G 535001010 038 903 023 H 535001010 038 903 023 J 535001010 038 903 023 K 535001210 038 903 023 L 535001210 045 903 023 535001210 045 903 023 B 535001210 045 903 023 E 535001210 058 903 016 D 535000710 06B 903 016 AB 535004110 06B 903 016 B 535000810 06B 903 016 P 535004110 06B 903 016 Q 535004110 071 903 016 C 535001410 071 903 016 D 535001410 071 903 016 G 535001410 071 903 016 H 535001410 071 903 023 A 535001010 074 903 025 L 535005210 074 903 025 S 535005210 074 903 025 T 535005210 074 903 026 535005210 128 903 027 Q 535000410 6K0 903 028 535000110 VAG (Hitachi) 028 903 029 G 535001210 VAG (Valeo) 028 903 016 A 535000510 028 903 016 D 535000510 028 903 016 E 535000510 028 903 027 T 535000510 028 903 029 D 535000510 028 903 029 E 535000510 028 903 029 R 535000510 028 903 031 A 535000510 038 903 023 S 535001210 Valeo 2542272E 535003010 437208 535004810 437351 535004810 439257 535003910 439341 535004810 9640878780 535007310 A14VI35 535003910 SG12B012 535000510 SG12B017 535003010 SG12B050 535004810 SG12B071 535003010 SG12B095 535004810 SG12B096 535003010 SG12B108 535004810 Volvo 2542523 535004810 Volvo (Bosch) 3803645 535007210 8 111 119 535005210 8 111 122 535005210 8601841 535007210 8602276 535007210 8602343 535007210 8602629 535007210 8602710 535007210 8602714 535007210 8622786 535007210 8637848 535007210 8651665 535007210 8676496 535007210 8676498 535007210 8676499 535007210 9 442 130 535005210 9 459 093 535005210 9459077 535007210 9459092 535007210 Volvo (Denso) 8 601 699 535002410 9 459 077 535002410 9 459 092 535002410 9 472 908 535002410 Volvo (Valeo) 30620870 535004810 8251635 535002810 8251637 535002810 8251638 535002810 8251641 535002810 535003010 8251646 535002810 8251647 535002810 8251648 535002810 8602185 535002810 8602356 535004810 8602806 535002810 535003010 4

OAP INTERCHANGE OAP INTERCHANGE INA INA BMW 11 28 1 727 159 F225653-91 11 31 4 466 271 535007510 12 31 751 6105 535012710 12 31 753 6960 535012710 12 31 755 0001 535012710 Bosch 120936706 535004110 0 122 1AA 7V0 535001610 1 120 591 505 F226556-51 1 120 591 506 F225653-91 1 126 601 102 535007810 1 126 601 556 535000910 1 126 601 557 535000910 1 126 601 559 535001010 1 126 601 565 535000110 1 126 601 566 535000410 1 126 601 567 535000710 1 126 601 568 535000310 1 126 601 572 535007710 1 126 601 593 535001410 1 126 601 597 535001510 6 033 GD5 036 535001310 F00M061005 535005210 F00M061016 535002610 F00M061023 535001510 F00M991002 535001210 F00M991016 535007210 F00M991042 535000810 F00M991044 535001410 F00M991045 535000510 F00M991061 535007210 F00M991095 535005210 F00M991105 535002510 F00M991108 535004110 F00M991122 535001210 F00M991125 535005010 F00M991138 535004210 F00M991142 535007510 F00M991156 535007210 F00M991167 535008310 F00M991181 535008610 F00M991190 535005010 F00M991220 535010610 F00M991232 535007210 F00M991252 535009910 F00M991255 535008610 F00M991273 535007510 F00M991284 535001210 F00M991308 535005210 Delphi 211242 535007710 10454850 F226556-51 10484671 F225653-91 Delphi 10451570 535001610 10453582 535001610 1048 4670 535003310 10493077 535008310 Denso 021040-0960 535003110 021040-0970 535002410 Ford 1S7U-10A352-DB 535007410 339 54 59 535001710 XW4U-10A352-AA 535001710 YM2E-10N356-AA 535001710 Hitachi GD 214998-1 535001210 GD 215541 535005310 GD 216009 535004410 GD 216009-2 535004410 GD 217756 535008310 Hyundai 50210-40108 535011010 Isuzu 8-97229-366-0 535003810 Kia 72011-0800 535009710 OK588-18-W11 535003410 Mazda GY02-18-330 535001710 GY02-18-330 A 535003510 GY02-18-W37Z 535003510 K801-18-W11 535001710 LF1818330 535009410 Mercedes 1204378 535008610 55 438 14 535008610 000 155 09 02 F226556-51 000 155 10 02 F225653-91 271 155 00 16 535004210 271 155 01 15 535004210 602 150 00 60 535001310 604 150 00 60 535000310 604 150 01 60 535007710 604 150 05 60 535007710 611 150 01 60 535001510 611 155 00 15 535001610 611 155 02 15 535001510 611 155 03 15 535001510 535005010 611 155 04 15 535001610 611 155 06 15 535001510 611 155 07 15 535005010 642 150 06 60 535014010 906 155 02 15 535006810 906 155 03 15 535007810 906 155 12 15 535006810 906 155 13 15 535007810 906 155 21 15 535007810 Mitsubishi 1800A061 535014510 Nippon Denso 72011-0750 535004610 810200010 535011010 5

