Manual Transmission

Surge Tank Replacement (LHD M 35)

Tools Required
- J 38185 Hose Clamp Pliers

Removal Procedure
1. Drain the coolant.







2. Remove the upper surge tank bolt (1).
3. Disconnect the surge tank inlet hose.







4. Remove the clutch master cylinder reservoir bolts (1).
5. Position the clutch master cylinder reservoir out of the way.
6. Without disconnecting brake lines separate the master cylinder from the brake booster.
7. Using the J 38185, loosen and slide the clamp on the surge tank outlet hose.
8. Disconnect the surge tank outlet hose.
9. Remove the lower surge tank bolt.
10. Remove the surge tank bolt at the air inlet grille.
11. Lift the air inlet grille panel partially out of the way to remove the surge tank.
12. Disconnect the low coolant sensor electrical connector.
13. Remove the surge tank.



Installation Procedure
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. Reposition the air inlet grille.

Notice: Refer to Fastener Notice in Service Precautions.
Fastener Notice

5. Install the surge tank nut.
Tighten the nut to 9 Nm (80 inch lbs.).

6. Connect the surge tank outlet hose.
7. Using the J 38185 reposition the surge tank outlet hose clamp into the original position.
8. Connect the surge tank inlet hose.
9. Install the lower surge tank bolt.
Tighten the bolts to 9 Nm (80 inch lbs.).







10. Install the surge tank bolt (1).
Tighten the bolts to 9 Nm (80 inch lbs.).

11. Reposition the clutch master cylinder reservoir.







12. Install the clutch master cylinder reservoir bolts (1).
Tighten the bolts to 50 Nm (37 ft. lbs.).

13. Connect the master cylinder to the vacuum booster.
14. Fill the cooling system.