Remove/install end cover together with shaft seal

AR01.40-D-8920R

Remove/install end cover together with shaft seal

04.09.2018

Engine

646 in model 909

Modification notes

22.11.2016

Lightly tighten screw/bolts by hand, added.

Operation step 8

22.11.2016

The tightening sequence of the screw/bolts (2, 3) for installation is altered, added.

Operation step 10, 11

1

Assembly sleeve

4

Oil pan

7

Crankshaft

2

Screw/bolts

5

Bottom half of crankcase

3

Screw/bolts

6

Radial shaft sealing ring

 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



Remove

1

Remove flywheel

AR03.30-D-8002R

2

Remove screw/bolts (2)

3

Remove screw/bolt (3)

4

Remove bottom half of crankcase (5) and catch escaping engine oil in a suitable container



Install

5

Clean contact surfaces of crankcase cover (5) on crankcase and clean oil pan (4)


Do not use sharp-edged or pointed objects to clean sealing surface.
The sealing surface can get damaged otherwise.

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

*BR00.45-Z-1051-04A

6

Position assembly sleeve (1) on crankshaft (7)

 Assembly sleeve

*611589011400

7

Position new crankcase cover (5) on crankcase

 The radial shaft sealing ring (6) is vulcanized into the end cover (5) and cannot be replaced separately.

8

Lightly tighten screw/bolts (2) by hand

9

Remove assembly sleeve (1) from crankshaft (7)

 Assembly sleeve

*611589011400

10

Fully tighten screw/bolts (3)

 Bolt, oil pan to rear crankshaft seal

*BA01.45-N-1006-01H

11

Fully tighten screw/bolts (2)

 Screw/bolt, rear end cover to crankcase

*BA01.40-N-1002-01Q

12

Install flywheel

AR03.30-D-8002R

13

Check engine oil level; correct if necessary


The engine oil level must not lie above the maximum marking.
Engine damage will occur otherwise..

 Engine oil

*BF18.00-N-1001-01L

 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

14

Perform an engine test run and check engine for leaktightness

 Crankcase, timing case cover, end cover

Number

Designation

Engine 646.701 in model 909

BA01.40-N-1002-01Q

Screw/bolt, rear end cover to crankcase

Nm

8

 Oil pan

Number

Designation

Engine 646.701/984/985/986/989/990

BA01.45-N-1006-01H

Bolt, oil pan to rear crankshaft seal

M6

Nm

8,5

 Filling capacities for engine lubrication system

Number

Designation

Engine 646 in model 909

BF18.00-N-1001-01L

Engine oil

Filling capacity (oil and filter change)

Liter

9,8

Sheet

BB00.40-P-0228-51A

Sheet

BB00.40-P-0229-31A

Sheet

BB00.40-P-0229-51A

Sheet

BB00.40-P-0229-52A

Sheet

-

Sheet

-

Sheet

-

Sheet

-

Repair materials

Number

Designation

Order number

BR00.45-Z-1051-04A

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

Chemische Werke Kluthe GmbH
Gottlieb-Daimler-Str. 12
69115 Heidelberg
Germany
Tel. +49 6221 5301-0
Fax +49 6221 5301-176
http://kluthe.com