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Oil Pan o-rings - replacement procedure

Old 04-29-2005, 06:04 PM
Thread Starter
Join Date: Jan 2005
Posts: 13
Default Oil Pan o-rings - replacement procedure

Hi there,

I am pretty sure that lot of people would like to know detailed procedure on how to replace oil pan o-rings on S80 as it looks like they are source of many problems that people posted on this forum.

Please include all parts needed, tools and step-by-step procedure. If it is too much, please refer to proper link, or maybe if you can attach a scanned image from a tech book or similar...

Thank you very much,


p.s. it would cost me around $650 CDN if I would go to dealer....
Old 04-29-2005, 09:52 PM
tech's Avatar
Join Date: Sep 2004
Location: Orlando, Florida
Posts: 36,351
Default RE: Oil Pan o-rings - replacement procedure

These are Volvo instructions.
The oil dipstick and its pipe.
The splashguard under the engine.

Drain the oil and remove the oil filter.
Release the oil cooler from the sump.Hang up at the rear.
Remove the screw from the bracket for the fuel line.

Removing the oil sump(oil pan)

Slacken off all screwsholding the oil sump.
Remove all screws except fro four.
It is reccommended that four screws in the corners of the sump are left in place
Carefully tap the sump with a rubber mallet until the joint and its liquid gasket releases.
Remove the remaining screws.
Remove the sump.


Clean the gasket surfaces on the oil sump and cylinder block.
Use a razor blade or a gasket scraper and gasket solvent P/N 1161440

Warning Use a fume hood or extractor when using gasket solvent.(Fan if inside a garage)

Installing the oil pan

Apply liquid gasket P/N 1161 059-9 to the sump use roller P/N 951 2767 (Or mini roller from hardware store)

Install new o-rings
The oil sump.
Secure it loosely with a few screws.
Then the remaining screws.

Press the pump against the transmission
Tighten the screws (1),(2),(3) and (4) to 3Nm.

First tighten the screws (5) to 25Nm.
Then tighten to 48 Nm.
Tighten all screws in the sump joint to 17 Nm.
Start at the transmisson and continue fowards in pairs.
Install the screw for the bracket for the fuel line.
Connect the oil cooler to the sump.
Use new o-rings.
Reinstall the pipe to the subframe.

A new oil filter
The oil drain plug with a new o-ring
The dipstick and its pipe also use a new o-ring.

Note: check that all the o-rings are positions are correctly.

Fill the engine oil.
Run the engine to operating temp.
Check for oil leaks from the sump or the oil cooler.
Install the splash sheild under the engine.
Check the oil level.Top it off if needed.

Some more notes:
You may have to support the Right side of the engine and drop the subframe a little to get the pan out.

Have someone help you when installing the pan and watch the o-rings to make sure they do not fall while installing the pan.

Make sure when the pan is off you remove the pipe in the oil pan and replace those o-rings at the same time when you have it apart.

Also make sure you remove the oil pick up tube and replace that o-ring.

I think that is about all.
If there is anymore quiestions feel free to ask.

Sorry but I don't have part #'s for the o-ring kit they sell it as a kit that gives you all o-rings.



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