# 22092538 Cap | Genuine Volvo Penta Part

## 🔧 Product Description

Charge-air-cooler end cap for Volvo Penta D4 and D6 marine diesel engines. It closes the cooler housing and seals the raw-water or air passage at the end of coolers including 22092525, 22437210 and 21781663.

## 🚤 Compatibility

Typically suits:

-   Volvo Penta D6-440I-G
-   Volvo Penta D6-480I-G
-   Volvo Penta D6-440I-WJ-G
-   Volvo Penta D6-480I-WJ-G
-   Volvo Penta D6-440D-G
-   Volvo Penta D6-480D-G
-   Volvo Penta D6-400A-G
-   Volvo Penta D6-440A-G
-   Volvo Penta D6-480A-G

-   **Engine Family:** D
-   **HP Range:** 400-480 HP

## ⚙️ Key Features

-   D4/D6 charge-air-cooler end cover
-   Machined sealing and hose interfaces
-   Used on multiple later cooler assemblies
-   Related earlier cover 3583628
-   Bronze aftermarket upgrades available
-   Engine type: Turbocharged and aftercooled marine diesel

## 🔌 Function

Closes and seals the charge-air cooler so compressed air and cooling water remain separated and correctly routed.

## ⚠️ Common Signs of Failure

-   Raw-water leakage at the end cap
-   Corrosion or perforation of aluminium cover
-   Boost leak at the cooler end
-   Salt deposits around the joint
-   Coolant/air cross-leak or reduced charge-air cooling

## 🛠️ Service Notes

-   Clean and inspect the seating face on the housing as well as the cap — most leaks past a cap are the seat or the seal rather than the cap body
-   Renew any separate O-ring or gasket that goes with the cap, and lubricate rubber seals lightly with clean oil or grease so they slide home instead of rolling or tearing
-   Do not over-tighten a cap into a plastic or aluminium housing; it seals on its gasket or O-ring, not on force, and stripped threads mean a much bigger repair
-   Where a cap blanks a port during a repair, keep it fitted right up to the moment of assembly so nothing enters the opening
-   Check the cap is fully home and that any retaining clip, lanyard or locking tab is secure before returning the boat to service

## 🔄 Supersession & Cross Reference

### OEM Supersession Chain

-   22092538 → Supersedes 3583628

### OEM / Related Numbers

-   3583628 earlier number superseded by this part
-   22092525 (related charge-air coolers)
-   22437210 (related charge-air coolers)
-   21781663 (related charge-air coolers)
-   CAP-538 bronze charge-air-cooler end cap

## 📦 Condition

-   Genuine Volvo Penta part
-   Brand new
-   Supplied in original or equivalent packaging

## Details

- **Price:** 517.64 AUD
- **Vendor:** Volvo Penta
- **Type:** Cooling System
- **Tags:** Volvo Penta

## Variants

| Variant | Price | Available |
|---------|-------|-----------|
| Default Title | 517.64 AUD | In stock |

## Images

- 22092538 Cap | Genuine Volvo Penta Part

---

> Source: [Sawley's Auto and Marine](https://www.sawleysautoandmarine.com.au/products/22092538-cap-genuine-volvo-penta)
> Updated: 2026-10-10