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Hi,
That sounds about right - the larger idler pulley will mean less room for play and a bit tighter fit.
I wouldn't worry too much about it - so long as it's back together and the belt is tensioned correctly then you'll be fine.
Did you replace all the bearings as well? If so, then check the nuts that hold the worm drive gears in place are tightened up correctly. One of mine worked loose and introduced a load of backlash. Took me ages to work out what had happened.
Cheers,
V
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