GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Special Tools

J 38185 Hose Clamp Pliers

    Warning: 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. Partially drain the cooling system. Refer to Cooling System Draining and Filling.

  2. Object Number: 1651882  Size: SH
  3. Remove the overflow hose from the surge tank.

  4. Object Number: 1651896  Size: SH
  5. Using J 38185 , reposition the surge tank inlet hose clamp.
  6. Remove the surge tank inlet hose from the surge tank.

  7. Object Number: 1651889  Size: SH
  8. Using J 38185 , reposition the surge tank outlet hose clamp.
  9. Disconnect the surge tank outlet hose from the surge tank.

  10. Object Number: 1651893  Size: SH
  11. Remove the surge tank retaining bolt.

  12. Object Number: 1651865  Size: SH
  13. Tilt the surge tank assembly and disconnect the surge tank electrical connector.
  14. Remove the surge tank from the vehicle.

Installation Procedure


    Object Number: 1651865  Size: SH
  1. Connect the surge tank electrical connector.
  2. Note: Lubricate the inside diameters of the hoses with clean coolant prior to installation.

  3. Install the surge tank to the vehicle.
  4. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1651893  Size: SH
  5. Install the surge tank retaining bolt and tighten to 9 N·m (80 lb in).

  6. Object Number: 1651889  Size: SH
  7. Install the surge tank outlet hose to the surge tank.
  8. Using J 38185 , reposition the surge tank outlet hose clamp.

  9. Object Number: 1651896  Size: SH
  10. Install the surge tank inlet hose to the surge tank.
  11. Using J 38185 , reposition the surge tank inlet hose clamp.

  12. Object Number: 1651882  Size: SH
  13. Install the overflow hose to the surge tank.
  14. Fill the cooling system. Refer to Cooling System Draining and Filling.