Volvo Penta D4 D6 Fuel Cooler Removal, Installation and Pressure Testing

I created this video to demonstrate how to remove, install and pressure test a fuel cooler. It's not to long due it is not a very difficult job.
The cooler is on the return side of the fuel system and is cooled by raw water.

[@nickpm3273]

Thanks for this, had the pipe on my D4 between fuel cooler and sea water strainer leaking and thanks to your video have been able to replace both.

[@alexlorberg9419]

Thank you so much for a helpful video. Would love to see a video on how to remove and clean a heat exchanger on the d4.

[@tedsmarinerepair8956]

That one will be long, but I will put it on my list. I will also put a video together on how to flush the raw water side.

[@alexlorberg9419]

@@tedsmarinerepair8956 I installed a bypass on the intake hose. If the boat sits for more than a couple of days, I fill a 5 gallon bucket with fresh water, put a hose with a strainer inside it, then while the engine is running, I open the valve for the bypass and close the intake valve. The engine sucks out the bucket in under a minute with the hose still running inside the bucket. I then shutdown the engine using the red button above the oil filters. Very open to hear how you would recommend to do this. I use the same process for winterization except I have two buckets filled with anti freeze - takes about 8 gallons before I see a trifle ear shooting out of the exhaust.

[@mshawct]

Great video. Thanks. Hope to see a video on how to winterize the D4/D6. It's getting chilly....

[@tedsmarinerepair8956]

Can do

[@mikepruett1364]

Thanks Ted!!!!

[@albertshilton5336]

Great video. Do you have a video rebuilding the heat exchanger? I have the same engine and a freeze damaged the gasket. It leaks. Thanks, Al

[@tedsmarinerepair8956]

Frozen is NG best to buy a new unit.

[@4evaMobnJohn146]

Friend of mine has d6 and when he comes backs off to neutral oil light comes on! Not every time only few times it has done it!! Any idea what might be causing it

[@tedsmarinerepair8956]

Verify the oil pressure on the gauge when the light comes on. Minimum oil pressure is 18-28psi @ idle hot.
Ensure oil level is not too high this may be a sign of fuel in the oil thinning it out.
Or the oil is worn out.
I would change the oil and filter and see if that makes the issue stop.

[@esbfco]

Hi Ted, I have run into this video whişe checking for my problem.I have volvo penta D4 260A-B and I have noticed a brown clored liquid coming out on the back of the engine. They have told that water and oil probably mixed and oil cooler might be the problem.Do you have any thoughts?

[@andrewgilbert6765]

What are the symptoms of a bad fuel cooler?

[@tedsmarinerepair8956]

If a fuel cooler fails, it allows water to enter the fuel return hose and starts to slowly fill the fuel tank with raw water.

[@andrewgilbert6765]

@@tedsmarinerepair8956 Oh man that would be bad. Thank you for sharing your knowledge. Love the videos!

[@colinlemmon1420]

Ted. Are you able to offer advice by email? Many thanks