Radiator Surge Tank Outlet Hose/Pipe Replacement LH2

1. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
3. Compress the clamp (1) and remove the surge tank outlet hose from the surge tank (2).



4. Separate the hose (2) from the retaining features (1 and 3) on the front of dash.



5. Compress the clamp (2) and remove the surge tank outlet hose from the heater hose (1).
6. Remove the surge tank outlet hose/pipe from the engine compartment.

1. Position the surge tank outlet hose/pipe to the engine compartment.
2. Compress the clamp (2) and connect the surge tank outlet hose to the heater hose (1).



3. Install the hose (2) to the retaining features (1 and 3) on the front of dash.



4. Compress the clamp (1) and connect the surge tank outlet hose to the surge tank (2).
5. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
6. Fill the cooling system. Refer to Cooling System Draining and Filling .

Radiator Surge Tank Outlet Hose/Pipe Replacement Right Hand Drive

Radiator Surge Tank Outlet Hose/Pipe Replacement LHD, LY7

Special Tools

J 38185 Hose Clamp Pliers

1. Drain the cooling system. Refer to Cooling System Draining and Filling.



2. Position J 38185 to the clamp in order to remove the outlet hose (2) from the surge tank (1).
3. Loosen the bolt on the bracket which secures the surge tank outlet hose to the engine.
4. Position J 38185 to the clamp in order to remove the surge tank outlet hose from the thermostat assembly.
5. Remove the surge tank outlet hose/pipe from the engine.

1. Position the surge tank outlet hose/pipe to the engine.
2. Position J 38185 to the clamp in order to connect the surge tank outlet hose to the thermostat assembly.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the bolt to the bracket securing the surge tank outlet pipe to the engine.

Tighten
Tighten the bolt to 9 N·m (80 lb in).




4. Position J 38185 to the clamp in order to connect the outlet hose (2) to the surge tank (1).
5. Fill the cooling system. Refer to Cooling System Draining and Filling.