Remove/install housing cover at front

AR01.40-W-8800B

Remove/install housing cover at front

01.10.2019

Engine

541.9 in model 950, 952, 953, 954

Engine

542.9 in model 950, 952, 954

Modification notes

01.10.2019

Cut off sealing lip of the rubber disk on the cassette-type sealing ring all around on the collar of the race, added.

Operation step 4

AR03.20-W-3001-02G

1

Belt pulley/vibration damper

2

Slinger

3.1

Radial shaft sealing ring

3.2

Cassette-type sealing ring

4

Housing cover

5

Seal

6

Dowel pins

7

Oil pan

8

Drift

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H



Remove

1

Remove belt pulley/vibration damper (1).

Vehicles without code ML3 (High-speed fan drive with belt drive) and without code MZ5 (Electromagnetic fan drive (Linnig clutch)

AR03.30-W-1600B

Vehicles with code ML3 (High-speed fan drive with belt drive)

AR03.30-W-1600BA

Vehicles with code MZ5 (Electromagnetic fan drive (Linnig coupling))

AR03.30-W-1600BB

2

Remove slinger (2).

3

Remove oil pan (7).

AR01.45-W-7500B

4

Remove cassette-type sealing ring (3.2).

Only if cassette-type sealing ring (3.2) is installed.

AR03.20-W-3001-02G



Front crankshaft seal - altered

BT03.20-W-0004-01A


The respective separate part of the  pulling device must always be used.
Otherwise the housing cover (4) can be damaged.

MB multipurpose grease, 400 g

*BR00.45-Z-1017-06A

 Extraction and insertion tool

*700589084300

 Pulling device

*457589013300

5

Remove housing cover (4).

6

Remove seal (5).

7

Place housing cover (4) flat on two wood strips and press out radial shaft sealing ring (3.1) with drift (8).

Only if a radial shaft sealing ring (3.1) is installed.



Front crankshaft seal - altered

BT03.20-W-0004-01A

 Drift

*312589131500



Check

8

Check tread of the radial shaft sealing ring (3.1) on the crankshaft flange or on the race.

Only if a radial shaft sealing ring (3.1) was installed.

If galling is present on the crankshaft flange or on the race,



Mount new race onto crankshaft flange or repair crankshaft.

Remove/install race on the crankshaft
Engine 541.9, 542.9 up to engine end number 709510

AR03.20-W-2570A



Clean

9

Clean sealing surfaces.



Install

10

Install new seal (5).

11

Attach housing cover (4) via the dowel pins (6) to the crankcase.

 Bolt, front housing cover to crankcase

*BA01.40-N-1009-01D

12

Install oil pan (7).

AR01.45-W-7500B

13.1

Install new radial shaft sealing ring (3.1).

Engine 541.9, 542.9 up to engine end number 709510
If a race was mounted or if necessary.

AR03.20-W-3000-01A



Front crankshaft seal - altered

BT03.20-W-0004-01A

 Install radial shaft sealing ring (3.1) dry on the outer surface and coated with engine oil on the contact surface.

 Removal and insertion device

*541589023300

13.2

Install new cassette-type sealing ring (3.2).

If necessary

AR03.20-W-3001-01G



Front crankshaft seal - altered

BT03.20-W-0004-01A


The respective separate part of the  pulling device must always be used.
Otherwise the housing cover (4) is damaged or the cassette-type sealing ring (3.2) is not sealed.

 Install cassette-type sealing ring (3.2) on the outer surface dry.

 Pulling device

*457589013300

14

Install slinger (2).

 Pay attention to installation position. The slinger (2) must be installed with the flat side toward belt pulley/vibration damper (1).

15

Install belt pulley/vibration damper (1).

Vehicles without code ML3 (High-speed fan drive with belt drive) and without code MZ5 (Electromagnetic fan drive (Linnig clutch)

AR03.30-W-1600B

Vehicles with code ML3 (High-speed fan drive with belt drive)

AR03.30-W-1600BA

Vehicles with code MZ5 (Electromagnetic fan drive (Linnig coupling))

AR03.30-W-1600BB

16

Perform engine test run, switch off engine, and check in the area of the housing cover (4) and the oil pan (7) for leak tightness.

 Visual inspection.

 Cylinder crankcase, timing case cover, end cover

Number

Designation

ENGINE 541.9, 542.9

BA01.40-N-1009-01D

Bolt, front housing cover to crankcase

M8

10.9

Nm

25

M8

12.9

Nm

40

M10

10.9

Nm

70

Repair materials

Number

Designation

Order number

BR00.45-Z-1017-06A

MB multipurpose grease, 400 g

A 001 989 34 51 11