GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


    Object Number: 898638  Size: SH
  1. Disconnect the negative battery cable.
  2. Drain the coolant. Refer to Cooling System Draining and Filling .
  3. Remove the cylinder head degas hose to surge tank clamp and remove the hose.

  4. Object Number: 931349  Size: SH
  5. Remove the tank to upper motor rail bolts and lift the tank.
  6. Remove the return hose clamp and return hose.
  7. Disconnect the coolant level switch from the engine harness and remove the surge tank.

Installation Procedure


    Object Number: 931349  Size: SH
  1. Connect the coolant level switch to the engine harness.
  2. Install the return hose and clamp. With the clamp at the 7 o'clock position.
  3. Install the surge tank by inserting the surge tank retention tab into the upper motor rail while lowering the tank into place. Install the tank to upper motor rail bolts.

  4. Object Number: 898638  Size: SH
  5. Install the cylinder head degas hose and clamp.
  6. Notice: Refer to Fastener Notice in the Preface section.

  7. Connect the negative battery cable.
  8. Tighten
    Tighten the negative battery cable bolt to 17 N·m (13 lb ft).

  9. Fill the cooling system. Refer to Coolant Replacement in this section of the service manual.