Transmission Cooler: Service and Repair
Auxiliary oil cooler, installation
Special tools:
998 5972 JACK 998 5972 Jack
999 5972 FIXTURE 999 5972 Fixture
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.
Note! When driving longer distances at high speeds, the vehicle must be equipped with an auxiliary oil cooler for the automatic transmission oil.
Note! Vehicle in high speed markets and countries with hot climates are equipped with the auxiliary oil cooler as standard.
Installation
Components included for the installation of an auxiliary oil cooler
Components for the installation of an auxiliary oil cooler:
1 Cooler, P/N 3063 6905, x 1.
2 Inlet hose, P/N 3063 6906, x 1.
3 Return hose, P/N 3063 6907, x 1.
4 Mounting lower, P/N 3063 6908, x 1.
5 Mounting upper, P/N 3068 0112, x 1.
6 Screw M6x10, P/N 969 419, x 1.
7 Screw M6x12, P/N 979 615, x 2.
8 Screw M14x100, P/N 981 062, x 1.
9 Screw M6x20, P/N 980 960, x 1.
10 Screw M8x25, P/N 981 024, x 1.
11 Washer 6.4x18x2, P/N 960 139, x 2.
Transmission oil, P/N 116 1540 (1 liter container), 116 1640 (4 liter container), 220 ml is used during installation. The packaging is not shown in the illustration.
Cover left-hand side, P/N 3067 8288 (not shown in the illustration).
Cover right-hand side, P/N 3067 8289 (not shown in the illustration).
Preparatory work
Disconnecting the battery lead
Position the car on a hoist.
Disconnect the battery negative lead. See: Battery, disconnecting Battery Disconnecting.
Move the gear selector to position 1.
Removing the air cleaner (ACL)
Remove:
- the cover at the side of the air cleaner (ACL)
- the fresh air intake hose
- the air cleaner (ACL).
Removing the front bumper
Remove the front bumper. See: Bumper front, replacing Service and Repair.
Installation
Installing the mounting for the cooler
Install:
- the mounting on the right-hand side. Use 2 x M6x12 and washers
- the mounting on the left-hand side. Use an M6x10. Move the mounting so that it is 10-15 degrees above vertical
- tighten the screws on the mountings. Tighten to 8 Nm.
Removing screws
Raise the vehicle. Position mobile jack 998 5972 JACK 998 5972 Jack using universal plate 999 5972 FIXTURE 999 5972 Fixture. Position the hoist under the left-hand side of the sub-frame.
Remove:
- the front screw and washer on the sub-frame
- the rear screw for the bumper mounting.
Installing the cooler
Install the screw, M6x20, in the bumper mounting. Tighten the screw so that the end of the screw is flush with the nut on the body.
Move the metal tabs on the side of the nut to one side so that the welded nut on the mounting is released.
Align the upper left mounting for the cooler against the end of the screw. Tighten the screw to contact.
Hold the right-hand mounting for the cooler up against the sub-frame bushing. Install the M14x100 screw and the washer. Tighten to 105 Nm. Angle tighten 120°.
Tighten the screw for the upper mounting. Tighten to 6 Nm.
Rust-proof the lower section of the bracket where it is in contact with the sub-frame.
Installing the lines for the cooler
Note! Do not remove the protective plugs on the ends of the lines that will be connected in the engine compartment yet.
Insert the lines into the engine compartment inside the radius of the ground lead.
Remove the protective plugs from the cooler and from the ends of the lines to be connected to the cooler.
Lubricate the O-rings on the lines using automatic transmission fluid.
Install:
- line 1 first (this has a quick-release connector for the cooler terminal in the engine compartment)
- line 2 (this is connected to the transmission using a nut)
- the M8x20 screw for the mounting lug for the wiring and cooler. Tighten to 25 Nm.
Replacing the covers in the bumper
Position the bumper on a soft and protective underlay to protect the paint.
Remove the covers on the left and right sides.
Press in the hooks in the center of the cover. Remove the cover.
Install the new ventilated covers in the bumper.
Finishing
Installing the front bumper
Install the front bumper. See: Bumper front, replacing Service and Repair.
Removing the return line
Remove the return line between the standard cooler and the transmission.
Filling with oil
Warning! Avoid skin contact with the transmission fluid.
Caution! Absolute cleanliness is essential during this work.
Note! Use only transmission oil, Volvo P/N 116 1540-8 (1 liter container), 116 1640-6 (4 liter container).
Measure out 220 ml of the above oil. Fill through the terminal in the transmission cover.
Installing the wiring
Lubricate the O-rings on the line from the oil cooler (with the quick-release connector). Install the line on the oil cooler.
Install the line from the oil cooler (using the nut connection) to the transmission cover. Turn the line before tightening it so that there is a slight bend in the hose. Tighten the nut. Tighten to 40 Nm.
Installing the air cleaner (ACL)
Install:
- the air cleaner (ACL)
- the fresh air intake hose
- the cover at the side of the air cleaner (ACL).
Installing the battery lead
Connect the battery negative lead. See: Battery, disconnecting Battery Disconnecting.