OAP INTERCHANGE INA INA Nissan 23150-2W200 535005310 23150-2W20A 535005310 Porsche 996 603 152 50 535002510 996 603 153 50 F225653-91 PSA 59521 535003910 Renault 7700110616 535011710 Saab 53 40 393 535003810 VAG 021 903 119 H 535005210 021 903 119 J 535008310 022 903 119 B 535000510 028 903 119 AC 535000510 028 903 119 AM 535001210 028 903 119 S 535000910 028 903 119 T 535000410 028 903 165 535000410 037 145 291 F225653-91 038 903 119 535001010 038 903 119 A 535001210 038 903 119 L 535001410 038 903 119 M 535000510 038 903 119 P 535000810 038 903 119 T 535001210 038 903 165 535001010 058 903 119 C 535000710 06B 903 119 B 535004110 071 903 119 B 535001410 071 903 165 535001410 074 903 119 E 535005210 Valeo 593514 535003010 2546778 535001210 2547128 535000310 2547439 535000510 2547655 535003010 2547917 535003910 2548543 535007310 2548621 535004810 2549800 535005010 2549815 535012710 2549858 535004110 2600001 535003010 2602877 535007310 2603330 535014010 2603341 535012710 2604332 535012710 2604504 535001210 2650319 535013710 2655139 535007710 2655545 535013510 2655703 535007910 K406701 535007910 Visteon VP2M5U-10A352-AA 535010010 VP5L8U-10A352-AA 535013210 VP6S4U-10A352-AA 535010010 XW4U-10325AA F225653-91 Volvo 593516 535004810 2546952 535002810 8 641 982 535002810 8 658 644 535005210 8 676 497 535007210 9 404 328 535002610 9 442 945 F225653-91 9 459 747 535007210 9 472 909 535002410 3 073 7517 535007210 VW 028 903 119 AA 535000110 6

535000110 Lester # 7920-2019 Outer Diameter 2.19 55.50 Length 1.60 40.65 Bosch 1 126 601 565 VW 028 903 119 AA References BUYERS GUIDE BUYERS GUIDE Bosch 0 123 310 049 70A 0 123 320 038 90A 0 123 515 017 120A 0 123 515 020 120A Ford (Bosch) 1076005 120A 97VW10300EA 120A VAG (Bosch) 028 903 026G 120A 028 903 028J 90A 6K0 903 028 70A VW Golf III 1.9 D, TD, GTD, TDI, -Cabrio Golf IV 1.9 TDI Passat / -Variant 1.9 TDI, 2.9 VR6 Syncro Ford Galaxy 1.9 TDI 535000210 Lester # 7920-2026 Outer Diameter 2.40 61.00 Length 1.41 35.70 7

BUYERS GUIDE 535000310 Lester # 7920-2025 Outer Diameter 2.42 61.50 Length 1.48 37.70 Bosch 1 126 601 568 Mercedes 604 150 00 60 Valeo 2547128 References Bosch 0 123 320 041 90A 0 123 320 046 90A 0 123 510 038 115A 0 123 510 049 115A 0 123 510 080 115A 0 123 510 101 115A Mercedes (Bosch) 010 154 08 02 90A, 115A 010 154 48 02 90A 010 154 94 02 115A Mercedes All Models C 200 TD, 220 TD, 250 TD E 200 D, 220 D, 250 D, TD, 290 D, 300 D, TD G 300 DT, S 300 TD 535000410 Lester # 7920-2032 Outer Diameter 2.42 61.50 Length 1.44 36.50 Grooves5 Bosch 1 126 601 566 VAG 028 903 119 T 028 903 165 References Bosch 0 123 320 055 90A 0 123 515 003 120A VAG (Bosch) 028 903 027 S 90A 028 903 028 120A 028 903 028 F 120A 128 903 027 Q 70A VW Passat/ -Variant 1.9 TDI, -Syncro 8

