Radiator Surge Tank Replacement

Radiator Surge Tank Replacement

Tools Required

J 38185 Hose Clamp Pliers


Removal Procedure

1. Drain the cooling system. Refer to Cooling System Draining and Filling (GE 47716 Fill) (Service and Repair)Cooling System Draining and Filling (2.2L (L61), 2.4L (LE5)) (Service and Repair) .




2. Reposition the surge tank inlet hose clamp using J 38185 .
3. Remove the surge tank inlet hose from the surge tank.




4. Remove the underhood junction block bracket nuts (1, 2).
5. Remove the underhood junction block bracket bolt (3).
6. Lift the underhood junction block bracket and position away from the surge tank.




7. Remove the surge tank nut. Lift the surge tank and reposition the surge tank outlet hose clamp using J 38185 .
8. Remove the surge tank outlet hose.




9. Disconnect the coolant level sensor electrical connector.
10. Remove the surge tank.



Installation Procedure





1. Install the surge tank.
2. Connect the coolant level sensor electrical connector.




3. With the surge tank raised, install the surge tank outlet hose.
4. Reposition the hose clamp using J 38185 to secure the hose.

Notice: Refer to Fastener Notice .

5. Install the surge tank nut.

Tighten the nut to 10 N.m (89 lb in).





6. Set the underhood junction block bracket into position.
7. Install the underhood junction block bracket nuts (1, 2).

Tighten the nuts to 10 N.m (88 lb in).

8. Install the underhood junction block bracket bolt (3).

Tighten the bolt to 25 N.m (18 lb ft).





9. Install the surge tank inlet hose to the surge tank.
10. Reposition the hose clamp using J 38185 to secure the hose.
11. Fill the cooling system. Refer to Cooling System Draining and Filling (GE 47716 Fill) (Service and Repair)Cooling System Draining and Filling (2.2L (L61), 2.4L (LE5)) (Service and Repair) .