Remove/install oil pan

AR01.45-P-7500M

Remove/install oil pan

9.5.06

 

Remove/install

 Danger!

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof.

Keep body parts and limbs well clear of moving parts.

AS00.00-Z-0011-01A

 Danger!

Risk of explosion from fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure.

Keep all ignition sources out of hazard area.

Do not carry out any work on the system when it is pressurized.

AS07.16-Z-0001-01A

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

Open engine hood and raise to vertical position

 Have assistant secure hood.

AR88.40-P-1000GI

2

Disconnect ground cable from battery

AR54.10-P-0003A

3

Remove bottom section of soundproofing

4

Drain engine oil



*BA01.45-P-1003-01A



*BF18.00-P-1001-01A

5

Drain coolant

At radiator.

AR20.00-P-1142M

6

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

7

Detach coolant hose (3) at coolant connection fitting (4)

 Clamping device

*000589543700



*WH58.30-Z-1001-06A



*WH58.30-Z-1002-06A

8

Remove coolant connection fitting (4) from exhaust gas recirculation (5)

Installation: Replace seal (6).

9

Detach fuel hose (7) at preheater unit/fuel preheating system (9)

Detach

 Pinch off fuel hose (7) as close as possible to preheater unit/preheating system (9) to ensure that as little fuel as possible is able to flow out.

 Clamping device

*000589543700



*WH58.30-Z-1001-06A



*WH58.30-Z-1002-06A

10

Detach fuel line (8) at preheater unit/fuel preheating system (9)

 Pay attention to use of locking arm.

AR47.25-P-1000-01A

11

Detach preheater unit/fuel preheating system (9) at exhaust gas recirculation (5)

 Installation: Replace seal (10).

12

Remove coolant expansion reservoir (11)

13

Remove intake air scoop (12)

14

Remove charge air pipe (13)

 Installation: Replace O-ring (14).

Do not grease.

15

Disconnect charge air hose (15) at mixing housing

disconnect

Installation: Install new sealing ring (16).

16

Remove electric fan (17)

AR20.40-P-5000M

17

Take off coolant hose (18) at radiator (19)

18

Detach clutch at oil level sensor B40)

19

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

 Installation: Install new sealing cone (20).

20

Unscrew nuts (21) on threaded plate (22) of catalytic converter (111)

 Installation: Replace self-locking nuts (21).



*BA49.10-P-1003-01E

21

Detach torsion bar (24)

22

Unscrew nuts (23) at the front engine mounts



23

Raise engine

Ensure that injection lines are not damaged when attaching to engine lifting eyes!

AR01.10-P-7500-03HA



*WE58.40-Z-1012-11A

24

Unscrew bolts of oil pan (26, 27)

Installation: In vehicles with automatic transmission, pay attention to bracket for automatic transmission oil lines. Align oil pan (28) to rear contact face on transmission.

Pay attention to different bolt lengths and bolt diameters. See: 

Screw diagram for oil pan

AR01.45-P-7500-06M



*BA01.45-P-1001-01A



*BA01.45-P-1002-01A



*BA01.45-P-1004-01A



*BA01.45-P-1005-01A

25

Lower oil pan (28)

26

Unbolt oil pump from the crankcase



*BA18.10-P-1001-01E

27

Take off oil pump and place into the oil pan

Removal: Press off chain tensioner of oil pump chain, detach from oil pump chain.

Installation: Replace sealing ring.

Installation: Clean strainer of oil pump. If oil pump is dry, fill it with engine oil so that oil is transported when it is first started.

28

Take off oil pan (28) together with oil pan gasket (29)

Installation: Clean sealing surfaces. Insert oil pan (28) and only then fit on new oil pan gasket (29).

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

29

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 running engine

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

AS00.00-Z-0005-01A

30

Run engine and inspect for oil leaks

31

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. See: 

STAR DIAGNOSIS

Number

Designation

Engine 612.963

BA01.20-P-1002-01A

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

Nm

10

BA01.20-P-1003-01A

Bolt 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, oil pan to 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 connecting oil pan to rear crankshaft seal

M6

Nm

9

Number

Designation

Engine 612.961/
963/981/
990

BA18.10-P-1001-01E

Bolt, oil pump to crankcase

Nm

18

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
612.963

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-1012-11A

Load regulator (engine hoist), self-locking