Replacing Belt Pulley/Vibration Damper and Hub

NOTE: The crankshaft sprocket (10) and the hub (6) are seated on the front crankshaft stub, lined up by means of the Woodruff key (8). This assembly is pressed against the crankshaft with the bolt (4) and the 4 diaphragm springs (5) (2nd version as of 1985). The vibration damper (3) and the V-belt pulley (1) are bolted to the hub (6) in a certain position, since one of the six threaded holes is set off.

Crankshaft arrangement 2nd version:

1 V - belt pulley
2 Bolt M 8 x 22
3 Vibration damper
Engine 116.96 201.5 mm dia
Engine 117.96 214 mm dia
4 Dolt M 18 x 1.5 x 45
5 Diaphragm springs (4 required)
6 Hub
7 Radial Sealing ring
8 Woodruff key
9 Timing case cover
10 Crankshaft sprocket
11 Crankshaft

Hub, vibration damper and V-belt pulley can be renewed without balancing.

The vibration dampers of the engines 116.96 and 117.96 have a different outside diameter and characteristic frequency.

The V-belt pulleys of the different engines 116.96 and 117.96 are also different

From August 1983 until November 1984 vibration dampers with an aluminium primary part together with a modified hub were installed.

1st version - Vibration damper engine 116.95:

NOTE: The vibration damper of engines 116.960/961 (AUS) (J) (S) and (USA) with asymmetrical mounting bore at the outer circumference was replaced with the vibration damper 116 03007 03 with symmetrically arranged installation recesses as of January 1981.

Used in:
Engine No. 116.960 12 006407
116.961 12 011140

Removal
1 Remove radiator, fan and V-belt.





2 Use special tool detent to locate crankshaft in position.
3 Unscrew crankshaft and bolt
4 Use a chisel to mark crankshaft and hub relative to each other (arrow) so that the groove of the hub lines up with the Woodruff key upon assembly.
5 Manually pull off vibration damper together with V-belt pulley and hub, assisting with light taps with a plastic hammer if necessary.

CAUTION: Take care not to break the cast-iron V-belt pulley.

Installing
6 Screw vibration damper, belt pulley and hub together and install.
7 For this step, heat hub to approx. 50 °C so that it slips easily onto the crankshaft When fitting on, turn hub to ensure that the groove of the hub is aligned with the Woodruff key in the crankshaft.









CAUTION: The vibration damper, the belt pulley and the hub must be bolted together in a certain position.

One of the 6 holes is positioned off-center. The holes must be exactly aligned (see size 1.73).

The six M 8 x 22 bolts for attaching the belt pulley and the vibration damper are installed without spring lock washers in contrast to the cast iron engine.

8 Moisten dished springs and bolts with engine oil.
9 Install the M 18 x 1.5 x 45 bolt with 4 dished springs (2nd version) and tighten to the specified torque (see "Important Note"). Specifications

If the vibration damper has been replaced, the TDC sensor must be adjusted.