Volvo Truck 2003-05

Oil Pan

Print

Removal & Installation



Inline 6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the oil dipstick and pipe.
  4.  
  5. Remove:

    The connector and hose from the crankcase ventilation terminal in the plastic intake pipe
     
    The hose from the plastic charge air pipe
     
    The bolts 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
     
    The cover over the ignition coils
     
    The 2 bolts at the engine mounting
     

  6.  
  7. Install fixture 999 5717.
  8.  


NOTE
Position the stand for lifting beam 999 5716 on the upper wheel arch members.

  1. Then position the lifting beam directly above the engine lifting eyes on both sides.
  2.  
  3. Connect to the hole nearest the firewall. Connect lifting hook 999 5460.
  4.  
  5. Tighten to light contact.
  6.  
  7. Remove:

    The lower engine cover
     
    The front air baffle
     

  8.  
  9. Drain the engine oil. Remove the oil filter.
  10.  
  11. Remove:

    The front wheel
     
    The nuts for the lower ball joints
     
    The anti-roll bar links from the anti-roll bar
     
    The center bolt for the right-hand halfshaft
     
    The bolt and nuts for the steering gear
     
    The bolt for the front engine mounting
     
    The torque rod including the mounting in the sub-frame
     

  12.  
  13. Tension the trailing arms together to release the spindles. Use a retaining strap.
  14.  
  15. Unhook the right halfshaft from the wheel spindle. Tension the spring strut backwards. Use a retaining strap.
  16.  
  17. Remove the bolt for the cable duct.
  18.  
  19. Remove:

    The oil pipe for the steering gear from the snap fasteners along the sub-frame
     
    The hose for the EVAP canister in the clips on the upper side of the sub-frame
     
    any fuel line for the engine block heater and any engine block heater if mounted on the left hand side of the sub-frame
     
    The air duct from the clip
     
    The bolt for the ground cable bracket
     
    The connectors for the heated oxygen sensors in the clips at the rear of the sub-frame
     

  20.  
  21. Slacken off the subframe bolts. Lower the sub-frame slightly.
  22.  
  23. Remove the heated oxygen sensor bracket on the reverse of the sub-frame.
  24.  
  25. Unscrew the bolts for the sub-frame approximately 2.5 cm on the right-hand side.
  26.  
  27. Fully remove the bolts on the left-hand side.
  28.  
  29. Angle the sub-frame down on the left-hand side.
  30.  
  31. Ensure that the bolts for the steering gear release from the frame.
  32.  
  33. Disconnect the oil cooler from the oil pan. Hang the oil cooler from a suitable place.
  34.  
  35. Remove the bolt from the bracket for the fuel line.
  36.  
  37. Remove the bolt for the bracket for the fuel line on the auxiliary bracket.
  38.  
  39. Slacken off all the bolts holding the oil pan.
  40.  
  41. Remove all but four bolts. It is recommended that the four bolts in the corners of the pan are left in place.
  42.  
  43. Carefully tap the pan using a rubber mallet until the joint and its liquid gasket releases.
  44.  
  45. Remove:

    The four remaining bolts
     
    The oil pan
     

  46.  
  47. Clean the gasket surfaces on the oil pan and cylinder block.
  48.  


    Click image to see an enlarged view

    Fig. Tensioning the trailing arms

    Tensioning the trailing arms

    Click image to see an enlarged view

    Fig. 6-cylinder oil pan

    6-cylinder oil pan


WARNING
Use a fume hood or extractor when using gasket solvent. Note! Also clean the gasket faces for the bolts for the torque rod.

  1. Apply liquid gasket 116 1059-9 to the oil pan. Note! Also apply liquid gasket around the holes for the bolts for the torque rod.
  2.  

