Radiator Surge Tank Replacement Diesel

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Drain the coolant from the surge tank.



3. Disconnect the coolant outlet hose (3) from the surge tank.
4. Disconnect the coolant inlet hose from the surge tank.



5. Remove the bolts (2) and the clamps (4) from the surge tank (1).
6. Disconnect the coolant overflow hose from the surge tank.
7. Remove the lower radiator hose from the surge tank.
8. Disconnect the electrical connector.
9. Remove the surge tank (1) from the radiator (3).

1. Connect the surge tank (1) to the radiator (3).
2. Connect the electrical connector.

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.

3. Install the bolts (2) and the clamps (4) to the surge tank  (1).

Tighten
Tighten the bolts to 17 N·m (13 lb ft).

4. Connect the coolant overflow hose and the clamps to the surge tank.



5. Connect the coolant outlet hose (3) and the clamps to the surge tank.
6. Connect the coolant inlet hose and the clamps to the surge tank.
7. Install the lower radiator hose to the surge tank.
8. Add the coolant to the surge tank.
9. Connect the negative battery cable.