Tools Required

J 38185 Hose Clamp Pliers

Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.



2. Drain the cooling system. Refer to Cooling System Draining and Filling .
3. Reposition the inlet surge tank hose clamp from the surge tank use J 38185 .
4. Remove the inlet surge tank hose from the surge tank.



5. Reposition the outlet surge tank hose clamp from the surge tank use J 38185 .
6. Remove the outlet surge tank hose from the surge tank.



7. Remove the surge tank nuts.
8. Raise the surge tank.
9. Disconnect the wiring harness connector from the coolant level sensor.
10. Remove the surge tank.



11. Inspect the surge tank retainer mounted to the shock tower stud, replace if necessary.
12. If replacing the surge tank, remove the coolant level sensor.

1. If removed, install the surge tank retainer.
2. If removed, install the coolant level sensor into the surge tank.



3. Connect the wiring harness connector to the coolant level sensor.
4. Install the surge tank.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the surge tank nuts.

Tighten
Tighten the nuts to 3 N·m (30 lb in).




6. Install the outlet hose to the surge tank.
7. Install the outlet surge tank hose clamp to the surge tank use J 38185 .



8. Install the inlet hose to the surge tank.
9. Install the inlet surge tank hose clamp to the surge tank use J 38185 .
10. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Electrical.
11. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.