Surge Tank Replacement

Surge Tank Replacement

Removal Procedure

^ Tools Required
- J 38185 Hose Clamp Plier.

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. Drain the cooling system.
2. Remove the surge tank front bolt at the front mounting bracket.
3. Disengage tension on the Surge tank inlet hose clamp (1) using the J 38185.
4. Disconnect the surge tank inlet hose (1) from the surge tank.
5. Disengage tension on the surge tank outlet hose clamp using the J 38185.
6. Disconnect the surge tank outlet hose (3) from the surge tank.
7. Disengage tension on the throttle body coolant hose (2) using the J 38185.
8. Disconnect the throttle body coolant hose (2) from the surge tank.
9. Pull up on the rear of the surge tank to remove from the rear mounting bracket.
10. Remove the surge tank.

Installation Procedure

Important: Lubricate the inside diameters of the hoses with clean coolant prior to installation,





1. Install the surge tank into the rear mounting bracket.
2. Connect the surge tank outlet hose (3) to the surge tank.
3. Engage tension on the surge tank outlet hose clamp.
4. Connect the surge tank inlet hose (1) to the surge tank.
5. Engage tension on the surge tank inlet hose clamp.
6. Connect the throttle body coolant hose (2) to the surge tank.
7. Engage the tension on the throttle body coolant hose clamp.

Notice: Refer to Fastener Notice in Service Precautions.

8. Install the front surge tank bolt at the mounting bracket.
^ Tighten the nut to 9 Nm (80 inch lbs.).
9. Fill the cooling system.