Remove/install end cover

AR01.40-P-8913TC

11.3.11

ENGINES 646.951 in MODEL 211.004

ENGINES 646.961 in MODEL 211.006 /206 /606

ENGINES 647.961 in MODEL 211.016 /216 /616

ENGINES 648.961 in MODEL 211.026 /226 /023 /223

P01.40-2174-08

1 Assembly sleeve

2 Cover

3 Bolt

6 Crankshaft radial sealing ring

7 Crankshaft flange

4 Bolts

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
 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
1	Drain/collect engine oil
	Engine - oil and filter change		AP18.00-P-0101TC
2.1	Remove manual transmission	Transmission 716.604 in model 211.004 except Sequentronic automated manual transmission (SEQ) code 424 Transmission 716.649 in model 211.006/206/016/ 216 except Sequentronic automated manual transmission (SEQ) code 424	AR26.10-P-0020T
2.2	Remove the Sequentronic automated manual transmission	Transmission 716.604 in model 211.004 except Sequentronic automated manual transmission (SEQ) code 424 Transmission 716.649 in model 211.006/016 with Sequentronic automated manual transmission (SEQ) code 424	AR26.10-P-0020TA
2.3	Remove transmission with torque converter	Transmission 722.699 in model 211.004/006/606/ 206, transmission 722.640 in model 211.016/616/ 023/216/223, transmission 722.626 in model 211.026/226	AR27.10-P-0500T
3.1	Remove clutch	211.0/2 with transmission 716.6	AR25.10-P-0050P
4	Remove flywheel/drive plate
		Engine 646.951 in model 211.004 with transmissions 716.604, 722.699 Engine 646.961 in model 211.006/206 with transmissions 716.651, 722.699 Engine 647.961 in model 211.016/216 with transmissions 716.649, 722.640 Engine 648.961 in model 211.026/226 with transmission 722.626 Engine 648.961 in model 211.023/223 with transmission 722.640 Engine 646.961 in model 211.606 with transmission 722.699 Engine 647.961 in model 211.616 with transmission 722.640	AR03.30-P-8001T
5	Remove cover (2)
6	Remove bolts (3, 4)
7	Remove end cover (5)	 Do not damage oil pan gasket. Damaged oil pan gaskets must be installed new otherwise engine oil could leak out: 
		Remove oil pan	AR01.45-P-7500T
	Clean
8	Clean contact surfaces of end cover (5) to crankcase and clean the oil pan
	Install
9	Apply a string of sealant to joint of crankcase and oil pan (arrows)	 Sealant string: Height 2 mm, width 2 mm.
		Sealant	*BR00.45-Z-1009-01A
10	Push assembly sleeve (1) on crankshaft flange (7)
			*611589011400
11	Install end cover (5)	 Take care while mounting that the oil pan gasket is not damaged since this can cause leaks.
		 First tighten bolts (4), then bolt (3).
		 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
12	Install cover (2)
13	Install flywheel/drive plate
		Engine 646.951 in model 211.004 with transmissions 716.604, 722.699 Engine 646.961 in model 211.006/206 with transmissions 716.651, 722.699 Engine 647.961 in model 211.016/216 with transmissions 716.649, 722.640 Engine 648.961 in model 211.026/226 with transmission 722.626 Engine 648.961 in model 211.023/223 with transmission 722.640 Engine 646.961 in model 211.606 with transmission 722.699 Engine 647.961 in model 211.616 with transmission 722.640	AR03.30-P-8001T
14.1	Install clutch	211.0/2 with transmission 716.6	AR25.10-P-0050P
15.1	Install manual transmission	Transmission 716.604 in model 211.004 except Sequentronic automated manual transmission (SEQ) code 424 Transmission 716.649 in model 211.006/206/016/ 216 except Sequentronic automated manual transmission (SEQ) code 424	AR26.10-P-0020T
15.2	Install the Sequentronic automated manual transmission	Transmission 716.604 in model 211.004 except Sequentronic automated manual transmission (SEQ) code 424 Transmission 716.649 in model 211.006/016 with Sequentronic automated manual transmission (SEQ) code 424	AR26.10-P-0020TA
15.3	Install transmission with torque converter	Transmission 722.699 in model 211.004/006/606/ 206, transmission 722.640 in model 211.016/616/ 023/216/223, transmission 722.626 in model 211.026/226	AR27.10-P-0500T
16	Pour in engine oil	 Replace sealing ring of oil drain screw to avoid leaks.
	Changing the engine oil and filter		AP18.00-P-0101TC
		 Oil drain screw to oil pan	*BA01.45-P-1003-01G
		 Engine oil, engine 646 without particulate filter, engine 647	*BF18.00-P-1001-01A
		 Engine oil, engine 648 without particulate filter	*BF18.00-P-1001-01Y
		 Engine oil, engine 646 with particulate filter	*BF18.00-P-1001-01S
		 Engine oil, engine 648 with particulate filter	*BF18.00-P-1001-01X
17	Check engine oil level, and correct	 The vehicle must be parked on a level surface, otherwise false measurements can occur.
		Engine 646.951/961 in model 211	AR18.00-P-3035-01T
		 Oil level check:
		 Oil level Engine 646.951	*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 646.961	*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
		Engine 647 in model 211	AR18.00-P-3035-01S
		 Oil level check:
		Oil level	*BF18.00-P-1001-03N
		Dipstick indication from 108 mm to 136 mm (oil level too low)	*BF18.00-P-1002-03N
		Dipstick indication from 138 mm to 140 mm (oil level correct)	*BF18.00-P-1003-03N
		Dipstick indication from 142 mm to 152 mm (oil level too high)	*BF18.00-P-1004-03N
		Engine 648 in model 211	AR18.00-P-3035-01BD
		 Oil level check:
		 Engine 646 without particulate filter, engine 647	*BF18.00-P-1001-01A
		 Engine 648 without particulate filter	*BF18.00-P-1001-01Y
		 Engine 646 with particulate filter	*BF18.00-P-1001-01S
		 Engine 648 with particulate filter	*BF18.00-P-1001-01X
		 Dipstick	*120589062100
		 Dipstick	*120589072100
18	Test run engine and check for leaks

