Remove/install oil pan

AR01.45-P-7500FC

Remove/install oil pan

25.03.2020

Engine

112 in model 202, 208

Engine

113 in model 208

Engine

113.944 in model 202.033/093

Modification notes

24.03.2020

Document completely revised.

Shown on engine 112

1

Fan

5

Screw, engine mount

9

Resonator

2

Fan shroud

6

Stabilizer bar

10

Resonance unit

3

Oil pan bottom section

7

Oil pan top section

B40

Oil sensor (oil level, temperature and quality)

4

Oil pipe

8

Engine mount

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

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

AS00.00-Z-0009-01A

 Caution

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on automatic transmission

Engine 112 in model 202, 208 with transmission 722.6
Engine 113 in model 208 with transmission 722.6
Engine 113.944 in model 202.033/093 with transmission 722.6

AH27.19-P-0001-01NKB

 

Remove/install

1

Lift vehicle with lifting platform.

AR00.60-P-1006A

2

Remove lower engine compartment paneling.

AR61.20-P-1105AB

 Installation: Only install lower engine compartment paneling after leak test.

3

Drain engine oil and catch in a suitable container.

 Oil drain screw to oil pan

*BA01.45-P-1003-01B

 Engine oil

*BF18.00-P-1001-01H

4.1

Detach engine cover vertically upwards from cylinder head covers and remove.

Engine 113 in model 208.370/374/470
Engine 113.944 in model 202.033/093

4.2

Detach air filters vertically upwards from cylinder head covers and remove.

Engine 112 in model 202, 208
Engine 113 in model 208 (except 208.370/374/470)

5

Release and disconnect electrical connector of fan (1).

In vehicles with electric fan (1).

6

Remove fan (1).

Engine 112 in model 202
Engine 112 in model 208 (except 208.365)
Engine 112 in model 208 (except 208.465)
Engine 113 in model 208
Engine 113.944 in model 202.033/093

AR20.40-P-5660C

7

Remove fan shroud (2).

8

Disconnect electrical connector from hot film MAF sensor (B2/5).

9

Remove resonator (9) with resonance body (10).

Engine 112 in model 202, 208

AR07.07-P-1454A


Handle plastic lug carefully.
Plastic lug will otherwise be damaged.

 Resonator (9) is secured at rear on intake manifold with a plastic lug.

10

Remove hot film MAF sensor (B2/5) with air intake pipe.

Model 202.033/093 model 208.370/374/470

AR07.07-P-1454AG

11

Remove stabilizer bar (6).

AR32.20-P-0300C

12

Remove brackets of automatic transmission oil lines at oil pan top section (7) and oil pan bottom section (3).

 M6

*BA00.10-P-1002-01A

13

Remove bracket of positive line at oil pan top section (7).

 M6

*BA00.10-P-1002-01A

14

Release and disconnect electrical connectors of left lambda sensors upstream and downstream of catalytic converter.

Model 208.370/374/470

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

15

Remove left catalytic converter.

Engine 113 in model 208.370/374/470

AR49.10-P-5531AV

 Installation: Replace sealing ring.

 Clean connecting points of combustion and corrosion residues using emery cloth. Replace nuts.

 Flange connection of exhaust manifold and front exhaust pipes

*BA14.10-P-1002-01B

16

Release and disconnect electric line at oil sensor (oil level,temperature and quality) (B40).

17

Remove left and right automatic transmission oil lines at transmission bell housing, place automatic transmission oil lines to one side and collect transmission oil with suitable container.

 Installation: Replace seals.

 Engine 112 in model 202, 208 with transmission 722.6
Engine 113 in model 208 with transmission 722.6
Engine 113.944 in model 202.033/093 with transmission 722.6Banjo bolt or union nut, oil cooler line to torque converter and transmission housing

*BA27.55-P-1002-01B

18

Seal openings with suitable stop plug.

 Record plug

*129589009100

19

Remove ground line from left engine carrier to front axle carrier.

 M61

*BA00.10-P-1002-04A

20

Unscrew screw and remove oil pipe (4) from oil dipstick.

 Installation: Replace sealing ring and cable tie.

 Screw/bolt, cylinder head cover

*BA01.20-P-1001-01E

21

Remove oil pan bottom section (3).

AR01.45-P-7555VA

22

Remove engine mount screws (5) from engine mounts (8) at front at front axle carrier.

 Engine 112.910 in model 202.026/086
Engine 112.915 in model 202.088
Engine 112.920 in model 202.029/089
Engine 112.940 in model 208.365/465
Engine 113.943 in model 208.370/470
Engine 113.944 in model 202.033/093
Engine 113.984 in model 208.374Bolt, front engine mount to front axle carrier

*BA22.10-P-1001-01L

23

Attach engine carrier.

AR33.10-P-0100-01AV

 Commercially available devices/tools
Blitz Rotary M30

24

Lift engine.


Do not subject coolant lines to stress.
Otherwise damage and leaks can occur.


Engine and its detachable parts may not be in contact with body.
Body, engine or detachable parts on engine will otherwise be damaged.

25

Remove oil pan top section (7).

Bolt plan for oil pan

AR01.45-P-7500-06F

Notes on sealant path for oil pan

Motor 113.943/944/984

AH01.45-P-0001-01CD

Notes on sealant path for oil pan

Motor 112

AH01.45-P-0001-01C

 Remove oil pan top section (7) in direction of travel towards front and slightly turn crankshaft in direction of engine rotation if necessary.