To install:

  1. Install:

    new O-rings
     
    The oil pan. Secure the oil pan loosely using a few bolts
     
    The remaining bolts loosely
     

  2.  
  3. Press the oil pan against the transmission. Tighten the bolts (1), (2), (3) and (4). Tighten to 26 inch lbs. (3 Nm).
  4.  
  5. Tighten the bolts 5. First tighten to 18 ft. lbs. (25 Nm). Then tighten to 35 ft. lbs. (48 Nm).
  6.  
  7. Tighten all bolts in the oil pan flange. Tighten to 12 ft. lbs. (17 Nm). Start at the transmission and continue forwards in pairs.
  8.  
  9. Connect the oil cooler to the oil pan. Use new O-rings.
  10.  
  11. Install the bolt for the bracket for the fuel line.
  12.  
  13. Install:

    A new oil filter
     
    The oil plug with a new gasket
     

  14.  
  15. Lift the sub-frame. Use a mobile jack.
  16.  
  17. Install:

    The bracket for the heated oxygen sensors in the rear edge of the sub-frame
     
    New bolt in the sub-frame. Lubricate the bolts
     
    The washers at the front edge and the support plates at the rear edge of the sub-frame.
     

  18.  
  19. Tighten the bolts for the sub-frame. Tighten to 77 ft. lbs. (105 Nm). Angle-tighten 120°.
  20.  
  21. Start on the left hand side of the sub-frame. Continue with the right hand side.
  22.  
  23. Tighten the bolts for the brackets at the rear of the sub-frame. Tighten to 37 ft. lbs. (50 Nm).
  24.  
  25. Install:

    The bolt for the cable and air duct
     
    The oil pipe for the steering gear in the snap fasteners along the sub-frame
     
    The hose for the EVAP canister in the clip on the upper side of the sub-frame
     
    The engine block heater and the fuel line to the engine block heater if applicable
     
    The air duct in the clips
     
    The bolt for the ground cable bracket
     
    The connectors for the heated oxygen sensors in the clips at the rear of the sub-frame
     

  26.  
  27. Slacken off the retaining straps for the spring strut. Thread the halfshaft into the wheel spindle.
  28.  
  29. Carefullyrelease the retaining strap for trailing arms. At the same time guide the lower ball joints into the trailing arms.
  30.  
  31. Install new nuts on the ball joints. Tighten to 58 ft. lbs. (80 Nm).
  32.  
  33. Counterhold using a Torx wrench so that the ball joint boot is not damaged.
  34.  
  35. Install the anti-roll bar links. Use new nuts. Tighten to 37 ft. lbs. (50 Nm).
  36.  
  37. Counterhold using a Torx wrench so that the boot is not damaged.
  38.  
  39. Install:

    The bolt and nuts for the steering gear. Use new nuts and new bolts. Tighten to 37 ft. lbs. (50 Nm)
     
    The front engine pad. Tighten to 37 ft. lbs. (50 Nm)
     
    The torque rod. Tighten the bolts through the oil pan. Tighten to 37 ft. lbs. (50 Nm). Tighten the nuts in the sub-frame. Tighten to 47 ft. lbs. (65 Nm)
     
    The center bolt for the halfshaft. Use a new bolt. Counterhold using a prybar in the brake disc vents. Tighten to 37 ft. lbs. (50 Nm)
     
    The front air baffle
     
    The front wheel
     
    The lifting beam
     
    The lifting hooks
     
    The lifting fixture from the engine. Install the bolts in the engine mounting
     
    The cover over the ignition coils
     
    The oil dipstick and pipe. Use a new O-ring. Check that the O-ring is correctly positioned
     
    The plastic pipes. Tighten the hose clamps
     
    The bolts 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
     

  40.  
  41. Fill with new engine oil.
  42.  
  43. Start the engine and check for oil leakage.
  44.  
  45. Stop the engine. Give the oil time to run down into the oil pan. Then check the oil level.
  46.  
  47. Top up if necessary but do not overfill.
  48.  
  49. Wipe the engine compartment clean.
  50.  
  51. Install the lower engine cover.
  52.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the oil dipstick and pipe.
  4.  
  5. Remove:

    The connector and hose from the crankcase ventilation terminal in the plastic intake pipe
     
    The hose from the plastic charge air pipe
     
    The bolts 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
     
    The cover over the ignition coils
     
    The 2 bolts at the engine mounting
     

  6.  
  7. Install fixture 999 5717.
    NOTE
    Position the stand for lifting beam 999 5716 on the upper wheel arch members.

