Installing the upper oil sump section

• Clean all threads for attachment with a suitable screw tap M8 (1)  .

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• Clean sealing surface (1)  .

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• Clean sealing surface (1)  .

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• Position special tool 0 496 120 (11 8 780)  with transmission bolts (1)  in such a way that the oil pan aligns exactly with the engine block.
• If necessary, renew fitting sleeves.

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• Apply the sealant (1) as shown on the special tool 2 469 803  .

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• Apply the prescribed amount of sealant to the separation points in the marked area.

  Using more than the recommended amount  of sealant may result in leaks  .

  SEALING COMPOUND AMOUNT SPECIFICATION
  
  

  Height	4	mm
  Diameter	4	mm

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• Apply the prescribed amount of sealant to the separation points in the marked area.

Using more than the recommended amount  of sealant may result in leakage  .

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• Renew the seal (1)  .

  Parts:  Seal

• Position seal (1)  on upper oil sump section.

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• Position the oil pan on the crankcase using the special tools  2 219 012  and  0 495 498 (23 4 050)  and with the help of an support person  .

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• Position upper oil sump section (3)  with the seal on the crankcase.
• Renew screws (1)  and (2)  . Observe screw lengths.

• Tighten down screws (1)  and (2)  .

• Tighten transmission screws (1)  .

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• Remove special tools  2 219 012  and  0 495 498 (23 4 050)  .

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• Renew screws (3)  to (25)  . Observe screw lengths.

Fig 1: Upper Oil Sump Section Screws Loosening Sequence

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• Tighten the screws in the sequence (1)  to (25)  .

• Secure cable (1)  to the clamp (2)  .

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• Secure clamp (arrow).
• Install and tighten the oil pressure sensor (3)  .

• Connect connectors (2)  and lock.

  The connector (2)  must engage audibly.

• Connect connectors (1)  and lock.

  The connector (1)  must engage audibly.

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• Install rubber plugs (1)  .

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Follow-up work 

• Refer to INSTALLING OIL PUMP .
• Refer to INSTALLING THE LOWER OIL PAN SECTION 
• Refer to REPLACING OIL FILTER ELEMENT .
• Refer to INSTALLING THE OIL FILTER ELEMENT .
• Refer to INSTALLING FRONT AXLE DIFFERENTIAL .
• Refer to INSTALLING THE ENGINE MOUNT ON THE LEFT , and INSTALLING THE RIGHT ENGINE MOUNT
• Refer to INSTALLING FRONT PROPELLER SHAFT AT THE FRONT AXLE TRANSMISSION
• Refer to INSTALLING GUIDE TUBE FOR OIL DIPSTICK .
• Refer to INSTALLING FRONT AXLE .
• Refer to TIGHTENING THE BOLTS ON THE FRONT AXLE SUPPORT .
• Refer to FASTENING THE SWIVEL BEARING ON THE LEFT AND RIGHT .
• Refer to REMOVING THE MOBILE LIFTING TABLE .
• Refer to FASTENING COOLANT HOSE TO THE FRONT SUBFRAME .
• Refer to SECURING THE TRANSMISSION OIL COOLING BRACKET .
• Refer to REPLACING RADIAL SHAFT SEALS .
• Installing left output shaft.
  NOTE: Description is for left component only. Procedure on the right side is identical.
  • Fold open the assembly protection ring (1).

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    NOTE: Conduct the following operation with the assistance of a second person.
  • Release swivel bearing (1) from the special tool 2 413 317 on the upper wishbone. Swivel bearing (1) must not hang down from the brake hose.

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  • Guide the output shaft into the front axle differential.
  • Pull on the lug (1) of the installation protection ring until one of the two predetermined breaking points breaks.

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  • Pull out and dispose of the installation protection ring.
  • Press the output shaft (1) into the front axle differential up to the stop with a jerky movement.

    The output shaft (1) must engage perceptibly and audibly.

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  • Fasten the swivel bearing (1) using special tool 2 413 317 to protect it from tilting outwards.

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• Installing spring suspension strut
  NOTE: TECHNICAL INFORMATION 

  Keep the connection of the spring strut holder to the spring strut clean and free from oil and grease.

  • Spread spring strut holder (3) using the special tool 0 494 541 (31 2 230).
  • Protecting the output shaft from damage with a towel is mandatory  (1).
  • Release swivel bearing (2) from the attachment on the upper wishbone.
  • Feed in the spring strut holder (3) in the arrow direction and use the gap to align it with the positioning pin on the suspension strut.
  • The spring strut holder (3) must be pushed upwards onto the spring strut to the stop.
  • Remove towel (1).

