Remove/install end cover - AR01.40-P-8913GZB

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ENGINE 642 in MODEL 164

Fig 1: Removing/Installing End Cover

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Removing
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
1	Remove automatic transmission		AR27.10-P-0500GZ
2	Remove flywheel/drive plate		AR03.30-P-8001GZB
3	Remove bolt (1)
4	Remove end cover (2)	The end cover (2) must be completely replaced since the crankshaft radial sealing ring (3) is in vulcanized into the end cover (2) and can otherwise lead to leaks.
	Clean
5	Clean the sealing surfaces of cylinder crankcase, oil pan and end cover (2)	Do not use any sharp-edged tools or abrasive paper as this will damage the sealing surfaces.	AR01.00-P-0050-01A
		Loctite 7200	*BR00.45-Z-1038-04A
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
	Install
6	Install end cover (2)		AR03.20-P-3063-01OM
6	Install end cover (2)		Fig 2
Loctite sealant 5970			*BR00.45-Z-1013-01A
7	Screw in bolts (1).	Remove excess sealant after first tightening stage.
7	Screw in bolts (1).	Bolt, rear end cover to crankcase	*BA01.40-P-1001-01S
8	Install flywheel/drive plate		AR03.30-P-8001GZB
9	Install automatic transmission		AR27.10-P-0500GZ
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
10	Carry out engine test run	Check engine for leaks.
11	Check engine oil level	In order to avoid measurement errors, vehicle must be parked on an even surface. Inspect engine oil level about 5 minutes after switching off warm engine.	AR18.00-P-3035-01PI
		With code 474 Particulate filter	*BF18.00-P-1001-01S
		Without particulate filter	*BF18.00-P-1001-01A

CRANKCASE, TIMING CASE COVER, END COVER

Number	Designation			Engine 642
BA01.40-P-1001-01S	Bolt connecting rear end cover to crankcase	Stage 1	Nm	8
BA01.40-P-1001-01S	Bolt connecting rear end cover to crankcase	Stage 2	Nm	10

ENGINE LUBRICATION SYSTEM

Number	Designation			Engine 642 without particulate filter
BF18.00-P-1001-01A	Engine oil	Filling capacity (oil and filter change)	Liters	8.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0228-03A
			Sheet	BB00.40-P-0228-05A
			Sheet	BB00.40-P-0228-51A
			Sheet	BB00.40-P-0229-03A
			Sheet	BB00.40-P-0229-31A
			Sheet	BB00.40-P-0229-05A
			Sheet	BB00.40-P-0229-51A

ENGINE LUBRICATION SYSTEM

Number	Designation			Engine 642 with particulate filter
BF18.00-P-1001-01S	Engine oil	Filling capacity (oil and filter change)	Liters	8.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0228-51A
			Sheet	BB00.40-P-0229-31A
			Sheet	BB00.40-P-0229-51A

Fig 2: Identifying Insertion Tool (271 589 00 43 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1013-01A	Loctite sealant 5970	A 003 989 98 20
BR00.45-Z-1038-04A	Loctite 7200	Henkel Loctite Deutschland GmbH Arabellastrasse 17 81925 Munchen Germany Tel. +49 899268-0 Fax + 49 899101978 www.Loctite.de
BR00.45-Z-1046-04A	Cleaning spray, Loctite 7063 (150ml)	A 001 986 71 71 10