Removing and installing end cover - RA01001202220X(01-2220)

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

Preceding work:

Transmission removed (27-6000).

Driven plates (20) with ring gear removed (03-4100) .

Operation no. of operation texts and work units or standard texts and flat rates

01-8913

Fig 1: Identifying End Cover Remove/Install Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Bolts (1), (2) and (3)	unscrew.
End cover (14) with radial seal (15) and gasket (16)	take off (steps 2 and 3).
Sealing surfaces	clean (step 4).
Gasket (16)	replace.
Sealing lip of radial seal	coat with engine oil (step 6).
End cover (14) with radial seal (15)	press on over insertion tool 117 589 00 43 00 (step 7).
Bolts (1 and 2)	tighten first of all (9 Nm) (step 9).
Bolts (3)	tighten (9 Nm).
Oil level in engine	check and adjust to correct level.
Driven plates (20) with ring gear	install (03-4100) .
Leakage	check with engine running before installing transmission (01-2240) .

TIGHTENING TORQUE SPECIFICATION

End cover to crankcase		9 Nm
Stretch bolts for driven plates	Initial tightening torque	30-40 Nm
Stretch bolts for driven plates	Tightening angle	90-100°

Special tools

Fig 2: Identifying Special Tool (001 589 72 21 00 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Special Tool (117 589 00 43 00 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Insertion tool

Use only insertion sleeve 117 589 00 43 00 (2nd version) with hole for locating pin.

Insertion sleeve 117 589 00 43 00 (1st version) can be modified by drilling a hole with the sizes "A, B, C" as shown in drawing.

Size A = 38 mm

B = 15.6 mm

C = 10 mm

Fig 4: Identifying Hole Sizes

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

NOTE: The end cover closes the main oil passage (arrow). For this reason, particular care must be employed when installing end cover. The sealing surfaces of the crankcase and of the end cover must not show any scoring.

Fig 5: Identifying Main Oil Passage

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing, installing

Unscrew end cover (14) together with radial seal (15).
Press off end cover (14) together with radial seal (15) at the side (arrows) with a screwdriver.

Do not damage oil pan gasket.

Fig 6: Identifying End Cover And Radial Seal
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Take off gasket (16).
Carefully clean sealing surface on crankcase and on end cover.
Install new gasket (16) without sealant.
NOTE: Pay attention to locating sleeves (4).
Coat radial seal between dust and sealing lips with engine oil.

Do not use grease. Grease prevents the angled webs on the sealing lips transporting back the engine oil.

Fig 7: Identifying Sleeves And Gasket
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Push end cover (14) together with radial seal (15) over the screwed-on inner part of insertion tool (6) 117 589 00 43 00 and screw on.

Do not damage oil pan gasket (arrows) ; to avoid this, tilt end cover (14) back slightly at the top when fitting on.

If necessary, replace oil pan gasket.

Fig 8: Identifying End Cover, Radial Seal And Insertion Tool
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install bolts according to bolt diagram.
Tighten front cover bolt (1 and 2) first of all.
Tightening torque 9 Nm.

Bolt diagram
1. Hexagon bolt+washer M6 X 20
2. Hexagon bolt+washer M6 X 25
3. Hexagon bolt+washer M6 X 50
4. Holes for locating sleeves
  
  Fig 9: Identifying Tightening Sequence Of Front Cover Bolts
  Courtesy of MERCEDES-BENZ OF NORTH AMERICA.