The D5 oil cooler is noticeably bigger than a stock T5/R oil cooler or any cooler fitted to a petrol P2.
It's been compared by trusted sources and the differences are most excellent IMH and worth changing.
Notably, the car's engine oil will warm up 1-2 miles sooner and the temperature of the oil will be much closer to that of the coolant. Also, when driven hard, the oil will be 10 - 15*C cooler than a stock cooler.
You can buy a new cooler from Volvo for about £200 or get a get used one on eBay for around £40.
I, luckily have a mate with a D5 engine that he just scrapped, so he gave me the cooler for free!
You'll need to purchase two new 'O' rings from Volvo. Part# 30637339 £5.70 ea:
Firstly, remove the plastic cowling. This aids cooling as the cooler is made of aluminium and the plastic jacket acts just like....'a jacket!'
Then, give the old girl a good clean up with some GUNK and a plastic brush, not forgetting to rinse out the cooler with petrol, making sure you don't pour petrol down the coolant hoses!!
Then very gently, clean the face of the cooler with a razor blade getting all the hard deposits off until it's smooth:
Then you can fit to the car.
You'll need two new 16-25mm Hose clips, two good hose clamps, a T40 and a flat blade screw driver to remove the non reuseable clip and safety glasses.
remove the black coolant hose from the oil cooler....you'll be using the hose on your car!
I had my car on quality ramps for this job. Make sure the engine is cold as you don't want to burn your arms on hot oil or coolant!
Undo the 4 x T40 bolts partially and use the flat blade screwdriver to crack the seal on the cooler and Sump. Have a catch can ready for the escaping oil.
You'll only lose about 400ml of oil. Do NOT drain the sump!!
Then break the non reusable seal on the hose. Clamp off both coolant lines and use a small screwdriver to break the seal of the coolant hoses. The hoses are lined and very sticky when warm, so they grip very well. Getting a clamp on the right hand hose is a real PITA but is possible with care.
Once clamped and hose clamps removed, gently pull off the old cooler.
Wipe away any oil from the sump and remove the two old GREEN 'O' rings replacing them with the new BLACK 'O' rings.
Fit new cooler and tighten hose clamps.
Remove hose clamps.
Fit T40 bolts and tighten in the same fashion as doing up wheel bolts.....ie, top left, bottom right, top right, bottom left. Do them by hand first, then tighten securely but do not overtighten!! The sump is Alloy and if you strip the thread it will cost you around £400 for a new sump!
Here you can see the D5 cooler fitted versus the old one:
Once complete, start the engine and drive off your ramps then switch off!
Go and make a cuppa tea (not a beer cos you'll need to road test) as you'll need the oil level to settle....................10 minutes later..........
Check your oil level and top up accordingly. I had to add 0.5 litre.
Check your coolant level...initially, mine didn't move but I knew that it would be low in the morning.
ROAD TEST........then check for any oil/coolant leaks.
Park car on level ground because you will need to top up coolant the next day. I topped up mine by about 0.5 litre with 50/50 mix.
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