Radiator Surge Tank Replacement Gasoline

Warning: Refer to Radiator Cap Removal Warning in the Preface section.




1. Drain the engine coolant to below the level of the surge tank.
2. Loosen the return hose clamp and disconnect the return hose from the top of the surge tank.
3. Loosen the throttle body hose clamp and disconnect the throttle body hose from the top of the surge tank.
4. Loosen the feed hose clamp and disconnect the feed hose from the bottom of the surge tank.



5. Remove the surge tank attaching bolt.
6. Remove the surge tank from the support mount.
7. Clean the inside and the outside of the surge tank and the surge tank cap with soap and water.
8. Rinse the surge tank and the cap thoroughly.

1. Install the surge tank to the support mount.

Caution: Refer to Fastener Caution in the Preface section.

2. Secure the surge tank with the attaching bolt and tighten to 4 N·m (35 lb in).



3. Connect the return hose and the throttle body hose to the top of the surge tank.
4. Connect the feed hose to the bottom of the surge tank.
5. Secure the return hose, the throttle body hose, and the feed hose to the surge tank with the hose clamps.
6. Fill the surge tank with the coolant to the center ridge, or to the MAX mark.

Radiator Surge Tank Replacement Diesel

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. Drain the engine coolant to below the level of the surge tank.
2. Disconnect the return hose clamp and disconnect the return hose from the top of the surge tank.
3. Disconnect the thermostat by-pass hose clamp and disconnect the thermostat by-pass hose from the top of the surge tank.
4. Disconnect the feed hose clamp and disconnect the feed hose from the bottom of the surge tank.



5. Remove the surge tank attaching bolt and nut.
6. Remove the surge tank.
7. Clean the inside and the outside of the surge tank and the surge tank cap with soap and water.
8. Rinse the surge tank and the cap thoroughly.

1. Install the surge tank.

Caution: Refer to Fastener Caution in the Preface section.

2. Secure the surge tank with the attaching bolt and nut, tighten to 8 N·m (71 lb in)



3. Connect the return hose and the thermostat bypass hose to the top of the surge tank.
4. Connect the feed hose to the bottom of the surge tank.
5. Fill the surge tank with the coolant to the center ridge or the MAX mark