GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 1999 🢒 GMC K Sierra - 4WD 🢒 Body and Accessories 🢒 Body Front End 🢒 Radiator Surge Tank Replacement

Removal Procedure

    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.

  1. Drain the cooling system. Refer to Cooling System Draining and Filling .
  2. Remove the surge tank overflow hose.
  3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-4.8L, 5.3L, 6.0L, or Air Cleaner Assembly Replacement in Engine Controls-4.3L.

    4. Object Number: 362172 Size: SH
  4. Remove the hoses at the surge tank.

    5. Object Number: 362166 Size: SH
  5. Remove the surge tank hose clamps.
  6. Remove the hoses at the surge tank.
  7. Disconnect the coolant level sensor electrical connector.

    8. Object Number: 362165 Size: SH
  8. Remove the surge tank nut.
  9. Remove the surge tank bolt.
  10. Remove the surge tank.

Installation Procedure

    Object Number: 362165 Size: SH
  1. Install the surge tank.

    2. 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.

  2. Install the surge tank bolt.

    3. Tighten

        • Tighten the surge tank nut to 10 N·m (89 lb in).
        • Tighten the surge tank bolt to 10 N·m (89 lb in).

    Object Number: 362172 Size: SH
  3. Install the surge tank hose clamps.

    4. Object Number: 362166 Size: SH
  4. Install the hoses to the surge tank.
  5. Install the surge tank hose clamps.
  6. Connect the coolant level sensor electrical connector.
  7. Install the surge tank overflow hose.
  8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-4.8L, 5.3L, 6.0L, Air Cleaner Assembly Replacement in Engine Controls-4.3L.
  9. Fill the cooling system. Refer to Cooling System Draining and Filling .