Surge Tank Replacement

Surge Tank Replacement
Removal Procedure





1. Drain the cooling system.
2. Remove the air cleaner assembly.
3. Remove the surge tank overflow hose from the surge tank.





4. Disconnect the coolant level sensor electrical connector (3).





5. Reposition the surge tank inlet and outlet hose clamps.
6. If equipped with a 4.3 L, 4.8 L, 5.3 L, 6.0 L, or 8.1 L engine, remove the surge tank inlet (1) and outlet (2) hoses from the surge tank.





7. Reposition the surge tank inlet hose clamp from the surge tank.
8. Remove the surge tank inlet hose (1) from the surge tank.





9. Reposition the surge tank outlet hose clamp from the surge tank.
10. Remove the surge tank outlet hose (2) from the surge tank.





11. Remove the bolt from the surge tank.
12. Remove the nut from the surge tank.
13. Remove the surge tank.

Installation Procedure





1. Install the surge tank.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the bolt to the surge tank.
^ Tighten the bolt to 9 Nm (80 inch lbs.).
3. Install the nut to the surge tank.
^ Tighten the nut to 9 Nm (80 inch lbs.).





4. Install the surge tank outlet hose (2) to the surge tank.
5. Position the surge tank outlet hose clamp to the surge tank.





6. Install the surge tank inlet hose (1) to the surge tank.
7. Position the surge tank inlet hose clamp to the surge tank.





8. Connect the coolant level sensor electrical connector (3).





9. Install the surge tank overflow hose.
10. Install the air cleaner assembly.
11. Fill the cooling system.