Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) .
Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Control - 4.3 L, Air Cleaner Assembly Replacement in Engine Controls - 4.8 L, 5.3 L, and 6.0 L or Air Cleaner Assembly Replacement in Engine Control - 8.1 L.
Remove the surge tank overflow hose from the surge tank.

Fig 1: View Of Surge Tank & Overflow Hose

GM659051

Courtesy of GENERAL MOTORS CORP.

Disconnect the coolant level sensor electrical connector (3).

Fig 2: View Of Auxiliary Battery Relay, MAF, IAT & Coolant Level Sensor Electrical Connectors

GM674702

Courtesy of GENERAL MOTORS CORP.

Reposition the surge tank inlet and outlet hose clamps.
If equipped with a 4.3 L, 4.8 L, 5.3 L, 6.0 L, or 8.1 L engine, remove the surge tank inlet (1) and outlet (2) hoses from the surge tank.

Fig 3: View Of Surge Tank Outlet Hose & Surge Tank

GM659059

Courtesy of GENERAL MOTORS CORP.

Reposition the surge tank inlet hose clamp from the surge tank.
Remove the surge tank inlet hose (1) from the surge tank.

Fig 4: View Of Surge Tank & Inlet Hose

GM721988

Courtesy of GENERAL MOTORS CORP.

Reposition the surge tank outlet hose clamp from the surge tank.
Remove the surge tank outlet hose (2) from the surge tank.

Fig 5: View Of Surge Tank Outlet Hose & Surge Tank

GM659059

Courtesy of GENERAL MOTORS CORP.

Remove the bolt from the surge tank.
Remove the nut from the surge tank.
Remove the surge tank.

Fig 6: View Of Surge Tank, Nuts & Bolts

GM362165

Courtesy of GENERAL MOTORS CORP.