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• 3583628 earlier number superseded by this part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