Radiator Surge Tank Replacement

Radiator Surge Tank Replacement

Special Tools

J 38185 Hose Clamp Pliers

Removal Procedure




1. Drain the coolant. Refer to Cooling System Draining and Filling (Static Fill) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE 47716) (Cooling System Draining and Filling (GE 47716)).
2. Disconnect the master cylinder fluid level sensor electrical connector and reposition aside.
3. Using the J 38185 , disengage and reposition the surge tank outlet hose clamp.
4. Disconnect the surge tank outlet hose.
5. Using the J 38185 , disengage and reposition the surge tank inlet hose clamp.
6. Disconnect the surge tank inlet hose.




7. Remove the surge tank bolt.
8. Remove the surge tank nut.
9. Disconnect the low coolant sensor electrical connector.
10. Remove the surge tank.

Installation Procedure

1. Install the surge tank.




2. Connect the low coolant sensor electrical connector.

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the surge tank nut and tighten to 9 Nm (80 lb in).
4. Install the surge tank bolt and tighten to 9 Nm (80 lb in).





Note: Lubricate the inside diameters of the hoses with clean coolant prior to installation.

5. Connect the surge tank inlet hose to the surge tank.
6. Using the J 38185 , reposition the hose clamp to secure the surge tank inlet hose.
7. Connect the surge tank outlet hose.
8. Using the J 38185 , reposition the hose clamp to secure the surge tank outlet hose.
9. Connect the master cylinder fluid level sensor electrical connector.
10. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE 47716) (Cooling System Draining and Filling (GE 47716)).