Remove/install oil pan

AR01.45-P-7500PM

14.2.12

ENGINES 646 in MODEL 203, 209

P01.45-2057-09

 	Remove/install
 Danger!	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between columns of lifting platform and position the four support plates at lifting platform support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
 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
 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, in order to avoid damage to control units.
		Model 203	AR54.10-P-0003P
		Model 209	AR54.10-P-0003Q
	Notes on battery		AH54.10-P-0001-01A
2	Remove cylinder head cover trim		AR01.20-P-5014-02A
3	Separate charge air hose from mixing chamber	 Installation: Thoroughly clean connection points, do not grease.
4	Remove the intake air duct
5	Separate charge air hose from turbo charger	 Installation: Thoroughly clean connection points, do not grease.
6	Remove bottom sections of soundproofing		AR94.30-P-5300P
7	Drain/collect engine oil	 Installation: Replace seal on oil drain screw to prevent leakage.
		 Oil drain screw to oil pan	*BA01.45-P-1003-01G
		Engine 646.962/963 without particulate filter
		 Engine oil	*BF18.00-P-1001-01A
		Engine 646.962/963 with particulate filter
		 Engine oil	*BF18.00-P-1001-01S
8	Remove bolts on front engine mounts	Model 203
		 Bolt, front engine mount to front axle carrier	*BA22.10-P-1001-01D
		Model 209
		Bolt connecting front engine mount to front axle crossmember	*BA22.10-P-1002-03B
9	Detach hose clamp of primary catalytic converter at catalytic converter	 Assembly device	*211589046300
10.1	Detach right automatic transmission wiring harness from shield	Transmission 722.6
11	Loosen oil dipstick guide tube (5) retaining clamp at charge air manifold
12	Put on engine carrier arm		AR33.10-P-0100-01P
13	Raise engine	 Ensure that when hooking onto engine suspension lugs, injection lines are not damaged to avoid leaks.
14	Disconnect electrical connector at oil sensor (oil level, temperature and quality) (B40)
15.1	Unscrew transmission oil lines (6) at transmission and engine	Transmission 722.6
16	Disconnect positive cables at alternator
17	Unscrew bracket for positive lead (7) at transmission
18	Extend steering wheel and fix with a retainer	 On a disengaged steering coupling (8) the steering wheel should not be turned because the spiral contact coil will be destroyed.
		 Front wheels in straight-ahead position.
		 Holding device	*129589012100
19	Detach steering shaft from steering joint (8)	 Bolt, steering coupling to steering shaft	*BA46.10-P-1001-01E
20	Unscrew retaining clamp (9) of power steering oil lines at front axle carrier (25)
21	Extract steering oil from reservoir	 Hand pump	*210589007100
22	Detach return flow line to power steering pump	 Close return line.
		 Clamping device	*000589543700
		 Set of stop plugs	*129589009100
23	Unscrew oil dipstick guide tube (5) from oil pan (18)	 Installation: Replace seal ring in order to avoid leaks.
24.1	Unscrew ball joint of front axle sensor (headlamp range adjustment)	For xenon headlamp unit code 612
25	Detach torsion bar (26)	 Detach brackets (27) on stabilizer bar (26) on both sides.
		 Bolt, torsion bar retaining bracket to front axle carrier	*BA32.20-P-1009-02B
26	Prop front axle carrier (25) with assembly lift		AR33.10-P-0100-03P
27	Remove front axle carrier (25)	 Lower front axle carrier (25).
		Model 203
		 Bolt of front axle carrier at front end	*BA33.10-P-1003-01A
		Model 209
		 Bolt, front axle carrier to front end	*BA33.10-P-1001-01H
28	Remove bolts (14, 15) at oil pan (18)	 Installation: For vehicles with automatic transmission, pay attention to bracket for automatic transmission oil lines. Align the oil pan (18) to the rear contact surface of the transmission; otherwise, the brackets may get damaged.
		 Installation: Observe different bolt lengths and diameters: 
		Bolt plan for oil pan	AR01.45-P-7500-06T
		 Bolt, oil pan to cylinder crankcase	*BA01.45-P-1001-01G
		 Bolt, transmission bell housing to oil pan	*BA01.45-P-1002-01G
		 Bolt, oil pan to timing case cover	*BA01.45-P-1004-01G
		 Bolt, oil pan to rear crankshaft seal	*BA01.45-P-1005-01G
29	Lower oil pan (18)
30	Remove oil pan (18) together with oil gasket (16)	 Take out oil pan (18) downwards to the bottom right.
		 Installation: Clean sealing surfaces. Insert oil pan (18), and only then fit on new oil pan gasket (16).
31	Install in the reverse order
32	Fill power steering pump and bleed
		Model 203.0/7, model 209, model 203.2 except with rear axle level control system, code 480	AR46.30-P-0010P
		 Power steering	*BF46.20-P-1001-01A
33	Check for oil leaks with engine running
34	Check engine oil level		AR18.00-P-3035-01T
		 Oil level Engine 646.962	*BF18.00-P-1001-03L
		 Dipstick indication from 108 mm to 140 mm (oil level too low)	*BF18.00-P-1002-03L
		 Dipstick indication from 142 mm to 144 mm (oil level correct)	*BF18.00-P-1003-03L
		 Dipstick indication from 146 mm to 154 mm (oil level too high)	*BF18.00-P-1004-03L
		 Oil level Engine 646.963/966	*BF18.00-P-1001-03OA
		 Dipstick indication from 132 mm to 160 mm (oil level too low)	*BF18.00-P-1002-03OA
		 Dipstick indication from 162 mm to 164 mm (oil level correct)	*BF18.00-P-1003-03OA
		 Dipstick indication from 166 mm to 174 mm (oil level too high)	*BF18.00-P-1004-03OA
			*120589072100
	Specified engine oils (service) - overview		BB00.40-P-0223-02A
35	Perform basic programming	Model 203	AR00.19-P-0200P
		Model 209	AR00.19-P-0200Q
36	Read out fault memory and erase	 Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnosis system
37	Carry out function check

