Oil Pan: Service and Repair
Oil sump (in car)
To remove
1. Remove the dipstick and place a cloth over the tube. Unplug the oxygen sensor's connector.
2. Raise the car and remove the lower engine cover.
3. Remove the front steady bar from the gearbox and detach the A/C compressor's pipe from the subframe.
4. Tie the condenser, radiator and charge air cooler to the radiator crossmember.
5. Raise the car, remove the wheels and drain the engine oil.
6. Remove the panel between the subframe arms, 6 bolts.
7. Remove the front part of the exhaust system.
8. Undo the air cleaner's retaining nuts and remove the power steering pipes and oil cooler from the subframe.
9. Unbolt the anti-roll bar from the suspension strut on both sides.
10. Disconnect the bolt that goes completely through the steering spindle swivel joint from the steering spindle swivel member.
11. Remove the steering gear's 2 retaining bolts.
12. Position the lifting table with fixture under the subframe.
13. Remove the subframe retaining screws and lower the table. Disconnect the spindles.
From chassis number W3050999, the inner sleeve in the subframe bushings have been made 38 mm long instead of previously 35 mm. If the bushing is 35 mm, a 3 mm spacer must be fitted between the bushing and washer.
WARNING: The spacer washer must not be fitted together with bushing in 38 mm inner sleeve.
14. Disconnect the crankcase breather hose from the oil sump.
15. Remove the protective plate and the oil sump. Wipe up any oil that has dripped out.
To fit
1. Check that there are no impurities or other foreign matter in the sump and clean the sealing surfaces with benzine.
2. Apply an even bead of flange sealant, part no. 93 21 795, to the sealing surface of the oil sump and fit the oil sump.
Tightening torque 22 Nm (16 ft. lbs.).
3. Fit the protective plate.
4. Fit the crankcase breather hose.
5. Raise the subframe by a sufficient amount to allow the retaining nuts for the steering swivel joints to be fitted.
Tightening torque: 39 Nm (22 ft. lbs.) + 90.
6. Fit the servo pipes and fit the engine oil cooler hoses in the bracket.
7. Lift up the subframe and bolt it in place.
Tightening torques
- Subframe 115 Nm (84 ft. lbs.)
- Supporting plate 65 Nm (48 ft. lbs.).
From chassis number W3050999, the inner sleeve in the subframe bushings have been made 38 mm long instead of previously 35 mm. If the bushing is 35 mm, a 3 mm spacer must be fitted between the bushing and washer.
WARNING: The spacer washer must not be fitted together with bushing in 38 mm inner sleeve.
8. Fit the steering gear retaining bolts.
9. Fit the clamps for the steering servo pump pipes, screw on the air cleaner retaining nuts and mount the oil cooler on the subframe.
10. Clean the joints, lubricate the studs on the turbocharger with Molycote 1009 and fit the exhaust pipe and protective plates.
11. Bolt the anti-roll bar in place on both sides.
Tightening torque 90 Nm (66 ft. lbs.).
12. Fit the wheels and tighten the wheel bolts, using a torque wrench.
Tightening torque: 110 Nm (80 ft. lbs.).
IMPORTANT: The wheels must be hanging freely when the wheel bolts are tightened.
13. Make sure the oil plug is tight, lower the car and fill with engine oil. Put back the dipstick and connect the oxygen sensor cables. Lower the car.
14. Fit the engine mounting's retaining bolts and tighten them, using a torque wrench.
Tightening torque: 50 Nm (36 ft. lbs.).
15. Fit the front gearbox steady bar and press the A/C-compressor pipes into place on the subframe.
16. Warm up the engine and check for leaks round the sealing surfaces.
17. Raise the car after the test drive and fit the lower engine cover.
18. Check the oil level and top up as necessary.