  8.  
  9. Then position the lifting beam directly above the engine lifting eyes on both sides.
  10.  
  11. Connect to the hole nearest the firewall. Connect lifting hook 999 5460.

    Click image to see an enlarged view

    Fig. Tensioning the trailing arms

    Tensioning the trailing arms

    Click image to see an enlarged view

    Fig. 6-cylinder oil pan

    6-cylinder oil pan
  12.  
  13. Tighten to light contact.
  14.  
  15. Remove:

    The lower engine cover
     
    The front air baffle
     

  16.  
  17. Drain the engine oil. Remove the oil filter.
  18.  
  19. Remove:

    The front wheel
     
    The nuts for the lower ball joints
     
    The anti-roll bar links from the anti-roll bar
     
    The center bolt for the right-hand halfshaft
     
    The bolt and nuts for the steering gear
     
    The bolt for the front engine mounting
     
    The torque rod including the mounting in the sub-frame
     

  20.  
  21. Tension the trailing arms together to release the spindles. Use a retaining strap.
  22.  
  23. Unhook the right halfshaft from the steering knuckle. Tension the spring strut backwards. Use a retaining strap.
  24.  
  25. Remove the bolt for the cable duct.
  26.  
  27. Remove:

    The oil pipe for the steering gear from the snap fasteners along the sub-frame
     
    The hose for the EVAP canister in the clips on the upper side of the sub-frame
     
    any fuel line for the engine block heater and any engine block heater if mounted on the left-hand side of the sub-frame
     
    The air duct from the clip
     
    The bolt for the ground cable bracket
     
    The connectors for the heated oxygen sensors in the clips at the rear of the sub-frame
     

  28.  
  29. Slacken off the sub-frame bolts. Lower the sub-frame slightly.
  30.  
  31. Remove the heated oxygen sensor bracket on the reverse of the sub-frame.
  32.  
  33. Unbolt the bolts for the sub-frame approximately 1 inch (3cm) on the right-hand side.
  34.  
  35. Fully remove the bolts on the left-hand side.
  36.  
  37. Angle the sub-frame down on the left-hand side.
  38.  
  39. Ensure that the bolts for the steering gear release from the frame.
  40.  
  41. Disconnect the oil cooler from the oil pan. Hang the oil cooler from a suitable place.
  42.  
  43. Remove the bolt from the bracket for the fuel line.
  44.  
  45. Remove the bolt for the bracket for the fuel line on the auxiliary bracket.
  46.  
  47. Slacken off all the bolts holding the oil pan.
  48.  
  49. Remove all but four bolts. It is recommended that the four bolts in the corners of the pan are left in place.
  50.  
  51. Carefully tap the pan using a rubber mallet until the joint and its liquid gasket releases.
  52.  
  53. Remove:

    The four remaining bolts
     
    The oil pan
     

  54.  
  55. Clean the gasket surfaces on the oil pan and cylinder block.
    WARNING
    Use a fume hood or extractor when using gasket solvent. Note! Also clean the gasket faces for the bolts for the torque rod.

  56.  
  57. Apply liquid gasket 116 1059-9 to the oil pan. Note! Also apply liquid gasket around the holes for the bolts for the torque rod.
  58.  

To install:

  1. Install:

    new O-rings
     
    The oil pan. Secure the oil pan loosely using a few bolts
     
    The remaining bolts loosely
     

  2.  
  3. Press the oil pan against the transaxle. Tighten the bolts (1), (2), (3) and (4). Tighten to 27 inch lbs. (3 Nm).
  4.  
  5. Tighten the bolts 5. First tighten to 18 ft. lbs. (25 Nm). Then tighten to 35 ft. lbs. (48 Nm).
  6.  
  7. Tighten all bolts in the oil pan flange. Tighten to 12 ft. lbs. (17 Nm). Start at the transaxle and continue forwards in pairs.
  8.  
  9. Connect the oil cooler to the oil pan. Use new O-rings.
  10.  
  11. Install the bolt for the bracket for the fuel line.
  12.  
  13. Install:

    A new oil filter
     
    The oil plug with a new gasket
     

  14.  
  15. Lift the sub-frame. Use a mobile jack.
  16.  
  17. Install:

    The bracket for the heated oxygen sensors in the rear edge of the sub-frame
     
    New bolt in the sub-frame. Lubricate the bolts
     
    The washers at the front edge and the support plates at the rear edge of the sub-frame.
     

