D4 260 2007 Heat exchangers, Charge Air coolers. Problem

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Dog's dinner

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About 18 months ago our heat exchangers and air coolers started leaking salt water around their end caps etc. We had them removed stripped cleaned with Rydlyme and reassembled with new O rings and some type of Volvo sealant as recommended by volvo parts dept. Managed to clean up the starter motors.
Luckily the heat exchanges seem fine but disappointingly the end caps inlet end on the air coolers have started to show white deposits around the joint again.
These are the original end caps part 3583628 which is some type of bakelite material.
I have read Spannermans Post 2012.. Well known fault replacement cover made in brass..
I have found pictures of brass ones in America but no part number.
But the local volvo dealer showed me the new ones part 22092538 which are the same as ours a bakelite type material.
Question : Shall I clean and put the original end caps back on or shall I buy the new type end caps and what has happened to the metal ones referred to on this forum.
Has any one fitted the metal or new type ones ?
 
The metal ones did a better job but sadly the difference in metals is the cause and obviously the design company that make them . Looking at the older engines 41 and 63/74 series they don’t leak like the D range motor.
Sadly a great base unit letdown by bolting a pile of crap to it.
I can only think that it’s the aftersales parts supply that’s propping up Sweden’s migrants .
 
I have a 2006 d4 260, and had the new end caps fitted last year - they're leaking again now.....

So i'd say you'll be better off just reusing what your existing end caps and stripping and cleaning them up.
 
I didnt do the work, it was done by the chap that services the engine for me, so i dont know im afraid.
 
Dog's dinner said:
Thanks for your reply Volvopaul do you have any suggestions as to how to cure the problem ?
Click to expand...

Sadly there isn’t one.
Volvo did after a few owners got together and drew up some kind of law suit based on the 6 year EU law warranty , provide a repair at there cost , I’ve not heard of anyone since getting any recompense on the failure of the integrity of coolers not leaking.
 
Hi Volvopaul,
Why / how is it the salt water leaks past the O ring ?
It there too much water pressure in that area, or do they get hot. ?
 
Can anyone tell me if there is much pressure in the Charge Air cooler.
I have noticed there is a drain plug tap in the rear facing end cap next to the pencil anode.
I am wondering if its feasible to leave the drain plug open and permanently attach a hose to it with an in-line tap in the hose at an accessible place.
So every time I use the boat I can drain down the Air cooler therefore stopping it scaling up.
Any one with thoughts on this ?
 
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