Radiator Surge Tank Replacement LP1, LY7

Tools Required

J 38185 Hose Clamp Pliers

1. Drain the coolant. Refer to Cooling System Draining and Filling.
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. Remove the left air inlet grill panel. Refer to Air Inlet Grille Panel Replacement
14. Disconnect the low coolant sensor electrical connector.
15. Remove the surge tank.

1. Connect the low coolant sensor electrical connector.
2. Install the surge tank.
3. Position the surge tank tab behind the air inlet grille screen.
4. Install the left air inlet grill panel. Refer to Air Inlet Grille Panel Replacement



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

Notice: Refer to Fastener Notice in the Preface section.

7. Install the surge tank nut.

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

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

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




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

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

13. Fill the cooling system. Refer to Cooling System Draining and Filling.



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

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

Radiator Surge Tank Replacement LS2

Tools Required

J 38185 Hose Clamp Pliers

1. Drain the coolant. Refer to Cooling System Draining and Filling .
2. Remove the left air inlet grille. Refer to Air Inlet Grille Panel Replacement .



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



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



10. Remove the 2 surge tank bolts.
11. Disconnect the low coolant sensor electrical connector.
12. Remove the surge tank.

1. Connect the low coolant sensor electrical connector.
2. Install the surge tank.



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

Notice: Refer to Fastener Notice in the Preface section.

5. Install the surge tank bolts.

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

6. Connect the surge tank inlet hose.
7. Using the J 38185 , reposition the clamp on the surge tank inlet hose .



8. Connect the master cylinder to the vacuum booster.
9. Install the master cylinder nuts.

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

10. Install the left air inlet grille. Refer to Air Inlet Grille Panel Replacement .
11. Fill the cooling system. Refer to Cooling System Draining and Filling .