  18.  
  19. Tighten the bolts for the sub-frame. Tighten to 77 ft. lbs. (105 Nm). Angle-tighten 120°.
  20.  
  21. Start on the left-hand side of the sub-frame. Continue with the right-hand side.
  22.  
  23. Tighten the bolts for the brackets at the rear of the sub-frame. Tighten to 37 ft. lbs. (50 Nm).
  24.  
  25. Install:

    The bolt for the cable and air duct
     
    The oil pipe for the steering gear in the snap fasteners along the sub-frame
     
    The hose for the EVAP canister in the clip on the upper side of the sub-frame
     
    The engine block heater and the fuel line to the engine block heater if applicable
     
    The air duct in the clips
     
    The bolt for the ground cable bracket
     
    The connectors for the heated oxygen sensors in the clips at the rear of the sub-frame
     

  26.  
  27. Slacken off the retaining straps for the spring strut. Thread the halfshaft into the steering knuckle.
  28.  
  29. Carefully release the retaining strap for trailing arms. At the same time guide the lower ball joints into the trailing arms.
  30.  
  31. Install new nuts on the ball joints. Tighten to 59 ft. lbs. (80 Nm).
  32.  
  33. Counterhold using a Torx wrench so that the ball joint boot is not damaged.
  34.  
  35. Install the anti-roll bar links. Use new nuts. Tighten to 37 ft. lbs. (50 Nm).
  36.  
  37. Counterhold using a Torx wrench so that the boot is not damaged.
  38.  
  39. Install:

    The bolt and nuts for the steering gear. Use new nuts and new bolts. Tighten to 37 ft. lbs. (50 Nm)
     
    The front engine pad. Tighten to 37 ft. lbs. (50 Nm)
     
    The torque rod. Tighten the bolts through the oil pan. Tighten to 37 ft. lbs. (50 Nm). Tighten the nuts in the sub-frame. Tighten to 48 ft. lbs. (65 Nm)
     
    The center bolt for the halfshaft. Use a new bolt. Counterhold using a prybar in the brake disc vents. Tighten to 37 ft. lbs. (50 Nm)
     
    The front air baffle
     
    The front wheel
     
    The lifting beam
     
    The lifting hooks
     
    The lifting fixture from the engine. Install the bolts in the engine mounting
     
    The cover over the ignition coils
     
    The oil dipstick and pipe. Use a new O-ring. Check that the O-ring is correctly positioned
     
    The plastic pipes. Tighten the hose clamps
     
    The bolts 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
     

  40.  
  41. Fill with new engine oil.
  42.  
  43. Start the engine and check for oil leakage.
  44.  
  45. Stop the engine. Give the oil time to run down into the oil pan. Then check the oil level.
  46.  
  47. Top up if necessary but do not overfill.
  48.  
  49. Wipe the engine compartment clean.
  50.  
  51. Install the lower engine cover.
  52.  

8-Cylinder Engines
  1. Drain the engine oil, remove the oil filter.
  2.  
  3. Remove the exhaust manifolds.
  4.  
  5. Remove the right-hand engine mounting.

    Click image to see an enlarged view

    Fig. Right side engine mount-V8

    Right side engine mount-V8

    Click image to see an enlarged view

    Fig. M10 bracket bolt-V8

    M10 bracket bolt-V8
  6.  
  7. Remove the 1 M10 bolts for the bracket.
  8.  
  9. Remove the 4 M10 bolts for the transaxle.

    Click image to see an enlarged view

    Fig. Transaxle bolts-V8

    Transaxle bolts-V8

    Click image to see an enlarged view

    Fig. Oil cooler-V8

    Oil cooler-V8
  10.  
  11. Remove the oil cooler. Discard the O-ring.

