Tools Required

J 38185 Hose Clamp Pliers

Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

1. Drain the cooling system. Refer to Cooling System Draining and Filling .



2. Disengage tension on the surge tank inlet hose clamp.
3. Disconnect the surge tank inlet hose from the surge tank.



4. Disengage tension on the surge tank outlet hose clamp using the J 38185 .
5. Disconnect the surge tank outlet hose from the surge tank.
6. Remove the protective cap on the surge tank upper stud.
7. Remove the surge tank upper nut.



8. Loosen the surge tank side nut.
9. Disconnect the coolant level sensor electrical connector.
10. Remove the surge tank.

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

1. Install the surge tank.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the upper surge tank nut.

Tighten
Tighten all nuts to 8 N·m (71 lb in).

3. Install the protective cap on the surge tank upper stud.



4. Connect the coolant level sensor electrical connector.



5. Connect the surge tank outlet hose to the surge tank.
6. Engage tension on the surge tank outlet hose clamp.



7. Connect the surge tank inlet hose to the surge tank.
8. Engage tension on the surge tank inlet hose clamp.
9. Fill the cooling system. Refer to Cooling System Draining and Filling .