Remove/Install Oil Pan - AR01.45-P-7500GQA

ENGINE 651 in MODEL 166 

Shown on model 205 with engine 651 

Shown on engine 651 with transmission 722.9 (except 722.96) 

Shown on engine 651 with transmission 722.96 

	Remove
1	Remove flywheel/drive plate		AR03.30-P-8001CD
2	Remove guide tube of oil dipstick
3	Detach bracket (1) with electrical wiring harness (2) from the rear right engine suspension lug and place to one side
4	Attach engine hoist		AR33.10-P-0105EW
5	Only raise engine sufficiently until the engine mounts are not under tension
6	Remove front axle		AR33.10-P-0100GQ
7	Remove front axle transmission	Model 166 (except 166.006) with engine 651	AR33.30-P-0525GQ
8	Remove screw/bolts (9) and detach front axle transmission support (10) at oil pan top section (4)	Engine 651 in model 166 (except 166.006)
9	Drain engine oil and catch in a suitable container		AP18.00-P-0101CWA
10	Remove oil pan bottom section		AR01.45-P-7555OLD
11	Detach electrical line (3) for temperature sensor upstream of diesel particulate filter at oil pan top section (4)
12	Detach electrical line (3) for switch oil level check at oil pan top section (4)
13	Disconnect electrical connection for oil level check switch
14	Detach the cable duct (5)	Remove screw/bolt (6) from carrier and press the cable duct (5) somewhat to one side
15	Detach A/T oil cooling line at oil pan top section (4)
16	Remove screw/bolts (7) at timing case cover
17	Remove screw/bolts (8) on oil pan top section (4)	Do not remove two opposite screw/bolts (8) yet but just unscrew by about four turns.
18	Pry off oil pan top section (4) from crankcase	Carefully screw in M6x60 screw/bolts. The oil pan top section (4) and the contact surface on the crankcase can get damaged otherwise. Screw screw/bolts M6x60 into the prying off threaded bores (arrow) and pry off oil pan top section (4) from crankcase through alternate tightening.
19	Remove remaining two screw/bolts (8) from oil pan top section (4) and remove oil pan top section (4)	If necessary, carefully remove engine until the oil pan top section (4) can be removed. Pay attention when lifting out engine that no lines and hoses are damaged and that the engine does touch the bulkhead.
20	Remove screw/bolts M6x60 for prying off the oil pan top section (4) from the prying off threaded bores (arrows)
21	Remove pilot bushing in crankcase	The pilot bushings are not needed anymore.
	Clean
22	Clean sealing surfaces for oil pan top section (4), the crankcase and the timing case cover		AR01.00-P-0050-01A
		Do not clean sealing surfaces with sharp-edged or tipped objects. Damage could occur on the sealing surfaces otherwise. Warm sealing surfaces on oil pan top section (4) in order to achieve better removal of the sealant. Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
		Loctite 7200	*BR00.45-Z-1038-04A
	Install
23	Apply sealant to sealing surface on oil pan top section (4) Notes on sealant path for oil pan		AH01.45-P-0001-01CD
		Sealant, Loctite 5970, 50 ml	*BR00.45-Z-1013-01A
		Application gun	Figure
24	Mount oil pan top section (4) on crankcase using screw/bolts (7, 8)	Only tighten screw/bolts (7, 8) hand-tight.
25	Fully tighten bolts (8)	Bolt, oil pan top section to crankcase/lower crankcase section	*BA01.45-P-1001-01S
26	Tighten screws/bolts (7)	Bolt plan for timing case cover	AR01.40-P-8000-01CD
		Follow the bolt plan. Bolt, timing case cover to crankcase/cylinder head/oil pan top section	*BA01.40-P-1001-01X
27	Mount A/T oil cooling line on oil pan top section (4)	Bolt, clamp of oil cooler oil line to bracket	*BA27.55-P-1005-01D
28	Mount cable duct (5)
29	Connect electrical connection for oil level check switch
30	Mount electrical line (3) for switch oil level check at oil pan top section (4)	Ensure correct seating of clamp and electrical line (3) on oil pan top section (4).
31	Mount electrical line (3) for temperature sensor upstream of diesel particulate filter at oil pan top section (4)	Ensure correct seating of clamp and electrical line (3) on oil pan top section (4).
32	Install oil pan bottom section		AR01.45-P-7555OLD
33	Pour in engine oil		AP18.00-P-0101CWA
34	Mount front axle transmission support (10) on oil pan top section (4)	Engine 651 in model 166.0 (except 166.006)
35	Install front axle transmission	Engine 651 in model 166 (except 166.006)	AR33.30-P-0525GQ
36	Install front axle		AR33.10-P-0100GQ
37	Remove engine hoist		AR33.10-P-0105EW
38	Mount bracket (1) with electrical wiring harness (2) on rear right engine suspension lug
39	Install guide tube of oil dipstick
40	Install flywheel/drive plate		AR03.30-P-8001CD
	Check
41	Check engine oil level, correct if necessary
			AP18.00-P-1811MP
42	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. Perform an engine test run and check the engine for leaks in the area of the oil pan top section (4) for leaktightness	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

Fig 1: Identifying Application Gun (112 589 00 25 00)

Courtesy of MERCEDES-BENZ USA