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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 912 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSSURGE TANK REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Removal Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Removal Procedure
WARNING: This page is about a different car, the 2007 GMC Savana Special, 2007 GMC Savana Camper Special, 2007 GMC Savana, and 2007 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required 

J 38185  Hose Clamp Pliers. See Special Tools .

    CAUTION: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.
  1. Partially drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill)  or Draining and Filling Cooling System (Vac N Fill) .
    2. Fig 1: View Of Surge Tank
    GM1651882Courtesy of GENERAL MOTORS CORP.
  2. Remove the overflow hose from the surge tank.
    3. Fig 2: View Of Surge Tank
    GM1651896Courtesy of GENERAL MOTORS CORP.
  3. Using J 38185  , reposition the surge tank inlet hose clamp. See Special Tools .
  4. Remove the surge tank inlet hose from the surge tank.
    5. Fig 3: View Of surge tank outlet hose clamp
    GM1651889Courtesy of GENERAL MOTORS CORP.
  5. Using J 38185  , reposition the surge tank outlet hose clamp. See Special Tools .
  6. Disconnect the surge tank outlet hose from the surge tank.
    7. Fig 4: Identifying surge tank retaining bolt
    GM1651893Courtesy of GENERAL MOTORS CORP.
  7. Remove the surge tank retaining bolt.
    8. Fig 5: Identifying surge tank assembly
    GM1651865Courtesy of GENERAL MOTORS CORP.
  8. Tilt the surge tank assembly and disconnect the surge tank electrical connector.
  9. Remove the surge tank from the vehicle.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.