Remove/install oil pan

AR01.45-P-7500T

Remove/install oil pan

2.11.11

 

Remove/install

 Danger!

Risk of death caused by vehicle slipping or tilting off of the vehicle lift.

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

AS00.00-Z-0010-01A

 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 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

1.1

Deactivate easy entry/exit function for driver seat and steering wheel

With code 275 Electrically adjustable driver seat, steering column and outside mirrors with memory

 Otherwise driver seat and steering wheel move to a different position, e.g. when driver door is opened/closed.

 Switching off takes place via buttons on steering wheel in the "Comfort" menu of the multifunction display, see operator's manual.

2

Move steering wheel to center position and fix in place

 To do this, turn sun visor to side and insert holding device.

Holding device

*129589012100

3

Open engine hood

AR88.40-P-1000T

4

Remove cylinder head cover trim

Engine 646.8/9, 647.9

AR01.20-P-5014-02A

Engine 648.9

AR01.20-P-5014-02C

Engines 646.9, 647.9, 648.9

 Bolt, cylinder head cover trim to cylinder head

*BA01.20-P-1002-01G

 Bolt, cover to charge air manifold

*BA01.20-P-1003-01G

5

Remove bottom sections of soundproofing

AR94.30-P-5300T

6

Drain/collect engine oil

 Installation: Replace sealing ring on oil drain screw.



Engine - oil and filter change

AP18.00-P-0101TC

Oil drain screw to oil pan

*BA01.45-P-1003-01G

Engine 646.8/9, 648 without code 474 Particulate filter, engine 647

Engine 646 without particulate filter, engine 647

*BF18.00-P-1001-01A

Engine 646.8/9 with code 474 Particulate filter

Engine 648 without particulate filter

*BF18.00-P-1001-01Y

Engine 646

*BF18.00-P-1001-01S

Engine 648.9 with code 474 Particulate filter

Engine 648

*BF18.00-P-1001-01X

7.1

Remove bolt (20) and loosen steering shaft (18) from rack-and-pinion steering (19)

Only for engine 648.9

8

Remove screw/bolts (1) of front engine mounts

Bolt, front engine mounts to front axle carrier

*BA22.10-P-1002-03A

9

Attach engine support frame and lift engine

 Ensure that injection lines are not damaged when attaching to engine suspension lugs.

AR33.10-P-0100-01T

Engine support device, engine hoist
gotis://A_01_09.0

10.1

Disconnect plug at oil level check switch (S43)

Only for engine 646.8

11.1

Disconnect plug at oil temperature sensor (B1)

Only for engine 646.8

12.1

Disconnect plug at oil sensor (oil level, temperature and quality) (B40)

Only for engine 646.9, 647.9, 648.9

13

Remove screw/bolts (4)

 Bolt, transmission bell housing to oil pan

*BA01.45-P-1002-01G

 Bolt, oil pan to cylinder crankcase

*BA01.45-P-1001-01G

14

Remove bracket for starter alternator line (3)

15

Remove hydraulic line bracket (5) from oil pan (6).

16

Remove oil dipstick guide tube (7) from oil pan (6).

 Installation: Install new O-ring.

 Bolt, oil dipstick guide tube to engine oil pan

*BA01.45-P-1007-01G

17.1

Remove oil lines (16, 17) from automatic transmission and oil pan (6)

Transmission 722.6

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

*BA27.55-P-1002-01B

 Bolt, oil cooler line retaining clamp to oil pan

*BA27.55-P-1008-01B

18

Loosen stabilizer bar (8); to do this, remove brackets (9) on both sides

 Bolt, stabilizer bar bushing to longitudinal member

*BA32.20-P-1005-02B

19

Support front axle carrier (10) with transmission jack and transmission platform

AR33.10-P-0100-03T

Telescoping transmission jack, 0.5 to 1.0 t

Transmission jack 2.0-7.0 t
gotis://H_00.10_01.0

Transmission plate for passenger cars and commercial vehicles
gotis://A_25/35/49_02.0

20

Unfasten front axle carrier (10); to do this remove screw/bolts (11)

 Bolt, front axle carrier to longitudinal member

*BA33.10-P-1005-01A

21

Lower front axle carrier (10)

Telescoping transmission jack, 0.5 to 1.0 t

Transmission jack 2.0-7.0 t
gotis://H_00.10_01.0

22

Remove cover (14)

23.1

Detach charge air pipe

Only for engine 646.8

 To do this, unscrew two screw/bolts.

24.1

Remove oil pan soundproofing

Only for engine 646.8

25

Detach oil pan (6), to do this, unscrew screw/bolts (12, 13)

 Installation: Observe different lengths of screw/bolts and different screw diameter, see:



Bolt plan for oil pan

Engine 646.8/951/961

AR01.45-P-7500-06T

Engine 647.961

AR01.45-P-7500-06TB

Engine 648.961

AR01.45-P-7500-06TA

 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

26

Remove oil pan (6) to the rear along with oil pan gasket (15)

 Installation: Clean sealing surfaces. Insert oil pan (6) and position new oil pan gasket (15)

27

Install in the reverse order

28.1

Check oil level in automatic transmission, correct if necessary

Transmission 722.6

AR27.00-P-0100AC

29

Check for oil leaks with engine running

30

Check/correct engine oil level

 The vehicle must be parked on a level surface, otherwise false measurements can occur.