535000510 Lester # 7920-2035 Outer Diameter 2.42 61.50 Length 1.38 35.00 Grooves5 Bosch F00M991045 VAG 022 903 119 B 028 903 119 AC 038 903 119 M Valeo 2547439 References BUYERS GUIDE Bosch 0 124 325 018 90A 0 124 325 049 90A 0 124 515 026 120A 0 124 515 083 120A 0 124 615 021 150A Ford (Bosch) 95VW 10300 ABA 120A VAG (Bosch) 028 903 029 B 120A 028 903 029 N 150A 028 903 029 Q 140A 028 903 029 S 120A 028 903 031 120A VAG (Valeo) 028 903 016 A 120A 028 903 016 D 120A 028 903 016 E 120A 028 903 027 T 90A 028 903 029 D 90A 028 903 029 E 120A 028 903 029 R 140A 028 903 031 A 120A 028 903 031 A 120A Valeo SG12B012 120A Audi A4 / A6 1.6, 1.8, 1.9 TD, 1.9 TDI VW Golf IV Variant, Passat 1.6, 1.8, 2.0, 1.9 TDI Ford Galaxy 1.9 TDI 535000710 Lester # 7920-2036 Outer Diameter 2.42 61.50 Length 1.44 36.50 Grooves5 References Bosch 0 123 510 045 120A VAG (Bosch) 058 903 016 D 120A Bosch 1 126 601 567 VAG 058 903 119 C Audi A6 1.8, 1.8 T, 1.8 T Quattro 9

BUYERS GUIDE 535000810 Lester # 7920-2040 Outer Diameter 2.42 61.50 Length 1.38 35.00 Grooves5 References Bosch 0 124 515 025 120A VAG (Bosch) 06B 903 016 B 120A Manufacturer Bosch VAG Manufacturer No. F00M991042 038 903 119 P Audi A4, A6 1.8 T, 1.8 T Quattro VW Passat 1.8, 1.8 T 535000910 Lester # 7920-2031 Outer Diameter 2.42 61.50 Length 1.46 37.20 Grooves5 Bosch 1 126 601 556 1 126 601 557 VAG 028 903 119 S References Bosch 0 123 310 038 70A 0 123 320 033 90A 0 123 325 006 90A 0 123 325 048 90A 1 123 325 036 70A VAG (Bosch) 028 903 026 A 90A 028 903 026 B 70A 028 903 028 P 90A VW All Models1.7 SDI 10

535001010 Lester # 7920-2015 Outer Diameter 2.42 61.50 Length 1.67 42.45 Bosch 1 126 601 559 VAG 038 903 119 038 903 165 References BUYERS GUIDE Bosch 0 123 310 035 70A 0 123 320 032 90A 0 123 510 047 120A 0 123 510 099 120A 0 123 515 021 120A Ford (Bosch) 98VW 10300 BA 90A VAG (Bosch) 038 903 023 G 70A 038 903 023 H 90A 038 903 023 J 120A 071 903 023 A 120A Audi A3 1.9 TDi VW Golf IV 1.9 SDI, 1.9 TDI 2.3 V5 New Beetle 1.9 TDI 535001210 Lester # 7920-2017 Outer Diameter 2.42 61.50 Length 1.77 45.00 Bosch F00M991002 F00M991122 F00M991284 Hitachi GD 214998-1 VAG 028 903 119 AM 038 903 119 A 038 903 119 T Valeo 2546778 2604504 References Audi A2 1.4 TDI A3 1.9 TDI, 1.9 TDI Quattro TT 1.8 T, 1.8 T Quattro VW Golf IV 1.9 SDI, 1.9 TDI New Beetle 1.9 TDI, 2.0 Ford Galaxy All Bosch 0 124 315 001 70A 0 124 315 013 70A 0 124 325 001 90A 0 124 325 012 90A 0 124 325 073 90A 0 124 515 010 120A 0 124 515 022 120A 0 124 515 101 120A 0 124 515 117 120A 0 124 525 027 140A 0 124 525 039 140A 0 124 525 050 140A 0 124 615 017 150A Ford 98VW 10300 EA 120A YM21 10300 CA 150A Ford (Bosch) 98VW 10300 CA 90A VAG (Bosch) 021 903 026 A 150A 028 903 026 H 120A 028 903 028 E 120A 038 903 023 K 70A 038 903 023 L 90A 045 903 023 90A 045 903 023 B 70A 045 903 023 E 90A VAG (Hitachi) 028 903 029 G 120A VAG (Valeo) 038 903 023 S 120A 11

