GM Service Manual Online
For 1990-2009 cars only

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure

  1. Drain the cooling system. Refer to Cooling System Draining and Filling.
  2. Remove the radiator support. Refer to Radiator Support Replacement.

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

  6. Object Number: 1481413  Size: SH
  7. Disconnect the surge tank outlet hose assembly from the support tabs on the cooling fan shroud.


    Object Number: 1481412  Size: SH
  8. Disengage tension on the surge tank outlet hose clamp at the water pump.
  9. Disconnect the surge tank outlet hose from the water pump.
  10. Using the J 38185 , disengage the tension on the surge tank outlet hose clamp at the heater pipe assembly.
  11. Disconnect the surge tank outlet hose from the heater pipe assembly.
  12. Remove the surge tank outlet hose assembly from the vehicle.

Installation Procedure

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


    Object Number: 1481412  Size: SH
  1. Install the surge tank outlet hose assembly to the vehicle.
  2. Connect the surge tank outlet hose to the heater pipe assembly.
  3. Using the J 38185 , engage tension on the surge tank outlet hose clamp at the heater pipe assembly.
  4. Connect the surge tank outlet hose to the water pump.
  5. Using the J 38185 , engage tension on the surge tank outlet hose clamp at the water pump.

  6. Object Number: 1481413  Size: SH
  7. Connect the surge tank outlet hose assembly to the support tabs on the cooling fan shroud.

  8. Object Number: 1481409  Size: SH
  9. Connect the surge tank outlet hose to the surge tank.
  10. Engage tension on the surge tank outlet hose clamp at the surge tank using the J 38185 .
  11. Install the radiator support. Refer to Radiator Support Replacement.
  12. Fill the cooling system. Refer to Cooling System Draining and Filling.