888773 Volvo.Penta Charge air pipe

Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Engine Oil Cooler
A. Drain the engine lubricating oil and coolant from the engine.
B. Inspect the oil cooler for signs of damage or leaks. Refer to Systems Operation, Testing and Adjusting, Engine Oil Cooler - Inspect for more information.
Oil cooler
Result: There is evidence of leaks from the oil cooler or damage to the oil cooler.
Repair: Install a new oil cooler. Refer to Disassembly and Assembly, "Engine Oil Cooler - Remove" and Disassembly and Assembly, "Engine Oil Cooler - Install" for the correct procedure.
Refill the engine oil and coolant. Refer to Operation and Maintenance Manual for the correct procedure.
Result: There is no evidence of damage or leaks.
Proceed to Test Step 2.
2. Engine Water Pump
A. Inspect the water pump for signs of damage or leaks. Refer to Systems Operation, Testing and Adjusting, Water Pump - Inspect for more information.
Water pump
Result: There is evidence of leaks from the water pump or damage to the water pump.
Repair: Install a new water pump. Refer to Disassembly and Assembly, "Water Pump - Remove" and Disassembly and Assembly, "Water Pump - Install" for the correct procedure.
Refill the engine oil and coolant. Refer to Operation and Maintenance Manual for the correct procedure.
Result: There is no evidence of damage or leaks.
Proceed to Test Step 3.
3. Cylinder Head and Gasket
A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove" for the correct procedure. Inspect the cylinder head gasket for faults and any signs of leakage.
B. Check the cylinder head for flatness. Refer to Systems Operation, Testing and Adjusting, "Cylinder Head - Inspect" for the correct procedure.
C. Check the mating face of the cylinder head for faults and signs of leakage. If a fault is found, replace the cylinder head. If signs of leakage are found, determine the cause of the leakage. Refer to Systems Operation, Testing and Adjusting, "Cylinder Head - Inspect" for the correct procedure.
D. Check the internal core plugs in the cylinder head for signs of leakage.
Cylinder head and gasket
Result: The cylinder head gasket is faulty or shows signs of leakage.
Repair: Check for faults in the corresponding areas of the cylinder head and cylinder block.
Result: The cylinder head is not within specification for flatness.
Repair: Install a new cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install" for the correct procedure.
Result: The cylinder head shows signs of a fault or leakage.
Repair: Install a new cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install" for the correct procedure.
Result: An internal core plug in the cylinder head shows signs of leakage.
Repair: Replace the faulty core plug.
Result: The cylinder head is OK.
Proceed to Test Step 4.
4. Cylinder Block
A. Inspect the top face of the cylinder block for faults and signs of leakage.
Cylinder block
Result: The top face of the cylinder block has a fault.
Repair: Replace the cylinder block.
Result: The top face of the cylinder block shows signs of leakage.
Repair: Determine the cause of the leakage. Refer to Systems Operation, Testing and Adjusting, "Cylinder Block - Inspect" for the correct procedure.
Result: The cylinder block is OK.
Repair: Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".
Remove the oil filter element. Install a new engine oil filter element. Fill the engine with clean engine oil to the correct level. Refer to the Operation and Maintenance Manual, "Engine Oil and Filter - Change" for more information.
Fill the cooling system. Refer to the Operation and Maintenance Manual for more information.
If coolant is found in the oil again, contact the Dealer Solutions Network (DSN).