BUYERS GUIDE 535001310 Lester # 7920-2046 Outer Diameter 2.40 61.00 Length 1.48 37.70 Bosch 6 033 GD5 036 Mercedes 602 150 00 60 References Bosch 6 033 GB3 030 80A 6 033 GB3 031 55A 6 033 GB3 040 80A Mercedes (Bosch) 011 154 54 02 80A Steyr 011 154 54 02 80A Mercedes G-Class All 535001410 Lester # 7920-2041 Outer Diameter 2.42 61.50 Length 1.44 36.50 Bosch 1 126 601 593 F00M991044 VAG 038 903 119 L 071 903 119 B 071 903 165 References Bosch 0 123 320 054 90A 0 123 510 091 120A 0 124 325 020 90A 0 124 515 024 120A VAG (Bosch) 071 903 016 C 90A 071 903 016 D 120A 071 903 016 G 90A 071 903 016 H 120A VW Passat 2.3 VR5, -syncro Golf IV, New Beetle 2.3 V5 12

535001510 Lester # 7920-2044 BUYERS GUIDE Outer Diameter 2.19 55.50 Length 1.59 40.50 Bosch 1 126 601 597 F00M061023 Mercedes 611 150 01 60 611 155 02 15 611 155 03 15 611 155 06 15 Mercedes C-Class, E-Class 2.0, 2.2 T References Bosch 0 123 320 051 90A 0 123 320 065 90A 0 123 510 082 115A 0 123 510 107 115A 0 123 510 108 115A 0 123 520 023 150A 0 124 325 105 120A Mercedes (Bosch) 010 154 59 02 115A 010 154 95 02 90A 010 154 96 02 115A 011 154 06 02 90A 011 154 09 02 115A 011 154 70 02 150A 011 154 78 02 115A 012 154 22 02 120A 012 154 54 02 115A 013 154 36 02 90A 535001610 Lester # 7920-2047 Outer Diameter 2.19 55.50 Length 1.44 36.60 References Mercedes (Delphi) 000 150 05 50 150A 000 150 17 50 190A 000 150 25 50 190A Bosch 0 122 1AA 7V0 Delphi 10451570 10453582 Mercedes 611 155 00 15 611 155 04 15 Mercedes C-Class, E-Class 2.0, 2.2, 2.7 T 13

BUYERS GUIDE 535001710 Lester # 7950-2279 Outer Diameter 2.58 65.50 Length 1.52 38.50 Ford 339 54 59 XW4U-10A352-AA YM2E-10N356-AA Mazda GY02-18-330 K801-18-W11 References Mazda K801-18 300AT 90A K801-18 300B 90A K801-18 300C 90A K801-18 300D 90A Ford Probe II 2.5 V6 Mazda 626 IV Hatchback All 535002410 Lester # 7990-9045 Outer Diameter 2.37 60.15 Length 1.70 43.10 Denso 021040-0970 Volvo 9 472 909 References Denso TN 102211-0500 120A Volvo (Denso) 8 601 699 120A 9 459 077 120A 9 459 092 120A 9 472 908 120A Volvo C 70, S 40, S 60, S 70, 2.0 T, 2.4 T, 2.5 T S 80, V 40, V 70 14

535002510 Lester # 7920-2018 Outer Diameter 2.28 58.00 Length 1.38 35.00 Bosch F00M991105 Porsche 996 603 152 50 References BUYERS GUIDE Bosch 0 124 515 042 120A 0 124 515 073 120A Porsche (Bosch) 916 603 012 00 120A 927 603 012 01 120A Porsche Boxter 986, Carrera 996 3.2, 3.4 GT3 535002610 Lester # 7920-2042 Outer Diameter 2.42 61.50 Length 1.48 37.60 References Bosch 0 123 510 109 115A Bosch F00M061016 Volvo 9 404 328 Chrysler Voyager 2.5 TD 15

