Oil Cooler

Oil cooler



















INTRODUCTION
- Read through all of the instructions before starting installation.
- Notifications and warning texts are for your safety and to minimize the risk of something breaking during installation.
- Ensure that all tools stated in the instructions are available before starting installation.
- Certain steps in the instructions are only presented in the form of images. Explanatory text is also given for more complicated steps.
- In the event of any problems with the instructions or the accessory, contact your local Volvo dealer.






Oil cooler

Preparations





- remove the two screws (1) from the intake pipe for the air cleaner (ACL)
- Remove the intake pipe. Place the intake manifold to one side.





- Fully disconnect the hose clamp (1)
- Remove the vacuum valve and its hoses and the cable (2) from the mounting on the reverse of the air cleaner (ACL), in the lower right-hand corner. Move the vacuum valve away from the gearbox
- Pull the air cleaner (ACL) from its mounting in the side member. Pull the air cleaner (ACL) up slightly. Detach the hose from the air cleaner (ACL). The hose may need to be heated with a hot-air gun before it can be detached
- Move the air cleaner (ACL) to one side so that the gearbox is accessible.





- Remove the hose (1) between the radiator and the gearbox
- Place the hose to one side. It will not be reused.





- Remove the front skid plate. First remove the six screws (1) on the underneath
- With the assistance of a colleague, pull the skid plate forwards. Pull one of the corners until the mounting lug on that side of the skid plate releases from the sub-frame. Then pull off the other corner

Note! It may be necessary to carefully bend down the lower edge of the bumper cover while pulling the skid plate forward.

Installing the oil cooler


Illustration A shows how the hoses are connected to the gearbox and oil cooler





Illustration B shows how the hoses are routed to the oil cooler




- Remove the two hoses from the kit and remove the dust covers
- Insert the hoses down to the left-hand side of the radiator. Connect the hoses in the engine compartment to the gearbox (1) and radiator (2) where the hose was removed earlier. Do not tighten the connection nut
- Route the hoses between the left-hand side of the radiator and the pipe to the air conditioning (A/C) system.





- Take the nut clip from the kit and press it into place on the lower left edge of the radiator on the existing mounting.


Illustration A shows how the hoses are connected to the oil cooler





Illustration B shows how the oil cooler is secured




- Take the oil cooler from the kit. Connect the hose from the gearbox (1) and the hose from the radiator (2) to the oil cooler
- Ensure that the mounting lug for the lower hose is beneath the mounting lug for the upper hose
- Take the two M6x16 screws from the kit. Secure the oil cooler to the existing mountings. Tighten the screws. Tighten to 10 Nm (7 lbf. ft).





- Take the M6x14 screw from the kit. Tighten both the mounting lugs for the hoses to the mounting in the radiator. Tighten the screw. Tighten to 10 Nm (7 lbf. ft)
- Tighten the connection nut on the hose to the gearbox. Tighten to 40 Nm ((29 lbf. ft.).

Finishing work

- Reinstall the front skid plate. Tighten the screws. Tighten to 50 Nm (37 lbf. ft.)
- Reinstall the air cleaner (ACL). Connect the removed components
- Reinstall the intake manifold on the air cleaner (ACL). Tighten the screws. Tighten to 10 Nm (7 lbf. ft.).

- Fill with 0.2 l of oil (see the manual for the oil type)
- Run the engine and top up the oil to the correct level.