20798914 Volvo.Penta Return line

Fluid Spillage ContainmentCare must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Product Guide, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
1. Drain the coolant from the radiator until the level is below the regulator housing.2. Remove bracket (2) from the top of housing assembly (3) and set it aside.3. Remove elbows (1) and (5) and the gaskets from housing assembly (3).4. Disconnect two tube assemblies (4) from the rear of housing assembly (3).5. Remove ten bolts (6) that fasten housing assembly (3) to the regulator housing. Remove housing assembly (3) and the gasket. 6. Remove four lip seals (7) from housing assembly (3).7. Remove the four bolts and the washers, and remove the cover from the top of housing assembly (3). Remove the gasket from the cover. Remove vent valve assembly (8) from housing assembly (3). 8. Remove four water temperature regulators (9) from the regulator housing. The following steps are for installation of the temperature regulators.9. Be sure all parts are clean and all gasket surfaces are smooth before assembly. Replace all gaskets and seals with new parts. 10. Install four water temperature regulators (9) in the regulator housing. 11. Install vent valve assembly (8) in housing assembly (3). Put the gasket and the cover in position, and install the four bolts and the washers on regulator housing (3).12. Using Tool (A) (not shown), install four lip seals (7) in housing assembly (3). Install lip seals (7) with the lip of the seal toward the inside of housing assembly (3) as shown.13. Use 1U-6396 O-ring Assembly Compound on lip seals (7) and the O-ring seal in elbow (1). 14. Put the gasket in position on regulator housing (3). Put housing assembly (3) in position, and install the ten bolts (6).15. Connect two tube assemblies (4) to the rear of housing assembly (3).16. Put the gaskets and elbows (1) and (5) in position on housing assembly (3). Install the bolts that hold elbows (1) and (5).17. Install bracket (2) on regulator housing (3).18. Fill the radiator with coolant to the correct level. Refer to the Operation & Maintenance Manual for all fluid capacities and the proper filling procedures.