BUYERS GUIDE 535002810 Lester # 7908-3409 Outer Diameter 2.40 61.00 Length 1.67 42.36 Volvo 2546952 8 641 982 References Volvo (Valeo) 8251635 120A 8251637 110A 8251638 80A 8251641 120A 8251646 110A 8251647 120A 8251648 120A 8602185 110A 8602806 120A Volvo S 40, V 40 1.9 DI, 1.9 DCI 535003010 Lester # 7908-3442 Outer Diameter 2.10 53.30 Length 1.57 39.80 Valeo 593514 2547655 2600001 References GM (Valeo) 4403540 125A 9111540 125A Mitsubishi (Valeo) S30638577 125A Renault (Valeo) 77 00 426 849 125A 82 00 162 474 125A Valeo 2542272E 125A SG12B017 125A SG12B071 125A SG12B096 125A Volvo (Valeo) 8251641 125A 8602806 125A Nissan All ModelsAll 16

535003110 Lester # 7990-9042 BUYERS GUIDE Outer Diameter 2.50 63.50 Length 1.70 43.10 Denso 021040-0960 Jaguar S-Type All 535003310 Lester # 7940-1283 Outer Diameter 2.42 61.50 Length 1.47 37.34 Delphi 1048 4670 GM All ModelsV6 LX5 17

BUYERS GUIDE 535003410 Lester # N/A Outer Diameter 2.52 64.00 Length 1.38 35.00 Grooves5 References Kia (Poong Sung) 0K552-18-300 85A 0K552-18-300A 85A 0K552-18-300B 85A Manufacturer Kia Manufacturer No. OK588-18-W11 Kia All Models2.9 TDI 535003510 Lester # 7903-2280 Outer Diameter 2.56 65.00 Length 1.52 38.70 Manufacturer Mazda Manufacturer No. GY02-18-330 A GY02-18-W37Z References Kia (Melco) 0K29T-18-300 80A Mazda (Melco) BPE8-18-300 80A BPE9-18-300 80A FS05-18-300 80A Mazda MPV II, B-Series 2.5 V6 MX-6 2.0 626 IV 1.8, 2.0 18

535003810 Lester # 7920-2213 Outer Diameter 2.18 55.40 Length 1.63 41.50 References BUYERS GUIDE Bosch 0 124 525 019 140A GM 5 350 087 140A Saab 5350087 140A Isuzu 8-97229-366-0 Saab 53 40 393 Saab 9-5 3.0, TiD 535003910 Lester # 7908-3415 Outer Diameter 2.15 54.65 Length 1.45 36.75 PSA 59521 Valeo 2547917 References Fiat (Valeo) 9621791480 150A Mitsubishi (Valeo) A004TF0091 150A A4TF0091 150A PSA (Valeo) 57054F 150A 57055H 150A 57055J 150A 5705GC 150A Valeo 439257 150A A14VI35 150A Peugeot All Models All 19

BUYERS GUIDE 535004110 Lester # 7920-2012 Outer Diameter 2.44 62.00 Length 1.40 35.60 Bosch 120936706 F00M991108 VAG 06B 903 119 B Valeo 2549858 References Bosch 0 124 515 059 120A 0 124 525 009 140A 0 124 615 009 150A VAG (Bosch) 06B 903 016 AB 140A 06B 903 016 P 120A 06B 903 016 Q 150A Audi A4 1.6, 1.8, -T, Cabriolet, 1.8 T Quattro, 2.0 A6 2.0, 2.0 FSI 535004210 Lester # 7920-2096 Outer Diameter 2.36 60.00 Length 1.82 46.20 Grooves7 Bosch F00M991138 Mercedes 271 155 00 16 271 155 01 15 References Bosch 0 124 515 062 120A 0 124 515 088 120A 0 124 615 022 90-150A 0 124 615 028 90-150A Mercedes (Bosch) 271 154 02 02 120A 271 154 08 02 120A Mercedes C, CLK Engine Code M271-20

535004310 Lester # 7990-9057 BUYERS GUIDE Outer Diameter 2.58 65.50 Length 1.51 38.47 535004410 Lester # 7904-4013 Outer Diameter 2.22 56.50 Length 1.59 40.30 Hitachi GD 216009 GD 216009-2 Nissan Altima 2.5 GDI 21

