GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Cadillac 🢒 2003 🢒 CTS - RHD 🢒 Engine 🢒 Engine Cooling 🢒 Radiator Surge Tank Replacement

Radiator Surge Tank Replacement RHD

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure
  1. Drain the coolant. Refer to Cooling System Draining and Filling.
  2. Using the J 38185 , loosen and slide the clamp (1).

    3. Object Number: 789009 Size: SH
  3. Disconnect the surge tank outlet hose.
  4. Remove the master cylinder nuts.

    5. Object Number: 420706 Size: SH
  5. Without disconnecting brake lines separate the master cylinder from the brake booster.
  6. Disconnect the surge tank inlet hose (1).

    7. Object Number: 789014 Size: SH
  7. Remove the surge tank bolt (4).

    8. Object Number: 789015 Size: SH
  8. Remove the surge tank nut (1).
  9. Remove the lower surge tank bolt.
  10. Remove the left air inlet grill panel. Refer to Air Inlet Grille Panel Replacement
  11. Disconnect the low coolant sensor electrical connector.
  12. Remove the surge tank.

Installation Procedure
  1. Connect the low coolant sensor electrical connector.
  2. Install the surge tank.
  3. Position the surge tank tab behind the air inlet grill screen.
  4. Install the left air inlet grill panel. Refer to Air Inlet Grille Panel Replacement
  5. Connect the surge tank outlet hose.

    6. Object Number: 789009 Size: SH
  6. Using the J 38185 position the surge tank outlet hose clamp (1).

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


    Object Number: 789015 Size: SH
  7. Install the surge tank nut (1).

    8. Tighten
    Tighten the nut to 9 N·m (80 lb in).

  8. Install the lower surge tank bolt.

    9. Tighten
    Tighten the bolt to 9 N·m (80 lb in).

  9. Connect the surge tank inlet hose (1).

    10. Object Number: 789014 Size: SH
  10. Install the surge tank bolt (4).

    11. Tighten
    Tighten the bolt to 9 N·m (80 lb in).


    Object Number: 420706 Size: SH
  11. Connect the master cylinder to the vacuum booster.
  12. Install the master cylinder nuts.

    13. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).

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

Radiator Surge Tank Replacement LHD M 82

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure
  1. Drain the coolant. Refer to Cooling System Draining and Filling.
  2. Using the J 38185 , loosen and slide the clamp (1).

    3. Object Number: 789009 Size: SH
  3. Disconnect the surge tank outlet hose (1).
  4. Remove the master cylinder nuts.

    5. Object Number: 420706 Size: SH
  5. Without disconnecting brake lines separate the master cylinder from the brake booster.
  6. Gently reposition the master cylinder out of the way.
  7. Disconnect the surge tank inlet hose (1).

    8. Object Number: 789014 Size: SH
  8. Remove the surge tank bolt (4).

    9. Object Number: 789015 Size: SH
  9. Remove the surge tank bolt (1).
  10. Remove the left air inlet grill panel. Refer to Air Inlet Grille Panel Replacement
  11. Disconnect the low coolant sensor electrical connector.
  12. Remove the surge tank.

Installation Procedure
  1. Connect the low coolant sensor electrical connector.
  2. Install the surge tank.
  3. Position the surge tank tab behind the air inlet grille screen.
  4. Install the left air inlet grill panel. Refer to Air Inlet Grille Panel Replacement

    5. Object Number: 789009 Size: SH
  5. Connect the surge tank outlet hose (1).

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


    Object Number: 789015 Size: SH
  6. Install the surge tank nut (1).

    7. Tighten
    Tighten the nut to 9 N·m (80 lb in).

  7. Connect the surge tank inlet hose (1).

    8. Object Number: 789014 Size: SH
  8. Install the surge tank bolt (4).

    9. Tighten
    Tighten the bolts to 9 N·m (80 lb in).


    Object Number: 420706 Size: SH
  9. Connect the master cylinder to the vacuum booster.
  10. Install the master cylinder nuts.

    11. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).

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

Radiator Surge Tank Replacement LHD M 35

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure
  1. Drain the coolant. Refer to Cooling System Draining and Filling.

    2. Object Number: 799119 Size: SH
  2. Remove the upper surge tank bolt (1).
  3. Disconnect the surge tank inlet hose.

    4. Object Number: 840262 Size: SH
  4. Remove the clutch master cylinder reservoir bolts (1).
  5. Position the clutch master cylinder reservoir out of the way.
  6. Remove the master cylinder nuts.

    7. Object Number: 420706 Size: SH
  7. Without disconnecting brake lines separate the master cylinder from the vacuum brake booster.
  8. Using the J 38185 , loosen and slide the clamp on the surge tank outlet hose.
  9. Disconnect the surge tank outlet hose.
  10. Remove the lower surge tank bolt.
  11. Remove the surge tank bolt at the air inlet grille.
  12. Remove the left air inlet grill panel. Refer to Air Inlet Grille Panel Replacement
  13. Disconnect the low coolant sensor electrical connector.
  14. Remove the surge tank.

Installation Procedure

    Object Number: 420706 Size: SH
  1. Connect the low coolant sensor electrical connector.
  2. Install the surge tank.
  3. Position the surge tank tab behind the air inlet grille screen.
  4. Install the left air inlet grill panel. Refer to Air Inlet Grille Panel Replacement

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

  5. Install the surge tank nut.

    6. Tighten
    Tighten the nut to 9 N·m (80 lb in).

  6. Connect the surge tank outlet hose.
  7. Using the J 38185 reposition the surge tank outlet hose clamp into the original position.
  8. Connect the surge tank inlet hose.
  9. Install the lower surge tank bolt.

    10. Tighten
    Tighten the bolts to 9 N·m (80 lb in).


    Object Number: 799119 Size: SH
  10. Install the surge tank bolt (1).

    11. Tighten
    Tighten the bolts to 9 N·m (80 lb in).

  11. Reposition the clutch master cylinder reservoir.

    12. Object Number: 840262 Size: SH
  12. Install the clutch master cylinder reservoir bolts (1).

    13. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).


    Object Number: 420706 Size: SH
  13. Connect the master cylinder to the vacuum brake booster.
  14. Install the master cylinder nuts.

    15. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).

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