"VCC139128 EN 20100619" 1(6) Replacing the sump Special tools: 951 1205, 999 5460, 999 5716, 999 5717 Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct. Preparation Remove the oil dipstick and pipe. Turbocharged engines only the connector and hose from the crankcase ventilation terminal in the plastic intake pipe the hose from the plastic charge air pipe the screws for the charge air pipe in the intake pipe. the hose clamps from the plastic pipe at the rear of the engine the plastic pipes. If necessary, heat carefully using a hot air gun. Leave the pipes lying on the spark plug cover. Installing the lifting fixture the cover over the ignition coils the 2 screws at the engine mounting. Install fixture999 5717. Installing the lifting beam and lifting hook on the engine lifting eyelet Note! Position the stand for lifting beam 999 5716 on the upper wheel arch members. Then position the lifting beam directly above the engine lifting eyes on both sides. Connect to the hole nearest the bulkhead. Connect lifting hook 999 5460. Tighten to light contact.
"VCC139128 EN 20100619" 2(6) Draining the engine oil the lower engine cover the front air baffle. Drain the engine oil. Remove the oil filter. Removing components the front wheel the nuts for the lower ball joints the antiroll bar links from the antiroll bar the centre screw for the righthand drive shaft the screw and nuts for the steering gear the screw for the front engine mounting the torque rod including the mounting in the subframe. Removing the spindles Tension the trailing arms together to release the spindles. Use a retaining strap. Unhook the right drive shaft from the stub axle. Tension the spring strut backwards. Use a retaining strap. Removing components from the subframe Remove the screw for the cable duct. the oil pipe for the steering gear from the snap fasteners along the subframe the hose for the EVAP canister in the clips on the upper side of the subframe any fuel line for the engine block heater and any engine block heater if mounted on the left hand side of the subframe the air duct from the clip the screw for the ground cable bracket the connectors for the heated oxygen sensors (HO2S) in the clips at the rear of the subframe. Lowering subframe Slacken off the subframe screws. Lower the
"VCC139128 EN 20100619" 3(6) subframe slightly. Remove the heated oxygen sensor (HO2S) bracket on the reverse of the subframe. Unscrew the screws for the subframe approximately 2.5 cm on the righthand side. Fully remove the screws on the lefthand side. Angle the subframe down on the lefthand side. Ensure that the screws for the steering gear release from the frame. Disconnecting the oil cooler Disconnect the oil cooler from the sump. Hang the oil cooler from a suitable place. Removing the sump Remove the screw from the bracket for the fuel line. Remove the screw for the bracket for the fuel line on the auxiliaries bracket. Slacken off all the screws holding the sump. Remove all but four screws. It is recommended that the four screws in the corners of the pan are left in place. Carefully tap the pan using a rubber mallet until the joint and its liquid gasket releases. the four remaining screws the oil sump. Cleaning Clean the gasket surfaces on the sump and cylinder block. Use a razor blade or a gasket scraper and gasket solvent 116 1440. Warning! Use a fume bonnet or extractor when using gasket solvent. Note! Also clean the gasket faces for the screws for the torque rod. Installing the sump Apply liquid gasket 116 1059 9 to the sump. Use roller 951 1205. Note! Also apply liquid gasket around the holes for the screws for the torque rod.
"VCC139128 EN 20100619" 4(6) Install new Orings the oil sump. Secure the oil sump loosely using a few screws the remaining screws loosely. Press the sump against the gearbox. Tighten the screws (1), (2), (3) and (4). Tighten to 3 Nm. Tighten the screws (5). First tighten to 25 Nm. Then tighten to 48 Nm. Tighten all screws in the sump joint. Tighten to 17 Nm. Start at the gearbox and continue forwards in pairs. Connect the oil cooler to the sump. Use new Orings. Install the screw for the bracket for the fuel line. a new oil filter the oil plug with a new gasket. Installing the subframe Lift the subframe. Use a mobile jack. the bracket for the heated oxygen sensors (HO2S) in the rear edge of the subframe new screw in the subframe. Lubricate the screws the washers at the front edge and the support plates at the rear edge of the subframe. Tighten the screws for the subframe. Tighten to 105 Nm. Angletighten 120. Use bevel protractor 951 2050. Start on the left hand side of the subframe. Continue with the right hand side. Tighten the screws for the brackets at the rear of the subframe. Tighten to 50 Nm. Installing components on the subframe the screw for the cable and air duct the oil pipe for the steering gear in the snap
"VCC139128 EN 20100619" 5(6) fasteners along the subframe the hose for the EVAP canister in the clip on the upperside of the subframe the engine block heater and the fuel line to the engine block heater if applicable the air duct in the clips the screw for the ground cable bracket the connectors for the heated oxygen sensors (HO2S) in the clips at the rear of the subframe. Removing retaining straps Slacken off the retaining straps for the spring strut. Thread the drive shaft into the stub axle. Carefully release the retaining strap for trailing arms. At the same time guide the lower ball joints into the trailing arms. Installing components Install new nuts on the ball joints. Tighten to 80 Nm. Counterhold using a Torx spanner so that the ball joint boot is not damaged. Install the antiroll bar links. Use new nuts. Tighten to 50 Nm. Counterhold using a Torx spanner so that the boot is not damaged. the screw and nuts for the steering gear. Use new nuts and new screws. Tighten to 50 Nm the front engine pad. Tighten to 50 Nm the torque rod. Tighten the screws through the sump. Tighten to 50 Nm. Tighten the nuts in the subframe. Tighten to 65 Nm the centre screw for the drive shaft. Use a new screw. Counterhold using a screwdriver in the brake disc vents. Tighten to 50 Nm the front air baffle the front wheel. Removing the lifting beam and the lifting hook the lifting beam the lifting hooks
"VCC139128 EN 20100619" 6(6) the lifting fixture from the engine. Install the screws in the engine mounting. Finishing the cover over the ignition coils the oil dipstick and pipe. Use a new Oring. Check that the Oring is correctly positioned. Turbocharged engines only the plastic pipes. Tighten the hose clamps the screws for the charge air pipe in the intake pipe the connector and hose to the crankcase ventilation terminal in the plastic intake pipe the hose to the plastic charge air pipe. Filling with engine oil Fill with 6.7 litres of new engine oil. Check Start the engine and check for oil leakage. Stop the engine. Give the oil time to run down into the sump. Then check the oil level. Top up if necessary but do not overfill. Wipe the engine compartment clean. Install the lower engine cover.