BUYERS GUIDE 535004610 Lester # 7990-9043 Outer Diameter 2.52 64.00 Length 1.40 35.60 References Hyundai (Nippon Denso)37300-27011 120A Nippon Denso 72011-0750 Hyundai Elantra, Santa Fe 2.0 D, Engine Code D4EA Kia Cerato, Sportage All 535004810 Lester # 7908-3410 Outer Diameter 2.18 55.40 Length 1.54 39.00 Grooves5 Valeo 2548621 Volvo 593516 References GM (Valeo) 9112331 120A Mitsubishi (Valeo) S620870 120A Nissan (Valeo 23100-00QAL 120A Valeo 437208 120A 437351 120A 439341 120A SG12B050 120A SG12B095 120A SG12B108 120A Volvo 2542523 120A Volvo (Valeo) 30620870 120A 8602356 120A Volvo 2 T, S 40, V 40 Engine Code D419 22

535005010 Lester # 7920-2044 Outer Diameter 2.17 55.00 Length 1.59 40.50 Manufacturer Bosch Manufacturer No. F00M991125 F00M991190 Mercedes 611 155 03 15 611 155 07 15 Valeo 2549800 References BUYERS GUIDE Bosch 0 124 325 039 90A 0 124 325 046 90A 0 124 515 061 120A 0 124 515 064 120A 0 124 515 084 120A 0 124 515 091 120A 0 124 615 015 150A 0 124 615 018 150A 0 124 615 019 150A Mercedes (Bosch) 011 154 66 02 120A 012 154 17 02 150A 012 154 24 02 120A 012 154 46 02 150A 012 154 63 02 150A Mercedes Sprinter 2-T, Engine Code 0M905.612, 0M905.613, 0M905.622, 0M905.623 Sprinter 3-T, Sprinter 4-T 535005210 Lester # 7920-2043 Outer Diameter 2.89 73.50 Length 1.64 41.60 Bosch F00M061005 F00M991095 F00M991308 VAG 021 903 119 H 074 903 119 E Volvo 8 658 644 References Bosch 0 123 520 014 150A 0 124 325 088 90A 0 124 515 110 120A VAG (Bosch) 074 903 025 L 150A 074 903 025 S 150A 074 903 025 T 120A 074 903 026 90A Volvo (Bosch) 8 111 119 120A 8 111 122 120A 9 442 130 120A 9 459 093 120A VW Transporter 2.5 TDI Volvo S 60, S 70, S 80, V 70, XC 70 Engine Code D5244T 23

BUYERS GUIDE 535005310 Lester # N/A Outer Diameter 2.54 64.50 Length 1.60 40.60 Grooves7 References Nissan (Hitachi) 23100-2W201 90A 23100-VC201 90A Hitachi GD 215541 Nissan 23150-2W200 23150-2W20A Nissan Terrano 2.7 ZD 535006810 Lester # 7920-2140 Outer Diameter 2.43 61.80 Length 1.54 39.10 Grooves8 References Bosch 0 120 468 145 100A Mercedes (Bosch) 010 154 00 02 100A Mercedes 906 155 02 15 906 155 12 15 Mercedes All ModelsEngine Code 0M904, 0M906, 0M924 24

535007210 Lester # 7920-2034 Outer Diameter 2.40 61.00 Length 1.49 37.80 Manufacturer Bosch Manufacturer No. F00M991016 F00M991061 F00M991156 F00M991232 Volvo 8 676 497 9 459 747 3 073 7517 Volvo C 70, S 60, V 70, S 80 2.0, 2.3 T, 2.4 T5 Turbo, XC 70 2.4 D5 XC 90 2.5 T, D5 References BUYERS GUIDE Bosch 0 124 515 019 120A 0 124 515 054 120A 0 124 525 014 140A 0 124 525 029 140A 0 124 625 003 160A Volvo (Bosch) 3803645 140A 8601841 120A 8602276 120A 8602343 140A 8602629 140A 8602710 140A 8602714 160A 8622786 140A 8637848 140A 8651665 160A 8676496 140A 8676498 140A 8676499 160A 9459077 120A 9459092 120A 535007310 Lester # N/A Outer Diameter 2.30 58.50 Length 1.28 32.60 Valeo 2548543 2602877 References Fiat (Valeo) 9640878780 150A PSA (Valeo) 5705A1 150A 5705ER 150A Valeo 9640878780 150A Suzuki Vitara 2.0 TDI 25

