Changing Oil Pan: Volvo S40 2.4 (2006) Guide

Changing the oil pan on a 2006 Volvo S40 2.4 can be a tricky task. The oil pan is located at the bottom of the vehicle, which makes it difficult to check for oil leaks. However, there are some signs that can indicate a problem with the oil pan, such as oil spots under the vehicle, a sudden drop in oil level, an overheated engine, or black smoke coming from the engine. If you suspect that your oil pan needs to be replaced, it is best to consult a professional mechanic. The average cost for an engine oil pan replacement on a Volvo S40 is around $1000, but this can vary depending on the location and severity of the damage.

Drain the coolant and oil

To drain the coolant, you will need to locate the drain point on the radiator. This could be a butterfly nut on the left-hand side of the radiator, or a drain valve at the bottom of the radiator. If you cannot locate the drain valve, you can instead undo the lower hose where it joins the radiator.

To drain the oil, you will need to locate the oil drain plug. This can be found on the backside of the engine, after removing the splash shield. Position a drain pan under the plug and remove the plug with a 17mm wrench.

Drain the coolant:

• Open the hood of your Volvo S40 and prop it open.
• Locate the coolant reservoir and clean it.
• Remove the coolant from the reservoir.
• Locate the drain point on the radiator, as mentioned above.
• Drain the coolant from the system.
• Run the engine with distilled water and flush.

Drain the oil:

• Jack up your car and remove the splash shield from the bottom of the car using a Phillips-head screwdriver.
• Locate the oil drain plug, as mentioned above.
• Position a drain pan under the plug and remove it with a 17mm wrench.
• Allow the oil to drain completely.
• Install a new crush washer and drain plug. Tighten the plug, but be careful not to use excessive force as the oil pan is made of aluminum and can crack.

Remove the subframe and cross member

To remove the subframe and cross member of a 2006 Volvo S40 2.4, follow these steps:

Firstly, it is important to understand the difference between a cross member and a subframe. Cross members are structural beams within a frame, while subframes are auxiliary frames attached to the main car body. Cross members provide structural support across the frame, often connecting the sides of the main frame and strengthening the chassis. Subframes, on the other hand, are designed to hold major components such as the engine or suspension.

Now, to begin the removal process, locate the subframe and cross member under the vehicle. They are typically found attached beneath the main body of the car. Place jack stands behind the rear subframe attaching bolts and plates. This will help keep the rear down and prevent the car from teeter-tottering on the stands.

Next, loosen the front subframe bolts to allow the forward attaching points some "give" so that the rear can be dropped. You may need to pile heavy items in the trunk to further stabilize the car and ensure it doesn't move during the process.

Once the car is securely in place, you can begin to remove the subframe and cross member. Start by detaching any connected components, such as suspension or powertrain mounts. Be sure to support the engine and transmission during this process to avoid placing strain on these components.

After all the connections have been detached, you can carefully lower the subframe and cross member using a floor jack. Take your time and be gentle to avoid damaging any surrounding components.

Finally, inspect the removed subframe and cross member for any damage or wear. If they are in good condition, you can set them aside for reinstallation. If they require repair or replacement, take the necessary steps before proceeding further with your oil pan change.

Loosen and remove oil pan bolts

To loosen and remove the oil pan bolts of a 2006 Volvo S40 2.4, you'll need to follow a specific process and sequence. Here's a detailed guide:

First, it's important to understand the different bolt lengths and locations. There are two 90mm bolts, two 100mm bolts, and three 40mm bolts. The 90mm and 100mm bolts are located on the outside and inside, respectively, while the 40mm bolts are shorter and located in specific positions.

Before removing any bolts, loosen them all. This will help ensure that you don't overtighten any bolts, which can crack the oil pan. Leave one bolt tightened in each corner to maintain the oil pan's position.

Now, you can start removing the bolts. Remove all the bolts except for the ones in each corner that you left tightened earlier. Once these are removed, use a rubber mallet to gently hit the oil pan and loosen it further.

