Mounting end pieces heath exchanger Volvo MD2010,MD2020,MD2030

[nepal]

These end pieces are all rubber and are mounted on the coolant reservoir
(see also appendix)

They have 3 functions:

- seal off the coolant from the outside air

- prevent the coolant from flowing internally to the heat exchanger

- supplying and exporting the external cooling water to the heat exchanger



Assembly is seemingly easy but the final loss of coolant from the reservoir fails.
I have played with tension and position of the tensioning rings and pressure.

Has anyone done this job before? I am curious about your method.

The loss is not due to a leaky head gasket because it occurs even when the engine is not running. The heat exchanger has been tested.

The end pieces and the tension rings are new.

On the internet one can only read that this is a challenge.

[

[bil56]

explain a little more, you have leaks, where?
the covers are new, the clamps also ?

[nepal]

I can not prevent completly the coolant from flowing internally to the heat exchanger.

Covers are new, the clamps also.

[skipperpete]

You need to pressure test the tubestack. Easy to do, pull it out of the housing and put on the end caps then plug one of the end caps and either extend the other end cap hose to maybe 6’ high and fill it with water or apply very low pressure air <10psi and submerge it in a bucket. If the core is ok you might have a leaking head gasket or a coolant leak where the mixer elbow bolts on, it’s possible to internally damage the housing if new flange bolts that are too long can bottom out, this is often a slow external leak from under the bolt heads but can also cross to the exhaust side and into the mixer elbow. If the engine angle is steep, the water disappears into the Aqualock.