 Installation: Observe sealant path at oil pan top section (7).

 Installation:
Pay attention to different screw/bolt lengths and screw/bolt diameters.

 Bolt, oil pan to cylinder crankcase

*BA01.45-P-1001-01B

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500

26

Clean sealing surfaces at oil pan top section (7) and at crankcase.

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

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

27

Install in the reverse order.

28

Check engine oil level and correct if necessary.



AP18.00-P-1848U

29

Check oil level in automatic transmission, correct if necessary.

Engine 112 in model 202, 208 with transmission 722.6
Engine 113 in model 208 with transmission 722.6
Engine 113.944 in model 202.033/093 with transmission 722.6

AR27.00-P-0100AC

30

Read out fault memory and delete if necessary.



AD00.00-P-2000-04A

If faults have been stored due to assembly or test work:



Clear these from the fault memory once the work has been completed. Diagnosis Manual Volume 2, Index 0: Connecting and using test equipment.

 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

31

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

32

Install lower engine compartment lining.

AR61.20-P-1105AB

33

Lower vehicle with vehicle lift.

AR00.60-P-1006A

 Headless screws: bolts and nuts, coarse-pitch thread

Number

Designation

Model all (4xWD, CAR, smart)

BA00.10-P-1002-01A

M6

8.8

Galvanized

Nm

9

Phosphated

Nm

9

10.9

Galvanized

Nm

13

Phosphated

Nm

12

12.9

Galvanized

Nm

16

Phosphated

Nm

14

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 112

Engine 113

BA01.20-P-1001-01E

Screw/bolt, cylinder head cover

Stage 1

Nm

9

9

Stage 2

°

–

–

 Oil pan

Number

Designation

Engine 112.910/ 911/912/913/914/ 915/917/920/921/ 922/923/940/941/ 942/943/944/945/ 946/947/949/951/ 954/955/960/961/ 970/972/973/976

Engine 113.940/ 941/942/943/944/ 960/961/962/963/ 965/967/968/969/ 980/981/982/984/ 986/992/995

BA01.45-P-1001-01B

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

M8

Nm

20

20

 Oil pan

Number

Designation

Engine 112.910/ 911/912/913/914/ 915/917/920/921/ 922/923/940/941/ 942/943/944/945/ 946/947/949/951/ 954/955/960/961/ 970/972/973/976

Engine 113.940/ 941/942/943/944/ 960/961/962/963/ 965/967/968/969/ 980/981/982/984/ 986/992/995

BA01.45-P-1003-01B

Oil drain screw to oil pan

M14

Nm

30

30

 Exhaust manifold

Number

Designation

Engine 113.940/941/942/943/944/948/960/961/962/963/964/965/966/967/968/969/971/980/981/982/984/986/992/993/995

BA14.10-P-1002-01B

Flange connection of exhaust manifold and front exhaust pipes

Nm

20

 Engine mounts, engine supports

Number

Designation

Engine 112.910/920, 113.944 in model 202.026/029/ 033/086/089/ 093

Engine 112.915 in model 202.088

BA22.10-P-1001-01L

Bolt, front engine mount to front axle carrier

Nm

35

35

 Engine mounts, engine supports

Number

Designation

Engine 113.984 in model 208.474

Engine 112.940, 113.943/984 in model 208.365/ 370/374/465/ 470

BA22.10-P-1001-01L

Bolt, front engine mount to front axle carrier

Nm

35

35

 Transmission oil cooling

Number

Designation

Transmission 722.6 in model 129, 202, 208

BA27.55-P-1002-01B

Banjo bolt or union nut, oil cooler line to torque converter and transmission housing

Stage 1

Nm

20

Stage 2

°

-

Hexalobular bolt

Nm

-

 Engine lubrication

Number

Designation

ENGINE 112 (except 112.916/953/975) shortened maintenance interval

ENGINE 112 (except 112.916/953/975) Maximum maintenance interval

BF18.00-P-1001-01H

Engine oil

Filling capacity with oil filter

Liter

8,0

8,0

Filling capacity without oil filter

Liter

7,5

7,5

Sheet

BB00.40-P-0229-01A

-

Sheet

BB00.40-P-0229-03A

-

Sheet

BB00.40-P-0229-05A

BB00.40-P-0229-05A

 Engine lubrication

Number

Designation

ENGINE 113.940/ 941/942/943/960/ 961/962/969/982 Shortened maintenance interval

ENGINE 113.940/ 941/942/943/960/ 961/962/969/982 Maximum maintenance interval

BF18.00-P-1001-01H

Engine oil

Filling capacity with oil filter

Liter

8,0

8,0

Filling capacity without oil filter

Liter

–

–

Sheet

BB00.40-P-0229-01A

-

Sheet

BB00.40-P-0229-03A

-

Sheet

BB00.40-P-0229-05A

BB00.40-P-0229-05A

 Engine lubrication

Number

Designation

ENGINE 113.944/ 980/981/984/986/ 991

BF18.00-P-1001-01H

Engine oil

Filling capacity with oil filter

Liter

7,5

Filling capacity without oil filter

Liter

–

Sheet

-

Sheet

-

Sheet

BB00.40-P-0229-05A

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-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09