Remove/install oil pan

AR01.45-P-7500FHA

Remove/install oil pan

18.02.2020

Engine

276.9 in model 204, 207

1

Oil pan bottom section

6

Rack-and-pinion steering

10

Pressure line D1

2

Oil pan

7

Front axle carrier

11

Transmission

2b

Disassembly bore hole

8

Diagonal struts

12

Sealing ring

3

Wheels

9L

Transmission oil line

G2

Alternator

5

Steering coupling

9R

Transmission oil line

1

Oil pan bottom section

1a

Screw

2

Oil pan

2a

Screw

4

Cylinder crankcase

 Warning

Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.

No parts of the body or limbs should be within the operating area when the components are moving.

AS00.00-Z-0011-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on threaded connections with aluminum screws/bolts

AH00.00-P-0006-01RM

 

Remove/install

1

Remove front engine cover

2

Remove engine air intake duct upstream of air filter

3

Secure vehicle on the vehicle lift

AR00.60-P-0100CW

4

Remove lower engine compartment paneling

Model 207, 204 except 204.9

AR61.20-P-1105EW

MODEL 204.9

AR61.20-P-1105CY

5

Drain engine oil and catch in a suitable container



AP18.00-P-0101CWZ

6

Detach front wheels (3)



AP40.10-P-4050CW

7

Disconnect electrical connection on oil level check switch

AR18.40-P-5113FH

8

Remove heat shield over crankshaft Hall sensor

AR15.12-P-2136FH

9

Remove oil dipstick guide tube

AR18.40-P-3510FH

 Installation: Check sealing ring (12) for oil dipstick guide tube in oil pan (2) and replace if necessary.

10

Mount engine hoist and raise engine slightly

AR33.10-P-0105CW

 Only raise engine sufficiently that the engine mounts are not under tension.

11

Detach steering coupling (5) from lower steering shaft

AR46.10-P-8000CW

 The steering coupling (5) remains on the rack-and-pinion steering (6).

12

Remove diagonal struts (8)

 Bolt, diagonal strut mount to front axle carrier/longitudinal member

*BA61.10-P-1004-01H

13.1

Lower front axle carrier (7)

Engine 276.9 in model 204, 207
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AR33.10-P-0100CW

13.2

Remove front axle carrier (7)

Engine 276.9 in model 204, 207
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR33.10-P-0001CW

14

Remove front axle transmission

Engine 276.9 in model 204, 207 with transmission 722.96
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR33.30-P-0525CWX

15

Raise engine with engine hoist

AR33.10-P-0105CW

 Make sure when lifting out engine that no cables and lines are damaged and that engine does not hit against partition wall.

16

Detach clamps and bracket for transmission fluid lines (9L, 9R) from oil pan (2) and transmission (11) and set aside

MODEL 204 except CODE M005 (4MATIC)

AR27.55-P-0600CV

MODEL 204, 207 with code M005 (4MATIC)

AR27.55-P-0600CWX

MODEL 207 except CODE M005 (4MATIC)

AR27.55-P-0600EV


Do not kink or bend the transmission fluid lines (9L, 9R).
This avoids leaks and damage occurring.

 Seal openings with  stop plugs.

 Record plug

*129589009100

17

Detach pressure line D1 (10) for P/S from bracket on alternator (G2) or oil pan (2)

 Nut, high-pressure line to alternator bracket

*BA46.30-P-1009-01R

18

Remove oil pan bottom section (1)

AR01.45-P-7500-04MM

Notes on sealant path for oil pan

AH01.45-P-0001-01MMA

 Installation: Notes on sealant path for oil pan bottom section (1).

 Bolt, oil pan bottom section to oil pan

*BA01.45-P-1003-01E

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

19

Remove screw/bolts connecting transmission to oil pan

Vehicles with code M005 (4M ATIC)

AR27.10-P-0500CWX

Vehicles without code M005 (4MATIC)

AR27.10-P-0500CV

20

Remove screw/bolts (2a) from oil pan (2)

 Installation: Pay attention to different lengths of screws.

 Screw/bolt, oil pan to crankcase/ timing case cover/rear end cover

*BA01.45-P-1001-01E

 Bolt, oil pan to crankcase

*BA01.45-P-1002-01E

21

Loosen oil pan (2) from cylinder crankcase (4) and remove to rear

AR01.45-P-7500-04MM

Notes on sealant path for oil pan

AH01.45-P-0001-01MMA

 Installation: Apply sealant to sealing surface of oil pan (2) and, in doing so, observe notes on sealant path on the oil pan (2).

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

22

Remove oil level check switch

When replacing the oil pan (2)

AR18.40-P-5113FH



Clean

23

Clean sealing surfaces on oil pan (2) and cylinder crankcase (4)

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

24

Install in the reverse order



Check

25

Perform wheel alignment check

model 204

AR40.20-P-0200CW

MODEL 207

AR40.20-P-0200EW

26

Check engine oil level; correct if necessary



AP18.00-P-0101CWZ

27

Check transmission oil level and correct if necessary

Vehicles without code M005 (4MATIC)

AR27.00-P-0270W

Vehicles with code M005 (4M ATIC)

AR27.00-P-0270SYZ

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

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

AS00.00-Z-0005-01A

28

Carry out engine test run while checking the engine and transmission (11) for leaktightness and proper function

 Oil pan

Number

Designation

Engine 276

BA01.45-P-1001-01E

Screw/bolt, oil pan to crankcase/ timing case cover/rear end cover

M6

Nm

9

 Oil pan

Number

Designation

Engine 276

BA01.45-P-1002-01E

Bolt, oil pan to crankcase

M8

Nm

20

 Oil pan

Number

Designation

Engine 276

BA01.45-P-1003-01E

Bolt, oil pan bottom section to oil pan

Nm

14

 Power steering pump

Number

Designation

Model 204 with engine 156, 271, 272, 274, 276, 642, 646

Model 207

BA46.30-P-1009-01R

Nut, high-pressure line to alternator bracket

Nm

8

8

 Frame floor assembly

Number

Designation

Model 204

Model 207.3

BA61.10-P-1004-01H

Bolt, diagonal strut mount to front axle carrier/longitudinal member

Nm

50

50

 Frame floor assembly

Number

Designation

Model 207.4

BA61.10-P-1004-01H

Bolt, diagonal strut mount to front axle carrier/longitudinal member

Nm

80

Repair materials

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant, Loctite 5970, 50 ml

A 003 989 98 20 10

BR00.45-Z-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09