GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL1/SC1 🢒 Engine 🢒 Engine Cooling 🢒 Radiator Surge Tank Replacement

Removal Procedure

    Object Number: 872047 Size: SH

    Caution: To avoid the danger of being burned, do not remove the cap while the engine, radiator, and surge tank are still hot. Scalding fluid and steam can be blown out under pressure.

  1. Drain the cooling system by opening the drain valve at the bottom of the radiator. Collect the fluid in a container.
  2. Remove the surge tank cap.

    3. Object Number: 873220 Size: SH
  3. Remove the surge tank screws. Move the washer fluid bottle off to the side.
  4. Disconnect the electrical harness from the low coolant sensor.

    5. Object Number: 873213 Size: SH
  5. Remove the clamps from the vent hose and the heater return pipe hose.
  6. Disconnect the hoses.
  7. Remove the surge tank and drain out any remaining fluid.

Installation Procedure

    Object Number: 873216 Size: SH

    Important: Check the low coolant sensor float by shaking the bottle. The float should rattle.

  1. Connect the electrical harness.
  2. Connect the heater return pipe hose.
  3. Connect the vent hose. Install the pipe hose clamp at the 3 o'clock position.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 873224 Size: SH
  4. Position the coolant surge tank and the washer bottle through holes in the body. Install and tighten the screws.

    5. Tighten
    Tighten the surge tank attachment bolts to 5 N·m (44 lb in).

  5. Close the radiator drain plug.
  6. Fill the cooling system with a 50/50 mixture of Dex-Cool™ antifreeze and clean water.
  7. Fill the coolant bottle to the FULL COLD range.
  8. Run the engine until the upper radiator hose is hot, then add additional coolant, if needed, to bring the level to the FULL COLD range.

    9. Object Number: 872298 Size: SH
  9. Install the coolant surge tank cap and check for leaks.