1. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the upper surge tank nuts.
3. Loosen the surge tank side nut.



4. Reposition the surge tank inlet hose (1) clamp.
5. Remove the surge tank inlet (1) hose from the surge tank.
6. Reposition the surge tank outlet hose (2) clamp.
7. Remove the surge tank outlet hose (2).



8. Reposition the heater outlet hose clamp from the surge tank.
9. Remove the heater outlet hose from the surge tank.
10. Remove the surge tank.

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

1. Install the surge tank.



2. Install the heater outlet hose to the surge tank.
3. Reposition the heater outlet hose clamp to the surge tank.



4. Install the surge tank inlet (1) hose to the surge tank.
5. Reposition the surge tank inlet hose clamp.
6. Install the surge tank outlet hose to the surge tank.
7. Reposition the surge tank outlet hose clamp (2) to the surge tank.




Important: When installing the surge tank ensure that the front stud is fully seated in the slot.

8. Install the surge tank onto the studs.

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.

9. Install the surge tank nuts.
10. Tighten the nuts.

10.1.

Bottom

10.2.

Top rear

10.3.

Top front

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

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