GM Service Manual Online
For 1990-2009 cars only

Radiator Surge Tank Outlet Hose/Pipe Replacement 4.8L, 5.3L, and 6.0L Engines

Tools Required

J 43181 Heater Line Quick Connect Release Tool

Removal Procedure


    Object Number: 307286  Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling .
  2. Loosen the air cleaner outlet duct clamps at the following locations:
  3. • Throttle body
    • Mass airflow/intake air temperature (MAF/IAT) sensor
  4. Remove the air cleaner outlet duct.

  5. Object Number: 659127  Size: SH
  6. If equipped without regular production option (RPO) C36 auxiliary heater, remove the surge tank/heater outlet hose (1) from the mounting clip.

  7. Object Number: 688023  Size: SH
  8. If equipped with RPO C36 auxiliary heater, remove the surge tank/heater outlet hose (1) from the mounting clip.

  9. Object Number: 362171  Size: SH
  10. Install the J 43181 to the surge tank outlet hose.
  11. Close the J 43181 around the surge tank outlet hose.
  12. Firmly pull the J 43181 into the quick connect end of the outlet hose.

  13. Object Number: 687495  Size: SH
  14. If equipped without RPO C36 auxiliary heater, firmly grasp the outlet hose. Pull the outlet hose in order to disengage the hose from the heater and blower module.

  15. Object Number: 687496  Size: SH
  16. If equipped with RPO C36 auxiliary heater, firmly grasp the outlet hose. Pull the outlet hose in order to disengage the hose from the heater and blower module.

  17. Object Number: 659059  Size: SH
  18. Reposition the surge tank outlet hose clamp at the surge tank.
  19. Remove the surge tank outlet hose (2) from the surge tank.

  20. Object Number: 659180  Size: SH
  21. Reposition the surge tank outlet hose clamp at the water pump.
  22. Remove the surge tank outlet hose from the water pump.
  23. Remove the surge tank outlet hose.

Installation Procedure


    Object Number: 659180  Size: SH
  1. Install the surge tank outlet hose.
  2. Install the surge tank outlet hose to the water pump.
  3. Position the surge tank outlet hose clamp to the water pump.

  4. Object Number: 659059  Size: SH
  5. Install the surge tank outlet hose (2) to the surge tank.
  6. Position the surge tank outlet hose clamp to the surge tank.

  7. Object Number: 687496  Size: SH
  8. If equipped with RPO C36 auxiliary heater, connect the surge tank outlet hose to the heater and blower module.

  9. Object Number: 687495  Size: SH
  10. If equipped without RPO C36 auxiliary heater, connect the surge tank outlet hose to the heater and blower module.
  11. Firmly push the hose onto the heater and blower module pipe until an audible click is heard.


    Object Number: 688023  Size: SH
  12. If equipped with RPO C36 auxiliary heater, install the surge tank/heater outlet hose (1) to the mounting clip.

  13. Object Number: 659127  Size: SH
  14. If equipped without RPO C36 auxiliary heater, install the surge tank/heater outlet hose (1) to the mounting clip.

  15. Object Number: 307286  Size: SH
  16. Install the air cleaner outlet duct.
  17. Important: Align the arrow at the throttle body end of the duct with the throttle body attaching stud.

  18. Tighten the air cleaner outlet duct clamps at the following locations:
  19. • Throttle body
    • MAF/IAT sensor

    Tighten
    Tighten the air cleaner outlet duct clamp screws to 7 N·m (62 lb in).

  20. Fill the cooling system. Refer to Cooling System Draining and Filling .