Remove/install oil pan

AR01.45-P-7500HC

Remove/install oil pan

27.10.09

 

Remove/install

1

Disconnect ground cable from battery

AR54.10-P-0003A

2

Remove bottom section of soundproofing

AR94.30-P-5300AB

3

Drain engine oil, pour in



*BF18.00-P-1001-01A



*BA01.45-P-1003-01A

4

Detach charge air hoses on left and right (110/5) to charge air cooler

 Replace gaskets (110/11).

6 mm socket hexagon on flexible shaft for hose clamps with worm drive

7 mm socket hexagon on flexible shaft for hose clamps with worm drive

5

Remove trim panels of the cylinder head cover (1, 2)

AR01.20-P-5014-02B



*BA01.20-P-1002-01A



*BA01.20-P-1003-01A

6

Detach vacuum supply line

At charge air manifold

Installation: carry out functional test as visual inspection during brief operation at full throttle.

7

Remove intake air scoop (7)

8

Detach electrical plug connection on oil level sensor (B40)

Attach connector in engine compartment.

9

Unplug electrical connector at front axle level controller (A52)

Attach connector in engine compartment.

10

Slacken connecting spring clamp between primary catalytic converter (120/1) and catalytic converter (111)

Installation: Install new sealing cone (3).

11

Unscrew nuts (9) on threaded plate (10) of catalytic converter (111)

 Installation: Replace self-locking nuts (9).



*BA49.10-P-1003-01E

12

Detach steering shaft from steering joint (8)



*BA46.10-P-1001-01B

13

Unscrew bolts of front engine mounts (12)



*BA22.10-P-1001-01D

14

Unbolt fixture (19) of brake fluid line at left front

15

Detach torsion bar (21)

Take off fixtures (20) of torsion bar on both sides.

16

Detach heating water circulation pump (M13)

 Detach only from the body and place to the side for installing engine supporting frame

17

Remove windscreen washer fluid reservoir (4)

For installing engine supporting frame

18

Fit on engine supporting frame (13) and lift engine

Ensure that no lines or cables are jammed in between when attaching to the engine lifting eye!

Engine supporting shackle

*140589016100

 Support for engine support bracket (2 ea.)

*210589006100

19

Remove front springs (11)

AR32.20-P-0200B

20

Detach power steering hydraulic fluid line (17) from fixture at front axle carrier (25)

21

Support front axle carrier (25) with pit or installation lift

AR33.10-P-0100-03B

 Assembly attachment

*210589006200

22

Unbolt front axle carrier and lower

AR33.10-P-0100B

23

Unscrew oil pan (14, 15) bolts

Installation: In vehicles with automatic transmission, pay attention to bracket for automatic transmission oil lines. Align oil pan (18) to rear contact surface on transmission.

Pay attention to different bolt lengths and bolt diameters. Refer to

Bolt plan for oil pan

AR01.45-P-7500-06HC



*BA01.45-P-1001-01A



*BA01.45-P-1002-01A



*BA01.45-P-1004-01A



*BA01.45-P-1005-01A

24

Lower oil pan (18)

25

Remove oil pan (18) together with oil gasket (16)

Installation: Clean sealing surfaces. Insert oil pan (18) and only then fit on new oil pan gasket (16).

Removal: Take out oil pan down and to the right in direction of travel.

26

Install in the reverse order

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

27

Check for oil leaks with engine running

28

Read out fault memory and erase

Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed. Refer to:

STAR DIAGNOSIS

Number

Designation

Engine 612.961/
962/967

BA01.20-P-1002-01A

Bolt, trim panel of cylinder head cover to cylinder head cover

Nm

10

BA01.20-P-1003-01A

Bolt, charge air distribution pipe cover to charge air manifold

Nm

10

Number

Designation

Engines
612.961/962/
963/965/966,
613.961

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

9

M8

Nm

20

M10

Nm

-

BA01.45-P-1002-01A

Bolt, transmission bell housing to oil pan

Nm

40

BA01.45-P-1003-01A

Oil drain screw to oil pan

M12

Nm

-

M14

Nm

30

BA01.45-P-1004-01A

Bolt, oil pan to timing case cover

M6

Nm

9

BA01.45-P-1005-01A

Bolt, oil pan to rear crankshaft seal

M6

Nm

9

Number

Designation

Engine
612 in model 210

BA22.10-P-1001-01D

Bolt, front engine mount to front axle carrier

Nm

35

Number

Designation

Model 210

BA46.10-P-1001-01B

Steering joint bolt

Nm

20

Number

Designation

Engine 612.961/
963/967

BA49.10-P-1003-01E

Nut, exhaust bracket to threaded plate of middle exhaust pipe

Nm

20

Number

Designation

Engine
612.961

BF18.00-P-1001-01A

Engine oil

Filling capacity
(oil and filter change)

Liters

7.0

Specifications for Operating Fluids

Sheet

BB00.40-P-0228-01A

Sheet

BB00.40-P-0228-03A

Sheet

BB00.40-P-0228-05A

Sheet

BB00.40-P-0229-01A

Sheet

BB00.40-P-0229-03A

Sheet

BB00.40-P-0229-05A

Sheet

BB00.40-P-0229-31A