03—340 Removal and installation of pulley, vibration damper and balancing disc
 
 

 
 
Tightening torques
Bolt M 18 x 1.5 x 45 on crankshaft Bolts M 8 x 30
Special tools
Socket 27 mm, 1/2" square
Torque wrench 150—500 Nm, 3/4" square
Detent
om617 - 0116-1.jpg
Nm
270-330
25
001 589 65 09 00 001 589 31 21 00 110 589 00 40 00
116 589 10 33 00
 
 
Puller for balancing disc
 
 

 
 
Conventional tool
 
 

 
 
Adaptor 3/4" hex. socket to 1/2" hex. head
e.g. made by Hazet, D-5630 Remscheid order no. 1058 R-1
 
 

 
 
Note
 
 

 
 
The vibration damper can be renewed without ba­lancing.
When the balancing disc is renewed, static balancing is absolutely required (03—344).
Since January 1979, the fastening screws (17) for pulley and vibration damper on engine 617.950 are inserted without washers (18). On engines 617.951/ 952 from start of series.
 
 

 
 
03.8-340/1 F 2
 
 

 
         

 

       
 

 
 
Removal
om617 - 0117-1.jpg
 
 
1 Remove radiator and fan.
 
 
2 Remove all V-belts (13-340).
 
 
3 Remove pulley and vibration damper.
 
 
           
 



15
 
 



16
 
 
15
BoltM 18x1.5x45
25
Radial sealing ring
 
 
16
Cup spring
26
Spacing ring
 
 
17
Bolt M 8 x 30
27
Woodruff key
 
 
18
Washer
28
Crankshaft gear
 
 
19
Pulley
30
Crankshaft
 
 
20
Vibration damper
55a
Cover
 
 
23
Fitted pin 8x8
a
Pin
 
 
24
Balancing disc


 
           
 
 

 
 
4 On models 116.120 and 123 with automatic trans­mission 722.120 (W4B 025), insert detent at flywheel as a couterhold when loosening screw in crankshaft.
om617 - 0117-2.jpg
 
 

 
 
103-9243
 
 

 
 
On models 126.120 and 123.with automatic trans­mission 722.303 (W4A 040) use a steel bolt as a counterhold in one of the recesses on balancing disc and on cylinder crankcase (arrow).
om617 - 0117-3.jpg
 
 

 
 
03.8-340/2 F 2
 
 

 
       

 

       
 

 
 
5 Remove screw on crankshaft.
om617 - 0118-1.jpg
 
 

 
 
6 Identify balancing disc and crankshaft by punch marks.
om617 - 0118-2.jpg
 
 

 
 
7 Pull off balancing disc by means of puller. For this purpose, place recess in balancing disc under water pump pulley.
Do not screw-in puller screws too far, since this might damage the radial sealing ring.
om617 - 0118-3.jpg
 
 

 
 
Installation
 
 

 
 
8 Place balancing disc on crankshaft in such a manner that the bores for the fitted pins are in align­ment.
Note: The balancing disc is located on crankshaft by means of two offset fitted pins.
 
 

 
 
03.8-340/3 F 2
 
 

 
       

 

           
 

 
 
9    Mount balancing disc on crankshaft with screw M 18 x 1.5 x 45 and cup springs.
10    Knock-in both fitted pins.
om617 - 0119-1.jpg
103-15477
 
 

 
 
11    Mount the three cup springs with crown toward bolt head.
12    Lubricate bolt on crankshaft and tighten to 270—330 Nm, while applying counterhold to crank­shaft with detent or steel bolt.
Z033- 4669/6
 
 

 
 
13 Install vibration damper, pulley, fan and radiator.
 
 

 
 
14 Tension V-belt.
 
 

 
 
Pulley, vibration damper and balancing disc
 
 

 
 
14    Adjusting indicator
15    Bolt M 18 x 1.5 x45
16    Cup springs
17    6 bolts M 8x30
18   6 washers 8.4
19    Pulley
20    Vibration damper
23    2 fitted pins 8x8
24    Balancing disc
25    Radial sealing ring
26   Spacing ring
27    Woodruff key
28    Crankshaft gear (sprocket)
om617 - 0119-2.jpg
 
 

 
 
03.8-340/4 F 2