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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1807 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSRADIATOR SURGE TANK REPLACEMENTREMOVAL PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Removal Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Removal Procedure
WARNING: This page is about a different car, the 2009 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Surge Tank Hose
    GM1334992Courtesy of GENERAL MOTORS CORP.
  1. Drain the coolant. Refer to Cooling System Draining and Filling (GE 47716)  or Cooling System Draining and Filling (Static Fill) .
  2. Disconnect the master cylinder fluid level sensor electrical connector and reposition aside.
  3. Using the J 38185  , disengage and reposition the surge tank outlet hose clamp. See Special Tools .
  4. Disconnect the surge tank outlet hose.
  5. Using the J 38185  , disengage and reposition the surge tank inlet hose clamp. See Special Tools .
  6. Disconnect the surge tank inlet hose.
    7. Fig 2: View Of Surge Tank
    GM1334991Courtesy of GENERAL MOTORS CORP.
  7. Remove the surge tank bolt.
  8. Remove the surge tank nut.
  9. Disconnect the low coolant sensor electrical connector.
  10. Remove the surge tank.
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.