V40 1.9 oil pan - sump replacement

[jgillmor]

Hi there, My wife did it again and tore a 4 cm hole in sump of 2002 TD. I've removed all 20 wee 'star' head bolts, and the two large (14mm ?) going horizontally into the rising, pasanger side of the sump. I tried to be gentle, but ended up prising the sump down by approx 2 cm on driver side with (gentle!) chisel... but passanger side of sump not coming away. Is there a bolt I missed, or is it just the old gasket that I have been unable to cut or force apart ?

Any tips on completing the replacement, and other jobs I should consider (I will keep the day job !!) when the sump is off. Thanks a million - great site !!

[billofdurham]

Welcome to Matthew's Volvo Site.

You have removed 20 torx screws. The Volvo parts list says there are 21 and the attached diagram for removing the sump has 22. However, the diagram also shows 4 other bolts holding it in on the gearbox side. So you have 2 more to find.

V40 sump removal.pdf

(227.05 KiB) Downloaded 445 times

The diagram refers to bolts A and B and did have a guide as to which they are but my printer cut it off. The heavy arrows are A and the light arrows are B.

I can't think of anything else you should tackle with the sump off, unless you are having problems with oil circulation apart, that is, from having no oil to circulate due to a hole in the sump. I am a great believer in the saying, "If it isn't broke, don't mend it."

Good luck and keep us updated.

Bill.

[jgillmor]

Good man Bill - very grateful for diagram... I had actually missed the four screws under the engine mount.. easy when you know how !! Replaced sump with old one (€160 versus €550 new) and used small amount of sealent below and above rubber seal, and a skim on the block. No leaks so far, and the missus thinks I can fix cars.. again!! I was nervous about working under proped car and jacked engine, but it all turned out very stable.

Great site and thanks again!

[billofdurham]

You are welcome. Thank you for the update.

Bill.