 Oil pan

Number	Designation			Engine 646.951/ 961/962/ 963/966


BA01.45-P-1001-01G	Bolt, oil pan to cylinder crankcase	M6	Nm	9
		M8	Nm	20
		M10	Nm	-
BA01.45-P-1002-01G	Bolt, transmission bell housing to oil pan		Nm	40
BA01.45-P-1003-01G	Oil drain screw on oil pan	M12	Nm	-
		M14	Nm	30
BA01.45-P-1004-01G	Bolt, oil pan to timing case cover	M6	Nm	9
BA01.45-P-1005-01G	Bolt, oil pan to rear crankshaft seal	M6	Nm	9

 Engine suspension, engine mounts, engine supports

Number	Designation		Engine 646 in model 203


BA22.10-P-1001-01D	Bolt, front engine mount to front axle carrier	Nm	35

 Engine mount, engine support (engine side)

Number	Designation		Model 209


BA22.10-P-1002-03B	Bolt connecting front engine mount to front axle crossmember	Nm	35

 Front axle stabilizer bar

Number	Designation			Model 203 except model 203.020/220/ 08/09/28/29	Model 209


BA32.20-P-1009-02B	Bolt, torsion bar retaining bracket to front axle carrier	Stage 1	Nm	40	40
		Stage 2	°	-	-

 Front axle carrier

Number	Designation		Model 203


BA33.10-P-1003-01A	Bolt, front axle carrier to front end	Nm	100

 Front axle carrier

Number	Designation		Model 209


BA33.10-P-1001-01H	Bolt, front axle carrier to front end	Nm	100

 Steering shaft

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	°	-	-

 Engine lubrication system

Number	Designation			Engine 646.951/961/ 962/963/966 without particulate filter


BF18.00-P-1001-01A	Engine oil	Filling capacity (oil and filter change)	Liters	6.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0228-03A
			Sheet	BB00.40-P-0228-05A
			Sheet	BB00.40-P-0228-51A
			Sheet	BB00.40-P-0229-03A
			Sheet	BB00.40-P-0229-31A
			Sheet	BB00.40-P-0229-05A
			Sheet	BB00.40-P-0229-51A