Engine 646.8/951/961 in model 211

AR18.00-P-3035-01T

 Oil level check:

 Oil level
engine 646.8

*BF18.00-P-1001-03LB

 Oil dipstick reading from 115 mm to 151 mm (oil level too low)

*BF18.00-P-1002-03LB

 Oil dipstick reading from 153 mm to 155 mm (oil level correct)

*BF18.00-P-1003-03LB

 Oil dipstick reading from 157 mm to 165 mm (oil level too high)

*BF18.00-P-1004-03LB

 Oil level
engine 646.951

*BF18.00-P-1001-03L

 Oil dipstick reading from 108 mm to 140 mm (oil level too low)

*BF18.00-P-1002-03L

 Oil dipstick reading from 142 mm to 144 mm (oil level correct)

*BF18.00-P-1003-03L

 Oil dipstick reading from 146 mm to 154 mm (oil level too high)

*BF18.00-P-1004-03L

 Oil level
engine 646.961

*BF18.00-P-1001-03OA

 Oil dipstick reading from 132 mm to 160 mm (oil level too low)

*BF18.00-P-1002-03OA

 Oil dipstick reading from 162 mm to 164 mm (oil level correct)

*BF18.00-P-1003-03OA

 Oil dipstick reading from 166 mm to 174 mm (oil level too high)

*BF18.00-P-1004-03OA

Engine 647 in model 211

AR18.00-P-3035-01S

 Oil level check:

Oil level

*BF18.00-P-1001-03N

Oil dipstick reading from 108 mm to
136 mm (oil level too low)

*BF18.00-P-1002-03N

Oil dipstick reading from 138 mm to
140 mm (oil level correct)

*BF18.00-P-1003-03N

Oil dipstick reading from 142 mm to
152 mm (oil level too high)

*BF18.00-P-1004-03N

Engine 648 in model 211

AR18.00-P-3035-01BD

 Oil level check:

 Engine 646 without particulate filter, engine 647

*BF18.00-P-1001-01A

 Engine 648 without particulate filter

*BF18.00-P-1001-01Y

 Engine 646 with particulate filter

*BF18.00-P-1001-01S

 Engine 648 with particulate filter

*BF18.00-P-1001-01X

 Dipstick

*120589062100

 Dipstick

*120589072100

31

Perform wheel alignment check

AR40.20-P-0200T

32

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

Number

Designation

Engine
646.951/961,
647.961

Engine
648

BA01.20-P-1002-01G

Bolt, cylinder head cover trim to cylinder head

Nm

9

9

BA01.20-P-1003-01G

Bolt, cover to charge air manifold.

Nm

9

9

Number

Designation

Engine
646.8

Engine 646.951/
961/962/
963/966

Engine
647

Engine 648

BA01.45-P-1001-01G

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

9

9

M8

Nm

20

20

20

20

M10

Nm

-

-

-

-

BA01.45-P-1002-01G

Bolt, transmission bell housing to oil pan

Nm

40

40

40

40

BA01.45-P-1003-01G

Oil drain screw to oil pan

M12

Nm

-

-

-

-

M14

Nm

30

30

30

30

BA01.45-P-1004-01G

Bolt, oil pan to timing case cover

M6

Nm

-

9

9

9

BA01.45-P-1005-01G

Bolt, oil pan to rear crankshaft seal

M6

Nm

9

9

9

9

BA01.45-P-1007-01G

Bolt, oil dipstick guide tube to engine oil pan

Nm

10

-

-

8

Number

Designation

Model
211 except model 211.08/09/28/29

BA33.10-P-1005-01A

Bolt, front axle carrier to longitudinal member

Nm

100

Number

Designation

Model
211
except
model
211.08/09/28/29

BA32.20-P-1005-02B

Bolt, stabilizer bar bushing to longitudinal member

Nm

50

Number

Designation

Model
211
except 4 MATIC

BA22.10-P-1002-03A

Front engine mount on front axle carrier

Nm

35

Number

Designation

Trans-mission 722.6 in model 211

BA27.55-P-1002-01B

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

Stage 1

Nm

5

Stage 2

°

90

Hexalobular bolt

Nm

-

BA27.55-P-1008-01B

Bolt, oil cooler line retaining clamp to oil pan

Nm

8

Number

Designation

Engine
646.8 without particulate filter

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

Engine
647.961

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-0228-03A

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-0228-51A

BB00.40-P-0228-51A

BB00.40-P-0228-51A

Sheet

BB00.40-P-0229-03A

BB00.40-P-0229-03A

BB00.40-P-0229-03A

Sheet

BB00.40-P-0229-31A

BB00.40-P-0229-31A

BB00.40-P-0229-31A

Sheet

BB00.40-P-0229-05A

BB00.40-P-0229-05A

BB00.40-P-0229-05A

Sheet

BB00.40-P-0229-51A

BB00.40-P-0229-51A

BB00.40-P-0229-51A

Number

Designation

Engine
648.961 without particulate filter

BF18.00-P-1001-01Y

Engine oil

Filling capacity
(oil and filter change)

