Special Tools

J 38185 Hose Clamp Pliers

Warning: 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.

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

1. Install the surge tank.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the upper surge tank nut and tighten 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.