Removing/installing the oil pan

AR01.45-P-7500HD

Removing/installing the oil pan

30.11.98

 

Removing/installing

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.

Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

1

Disconnect ground cable from battery

AR54.10-P-0003A

2

Remove bottom section of soundproofing capsule

AR94.30-P-5300AB

3

Draining/filling with coolant

 At radiator

AR20.00-P-1142HB

4

Detach coolant hose (5)

 Inspect condition of coolant hose and hose clamp, replace if necessary.

 Only on radiator



*WH58.30-Z-1001-06A



*WH58.30-Z-1002-06A

5

Drain engine oil, pour in



*BF18.00-P-1001-01A



*BA01.45-P-1003-01A

6

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

AR01.20-P-5014-02C



*BA01.20-P-1002-01A



*BA01.20-P-1003-01A

7

Remove intake air scoop (7)

8

Slacken fan shroud (6)

 When the engine is raised, the fan shroud is also pulled up.

 Installation: Insert retaining lugs (arrows) of fan shroud into the mounts on the radiator.

Align fan shroud to fan.

9

Detach heating water circulation pump (M13)

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

10

Remove windscreen washer fluid reservoir (4)

 For installing engine supporting frame.

11

Detach vacuum supply lines

 On charge air distribution pipe.

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

12

Detach electrical plug connection on oil level sensor (B40)

13

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

 Replace gaskets (110/11).



*WH58.30-Z-1001-06A



*WH58.30-Z-1002-06A

14

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

 Installation: Install new sealing cone (3).

15

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

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



*BA49.10-P-1003-01E

16

Detach steering shaft from steering joint (8)



*BA46.10-P-1001-01B

17

Unscrew bolts for front engine mounts (12)



*BA22.10-P-1001-01D

18

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

19

Detach torsion bar (21)

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

20

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 frame, model 210

*140589016100

 Supports, model 210

*210589006100

21

Remove front springs (11)

AR32.20-P-0200B

22

Prop front axle carrier with inspection pit lift or assembly lift

AR33.10-P-0100-03B



*210589006200

23

Unbolt front axle carrier and lower

AR33.10-P-0100B

24

Unscrew bolts of oil pan (14, 15)

 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:

Screw diagram foril pan

AR01.45-P-7500-06HD



*BA01.45-P-1001-01A



*BA01.45-P-1002-01A



*BA01.45-P-1004-01A



*BA01.45-P-1005-01A

25

Lower oil pan (18)

26

Remove oil pump (17)

 Replace sealing ring.

AR18.10-P-6020HB

27

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

 Installation: Clean sealing surfaces. Insert new oil pan gasket (16).

Sealant on oil pan gasket must point toward crankcase.

 Removal: Take oil pan down and out in direction of travel; rotate crankshaft slightly, if necessary, for this step.

28

Install in 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 engine

Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

29

Run engine and inspect for oil leaks

30

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

Engines 613.960/
961

BA01.20-P-1002-01A

Bolt for trim panel of cylinder head cover oncylinder head cover

Nm

10

BA01.20-P-1003-01A

Screw attaching cover panel to charge air distribution pipe

Nm

10

Number

Designation

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

BA01.45-P-1001-01A

Bolt for oil pan on crankcase

M6

Nm

9

M8

Nm

20

M10

Nm

-

BA01.45-P-1002-01A

Bolt for transmission bell housing on oil pan

Nm

40

BA01.45-P-1003-01A

Oil drain screw at oil pan

M12

Nm

-

M14

Nm

30

BA01.45-P-1004-01A

Bolt for oil pan on timing case cover

M6

Nm

9

BA01.45-P-1005-01A

Bolt for oil pan on rear crankshaft seal

M6

Nm

9

Number

Designation

Engine 613
in model 210

BA22.10-P-1001-01D

Bolt for front engine mounts on front axle carrier

Nm

35

Number

Designation

Model 210

BA46.10-P-1001-01B

Bolt for steering joint

Nm

20

BA46.10-P-1002-01B

Bottom clamping bolt on top steering shaft

Nm

-

BA46.10-P-1003-01B

Bottom bolt with nut on top
steering shaft if fixed or mechanically adjustable casing tube

Steel joint flange

Nm

28

Light-alloy joint flange

Nm

20

BA46.10-P-1004-01B

Nut on top steering shaft if electrically adjustable casing tube

Nm

110

Number

Designation

Engine 613.960

Engine
613.961

BA49.10-P-1003-01E

Nut for exhaust bracket on threaded plate of middle exhaust pipe

Nm

20

20

Number

Designation

Engine
613.961

BF18.00-P-1001-01A

Engine oil

Filling capacity
(oil and filter change)

Liters

7.5

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

Number

Designation

WH58.30-Z-1001-06A

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

WH58.30-Z-1002-06A

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

WE58.40-Z-1027-11A

Engine support frame