Radiator Surge Tank Outlet Hose/Pipe Replacement LX9, LZ9

Tools Required

J 38185 Hose Clamp Pliers

1. Drain the coolant. Refer to Cooling System Draining and Filling .
2. Remove the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement for the 3.5L engine or Air Cleaner Outlet Duct Replacement for the 3.9L engine.



3. Flex the surge tank mounting tabs outward to release the surge tank from the bracket.
4. Remove the surge tank from the surge tank bracket.



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



7. Reposition the surge tank outlet hose clamp at the radiator using the J 38185 .
8. Remove the surge tank outlet hose from the radiator.



9. Remove the surge tank outlet hose from the surge tank hose clip.
10. Remove the surge tank outlet hose from the vehicle.

1. Install the surge tank outlet hose to the surge tank hose clip.



2. Install the surge tank outlet hose to the radiator.
3. Reposition the surge tank outlet hose clamp at the radiator using the J 38185 .



4. Install the surge tank outlet hose to the surge tank.
5. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 .



6. Tilt the surge tank and lead the weld seam on the surge tank under the ribs at the rear of the mounting bracket.



7. Press down on the surge tank to engage the mounting tabs.
8. Install the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement for the 3.5L engine or Air Cleaner Outlet Duct Replacement for the 3.9L engine.
9. Fill the coolant. Refer to Cooling System Draining and Filling .

Radiator Surge Tank Outlet Hose/Pipe Replacement LE5, Early Production Only w/EOC

Tools Required

J 38185 Hose Clamp Pliers

1. Partially drain the coolant. Refer to Cooling System Draining and Filling .
2. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement for the 2.4L engine.



3. Flex the surge tank mounting tabs outward to release the surge tank from the bracket.
4. Remove the surge tank from the surge tank bracket.



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



7. Remove the surge tank outlet hose from the surge tank hose clip.



8. Use J 38185 to reposition the surge tank outlet hose clamp at the engine and engine oil cooler.
9. Remove the surge tank outlet hose from the engine.
10. Remove the surge tank outlet hose from the engine oil cooler.
11. Remove the surge tank outlet hose from the vehicle.

1. Install the surge tank outlet hose to the surge tank hose clip.



2. Install the surge tank outlet hose to the engine.
3. Install the surge tank outlet hose to the engine oil cooler.
4. Use J 38185 to reposition the surge tank outlet hose clamps at the engine and engine oil cooler.



5. Install the surge tank outlet hose to the surge tank.
6. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 .



7. Tilt the surge tank and lead the weld seam on the surge tank under the ribs at the rear of the mounting bracket.



8. Press down on the surge tank to engage the mounting tabs.
9. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement for the 2.4L engine.
10. Fill the coolant. Refer to Cooling System Draining and Filling .

Radiator Surge Tank Outlet Hose/Pipe Replacement LE5, Late Production Only w/o EOC

Tools Required

J 38185 Hose Clamp Pliers

1. Drain the coolant. Refer to Cooling System Draining and Filling .
2. Reposition the surge tank outlet hose clamp at engine using J 38185 .



3. Remove the surge tank outlet hose from the engine.



4. Flex the surge tank mounting tabs outward to release the surge tank from the bracket.
5. Remove the surge tank from the surge tank bracket.
6. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 .
7. Remove the surge tank outlet hose from the surge tank.
8. Remove the surge tank outlet hose clamps from the surge tank outlet hose.

1. Install the surge tank outlet hose clamps to the surge tank outlet hose.
2. Install the surge tank outlet hose to the surge tank.
3. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185 .



4. Tilt the surge tank and lead the weld seam on the surge tank under the ribs at the rear of the mounting bracket.



5. Press down on the surge tank to engage the mounting tabs.



6. Install the surge tank outlet hose to the engine.
7. Reposition the surge outlet hose clamp at the engine using J 38185 .
8. Fill the coolant. Refer to Cooling System Draining and Filling .