At this point, you can remove the remaining four bolts in the corners. The oil pan will then be free to drop down. Be careful, as you'll need to angle it slightly towards the transmission to clear the oil pickup.

It's crucial to work with clean surfaces. Clean both the oil pan and the mating surface on the block to ensure a proper seal when you reinstall the pan.

When reinstalling the oil pan, follow the correct torque specifications and sequence. Start by inserting the four corner bolts and finger-tightening them to ensure contact between the oil pan and the block. Then, tighten the longer bolts to the specified torque values.

The torque values for the oil pan bolts are as follows:

• 90mm bolts: 25 Nm, then 48 Nm
• 100mm bolts: 17 Nm
• 40mm bolts: 17 Nm

Remember to apply thread sealer to the longer bolts (90mm, 100mm, and 40mm) before tightening them. This will help create a tight seal and prevent leaks.

By following these steps and torque specifications, you'll be able to successfully loosen and remove the oil pan bolts on your 2006 Volvo S40 2.4.

Clean the engine block surface

To clean the engine block surface of your 2006 Volvo S40 2.4, you'll need to remove any remaining gasket material and ensure the surface is smooth and free of debris. Here's a step-by-step guide:

• Remove Gasket Material: Use a gasket scraper, razor blade, or plastic scraper to carefully remove any remaining gasket material from the engine block surface. Be gentle to avoid scratching the surface.
• Clean the Surface: Apply a chemical gasket remover or a solvent like brake cleaner, carb cleaner, lacquer thinner, or acetone to a clean rag and wipe down the engine block surface. This will help remove any residual oil, grease, or grime. You can also use compressed air to blow away any loose debris.
• Smooth the Surface: If there are any bumps or uneven areas on the engine block surface, use a fine-grit sandpaper or a Scotch-Brite surface conditioning disc to gently smooth out the surface. Work in a circular motion and be careful not to create any deep scratches or gouges.
• Final Wipe-Down: Once the surface is smooth and clean, give it a final wipe with a clean microfiber cloth to remove any remaining dust or residue. You can also use mineral spirits or mineral turpentine for this step.
• Protect the Cylinders: Before proceeding, protect the cylinders, valves, and other sensitive components by stuffing clean rags into the cylinders and covering the valves.

Remember to wear gloves and eye protection during the cleaning process, as some chemicals can be harsh on the skin and eyes. Additionally, always refer to your vehicle's repair manual for specific instructions and safety precautions.

Install a new oil pan gasket

To install a new oil pan gasket, you'll need to first lift your Volvo S40 using a floor jack with the correct lifting capacity. Place a drain pan underneath the vehicle, then gently undo the oil filter and oil drain plug, allowing the old oil to drain out.

You may need to remove the air conditioning bracketry and the exhaust manifold to access the oil pan. Once you've located the oil pan bolt, gently remove it, being careful not to damage the oil pick-up inside the oil pan.

You can now remove the engine mount, oil pan, and old gasket. Wipe clean the lower engine block, oil pan, and engine mount, and let them dry for a few minutes. Once dry, apply a thin film of RTV (a type of silicone rubber) to the mounting surface.

Position the new oil pan gasket correctly against the mounting surface and apply pressure. Take a few strands of wire, about 3-4 inches long, peel off the insulation, and twist them loosely around the new gasket to keep it in place. Install the pan bolt, then untwist the wire strands.

Refer to the manufacturer's specifications and torque the oil pan bolt accordingly. Some engines require you to torque the oil pan bolt identically, while others may need you to torque the rear bolt differently from the front bolt.

Finally, reinstall the oil filter, oil drain plug, and other parts. Refill the engine with new oil, ensuring there are no leaks. Lower the vehicle, start the engine, and let it run for a few minutes.

Turn off the engine and wait a few minutes before re-checking the oil level. Once checked, start the vehicle again and let it warm up, then take it for a short drive to ensure there are no signs of an oil leak.

Frequently asked questions