Remove/install oil pan

AR01.45-P-7500PP

Remove/install oil pan

14.2.12

 

Remove/install

 Danger!

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates 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 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 caused by 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

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

 Danger!

Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect battery ground line

 Do not connect quiescent current retention unit as this may cause disturbance to the control unit.

Model 203

AR54.10-P-0003P

MODEL 209

AR54.10-P-0003Q



Notes on battery

All models

AH54.10-P-0001-01A

2

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

Engine 611

AR01.20-P-5014-02A

Engine 612

AR01.20-P-5014-02B



*BA01.20-P-1002-01A



*BA01.20-P-1003-01A

3

Detach charge air hose (12) at mixing chamber

 Installation: Thoroughly clean connection points, do not grease.

4

Remove intake air scoop (4/3)

5

Detach charge air hose (19) at turbocharger

 Installation: Thoroughly clean connection points, do not grease.

6.1

Remove bottom sections of soundproofing

Except model 203.018/218/718 with Engine 612.990

AR94.30-P-5300P

6.2

Detach lower engine compartment paneling

Only model 203.018/218/718 with engine 612.990

AR61.20-P-1105P

7

Drain/collect engine oil

 Installation: Replace gasket of oil drain screw, in order to avoid leakage.



*BA01.45-P-1003-01A



*BF18.00-P-1001-01A

8

Unscrew screws (21) at the front engine mounts



*BA22.10-P-1001-01D

9

Release spring connection (22) between primary catalytic converter (120/1) and main catalytic converter (111)

 Installation: Install new sealing cone (23).

10.1

Unhook the right automatic transmission wiring harness at shield

Transmission 722.6

11

Detach retaining clamp at guide tube for engine oil dipstick (5) at charge air manifold

12

Raise engine

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

13

Unplug coupling at oil sensor (oil level, temperature and quality) (B40)

14.1

Unscrew transmission oil lines (6) at transmission and engine

Transmission 722.6

 Installation: Correct oil level.

15

Disconnect positive cables at alternator

16

Unbolt bracket of starter-generator cable (7) at transmission

17

Fit on steering wheel lock

18

Detach steering shaft from steering joint (8)



*BA46.10-P-1001-01E

19

Unbolt bracket (9) for pressurized oil lines at front axle carrier (25)

20

Extract steering oil from reservoir

 Installation: Fill power steering pump and bleed.



*BF46.20-P-1001-01A

Hand pump

*210589007100

21

Detach return flow line to power steering pump

Engine 611.962 in left side of engine compartment

Engine 612.962/967/990 right in engine compartment

 Seal off line.

Clamp

*000589543700

22

Unbolt guide tube for engine oil dipstick (5) at oil pan

 Installation: Replace O-ring, in order to avoid leakage.

23.1

Unbolt ball joint of front axle sensor of headlamp range adjustment front axle

If code 612b (xenon headlamp units) fitted.

24

Detach torsion bar (26)

 Detach brackets (27) on both ends of torsion bar.

Model 203

*BA32.20-P-1003-02B

25

Prop front axle carrier (25) with assembly lift

AR33.10-P-0100-03P

26

Unbolt front axle carrier (25), lower

Model 203

*BA33.10-P-1003-01A

Unbolt front axle carrier (25), lower

Model 209

*BA33.10-P-1001-01H

27

Unscrew oil pan (14, 15) bolts

 Installation: For 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.
See: 

Bolt plan for oil pan engine 611.962

AR01.45-P-7500-06PP

Bolt plan for oil pan, engine 612.962/967/990

AR01.45-P-7500-06PD



*BA01.45-P-1001-01A



*BA01.45-P-1002-01A



*BA01.45-P-1004-01A

28

Lower oil pan (18)

29

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 downward and to the rear right.

30

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

31

Check for oil leaks with engine running

32

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 611.960/
961/962

Engine 612.961/
962/967

Engine 612.990

BA01.20-P-1002-01A

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

Nm

10

10

8

BA01.20-P-1003-01A

Bolt, charge air distribution pipe cover to charge air manifold

Nm

10

10

-

Number

Designation

Engine 611.960/
961/962

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

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

M8

Nm

20

20

M10

Nm

-

-

BA01.45-P-1002-01A

Bolt, transmission bell housing to oil pan

Nm

40

40

BA01.45-P-1003-01A

Oil drain screw to oil pan

M12

Nm

-

-

M14

Nm

30

30

BA01.45-P-1004-01A

Bolt, oil pan to timing case cover

M6

Nm

9

9

Number

Designation

Engine 612.967

Engine
612.990

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

M8

Nm

20

20

M10

Nm

-

-

BA01.45-P-1002-01A

Bolt, transmission bell housing to oil pan

Nm

38

40

BA01.45-P-1003-01A

Oil drain screw to oil pan

M12

Nm

-

-

M14

Nm

30

30

BA01.45-P-1004-01A

Bolt, oil pan to timing case cover

M6

Nm

9

9

Number

Designation

Engine 611.962 in
model 203

Engine 612.962 in
model 203

Engine 612.967 in model 209.316

BA22.10-P-1001-01D

Bolt, front engine mount to front axle carrier

Nm

35

35

35

Number

Designation

Engine 612.990 in model 203

BA22.10-P-1001-01D

Bolt, front engine mount to front axle carrier

Nm

35

Number

Designation

Model 203
except
model
203.020/220/
08/09/28/29

BA32.20-P-1003-02B

Self-locking nut, torsion bar bracket to front axle carrier

Nm

40

Number

Designation

Model
203

BA33.10-P-1003-01A

Bolt, front axle carrier to front end

Nm

100

Number

Designation

MODEL 209

BA33.10-P-1001-01H

Bolt, front axle carrier to front end

Nm

100

Number

Designation

Model
203 except
203.081/
084/087/
092/281/
284/287/
292

Model
209

BA46.10-P-1001-01E

Bolt, steering coupling to steering shaft

Stage 1

Nm

30

30

Stage 2

°

-

-

Number

Designation

Engine
611.962 with ASSYST

Engine 612.962/967

Engine
612.990

BF18.00-P-1001-01A

Engine oil

Filling capacity
(oil and filter change)

Liters

6.5

6.5

6.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0228-01A

BB00.40-P-0228-01A

BB00.40-P-0228-01A

Sheet

BB00.40-P-0228-03A

BB00.40-P-0228-03A

BB00.40-P-0228-03A

Sheet

BB00.40-P-0228-05A

BB00.40-P-0228-05A

BB00.40-P-0228-05A

Sheet

BB00.40-P-0229-01A

BB00.40-P-0229-01A

BB00.40-P-0229-01A

Sheet

BB00.40-P-0229-03A

BB00.40-P-0229-03A

BB00.40-P-0229-03A

Sheet

BB00.40-P-0229-05A

BB00.40-P-0229-05A

BB00.40-P-0229-05A

Sheet

BB00.40-P-0229-31A

BB00.40-P-0229-31A

BB00.40-P-0229-31A

Number

Designation

Model 203

Model
209

BF46.20-P-1001-01A

Power steering

Filling capacity

Liters

1,0

1,0

MB steering gear oil

Sheet

BB00.40-P-0345-00A

BB00.40-P-0345-00A