GM Service Manual Online
For 1990-2009 cars only

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure

    Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

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

  2. Object Number: 1481407  Size: SH
  3. Disengage tension on the surge tank inlet hose clamp.
  4. Disconnect the surge tank inlet hose from the surge tank.

  5. Object Number: 1481409  Size: SH
  6. Disengage tension on the surge tank outlet hose clamp using the J 38185 .
  7. Disconnect the surge tank outlet hose from the surge tank.

  8. Object Number: 1481404  Size: SH
  9. Remove the protective cap on the surge tank upper stud.
  10. Remove the surge tank upper nut.
  11. Loosen the surge tank side nut.
  12. Remove the surge tank.

Installation Procedure


    Object Number: 1481404  Size: SH

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

  1. Install the surge tank.
  2. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the upper surge tank nut.
  4. Tighten
    Tighten all nuts to 8 N·m (71 lb in).

  5. Install the protective cap on the surge tank upper stud.

  6. Object Number: 1481409  Size: SH
  7. Connect the surge tank outlet hose to the surge tank.
  8. Engage tension on the surge tank outlet hose clamp.

  9. Object Number: 1481407  Size: SH
  10. Connect the surge tank inlet hose to the surge tank.
  11. Engage tension on the surge tank inlet hose clamp.
  12. Fill the cooling system. Refer to Cooling System Draining and Filling .