3889640 Volvo.Penta Charge air cooler

3. Remove bolt (2) that holds the hose clip to the oil cooler.4. Disconnect sump pump oil line (1) from the check valve. 5. Disconnect hose (3) from the gauge panel. Remove bolt (4) that holds the clip for hose (3) to the oil line elbow.6. Remove the bolts and retainers that hold tube (5) to elbow (6).7. Remove the bolts, and remove elbow (6) from the oil cooler. 8. Remove the four bolts to disconnect flange (7) and tube (8) from the water line adapter.9. Remove the bolts to disconnect the oil cooler from bracket (9). Steps 10 and 11 are for the 3512 Engine. 10. Remove the bolts to remove elbow (10) and the tube as a unit from oil cooler bonnet (11).11. Fasten a hoist to oil cooler (13). Remove the two bolts from oil cooler bonnet (11), and pull oil cooler (13) from oil tube (12). Remove the cooler from the engine. The weight of the oil cooler used on 3512 Engines is 65 kg (143 lb.). Step 12 is for the 3508 Engines. 12. Fasten a hoist to oil cooler (15). Remove the four bolts from oil cooler bonnet (16), and pull oil cooler (15) from oil tube (14). Remove the cooler from the engine. The weight of the oil cooler used on 3508 Engines is 50 kg (110 lb.). The weight of the oil cooler used on 3516 Engines is 78 kg (171 lb.).Install Oil Cooler
Step 1 is for the 3508 Engines. 1. Put clean engine oil on the O-ring seal on oil tube (2). Fasten a hoist to oil cooler (3), and put oil cooler (3) in position on oil tube (2). Make sure the gasket is in place for oil cooler bonnet (1), and install the four bolts to hold the oil cooler in position. Steps 2 and 3 are for the 3512 Engines. 2. Put clean engine oil on the O-ring seal on oil tube (5). Fasten a hoist to oil cooler (6), and put oil cooler (6) in position on oil tube (5). Install the two bolts in oil cooler bonnet (4) to hold the oil cooler in position. 3. Put clean engine oil on the O-ring seal on tube (7). Put elbow (8) on tube (7), and install the tube and elbow as a unit in oil cooler bonnet (4). Make sure the gasket is in place for elbow (8), and install the bolts to hold the elbow to the engine. 4. Install the bolts that hold the oil cooler to bracket (9). 5. Make sure the gasket is in place, and inltall the bolts to hold flange (11) and tube (10) to the water line adapter. 6. Install the ring and O-ring seal on oil line (15). Install the O-ring seal on elbow (14). Put clean engine oil on the O-ring seals.7. Install elbow (14) on the oil cooler. Install the bolts and retainers to hold oil line (15) and the ring in elbow (14).8. Connect hose (12) to the gauge panel, and install bolt (13) to hold the hose clip in position. 9. Install bolt (17) to hold the oil line clip to the oil cooler.10. Connect oil sump pump oil line (16) to the check valve.11. Fill the cooling system with coolant to the correct level. See the Maintenance Manual.12. Fill the engine with oil to the correct level. See the Maintenance Manual.Disassemble Oil Cooler
Start By:a. remove oil cooler 1. Remove the bolts from elbow (1), and remove elbow (1) and tube (2) as a unit from the oil cooler. 2. Remove tube (2) from elbow (1), and remove the O-ring seals from tube (2) and elbow (1). 3. Put alignment marks on bonnet (3) and core assembly (4) for correct alignment at assembly. Remove bonnet (3) from core assembly (4). 4. Remove flange (7) and tube (6) as a unit from bonnet (5). Remove the O-ring seals from tube (6). 5. Remove the bolts, and remove elbow (8) from core assembly (4). 6. Remove the bolts, and remove cover (9) from elbow (8). Remove the O-ring seal from cover (9). 7. Remove spring (10) and plunger (11) from elbow (8). 8. Remove the bolts to remove cover (13), and remove O-ring seals (12) from elbow (8). 9. Put alignment marks on bonnet (5) and core assembly (4) for correct alignment at assembly. Remove bonnet (5) from core assembly (4).Assemble Oil Cooler
1. Make sure the tubes in core assembly (1) are clean and free of dirt and foreign material. 2. Put the gasket and bonnet (2) in position on core assembly (1), and install the bolts. 3. Install O-ring seals (4) on elbow (3), and put clean engine oil on the seals. Install cover (5) on elbow (3). 4. Put plunger (7) and spring (8) in position in elbow (3). Install the O-ring seal in cover (6), and put clean engine oil on it. Install cover (6) on elbow (3). 5. Put elbow (3) in position on the core assembly, and install the bolts. 6. Install the O-ring seals on tube (9), and put clean engine oil on the seals. Install tube (9) and flange (10) as a unit in bonnet (2). 7. Put the gasket and bonnet (11) in position on core assembly (1), and install the bolts. 8. Install the O-ring seals on tube (13), and put clean engine oil on the seals. Install tube (13) in elbow (12). 9. Install the O-ring seal on elbow (12), and put clean engine oil on it. Put elbow (12) and tube (13) as a unit in position, and install the bolts in elbow (12) to hold the elbow and the tube in position.End By:a. install oil cooler