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Pelican Technical Article:

Oil Pan Gasket Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$100

Talent:

*****

Tools:

E10 external Torx, prybar, plastic scraper, floor jack, jack stands, wheel chocks, safety glasses, torque wrench

Applicable Models:

Mercedes-Benz W211 (2003-09)

Parts Required:

Oil pan gasket, engine oil, RTV sealant

Hot Tip:

Work with a cool engine.

Performance Gain:

Repair leak at oil pan

Complementary Modification:

Change engine oil

The engine oil pan on Mercedes-Benz W211 models is a sump for engine oil. It is an aluminum pan bolted to the bottom of the crankcase. It houses the oil pickup and engine oil. W211 models utilize a wet sump. This is a lubrication system for piston engines, which uses the crankcase as a built-in reservoir for oil, as opposed to an external or secondary reservoir used in a dry sump design.

The oil pan gasket on Mercedes-Benz W211 models tends to fail and leak over time. If you find an oil leak at the center of your engine, inspect the oil pan to see if it is the source. Clean the area around the oil pan and crankcase. Then run your engine and recheck the area for a leak. Be careful when diagnosing, as the valve covers can sometimes look like an oil pan leak. Confirm the leak is not coming from above the oil pan seam. If you determine the oil pan is in fact leaking, you will want to replace it and reseal the bottom of your crankcase. In this tech article, I will show you how to replace the oil pan gasket on Mercedes-Benz W211 models with a 6-cylinder engine and a 4MATIC drivetrain. Other models may be similar, check your vehicle to see if this procedure matches.

The gasket itself is an RTV (room temperature vulcanization silicone) silicone sealant. Once you remove the pan, allow the engine to drip drain the remaining oil until it stops. This will prevent contamination of the sealant with engine oil during reinstallation.

Remember that your car may have been serviced before and had parts replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

Our vehicle may vary slightly from yours as models do change and evolve, as they grow older. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

The oil pan (red arrow) is tucked away tightly into the engine compartment.
Figure 1

The oil pan (red arrow) is tucked away tightly into the engine compartment. The engine oil pan on Mercedes-Benz W211 models is a sump for engine oil. It is an aluminum pan bolted to the bottom of the crankcase that houses the oil pickup and engine oil. W211 models utilize a wet sump. This is a lubrication system for piston engines, which uses the crankcase as a built-in reservoir for oil, as opposed to an external or secondary reservoir used in a dry sump design. The oil pan gasket on Mercedes-Benz W211 models tends to fail and leak over time. If you find an oil leak at the center of your engine, inspect the oil pan to see if it is the source of the leak. Clean the area around the oil pan and crankcase. Then run your engine and recheck the area for a leak. Now be careful when diagnosing, as the valve covers can sometimes look like an oil pan leak. Confirm the leak is not coming from above the oil pan seam. If you determine the oil pan is in fact leaking, you will want to replace it and reseal the bottom of your crankcase. In this tech article, I will show you how to replace the oil pan gasket on Mercedes-Benz W211 models with a 6-cylinder engine and a 4MATIC drivetrain. Other models may be similar. Check your vehicle to see if this procedure matches. The gasket itself is an RTV (room temperature vulcanization silicone) silicone sealant. Once you remove the pan, allow the engine to drip drain the remaining oil until it stops. This will prevent contamination of the sealant with engine oil during reinstallation.

Jack the front of your vehicle See our tech article on jacking your vehicle.
Figure 2

Jack the front of your vehicle See our tech article on jacking up your vehicle. Remove the engine splash shields. Then, drain your engine oil. Remove the 13mm drain plug (red arrow) and allow the engine oil to drain until it stops dripping.

The first thing you have to do is detach the steel lines from the sides of the oil pan (red arrows).
Figure 3

The first thing you have to do is detach the steel lines from the sides of the oil pan (red arrows). Now it is time to remove the oil pan fasteners. Now would be a good time to clean the engine block before you remove the oil pan.

Starting at the left side of the oil pan, remove the two E10 Torx fasteners (red arrows).
Figure 4

Starting at the left side of the oil pan, remove the two E10 Torx fasteners (red arrows). Then follow the line (green arrow) toward the rear of the vehicle and remove the final E10 Torx fastener (yellow arrow).

Working at the right side of the oil pan, remove the two E10 Torx fasteners (red arrows).
Figure 5

Working at the right side of the oil pan, remove the two E10 Torx fasteners (red arrows). Then move the steel lines away from the oil pan. They will only move about an inch. This will allow access to the fasteners.

Working at the front of the oil pan, move the steel line slightly forward and down.
Figure 6

Working at the front of the oil pan, move the steel line slightly forward and down. Then remove the three E10 Torx fasteners (red arrows). I use a long extension and a swivel E10 socket. 

Working at the right side of the oil pan, remove the three E10 Torx fasteners (red arrows).
Figure 7

Working at the right side of the oil pan, remove the three E10 Torx fasteners (red arrows).

Now it is time to remove the remaining oil pan fasteners.
Figure 8

Now it is time to remove the remaining oil pan fasteners. On the rear and left side, remove the six E10 Torx fasteners (red arrow).

With all the fasteners removed, lightly tap the oil pan to break the sealant bond to the crankcase.
Figure 9

With all the fasteners removed, lightly tap the oil pan to break the sealant bond to the crankcase. As you tap, listen for the sound to change. Once it does, the sealant bond has been broken. Support the oil pan, as it may fall during this process. If the pan does not come off after tapping, see the next step.

On the left side of the oil pan there is a separating ledge (red arrow).
Figure 10

On the left side of the oil pan there is a separating ledge (red arrow). Use a small flathead screwdriver and gently lever the pan down away from the crankcase. I stress gently here. Do not break the crankcase or oil pan. If you lever too hard, they will be damaged. Support the oil pan, as it may fall during this process. If the pan will not drop down, lightly tap the corner again. Then try to lever it off.

Lower and remove the oil pan from the engine.
Figure 11

Lower and remove the oil pan from the engine. Once the oil pan is removed, clean it thoroughly, the inside and sealing surface.

This photo shows the oil pan cleaned.
Figure 12

This photo shows the oil pan cleaned. Be sure both surfaces are this clean, the crankcase and the oil pan. Otherwise the RTV will not seal. Apply RTV in a 1/8-inch bead. Then evenly spread it around with your finger. Do not overdo it. Lift the oil pan into place and install the fasteners to secure it in place. Do not tighten them yet. Once the pan is flush with the crankcase, tighten all the fasteners.

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Comments and Suggestions:
Dave Comments: How do I remove a cracked oil pan from a 1991 MB 190e 2.6L and replace with new. There appears to be something attached to the side of the pan...how do I deal with it? Also, new pans seem to need a diamond-shaped rear gasket/cover/plug...what's that?
October 19, 2015
  Followup from the Pelican Staff: It is quite involved. The engine mounts, sway bar, and trans cooler line shave to come out.
We don't currently have that tech article. If we get a chance to perform the procedure, we will be sure to document it.

I would grab a repair manual. It will have the procedure, special tools and torque specs.

Give our parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 
Codygurl Comments: OMG!! You guys are a god-send. Using BMW info too. Outstanding Information!!
October 7, 2015
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 

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