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Installation Procedure

WARNING: This page is about a different car, the 2005 Chevrolet Malibu. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing Surge Tank Outlet Hose From Surge Tank
    GM1202397Courtesy of GENERAL MOTORS CORP.
  1. Install the surge tank outlet hose to the surge tank.
  2. Reposition the surge tank outlet hose clamp at the surge tank using the J 38185  . See Special Tools .
  3. Connect the coolant level sensor wire harness connector.
    4. Fig 2: Tilting Surge Tank
    GM1335061Courtesy of GENERAL MOTORS CORP.
  4. Tilt the surge tank and lead the weld seam on the surge tank under the ribs at the rear of the mounting bracket.
    5. Fig 3: Flexing Surge Tank Mounting Tabs Outward
    GM1202387Courtesy of GENERAL MOTORS CORP.
  5. Press down on the surge tank to engage the mounting tabs.
    6. IMPORTANT: The tabs must lock into the mounting bracket.
  6. Pull upward on the surge tank to ensure that the tabs are engaged.
    7. Fig 4: Removing Surge Tank Inlet Hose From Surge Tank
    GM1215599Courtesy of GENERAL MOTORS CORP.
  7. Install the surge tank inlet hose to the surge tank.
  8. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185  . See Special Tools .
  9. Fill the coolant. Refer to Draining and Filling Cooling System (L61)  or Draining and Filling Cooling System (LX9) .
  10. Install the surge tank cap.
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