BUYERS GUIDE 535007410 Lester # 7950-2550 Outer Diameter 2.32 59.00 Length 1.51 38.45 Manufacturer Ford Manufacturer No. 1S7U-10A352-DB Ford All Models All 535007510 Lester # 7920-2092 Outer Diameter 1.93 49.00 Length 1.31 33.20 BMW 11 31 4 466 271 Bosch F00M991142 F00M991273 References BMW (Bosch) 12 31 7 521 488 110A 12 31 7 521 489 110A Bosch 0 124 325 072 90A 0 124 325 087 110A 26 BMW 316i, 316i Touring, 316Ci Coupe, 316ti Compact, 318i, 318i Touring, 318Ci Cabrio, 318Ci Coupe, 318ti Compact All

535007710 Lester # 7920-2026 Outer Diameter 2.40 61.00 Length 1.41 35.70 Bosch 1 126 601 572 Delphi 211242 Mercedes 604 150 01 60 604 150 05 60 Valeo 2655139 References BUYERS GUIDE Bosch 0 123 320 047 90A 0 123 510 058 115A 0 123 510 075 150A 0 123 510 102 115A 0 123 520 010 150A Mercedes (Bosch) 010 154 03 02 115A 010 154 16 02 150A 010 154 49 02 90A 010 154 74 02 115A 010 154 77 02 150A Hyundai Sorrento 2.5, 2.9 Mercedes Vito 108 D 2.3, 110 TD 2.3, V230 TD 535007810 Lester # 7920-2155 Outer Diameter 3.11 79.00 Length 1.63 41.35 Grooves8 References Bosch 0 120 469 115 80A Mercedes (Bosch) 009 154 98 02 80A Bosch 1 126 601 102 Mercedes 906 155 03 15 906 155 13 15 906 155 21 15 Mercedes All ModelsEngine Code 0M904, 0M907 27

BUYERS GUIDE 535007910 Lester # 7908-3453 Outer Diameter 2.91 74.00 Length 1.61 40.80 Grooves7 Valeo 2655703 K406701 Hyundai All Models All 535008310 Lester # 7920-2060 Outer Diameter 2.40 61.00 Length 1.37 34.90 Grooves7 Bosch F00M991167 Delphi 10493077 Hitachi GD 217756 VAG 021 903 119 J References Bosch 0 124 615 026 150A Porsche (Bosch) 021 903 026 B 150A 955 603 017 00 150A VAG (Bosch) 021 903 026 B 150A Porsche Cayenne 3.2 VW Touareg 3.2, 3.6 28

535008610 Lester # 7920-2128 Outer Diameter 2.18 55.40 Length 1.45 36.80 Manufacturer Bosch Manufacturer No. F00M991181 F00M991255 Mercedes 1204378 55 438 14 References BUYERS GUIDE Bosch 0 124 625 014 200A 0 124 625 033 200A Mercedes (Bosch) 012 154 98 02 200A 013 154 59 02 200A Mercedes E-Class W211, S211 535009410 Lester # 7903-2290 Outer Diameter 2.32 59.00 Length 1.51 38.30 Manufacturer Mazda Manufacturer No. LF1818330 Mazda All Models All 29

BUYERS GUIDE 535009710 Lester # 7903-3034 Outer Diameter 2.78 70.50 Length 1.44 36.70 Grooves5 Kia 72011-0800 Kia All Models All 535009910 Lester # 7920-2186 Outer Diameter 2.47 62.70 Length 1.42 36.10 Grooves8 References Porsche (Bosch) 997 603 022 00 150A 998 603 022 01 150A Manufacturer Bosch Manufacturer No. F00M991252 30

535010010 Lester # 7950-92281 BUYERS GUIDE Outer Diameter 2.44 62.00 Length 1.46 37.00 Manufacturer Visteon Manufacturer No. VP2M5U-10A352-AA VP6S4U-10A352-AA 535010610 Lester # 7920-2195 Outer Diameter 2.40 61.00 Length 1.37 34.70 Manufacturer Bosch Manufacturer No. F00M991220 Buick Regal 3.5 V6 31

BUYERS GUIDE 535011010 Lester # 7990-9057 Outer Diameter 2.58 65.50 Length 1.51 38.47 Hyundai 50210-40108 Nippon Denso 810200010 Hyundai All Models All 535011710 Lester # 7920-2228 Inner Diameter 1.57 40.00 Outer Diameter 3.07 78.00 Length 2.28 58.00 Renault 7700110616 References Nissan (Bosch) 23100 00QBB 150A Renault (Bosch) 0 124 525 028 150A 77 01 474 326 150A 82 00 122 976 150A 82 00 323 137 150A Renault All Models All 32

