Surge Tank (Diesel) Replacement

Surge Tank (Diesel) Replacement

1. Remove the front wheelhouse panel.




2. Remove the front intake air duct (1) from the air filter housing.
3. Partially drain the coolant. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.




4. Remove the coolant level sensor connector (1).




5. Remove the radiator surge tank inlet hose and the clamps.
6. Remove the radiator surge tank outlet hose and the clamps.
7. Remove the surge tank overflow hose and the clamp.
8. Remove the low coolant sensor.
9. Remove the radiator surge tank cap.




10. Remove the radiator surge tank bolts.
11. Remove the radiator surge tank from the mounting bracket.
12. Inspect the radiator surge tank mounting bracket for cracks. Replace the mounting bracket if it is damaged.

Installation Procedure




1. Install the radiator surge tank to the mounting bracket.

Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the radiator surge tank bolts.

Tighten the radiator surge tank bolts to 13 Nm (115 lb in).

3. Install the low coolant sensor.
4. Install the radiator surge tank inlet hose and the clamps.
5. Install the radiator surge tank outlet hose and the clamps.

Tighten the radiator surge tank hose clamps to 3 Nm (27 lb in).

6. Install the surge tank overflow hose and the clamp.




7. Connect the low coolant sensor connector (1).




8. Install the front air intake duct (1) to the air filter housing.
9. Install the front wheelhouse panel.
10. Fill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.
11. Inspect the system for leaks.