 Engine lubrication system

Number	Designation			Engine 646.962/963/966 with particulate filter


BF18.00-P-1001-01S	Engine oil	Filling capacity (oil and filter change)	Liters	6.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0228-51A
			Sheet	BB00.40-P-0229-31A
			Sheet	BB00.40-P-0229-51A

Oil level check

Number	Designation			Engine 646.951/962


BF18.00-P-1001-03L	Oil level	Maximum	mm	143
		Minimum	mm	118
BF18.00-P-1002-03L	Dipstick indication 108 mm to 140 mm (oil level too low)	108 mm	Replenish oil quantity in liters	+2.8
		110 mm	Replenish oil quantity in liters	+2.7
		112 mm	Replenish oil quantity in liters	+2.5
		114 mm	Replenish oil quantity in liters	+2.4
		116 mm	Replenish oil quantity in liters	+2.2
		118 mm	Replenish oil quantity in liters	+2.1
		120 mm	Replenish oil quantity in liters	+2.0
		122 mm	Replenish oil quantity in liters	+1.8
		124 mm	Replenish oil quantity in liters	+1.6
		126 mm	Replenish oil quantity in liters	+1.5
		128 mm	Replenish oil quantity in liters	+1.3
		130 mm	Replenish oil quantity in liters	+1.1
		132 mm	Replenish oil quantity in liters	+0.9
		134 mm	Replenish oil quantity in liters	+0.7
		136 mm	Replenish oil quantity in liters	+0.6
		138 mm	Replenish oil quantity in liters	+0.4
		140 mm	Replenish oil quantity in liters	+0.2
BF18.00-P-1003-03L	Oil dipstick indication 142 mm to 144 mm (oil level correct)	142 mm	Oil quantity in liters	0.0
		143 mm	Oil quantity in liters	0.0
		144 mm	Oil quantity in liters	0.0
BF18.00-P-1004-03L	Oil dipstick indication 146 mm to 154 mm (oil level too high)	146 mm	Extract oil quantity in liters	-0.2
		148 mm	Extract oil quantity in liters	-0.4
		150 mm	Extract oil quantity in liters	-0.5
		152 mm	Extract oil quantity in liters	-0.7
		154 mm	Extract oil quantity in liters	-0.9

Oil level check

Number	Designation			Engine 646.961/963/966


BF18.00-P-1001-03OA	Oil level	Maximum	mm	163
		Minimum	mm	139
BF18.00-P-1002-03OA	Oil dipstick reading 132 mm to 160 mm (oil level too low)	132 mm	Replenish oil quantity in liters	+2.8
		134 mm	Replenish oil quantity in liters	+2.6
		136 mm	Replenish oil quantity in liters	+2.4
		138 mm	Replenish oil quantity in liters	+2.2
		140 mm	Replenish oil quantity in liters	+2.0
		142 mm	Replenish oil quantity in liters	+1.8
		144 mm	Replenish oil quantity in liters	+1.6
		146 mm	Replenish oil quantity in liters	+1.4
		148 mm	Replenish oil quantity in liters	+1.3
		150 mm	Replenish oil quantity in liters	+1.1
		152 mm	Replenish oil quantity in liters	+0.9
		154 mm	Replenish oil quantity in liters	+0.8
		156 mm	Replenish oil quantity in liters	+0.6
		158 mm	Replenish oil quantity in liters	+0.4
		160 mm	Replenish oil quantity in liters	+0.3
BF18.00-P-1003-03OA	Oil dipstick reading 162 mm to 164 mm (oil level correct)	162 mm	Oil quantity in liters	0.0
		163 mm	Oil quantity in liters	0.0
		164 mm	Oil quantity in liters	0.0
BF18.00-P-1004-03OA	Oil dipstick reading 166 mm to 174 mm (oil level too high)	166 mm	Extract oil quantity in liters	-0.3
		168 mm	Extract oil quantity in liters	-0.4
		170 mm	Extract oil quantity in liters	-0.5
		172 mm	Extract oil quantity in liters	-0.6
		174 mm	Extract oil quantity in liters	-0.7

 Steering gear

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