535012710 Lester # 7908-3462 Outer Diameter 2.10 53.30 Length 1.51 38.25 BMW 12 31 751 6105 12 31 753 6960 12 31 755 0001 Valeo 2549815 2603341 2604332 References BUYERS GUIDE BMW (Valeo) 12 31 751 6721 90A 12 31 751 6722 90A 12 31 751 6723 120A 12 31 751 6724 120A 12 31 752 1488 110A 12 31 752 1489 110A 12 31 752 1490 140A 12 31 752 1491 140A 12 31 753 2968 110A 12 31 753 3272 110A BMW All ModelsN42, N52 Engine, Valeo 535013210 Lester # 7950-92280 Outer Diameter 2.32 59.00 Length 1.48 37.70 Manufacturer Visteon Manufacturer No. VP5L8U-10A352-AA 33

BUYERS GUIDE 535013510 Lester # N/A Outer Diameter N/A N/A Length N/A N/A GroovesN/A Valeo 2655545 535013710 Lester # N/A Outer Diameter N/A N/A Length N/A N/A GroovesN/A Valeo 2650319 34

535014010 Lester # N/A BUYERS GUIDE Outer Diameter 2.17 55.00 Length 1.94 49.30 GroovesN/A Mercedes 642 150 06 60 Valeo 2603330 535014510 Lester # N/A Outer Diameter N/A N/A Length N/A N/A GroovesN/A Manufacturer Mitsubishi Manufacturer No. 1800A061 35

BUYERS GUIDE 535016210 Lester # N/A Outer Diameter N/A N/A Length N/A N/A GroovesN/A 36

DESIGN DESIGN An overrunning clutch belt pulley consists of: 1) Belt pulley 2) Overrunning clutch unit 3) Integrated radial support bearings 4) Inner sleeve with ramp profile 5) Inner ring 6) Serration 7) Elastomer gasket 8) Contact plate with lip gasket 9) Plastic cover Axial belt guide forces are absorbed within the overrunning clutch unit. The axial clearance means the belt track is self -adjusting. This signifi cantly improves the noise behaviour of the belt running in the profile, as the belt is not positively driven on the alternator driving wheel. The mounting hole for the overrunning clutch belt pulley is designed so that no changes in the shaft of the alternator are necessary. The inner ring is secured on the shaft by a fi ne thread. The serration is used to transfer the tightening torque. A protection cover over the front protects the unit against dirt and spray. The visible surface of the belt pulley has an anti-corrosion layer. 1 2 5 6 9 4 8 7 3 1. Belt pulley 2. Overrunning clutch unit 3. Integrated radial support bearing 4. Inner sleeve with ramp profile 5. Inner ring 6. Serration 7. Elastomer gasket 8. Contact plate with lip seal 9. Plastic cover 37

FUNCTIONAL TEST FUNCTIONAL TEST Overrunning alternator pulley / Overrunning clutch belt pulley Checking the function of an overrunning alternator pulley/overrunning clutch belt pulley is difficult to assess while installed. It is recommended that you remove the OAP from the alternator before testing it. 1. Secure the inner ring (Fig. 1 and 2) 2. Turn the outer ring in the drive direction of the alternator. If working correctly, the outer ring will not turn. 3. Turn the outer ring against the drive direction of the alternator and hold the inner ring at the same time. The outer ring should turn with slight resistance. Fig. 1: Securing the inner ring Important: If either of these functionality tests fail, the overrunning clutch belt pulley must be replaced. Fig. 2: Securing the inner ring! Operation is only permitted while protection cover is in place! 38

DAMAGE SYMPTOMS DAMAGE SYMPTOMS Damage symptoms 1 Profile peaks very worn (Fig. 3) Causes: Tension in the drive is too low. The belt slips over the overrunning clutch. The overrunning alternator pulley does not work. Fig. 3: Worn profi le peaks Damage symptoms 2 Guide edge abraded (Fig. 4) Causes: Misalignment between the rolls of the assemblies (installation error) Belt fitted incorrectly Fig. 4: Guide edge abraded 39

NOTES 40

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Schaeffler Group USA Inc. 5370 Wegman Drive Valley City, OH 44280 Phone 800 274 5001 Fax 330 273 3522 LIT077