Remove/install end cover

AR01.40-P-8913PM

11.3.11

ENGINES 646 in MODEL 203, 209

P01.40-2063-08

01 Assembly sleeve

1 Cover

2 Bolts

6 Crankshaft radial sealing ring

7 Crankshaft flange

3 Bolt

4 Bolt

5 End cover

	Removing
 Danger!	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of lifting platform and position the four support plates at lifting platform support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
1	Drain/collect engine oil
2	Remove flywheel or driven plate		AR03.30-P-8001PM
3	Remove cover (1)
4	Remove screws (2, 3, 4)
5	Remove end cover (5)	 Do not damage oil pan gasket to avoid leaks. A damaged oil sump gasket must be replaced, see: 
		Remove/install oil pan	AR01.45-P-7500PM
	Clean
6	Clean the contact surfaces of end cover (5) to crankcase and clean the oil pan
	Install
7	Apply sealant cord at joint of crankcase and oil pan (arrows)	 Apply sealant cord with a height and width of 2 mm.
		Sealant	*BR00.45-Z-1009-01A
8	Push assembly sleeve (01) onto crankshaft flange (7)	 Assembly sleeve	*611589011400
9	Install end cover (5)	 Do not damage oil pan gasket. First tighten screws (2), then screws (3, 4).
		 The crankshaft radial sealing ring (6) is vulcanized in the end cover (5) and cannot be replaced separately
		 Bolt, oil pan to rear crankshaft seal	*BA01.45-P-1005-01G
10	Install cover (1)
11	Install flywheel or driven plate		AR03.30-P-8001PM
12	Screw in oil drain screw	 Replace seal of oil drain screw.
		 Oil drain screw on oil pan	*BA01.45-P-1003-01G
13	Pour in engine oil	Engine 646 without particulate filter code 474
		 Engine oil	*BF18.00-P-1001-01A
		Engine 646 with particulate filter code 474
		 Engine oil	*BF18.00-P-1001-01S
14	Check engine oil level		AR18.00-P-3035-01T
		 Oil level Engine 646.962	*BF18.00-P-1001-03L
		 Dipstick indication from 108 mm to 140 mm (oil level too low)	*BF18.00-P-1002-03L
		 Dipstick indication from 142 mm to 144 mm (oil level correct)	*BF18.00-P-1003-03L
		 Dipstick indication from 146 mm to 154 mm (oil level too high)	*BF18.00-P-1004-03L
		 Oil level Engine 646.963/966	*BF18.00-P-1001-03OA
		 Dipstick indication from 132 mm to 160 mm (oil level too low)	*BF18.00-P-1002-03OA
		 Dipstick indication from 162 mm to 164 mm (oil level correct)	*BF18.00-P-1003-03OA
		 Dipstick indication from 166 mm to 174 mm (oil level too high)	*BF18.00-P-1004-03OA
			*120589072100
	Specified engine oils (service) - overview		BB00.40-P-0223-02A
 Danger!	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
15	Check for leaks with engine running

 Oil pan

Number	Designation			Engine 646.951/ 961/962/ 963/966


BA01.45-P-1003-01G	Oil drain screw on oil pan	M12	Nm	-
		M14	Nm	30
BA01.45-P-1005-01G	Bolt, oil pan to rear crankshaft seal	M6	Nm	9

 Engine lubrication system

Number	Designation			Engine 646.951/961/ 962/963/966 without particulate filter


BF18.00-P-1001-01A	Engine oil	Filling capacity (oil and filter change)	Liters	6.5
		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 646.962/963/966 with particulate filter


BF18.00-P-1001-01S	Engine oil	Filling capacity (oil and filter change)	Liters	6.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0228-51A
			Sheet	BB00.40-P-0229-31A
			Sheet	BB00.40-P-0229-51A