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  Secure the swivel bearing 

  • Fasten the swivel bearing (1) by using the special tool 2 413 317 to protect it from tilting outwards.

    Swivel bearing (1) must not hang down from the brake hose.

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  • Remove the special tool 0 494 541 (31 2 230)  .

    The spring strut holder (1) must be pushed up to the limit position on the spring strut!

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    Checking the installation position of the spring strut holder 

    NOTE: TECHNICAL INFORMATION 
    Different variants may be installed depending on the vehicle equipment.
    • Version A: 

      Check the installation position of the spring strut holder (1) for the spring strut (2).

      The spring strut holder (1) must be correctly aligned to the spring strut (3) on the basis of the color coding (2).

      The color coding (3) runs in the extension of the edge (4).

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    • Version B: 

      Check the installation position of the spring strut holder (1) for the spring strut (2).

      The spring strut holder (1) must be correctly aligned to the spring strut (3) on the basis of the color coding (2).

      The color coding (3) runs in the extension of the edge (4).

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  • Renew the screw (1).

    Parts:  Screw

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  • Screw the bolt (1) into the spring strut holder (2) and tighten it.
    TIGHTENING TORQUE SPECIFICATIONS
    
    

    Spring strut holder on front spring strut
    M10x60 Replace screw.	Tightening torque  38 Nm Angle of rotation  90 °

    NOTE:

    TECHNICAL INFORMATION 

    Tighten the screw connection in the normal position.

    For additional information see: 31 00 GENERAL FRONT AXLE

  • Position spring strut holder on wishbone.
  • Renew the screw (3) and the nut (1).

    Parts:  Bolt and nut

  • Punch in the swivel bearing (2) at the front towards the inner.
  • Insert the screw (3).
  • Tighten the nut (1) in the normal position.

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    TIGHTENING TORQUE SPECIFICATIONS
    
    

    Spring strut holder to lower wishbone
    M14 Replace screw and nut Tighten in normal position	Tightening torque  165 Nm Angle of rotation  90°

• Refer to ATTACHING THE BRAKE CALIPER ON THE LEFT AND RIGHT .
• Refer to CONNECTING THE CONNECTORS ON LEFT AND RIGHT .
• Refer to CONNECTING THE CONNECTOR TO THE LEFT AND RIGHT VERTICAL ACCELERATION SENSOR .
• Refer to SECURING THE WISHBONE ON THE TOP LEFT AND RIGHT ON THE SWIVEL BEARING .
• Refer to FASTENING THE RIGHT AND LEFT OUTPUT SHAFTS ONTO THE WHEEL BEARING .
• Drain/top up the front axle transmission oil
  NOTE: RISK OF DAMAGE 

  Use only the approved front axle transmission oil.

  NOTE: TECHNICAL INFORMATION 

  Filling to the lower edge of the oil filler opening means that the front axle differential is overfilled. In some cases, this may lead to emerging oil from the ventilation opening on the front axle differential.

  After having drained the front axle transmission oil, repair the front axle differential or upon initial filling of a new replacement front axle differential, the transmission must be filled with 600 ml of oil.

  NOTE: TECHNICAL INFORMATION 

  Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

  • Place oil collecting apparatus underneath.
  • Release the oil filler plug (1).
  • Drain and dispose of front differential oil.
  • Replace (1) screw plug.

    Parts:  Plug

  • Tighten the oil filler plug (1).

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    TIGHTENING TORQUE SPECIFICATIONS
    
    

    Screw plug to front axle transmission
    M22 Replace screw plug with O-ring.	Tightening torque  60 Nm

  • Depending on the oil container, use the special tool (A) or (B) on the special tool 2460 340 if necessary.

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    NOTE:

    TECHNICAL INFORMATION 

    
    It is imperative to ensure that there is no air in the hose when topping up a defined (measured) oil quantity.
  • Use special tool 2 460 340 to top up the oil.
  • To top up a defined (measured) oil quantity, first fill hose (1) with oil. Connect adapter (2) to do this.

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  Supplementing the oil level with the oil spray 

  NOTE:

  TECHNICAL INFORMATION 

  The training video schematically shows the method for changing the oil in the rear axle differential using the oil sprayer special tool.

  The training video is not a replacement for the repair instructions.

  The training video is not subject to the update service.

