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. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the intake manifold cover if equipped. Refer to Intake Manifold Cover Replacement for the 2.2L engine or Intake Manifold Cover Replacement for the 2.4L engine.



3. Remove the surge tank cap.



4. Reposition the surge tank inlet hose clamp.
5. Remove the surge tank inlet hose from the surge tank.



6. Unclip the surge tank inlet hose from the underhood junction block bracket.
7. Remove the positive crankcase ventilation (PCV) hose from the camshaft cover and position the hose aside.



8. Unclip the surge tank inlet hose from the fuel rail.



9. Reposition the surge tank inlet hose clamp.
10. Remove the surge tank inlet hose from the engine.

1. Install the surge tank inlet hose to the engine.
2. Reposition the hose clamp to secure the hose.



3. Clip the surge tank inlet hose to the fuel rail.
4. Install the PCV hose to the camshaft cover.



5. Clip the surge tank inlet hose to the underhood junction block bracket.



6. Install the surge tank inlet hose to the surge tank.
7. Reposition the hose clamp to secure the hose.
8. Install the intake manifold cover if equipped. Refer to Intake Manifold Cover Replacement for the 2.2L engine or Intake Manifold Cover Replacement for the 2.4L engine.
9. Fill the cooling system. Refer to Cooling System Draining and Filling .