Radiator Surge Tank Replacement

Radiator Surge Tank Replacement

Removal Procedure

Warning

With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.

Note: Use only a GM released anti-freeze mixture and ensure a concentration of 50 percent water to 50 percent antifreeze. Antifreeze does not just prevent the cooling system from freezing up, it also protects all the components that are in contact with coolant from rust/limescale deposits. As a result, antifreeze should always be added, even in tropical countries.

In addition to the anti-freeze mixture,
water quality also plays an important role. Potable tap water should normally suffice to fulfil this requirement. The quality of regenerated sea water is not suitable.

1. Open the cooling system by removing the radiator surge tank cap.

2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.





Note: Do NOT drain more than 1.5 liter (1.36 quarts) of coolant fluid to avoid necessity of the coolant system bleeding procedure.

3. Install a drain hose, slowly open the drain screw (1) and allow the to drain out max. 1.5 liter (1.36 quarts) coolant fluid into a clean measuring pitcher.

4. Lower the vehicle.




5. Remove the engine coolant air bleed hose (6), remove the clamp.

6. Remove the radiator surge tank engine hose (5), remove the clamp.

7. Remove radiator surge tank clip (2).

8. Disconnect coolant level sensor wiring harness plug (4).

9. Remove the radiator surge tank (1), unclip from the bracket (3).

Installation Procedure




1. Install the radiator surge tank (1) and clip into the bracket (3).

2. Connect coolant level sensor wiring harness plug (4).

3. Install radiator surge tank clip (2).

4. Install the radiator surge tank engine hose (5), install the clamp.

5. Install the engine coolant air bleed hose (6), install the clamp.

6. Refill the radiator surge tank with the coolant fluid, which has been drained out before.