Coolant Reservoir: Service and Repair

Surge Tank Replacement

Removal Procedure





1, Drain the cooling system. Refer to Draining and Filling Cooling System.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.81L, 5.31L, and 6.01L or Air Cleaner Assembly Replacement in Engine Controls - 8.1 L.
3. Remove the surge tank overflow hose from the surge tank.





4. Disconnect the low coolant level switch electrical connector (3).





5. Reposition the surge tank inlet hose clamp.
6. Remove the surge tank inlet (1) hose from the surge tank.





7. Reposition the surge tank outlet hose clamp.
8. Remove the surge tank outlet hose (2) from the surge tank.





9. Remove the bolt from the surge tank.
10. Remove the nut from the surge tank.
11. Remove the surge tank.

Installation Procedure





1. Install the surge tank.

Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the bolt to the surge tank.
- Tighten the bolt to 9 Nm (80 inch lbs.).
3. Install the nut to the surge tank.
- Tighten the nut to 9 Nm (80 inch lbs.).





4. Install the surge tank outlet hose (2) to the surge tank.
5. Position the surge tank outlet hose clamp.





6. Install the surge tank inlet hose (1) to the surge tank.
7. Position the surge tank inlet hose clamp.





8. Connect the low coolant level switch electrical connector (3).





9. Install the surge tank overflow hose.
10. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.8L, 5.3L, and 6.01L or Air Cleaner Assembly Replacement in Engine Controls - 8.1 L.
11. Fill the cooling system. Refer to Draining and Filling Cooling System.