GM Service Manual Online
For 1990-2009 cars only

Radiator Surge Tank Outlet Hose/Pipe Replacement LHD, LY7

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure

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

  2. Object Number: 785754  Size: SH
  3. Position J 38185 to the clamp in order to remove the outlet hose (2) from the surge tank (1).
  4. Loosen the bolt on the bracket which secures the surge tank outlet hose to the engine.
  5. Position J 38185 to the clamp in order to remove the surge tank outlet hose from the thermostat assembly.
  6. Remove the surge tank outlet hose/pipe from the engine.

Installation Procedure

  1. Position the surge tank outlet hose/pipe to the engine.
  2. Position J 38185 to the clamp in order to connect the surge tank outlet hose to the thermostat assembly.
  3. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the bolt to the bracket securing the surge tank outlet pipe to the engine.
  5. Tighten
    Tighten the bolt to 9 N·m (80 lb in).


    Object Number: 785754  Size: SH
  6. Position J 38185 to the clamp in order to connect the outlet hose (2) to the surge tank (1).
  7. Fill the cooling system. Refer to Cooling System Draining and Filling .

Radiator Surge Tank Outlet Hose/Pipe Replacement LH2

Removal Procedure


    Object Number: 1285236  Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling .
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  3. Compress the clamp (1) and remove the surge tank outlet hose from the surge tank (2).

  4. Object Number: 1285238  Size: SH
  5. Separate the hose (2) from the retaining features (1 and 3) on the front of dash.

  6. Object Number: 1285240  Size: SH
  7. Compress the clamp (2) and remove the surge tank outlet hose from the heater hose (1).
  8. Remove the surge tank outlet hose/pipe from the engine compartment.

Installation Procedure


    Object Number: 1285240  Size: SH
  1. Position the surge tank outlet hose/pipe to the engine compartment.
  2. Compress the clamp (2) and connect the surge tank outlet hose to the heater hose (1).

  3. Object Number: 1285238  Size: SH
  4. Install the hose (2) to the retaining features (1 and 3) on the front of dash.

  5. Object Number: 1285236  Size: SH
  6. Compress the clamp (1) and connect the surge tank outlet hose to the surge tank (2).
  7. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  8. Fill the cooling system. Refer to Cooling System Draining and Filling .

Radiator Surge Tank Outlet Hose/Pipe Replacement Right Hand Drive


Object Number: 1858683  Size: MF

Callout

Component Name

Preliminary Procedure

  1. Drain the cooling system. Refer to Cooling System Draining and Filling .
  2. If necessary, reposition the wiring harness to access the surge tank outlet hose.

1

Surge Tank Outlet Hose Clamp (Qty: 2)

2

Surge Tank Outlet Hose