Volvo Penta Charge Air Cooler Cap 22092538
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Part Number: 22092538
Brand: Volvo Penta
Official Product Type: Charge Air Cooler Cap / Aftercooler End Cap
System: Charge Air / Intake Air Cooling
Supersedes: 3583628
Overview
The Volvo Penta 22092538 is the genuine OEM end cap for the charge air cooler (aftercooler) assembly on Volvo Penta D4 and D6 marine diesel engines. It closes and seals the end of the charge air cooler, maintaining the integrity of the pressurized intake-air system. A failed or leaking cap allows pressurized charge air to escape before it reaches the engine, reducing power output and potentially triggering boost-related fault codes.
Compatible Applications
- Volvo Penta D4-145, D4-150, D4-175, D4-180
- Volvo Penta D4-210, D4-225, D4-230, D4-260, D4-270, D4-300, D4-320
- Volvo Penta D6-280, D6-300, D6-310, D6-330, D6-350
- Volvo Penta D6-370, D6-400, D6-435, D6-440, D6-480
- Applies across A-, D-, and I-series configurations depending on engine generation and suffix
D4 and D6 engines were produced with different charge air cooler configurations across model years and variants. Confirm the complete engine model, suffix, and serial number against the Volvo Penta charge air cooler parts diagram before ordering.
Serial Number & Fitment Notice
Charge air cooler assembly configurations vary across D4 and D6 engine generations and suffixes. Do not order by engine displacement or model name alone — confirm fitment using your complete engine model designation, suffix, and serial number against the applicable Volvo Penta parts diagram.
Superseded Part Numbers
- 3583628 — previous Volvo Penta part number, superseded by 22092538
- 22092538 — current OEM part number
Dimensions & Weight
Approximate weight: 1.0 kg. Exact dimensions are not published in current Volvo Penta accessory literature. Confirm by part number and serial number match to the charge air cooler assembly diagram.
When to Replace
Replace the cap if it is cracked, distorted, heavily corroded, or damaged at its sealing surface. Also replace if inspection identifies an air or pressure leak around the charge air cooler end assembly. Inspect the associated seals and cooler housing at the same time.
Installation Notes
Clean and inspect the charge air cooler mating surface before installation. Check the related sealing components and fasteners for wear or corrosion. Follow the applicable Volvo Penta workshop procedure for assembly sequence and tightening torque. Pressure-test the charge air system after installation to confirm the repair is sealed before returning the vessel to service.
Technical FAQ
Q: What is a charge air cooler cap and why does it matter?
A: The charge air cooler (aftercooler) cools compressed air from the turbocharger before it enters the engine. The end cap seals the cooler assembly under boost pressure. A cracked or leaking cap reduces charge air density, lowering power output and fuel efficiency, and can trigger boost-related fault codes on D4 and D6 engines.
Q: Does 22092538 replace 3583628?
A: Yes. 22092538 is the current Volvo Penta OEM part number that supersedes 3583628.
Q: Does this fit all D4 and D6 engines?
A: It is documented across a wide range of D4 and D6 models, but charge air cooler configurations vary by engine generation and suffix. Always confirm by complete engine model, suffix, and serial number before ordering.
Q: What other parts should I inspect when replacing this cap?
A: Inspect the charge air cooler end seals, housing, and all related fasteners. If the cap failed due to pressure stress, also inspect the charge air hoses and clamps for signs of fatigue or leakage.
Parts Desk Insights
The key distinction with 22092538 is that it is the charge air cooler end cap — not a generic engine cover, filler cap, or coolant cap. Customers sometimes order the wrong cap because "cap" appears across many Volvo Penta part categories. On D4 and D6 engines, matching the exact aftercooler assembly and engine suffix is the safest way to confirm fitment. If a customer is replacing this cap due to a boost leak or power loss complaint, also recommend inspecting the charge air hoses and intercooler seals before closing the job.
Shipping information
In-stock and OEM parts: ship same or next business day.
Locally warehoused items: ship within 1-3 business days.
Special-order items: timeline confirmed after order.
Returns & warranty
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If you are not fully satisfied, you may request a return within 30 days of delivery. All returns must receive pre-approval prior to being sent back. Unauthorized returns will not be accepted.
To qualify for a return:
Item must be in new, unused condition
Product must be in its original packaging
All parts, components, hardware, manuals, and accessories must be included
Packaging must be undamaged and suitable for resale
Important:
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