Removing and installing end cover - RA01001192220X(01-2220)

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Preceding work:

Transmission removed (27-6000).

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.

Driven plates (20)	remove (03-4100) .
Bolts (11 and 13)	unscrew.
End cover (14) with radial seal (15)	press off (step 3) using M8 bolts at tapped holes (arrows).
Sealing surfaces	clean.
Sealant	apply (step 5).
Sealing lip of radial seal	coat with engine oil (step 6).
Bottom side of end cover	coat with sealant (step 7). Sealant 002 989 45 20.
End cover (14) with radial seal (15)	press on over insertion tool, special tool 117 589 00 43 00 (step 8).
Bolts (13)	tighten first of all (9 Nm).
Bolts (11)	tighten (9 Nm).
Leaks	check at rear of engine when running (01-2240) .

TIGHTENING TORQUE SPECIFICATION

End cover to crankcase

9 Nm

Special tools

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Special Tool (117 589 00 43 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 hole with the dimensions "A, B, C" as shown in drawing.

Size A = 38 mm

B = 15.6 mm

C = 10 mm

Fig 4: Identifying Holes Dimension

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

NOTE: The end cover seals the main oil gallery (arrow) ; for this reason, particular care must be employed when installing.

The sealing surfaces of the crankcase and of the end cover must not have any scoring.

The tapped holes in the crankshaft flange are drilled through. When the bolts are removed and the engine is tilted, engine oil runs out of the tapped holes.

Fig 5: Locating Main Oil Gallery

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removal

Remove driven plates together with ring gear (03-4100) .
Unscrew end cover together with radial seal.
Use bolts at M8 tapped holes (arrows) to press off tight end cover.

Do not damage gasket of oil sump.

Fig 6: Locating M8 Tapped Holes
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Installation
Carefully clean sealing surface on crankcase and on end cover.
Coat the sealing surface of the end cover evenly with sealant 002 989 45 20.
When doing this, ensure that no sealant gets into the oil gallery (arrow).

Fig 7: Locating Oil Gallery
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Coat radial seal between dust and sealing lip with engine oil.

Do not use grease. Grease prevents the angled webs on the sealing lip transporting back the engine oil.
Coat underside of end cover with sealant 002 989 00 20 10.
Push end cover (14) together with radial seal (15) over the inner part of the bolted-on insertion tool, special tool 117 589 00 43 00, and bolt on. Do not damage oil sump gasket. If necessary, replace oil sump gasket. First of all tighten bolts (13), then bolts (11).

Pay attention to different length of bolts (13).
Check for leaks at rear of engine when running (01-2240) .

Fig 8: Identifying End Cover And Radial Seal
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.