GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 1999 🢒 Isuzu MD Steel Tilt (F Model) 🢒 Engine 🢒 Engine Cooling 🢒 Surge Tank (Diesel) Replacement

Removal Procedure
  1. Tilt the cab.

    2. Refer to Cab Tilting in General Information.

    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.

  2. Disconnect the negative battery cable.
  3. Partially drain the cooling system.

    4. Refer to Cooling System Draining and Filling .


    Object Number: 209250 Size: SH
  4. Remove the following components:
    5. • The radiator surge tank inlet hose
    • The clamps
  5. Remove the following components:
    6. • The radiator surge tank outlet hose (1)
    • The clamps
  6. Remove the following components:
    7. • The surge tank overflow hose
    • The clamp

    Object Number: 209252 Size: SH
  7. Remove the low coolant sensor (1).
  8. Remove the radiator surge tank cap.
  9. Remove the radiator surge tank bolts.
  10. Remove the radiator surge tank from the mount.
  11. Inspect the radiator surge tank for cracks.
  12. Replace the surge tank if the surge tank is damaged.

Installation Procedure
  1. Install the radiator surge tank to the mount.

    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 radiator surge tank bolts.

    3. Tighten
    Tighten the radiator surge tank bolts to 6 N·m (53 lb in).


    Object Number: 209252 Size: SH
  3. Install the low coolant sensor (1).
  4. Install the radiator surge tank inlet hose and the clamps.

    5. Tighten
    Tighten the clamps to 3 N·m (27 lb in).

  5. Install the radiator surge tank outlet hose and the clamps.

    6. Tighten
    Tighten the clamps to 3 N·m (27 lb in).


    Object Number: 209250 Size: SH
  6. Install the surge tank overflow hose (1) and the clamp.
  7. Connect the negative battery cable.
  8. Fill the cooling system.
  9. Inspect the system for leaks.
  10. Install the surge tank pressure cap.
  11. Lower the cab.