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Home › Saturn › 2005 › Ion Red Line › Repair and Diagnosis › External Pages › Different car › Section 36 (Engine Cooling System) › Repair Instructions › Surge Tank Replacement › Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Saturn Ion Red Line, 2004 Saturn Ion 3, 2004 Saturn Ion 2, and 2004 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the surge tank.
  2. Connect the coolant level sensor electrical connector.
    3. Fig 1: View Of Coolant Level Sensor Electrical Connector
    GM873721Courtesy of GENERAL MOTORS CORP.
  3. With the surge tank raised, install the surge tank outlet hose.
  4. Reposition the hose clamp using SA9111E  to secure the hose. See Special Tools and Equipment .
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the surge tank bolt.

    Tighten:  Tighten the bolt to 8 N.m (70 lb in).

    6. Fig 2: View Of Surge Tank & Surge Tank Outlet Hose
    GM873720Courtesy of GENERAL MOTORS CORP.
  6. Set the underhood junction block bracket into position.
  7. Install the underhood junction block bracket nuts (1,2).

    Tighten:  Tighten the nuts to 10 N.m (88 lb in).

  8. Install the underhood junction block bracket bolt (3).

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    9. Fig 3: View Of Engine Compartment Component Locations
    GM889782Courtesy of GENERAL MOTORS CORP.
  9. Install the surge tank inlet hose to the surge tank.
  10. Reposition the hose clamp to secure the hose.
    11. Fig 4: View Of Surge Tank Inlet Hose
    GM873719Courtesy of GENERAL MOTORS CORP.
  11. Fill the cooling system. Refer to Draining and Filling Cooling System (2.2L (L61))  or Draining and Filling Cooling System (2.0L (LSJ)) .
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