Coolant Reservoir: Service and Repair

Surge Tank Replacement

^ Tools Required
- J 43181 Quick Connect Release Tool

Removal Procedure
1. Partially drain the engine coolant.





2. Disconnect the surge tank inlet hose (2) from the surge tank (1).





3. Disconnect the connector (2) from the coolant level sensor.





4. Remove the secondary AIR relay bracket mounting nuts (2).
5. Remove the secondary AIR relay bracket (1).
6. Using J 43181, release the quick connect fitting at the surge tank outlet hose.





7. Remove the surge tank mounting screw (3) and nuts (2).
8. Remove the surge tank (1) from the mounting studs.

Installation Procedure





1. Position the surge tank (1) on the mounting studs.

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

Install the surge tank bolt (3).
Tighten the bolt to 6 Nm (53 inch lbs.).
3. Install the surge tank nuts (2).
Tighten the nuts (2) to 6 Nm (53 inch lbs.).
4. Position the surge tank outlet hose and the quick connect fitting with the surge tank and press to engage.
5. Verify the quick connect fitting is fully seated.





6. Install the secondary AIR relay bracket (1) over the studs.
7. Install the 2 secondary AIR relay bracket nuts (2).
Tighten the nuts (2) to 6 Nm (53 inch lbs.).





8. Connect the connector (2) to the coolant level sensor.





9. Connect the surge tank inlet hose (2) to the surge tank (1).
10. Fill the cooling system.