Liters

7.3

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

Number

Designation

Engine
646.8 with particulate filter

Engine
646.951 with particulate filter

Engine
646.961 with particulate filter

BF18.00-P-1001-01S

Engine oil

Filling capacity
(oil and filter change)

Liters

6.5

6.5

6.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0228-51A

BB00.40-P-0228-51A

BB00.40-P-0228-51A

Sheet

BB00.40-P-0229-31A

BB00.40-P-0229-31A

BB00.40-P-0229-31A

Sheet

BB00.40-P-0229-51A

BB00.40-P-0229-51A

BB00.40-P-0229-51A

Number

Designation

Engine
648.961 with particulate filter

BF18.00-P-1001-01X

Engine oil

Capacity (oil and filter change)

Lowering

Liters

7.3

Suctioning off

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

Number

Designation

Engine 646.8

BF18.00-P-1001-03LB

Oil level

Maximum

mm

154

Minimum

mm

124

BF18.00-P-1002-03LB

Oil dipstick indication from 115 mm to
151 mm (oil level too low)

115 mm

Replenish oil quantity in liters

2.7

117 mm

Replenish oil quantity in liters

2.5

119 mm

Replenish oil quantity in liters

2.4

121 mm

Replenish oil quantity in liters

2.2

123 mm

Replenish oil quantity in liters

2.1

125 mm

Replenish oil quantity in liters

2.0

127 mm

Replenish oil quantity in liters

1.9

129 mm

Replenish oil quantity in liters

1.7

131 mm

Replenish oil quantity in liters

1.5

133 mm

Replenish oil quantity in liters

1.4

135 mm

Replenish oil quantity in liters

1.2

137 mm

Replenish oil quantity in liters

1.1

139 mm

Replenish oil quantity in liters

1.0

141 mm

Replenish oil quantity in liters

0.9

143 mm

Replenish oil quantity in liters

0.7

145 mm

Replenish oil quantity in liters

0.6

147 mm

Replenish oil quantity in liters

0.5

149 mm

Replenish oil quantity in liters

0.3

151 mm

Replenish oil quantity in liters

0.2

BF18.00-P-1003-03LB

Oil dipstick indication from 153 mm to
155 mm (oil level correct)

153 mm

Oil quantity in liters

0.0

154 mm

Oil quantity in liters

0.0

155 mm

Oil quantity in liters

0.0

BF18.00-P-1004-03LB

Oil dipstick indication from 157 mm to
165 mm (oil level too high)

157 mm

Extract oil quantity in liters

0.2

159 mm

Extract oil quantity in liters

0.4

161 mm

Extract oil quantity in liters

0.5

163 mm

Extract oil quantity in liters

0.7

165 mm

Extract oil quantity in liters

0.8

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

Number

Designation

Engine
647 in model 211

BF18.00-P-1001-03N

Oil level

Maximum

mm

139

Minimum

mm

116

BF18.00-P-1002-03N

Dipstick indication
108 mm to 136 mm (oil level too low)

108 mm

Replenish oil quantity in liters

+2.7

110 mm

Replenish oil quantity in liters

+2.5

112 mm

Replenish oil quantity in liters

+2.4

114 mm

Replenish oil quantity in liters

+2.2

116 mm

Replenish oil quantity in liters

+2.1

118 mm

Replenish oil quantity in liters

+1.9

120 mm

Replenish oil quantity in liters

+1.8

122 mm

Replenish oil quantity in liters

+1.6

124 mm

Replenish oil quantity in liters

+1.4

126 mm

Replenish oil quantity in liters

+1.3

128 mm

Replenish oil quantity in liters

+1.1

130 mm

Replenish oil quantity in liters

+0.9

132 mm

Replenish oil quantity in liters

+0.7

134 mm

Replenish oil quantity in liters

+0.5

136 mm

Replenish oil quantity in liters

+0.3

BF18.00-P-1003-03N

Oil dipstick indication 138 mm to 140 mm (oil level correct)

138 mm

Oil quantity in liters

0.0

139 mm

Oil quantity in liters

0.0

140 mm

Oil quantity in liters

0.0

BF18.00-P-1004-03N

Oil dipstick reading
142 mm to 152 mm (oil level too high)

142 mm

Extract oil quantity in liters

-0.3

144 mm

Extract oil quantity in liters

-0.6

146 mm

Extract oil quantity in liters

-0.7

148 mm

Extract oil quantity in liters

-0.9

150 mm

Extract oil quantity in liters

-1.1

152 mm

Extract oil quantity in liters

-1.3

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