968955 Volvo.Penta Expansion plug

Table 1
Required Tools
Tool Part Number Part Description Qty
A 5F-4764 Pry Bar 1 Start By:
Install the wheel chocks. Refer to Disassembly and Assembly, "Wheel Chocks (Front and Rear) - Remove and Install".
Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Position a suitable container under the radiator drain valves in order to contain the coolant for storage or disposal. Drain approximately 396 L (105 US gal) of coolant from the right side of the radiator. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct procedure.
Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help prevent dirt from entering the internal mechanism.
Raise the front hood assembly and the rear hood assembly.
Illustration 1 g00566844
Loosen two hose clamps (4) that hold hose (1) to outlet elbow (2) and tube assembly (3). Place hose (1) aside.
Illustration 2 g00566846
Loosen hose clamp (9) that holds hose (5) to tube assembly (7). Place hose (5) aside.
Loosen two hose clamps (10) that holds hose (8) to outlet elbow (11) and tube assembly (6). Place hose (8) aside.
Illustration 3 g00566847
Disconnect two tube assemblies (13) from regulator housing assembly (12).
Illustration 4 g00566848
Remove two bolts (14), the washers, and the retainers that hold tube assembly (16) to elbow (15). Remove tube assembly (16).
Illustration 5 g00566849
Put identification marks on two bolts (17) for installation purposes.
Remove two bolts (17) and the washers that hold two clips (19) to regulator housing assembly (12). Place hose assembly (18) aside.
Illustration 6 g00566850
Put identification marks on four bolts (20) for installation purposes.
Remove the remaining four bolts (20) and the washers that hold regulator housing assembly (12) to the regulator housing.
Use two people to remove regulator housing assembly (12). Remove housing cover gasket (21). The weight of regulator housing assembly (12) is 35 kg (77 lb).
Illustration 7 g00566851
Position regulator housing assembly (12), as shown. Remove remaining two bolts (22) that hold elbow (15) to regulator housing assembly (12). Remove elbow (15) and gasket (23) from regulator housing assembly (12).
Remove remaining bolt (26) and the washer that holds cover (25) to regulator housing (12). Remove cover (25) and gasket (24) from regulator housing assembly (12).
Remove four bolts (28) that hold outlet elbow (2) to regulator housing assembly (12). Remove outlet elbow (12) and gasket (27) from regulator housing assembly (12).
Illustration 8 g00566854
Remove four bolts (31) that hold outlet elbow (30) to regulator housing assembly (12). Remove outlet elbow (30) and gasket (32) from regulator housing assembly (12).
Remove four bolts (32) and the washers that hold cover (33) to regulator housing assembly (12). Remove cover (33) and gasket (31) from regulator h