Oil level check

Number	Designation			Engine 646.951/962


BF18.00-P-1001-03L	Oil level	Maximum	mm	143
		Minimum	mm	118
BF18.00-P-1002-03L	Dipstick indication 108 mm to 140 mm (oil level too low)	108 mm	Replenish oil quantity in liters	+2.8
		110 mm	Replenish oil quantity in liters	+2.7
		112 mm	Replenish oil quantity in liters	+2.5
		114 mm	Replenish oil quantity in liters	+2.4
		116 mm	Replenish oil quantity in liters	+2.2
		118 mm	Replenish oil quantity in liters	+2.1
		120 mm	Replenish oil quantity in liters	+2.0
		122 mm	Replenish oil quantity in liters	+1.8
		124 mm	Replenish oil quantity in liters	+1.6
		126 mm	Replenish oil quantity in liters	+1.5
		128 mm	Replenish oil quantity in liters	+1.3
		130 mm	Replenish oil quantity in liters	+1.1
		132 mm	Replenish oil quantity in liters	+0.9
		134 mm	Replenish oil quantity in liters	+0.7
		136 mm	Replenish oil quantity in liters	+0.6
		138 mm	Replenish oil quantity in liters	+0.4
		140 mm	Replenish oil quantity in liters	+0.2
BF18.00-P-1003-03L	Oil dipstick indication 142 mm to 144 mm (oil level correct)	142 mm	Oil quantity in liters	0.0
		143 mm	Oil quantity in liters	0.0
		144 mm	Oil quantity in liters	0.0
BF18.00-P-1004-03L	Oil dipstick indication 146 mm to 154 mm (oil level too high)	146 mm	Extract oil quantity in liters	-0.2
		148 mm	Extract oil quantity in liters	-0.4
		150 mm	Extract oil quantity in liters	-0.5
		152 mm	Extract oil quantity in liters	-0.7
		154 mm	Extract oil quantity in liters	-0.9

Oil level check

Number	Designation			Engine 646.961/963/966


BF18.00-P-1001-03OA	Oil level	Maximum	mm	163
		Minimum	mm	139
BF18.00-P-1002-03OA	Oil dipstick reading 132 mm to 160 mm (oil level too low)	132 mm	Replenish oil quantity in liters	+2.8
		134 mm	Replenish oil quantity in liters	+2.6
		136 mm	Replenish oil quantity in liters	+2.4
		138 mm	Replenish oil quantity in liters	+2.2
		140 mm	Replenish oil quantity in liters	+2.0
		142 mm	Replenish oil quantity in liters	+1.8
		144 mm	Replenish oil quantity in liters	+1.6
		146 mm	Replenish oil quantity in liters	+1.4
		148 mm	Replenish oil quantity in liters	+1.3
		150 mm	Replenish oil quantity in liters	+1.1
		152 mm	Replenish oil quantity in liters	+0.9
		154 mm	Replenish oil quantity in liters	+0.8
		156 mm	Replenish oil quantity in liters	+0.6
		158 mm	Replenish oil quantity in liters	+0.4
		160 mm	Replenish oil quantity in liters	+0.3
BF18.00-P-1003-03OA	Oil dipstick reading 162 mm to 164 mm (oil level correct)	162 mm	Oil quantity in liters	0.0
		163 mm	Oil quantity in liters	0.0
		164 mm	Oil quantity in liters	0.0
BF18.00-P-1004-03OA	Oil dipstick reading 166 mm to 174 mm (oil level too high)	166 mm	Extract oil quantity in liters	-0.3
		168 mm	Extract oil quantity in liters	-0.4
		170 mm	Extract oil quantity in liters	-0.5
		172 mm	Extract oil quantity in liters	-0.6
		174 mm	Extract oil quantity in liters	-0.7

120 589 07 21 00

Dipstick

Assembly sleeve

611 589 01 14 00

Repair materials

Number	Designation	Order number
BR00.45-Z-1009-01A	Sealing compound Loctite 574, 50 ml	A 001 989 89 20 10

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