Replacement of the core hole plug caps in the crankcase - ra01006010140x(0140)

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.

Engines 601, 602 (except 602.98), 603

Preceding work:

Coolant drained

Attachment parts in area of core hole plug cap removed.

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

Fig 1: Identifying Core Hole Plug Cap, Left, 34 mm Dia

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Core hole plug cap, left, 34 mm dia. (8)

Fig 2: Identifying Core Hole Plug Cap, Right, 34 mm Dia

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Core hole plug cap, right, 34 mm dia. (8b)

Fig 3: Identifying Core Hole Plug Cap, Front, 17 mm Dia

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Core hole plug cap, front, 17 mm dia. (8a)

Fig 4: Identifying Core Hole Plug Cap, Rear, 34 mm Dia

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Core hole plug cap, rear, 34 mm dia. (11)

Core hole plug caps (8, 8a, 8b, 11)	remove, knock in. Installation punch 102 589 12 15 00, 17 mm dia. or punch 102 589 00 15 00, 34 mm dia. (steps 1 - 6). NOTE: Seal core hole plug caps with sealant 002 989 94 71. Allow sealant to harden for approx. 45 minutes.
After reassembling engine	allow engine to warm up and check for leakage at new core hole plug cap installed.

NOTE: The number of core hole plug caps differs on the individual engine models. The figure shows engine model 603 as an example.

Engine	left, 34 mm dia.	right, 34 mm dia.	front, 17 mm dia.	rear, 34 mm dia.
601	2	2	1	1
602	3	3	1	1
603	3	4	1	1

SEALANT

Loctite 241

002 989 94 71

Special tools

Fig 5: Identifying Special Tools (102 589 12 15 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Special Tools (102 589 00 15 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removal

Position chisel with small blade or screwdriver in deep-drawn edge of core hole plug cap.

Fig 7: Positioning Chisel With Small Blade Or Screwdriver In Deep-Drawn Edge Of Core Hole Plug Cap
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Carefully knock in core hole plug cap at one side until it rotates around its own longitudinal axis and can be gripped with a pair of pliers.
Pull out core hole plug cap.
Clean sealing surface; surface must be free of grease.

Fig 8: Pulling Out Core Hole Plug Cap
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Installation
Coat sealing surface with sealant 002 989 94 71.
Knock in new core hole plug cap with installation punch 102 589 12 15 00 (17 mm dia.) or 102 589 00 15 00 (34 mm dia.).
Allow sealant to harden for approx. 45 minutes before filling coolant.
After reassembling engine, allow engine to warm up and check for leakage at new core hole plug cap installed.

Fig 9: Knocking In Core Hole Plug Cap
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.