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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 620 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSSURGE 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 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Drain the cooling system. Refer to Draining and Filling Cooling System .
  2. Remove the air cleaner assembly. Refer to AIR CLEANER ASSEMBLY .
  3. Remove the surge tank overflow hose from the surge tank.
    Fig 1: Remove Surge Tank Overflow Hose
    G02108967Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the coolant level sensor electrical connector (3).
    Fig 2: Disconnect Coolant Level Sensor Electrical Connector
    G02108968Courtesy of GENERAL MOTORS CORP.
  5. Reposition the surge tank inlet and outlet hose clamps.
  6. 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: Remove Surge Tank Inlet & Outlet Hoses
    G02108969Courtesy of GENERAL MOTORS CORP.
  7. Reposition the surge tank inlet hose clamp from the surge tank.
  8. Remove the surge tank inlet hose (1) from the surge tank.
    Fig 4: Remove Surge Tank Inlet Hose
    G02108970Courtesy of GENERAL MOTORS CORP.
  9. Reposition the surge tank outlet hose clamp from the surge tank.
  10. Remove the surge tank outlet hose (2) from the surge tank.
    Fig 5: Remove Surge Tank Outlet Hose
    G02108971Courtesy of GENERAL MOTORS CORP.
  11. Remove the bolt from the surge tank.
  12. Remove the nut from the surge tank.
  13. Remove the surge tank.
    Fig 6: Remove Surge Tank, Bolt & Nut
    G02108972Courtesy of GENERAL MOTORS CORP.
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.