GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Optra 🢒 Preface 🢒 Cautions and Notices 🢒 Radiator Surge Tank Replacement

Removal Procedure

    Caution: Refer to Radiator Cap Removal Caution in the Preface section.


    Object Number: 1291103 Size: SH
  1. Drain the engine coolant to below the level of the surge tank.
  2. Loosen the return hose clamp and disconnect the return hose from the top of the surge tank.
  3. Loosen the throttle body hose clamp and disconnect the throttle body hose from the top of the surge tank.
  4. Loosen the feed hose clamp and disconnect the feed hose from the bottom of the surge tank.

    5. Object Number: 1291113 Size: SH
  5. Remove the surge tank attaching bolt.
  6. Remove the surge tank from the support mount.

    7. Caution: Wear safety glasses in order to avoid eye damage.

  7. Clean the inside and the outside of the surge tank and the surge tank cap with soap and water.
  8. Rinse the surge tank and the cap thoroughly.

Installation Procedure

    Object Number: 1291113 Size: SH
  1. Install the surge tank to the support mount.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Secure the surge tank with the attaching bolt.

    3. Tighten
    Tighten the surge tank attaching bolt to 5 N·m (44 lb in).


    Object Number: 1291103 Size: SH
  3. Connect the return hose and the throttle body hose to the top of the surge tank.
  4. Connect the feed hose to the bottom of the surge tank.
  5. Secure the return hose, the throttle body hose, and the feed hose to the surge tank with the hose clamps.
  6. Fill the surge tank with the coolant to the center ridge, or to the MAX mark.