Tools Required

J 38185 Hose Clamp Pliers

1. Caution: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.

   Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.




2. Drain the cooling system. Refer to Cooling System Draining and Filling .
3. Remove the surge tank hose clamps.
4. Remove the hoses at the surge tank.



5. Remove the surge tank nuts.
6. Remove the surge tank.

1. Install the radiator surge tank.
2. Install the lower radiator surge tank nut.
3. Install the upper radiator surge tank nuts.

Tighten
Tighten the radiator surge tank nuts to 10 N·m (89 lb in).

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.




4. Install the hoses to the radiator surge tank.
5. Install the radiator surge tank hose clamps.
6. Fill the cooling system. Refer to Cooling System Draining and Filling .