  We can assume no liability for printing errors or inaccuracies in this document and reserve the right to introduce technical modifications at any time.

  multimedia:A supplement to the article is available.

  • Follow repair instructions!
  • Release the oil filler plug (1).

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  • Fill the front axle transmission oil with the special tool 2 460 340 into the front axle transmission.
    TECHNICAL DATA
    
    

    Front axle transmission oil
    Filling capacity for front axle differential 175AL	600 ml

    TECHNICAL DATA
    
    

    Transmission oil
    Hypoid Axle Oil G2 (up to 02/2020)	500 ml, Bottle	83222413511
    Hypoid Axle Oil G5 (from 03/2020)	500 ml, Bottle	83222471487

  • Replace (1) screw plug.

    Parts:  Plug

  • Tighten the oil filler plug (1).
    TIGHTENING TORQUE SPECIFICATIONS
    
    

    Screw plug to front axle transmission
    M22 Replace screw plug with O-ring.	Tightening torque  60 Nm

• Refer to SECURING THE UNIVERSAL JOINT ON THE STEERING GEAR .
• Refer to ATTACHING THE WIRING HARNESS OF THE ACTIVE STABILIZER .
• Refer to FASTENING WIRING HARNESS TO THE EPS .
• Refer to IF INSTALLED: FASTEN THE AUXILIARY HEATER .
• Refer to INSTALLING LEFT AND RIGHT BRAKE VENTILATION DUCT .
• Refer to INSTALLING THE LEFT AND RIGHT CRASH LEVER .
• Refer to INSTALLING THE WHEEL ARCH COVER ON THE FRONT, BOTTOM LEFT AND RIGHT .
• Refer to INSTALLING THE RIGHT REINFORCEMENT STRUT .
• Refer to TAKING ENGINE OUT OF INSTALLATION POSITION .
• Refer to INSTALLING THE STIFFENING PLATE .
• Refer to INSTALLING FRONT UNDERBODY PROTECTION .
• Refer to INSTALLING THE COVER OF THE STEERING ASSEMBLY ON THE LEFT AND RIGHT .
• Refer to PARTIALLY INSTALLING THE FRONT WHEEL ARCH TRIM (DOOR SILL) AT LEFT AND RIGHT .
• Refer to INSTALLING THE COVER OF THE STEERING ASSEMBLY ON THE LEFT AND RIGHT .
• Refer to INSTALLING THE FRONT LEFT AND RIGHT WHEELS .
• Refer to ATTACHING THE SPRING STRUT (AIR SUSPENSION) RIGHT FRONT .
• Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
• Refer to INSTALLING THE RIGHT-HAND CHARGE AIR COOLER .
• Refer to INSTALLING RIGHT CLEAN AIR PIPE .
• Refer to CONNECTING THE RIGHT CHARGE AIR LINE TO THE EXHAUST TURBOCHARGER .
• Refer to CONNECTING THE COOLANT HOSE TO THE AUXILIARY COOLANT PUMP .
• Refer to INSTALLING FAN COWL .
• Refer to INSTALLING THE LEFT UNFILTERED-AIR DUCT .
• Refer to INSTALLING INTAKE FILTER HOUSING .
• Refer to INSTALLING THE RIGHT STRUT BRACE .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
• Refer to INSTALLING TENSION STRUT ON LEFT AND RIGHT SHOCK TOWER .
• Refer to INSTALLING UPPER CROSS CONNECTION .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT , and INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE TOP RIGHT .
• Refer to INSTALLING THE FRONT HOOD SEAL .
• Refer to INSTALLING THE CENTER COWL UPPER PART .
• Refer to INSTALLING WINDSHIELD PANEL COVER .
• Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
• Refer to INSTALLING THE FRONT HOOD SEAL AT THE REAR .
• Refer to INSTALLING THE REAR RIGHT ENGINE COMPARTMENT COVER .
• Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
• Refer to TAKING HOOD OUT OF THE SERVICE POSITION .
• Refer to CONNECTING ALL BATTERY GROUND LEADS .
• Refer to REMOVING THE OIL FILLER CAP .
• Refer to FILLING ENGINE OIL .
• Refer to INSTALLING THE OIL FILLER CAP .
• Refer to CHECKING ENGINE OIL LEVEL .
• Refer to PLACING BRAKE PADS ON BRAKE DISC/COMMISSIONING .
• Refer to FILLING AND VENTING THE LOW-TEMPERATURE COOLANT CIRCUIT .