Surge Tank Hose Replacement Inlet

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.

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.5L.



2. Partially drain the cooling system. Refer to Cooling System Draining and Filling .
3. Remove the inlet surge tank hose from the surge tank.
4. Disconnect the inlet surge tank hose from the surge tank.



5. Remove the surge tank inlet hose bracket bolt from the lift hook bracket.
6. Remove the inlet surge tank hose clamp from the throttle body heater outlet hose.
7. Remove the inlet surge tank hose.

1. Install the inlet surge tank hose.
2. Connect the inlet surge tank hose to the throttle body heater outlet hose.
3. Install the inlet surge tank hose clamp to the throttle body heater outlet hose.

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.

4. Install the surge tank inlet hose bracket bolt to the lift hook bracket.

Tighten
Tighten the surge tank inlet hose bracket bolt to 10 N·m (89 lb in).




5. Connect the inlet surge tank hose clamp to the surge tank.
6. Fill the cooling system. Refer to Cooling System Draining and Filling .
7. Install the fuel injector sight shield cover.
8. Inspect for leaks.

Surge Tank Hose Replacement Outlet

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



2. Remove the surge tank outlet hose clamp from the surge tank.
3. Disconnect the surge tank outlet hose from the surge tank.



4. Remove the surge tank outlet hose clamp from the thermostat housing.
5. Disconnect the surge tank outlet hose from the thermostat housing.
6. Remove the surge tank outlet hose.

1. Install the surge tank outlet hose.
2. Connect the surge tank hose to the thermostat housing.
3. Install the surge tank outlet hose clamp to the thermostat housing.



4. Connect the surge tank outlet hose to the surge tank.
5. Install the surge tank outlet hose clamp to the surge tank.
6. Fill the cooling system. Refer to Cooling System Draining and Filling .
7. Inspect for leaks.