    Click image to see an enlarged view

    Fig. Oil pan bolts-V8

    Oil pan bolts-V8

    Click image to see an enlarged view

    Fig. Intermediate section bolts-V8

    Intermediate section bolts-V8
  12.  
  13. Remove the 20 M6 bolts.
  14.  
  15. Remove the oil level sensor.
  16.  
  17. Remove the 17 x M8 bolts and the 1 x M6 bolt securing the intermediate section.
  18.  
  19. Carefully tap the side of the oil pan using a rubber mallet. Lift out the oil pan.
  20.  
  21. Discard the O-rings.
  22.  

To install:

Click image to see an enlarged view

Fig. Liquid gasket application-V8

Liquid gasket application-V8


NOTE
Clean the surface, using a razor blade or plastic scraper.

  1. Apply liquid gasket 307 57050 as illustrated.
    NOTE
    Minimum 0.039 inch (1mm) bead width.


    NOTE

  2.  
  3. Install the oil pan within 5 minutes (curing time for liquid gasket).
  4.  
  5. Install the oil pan, use new O-rings
  6.  
  7. Install the 17 x M8 bolts.
  8.  
  9. Install the bolt securing the intermediate section.
    NOTE
    Clean the surface, using a razor blade or plastic scraper.

  10.  
  11. Apply liquid gasket 307 57050 as illustrated.
    NOTE
    Minimum 0.039 inch (1mm) bead width.


    NOTE

  12.  
  13. Install the oil pan within 5 minutes (cure time for liquid gasket)
  14.  
  15. Install the 20 M6 bolts.
  16.  
  17. Install the oil level sensor.
  18.  
  19. Install the oil filter, using a new O-ring.
  20.  
  21. Install the oil cooler. Use new O-ring
  22.  
  23. The remainder of installation is the reverse of removal.
  24.  
  25. Top up oil.
  26.  

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the oil dipstick and its pipe.
  4.  
  5. Remove the splashguard under the engine.
  6.  
  7. Drain the engine oil and remove the oil filter.
  8.  
  9. Release the oil cooler from the oil pan. Hang up at the rear.
  10.  
  11. Remove the bolt from the bracket for the fuel line.
  12.  
  13. Removing the oil pan
  14.  
  15. Back off all bolts holding the oil pan.
  16.  
  17. Remove all bolts except for four. It is recommended that the four bolts in the corners of the oil pan are left in place.
  18.  
  19. Carefully tap the oil pan with a rubber mallet until the joint and its liquid gasket releases.
  20.  
  21. Remove the four remaining bolts.
  22.  
  23. Remove the oil pan.
  24.  

To install:

  1. Apply liquid gasket 1161 059-9, or equivalent, to the oil pan.
  2.  
  3. Install new O-rings.
  4.  
  5. Position the oil pan. Secure it loosely with a few bolts.
  6.  
  7. Install the remaining bolts loosely.
  8.  
  9. Press the oil pan against the transaxle. Tighten bolts 1, 2, 3 and 4 to 27 inch lbs. (3 Nm). Tighten bolt 5 to 18 ft. lbs. (25 Nm); then tighten to 35 ft. lbs. (48 Nm).
  10.  
  11. Tighten all bolts in the oil pan flange to 12 ft. lbs. (17 Nm). Start at the transaxle end and continue forwards in pairs.

    Click image to see an enlarged view

    Fig. 5-cylinder oil pan

    5-cylinder oil pan
  12.  
  13. Install the bolt for the bracket for the fuel line.
  14.  
  15. Connect the oil cooler to the oil pan. Use new O-rings. Reinstall the pipe on the sub-frame.
  16.  
  17. Install a new oil filter.
  18.  
  19. Install the oil drain plug with a new gasket.
  20.  
  21. Install the oil dipstick and its pipe. Use a new O-ring.
    NOTE
    Check that the O-ring is correctly positioned.

  22.  
  23. Fill with engine oil. Run the engine to operating temperature.
  24.  
  25. Check for oil leaks from the oil pan or oil cooler.
  26.  
  27. Install the splashguard under the engine.
  28.  
  29. Check the oil level. Top up if required.
  30.  

 
label.common.footer.alt.autozoneLogo