Surge Tank Replacement

Surge Tank Replacement (LP1, LY7)

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure




1. Drain the coolant. Refer to Draining and Filling Cooling System (GE 47716) Draining and Filling Cooling System (LP1, LY7 Static Fill) Draining and Filling Cooling System (LS2 Static Fill).
2. If equipped with a manual transmission, remove the clutch master cylinder reservoir bolts (1).
3. Position the clutch master cylinder reservoir out of the way.




4. Using J 38185, loosen and slide the clamp from the surge tank inlet hose.
5. Disconnect the surge tank inlet hose.
6. Using J 38185, loosen and slide the clamp from the surge tank outlet hose.
7. Disconnect the surge tank outlet hose.




8. Remove the master cylinder nuts.
9. Without disconnecting brake lines, separate the master cylinder from the brake booster.
10. Gently reposition the master cylinder out of the way.




11. Remove the 2 surge tank bolts.
12. Remove the surge tank nut.
13. Lift the air inlet grille panel partially out of the way to remove the surge tank.
14. Remove the surge tank.

Installation Procedure

1. Install the surge tank.
2. Position the surge tank tab behind the air inlet grille screen.
3. Reposition the air inlet grille.




4. Connect the surge tank outlet hose.
5. Using J 38185, reposition the clamp on the surge tank outlet hose.

Notice: Refer to Fastener Notice.

6. Install the surge tank nut.

Tighten the nut to 9 N.m (80 lb in).

7. Connect the surge tank inlet hose.
8. Using the J 38185, reposition the clamp on the surge tank inlet hose.
9. Install the 2 surge tank bolts.

Tighten the bolts to 9 N.m (80 lb in).




10. Connect the master cylinder to the vacuum booster.
11. Install the master cylinder nuts.

Tighten the nuts to 25 N.m (18 lb ft).

12. Fill the cooling system. Refer to Draining and Filling Cooling System (GE 47716) Draining and Filling Cooling System (LP1, LY7 Static Fill) Draining and Filling Cooling System (LS2 Static Fill).




13. If equipped with a manual transmission, position the clutch master cylinder reservoir to the bracket.
14. Install the clutch master cylinder reservoir bolts (1).

Tighten the bolts to 50 N.m (37 lb ft).