 Oil pan

Number	Designation			Engine 646.951/ 961/962/ 963/966	Engine 647	Engine 648


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

 Engine lubrication system

Number	Designation			Engine 646.951/961/ 962/963/966 without particulate filter	Engine 647.961


BF18.00-P-1001-01A	Engine oil	Filling capacity (oil and filter change)	Liters	6.5	6.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0228-03A	BB00.40-P-0228-03A
			Sheet	BB00.40-P-0228-05A	BB00.40-P-0228-05A
			Sheet	BB00.40-P-0228-51A	BB00.40-P-0228-51A
			Sheet	BB00.40-P-0229-03A	BB00.40-P-0229-03A
			Sheet	BB00.40-P-0229-31A	BB00.40-P-0229-31A
			Sheet	BB00.40-P-0229-05A	BB00.40-P-0229-05A
			Sheet	BB00.40-P-0229-51A	BB00.40-P-0229-51A

 Engine lubrication system

Number	Designation			Engine 648.961 without particulate filter


BF18.00-P-1001-01Y	Engine oil	Filling capacity (oil and filter change)	Liters	7.3
		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 646.951 with particulate filter	Engine 646.961 with particulate filter


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

 Engine lubrication system

Number	Designation				Engine 648.961 with particulate filter


BF18.00-P-1001-01X	Engine oil	Capacity (oil and filter change)	Lowering	Liters	7.3
			Suctioning off	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 647 in model 211


BF18.00-P-1001-03N	Oil level	Maximum	mm	139
		Minimum	mm	116
BF18.00-P-1002-03N	Dipstick indication 108 mm to 136 mm (oil level too low)	108 mm	Replenish oil quantity in liters	+2.7
		110 mm	Replenish oil quantity in liters	+2.5
		112 mm	Replenish oil quantity in liters	+2.4
		114 mm	Replenish oil quantity in liters	+2.2
		116 mm	Replenish oil quantity in liters	+2.1
		118 mm	Replenish oil quantity in liters	+1.9
		120 mm	Replenish oil quantity in liters	+1.8
		122 mm	Replenish oil quantity in liters	+1.6
		124 mm	Replenish oil quantity in liters	+1.4
		126 mm	Replenish oil quantity in liters	+1.3
		128 mm	Replenish oil quantity in liters	+1.1
		130 mm	Replenish oil quantity in liters	+0.9
		132 mm	Replenish oil quantity in liters	+0.7
		134 mm	Replenish oil quantity in liters	+0.5
		136 mm	Replenish oil quantity in liters	+0.3
BF18.00-P-1003-03N	Oil dipstick indication 138 mm to 140 mm (oil level correct)	138 mm	Oil quantity in liters	0.0
		139 mm	Oil quantity in liters	0.0
		140 mm	Oil quantity in liters	0.0
BF18.00-P-1004-03N	Oil dipstick indication 142 mm to 152 mm (oil level too high)	142 mm	Extract oil quantity in liters	-0.3
		144 mm	Extract oil quantity in liters	-0.6
		146 mm	Extract oil quantity in liters	-0.7
		148 mm	Extract oil quantity in liters	-0.9
		150 mm	Extract oil quantity in liters	-1.1
		152 mm	Extract oil quantity in liters	-1.3

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 06 21 00

Dipstick

Assembly sleeve

611 589 01 14 00

120 589 07 21 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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