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Home >> Saturn >> 2004 >> Ion Red Line >> Repair and Diagnosis >> External Pages >> Different car >> Section 60 (Engine Cooling System) >> Repair Instructions >> Surge Tank Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2005 Saturn Ion Red Line, 2005 Saturn Ion 3, 2005 Saturn Ion 2, and 2005 Saturn Ion 1. 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 (2.2L (L61))  or Draining and Filling Cooling System (2.0L (LSJ)) .
  2. Lower the vehicle.
  3. Reposition the surge tank inlet hose clamp.
  4. Remove the surge tank inlet hose from the surge tank.
    5. Fig 1: View Of Surge Tank Inlet Hose
    GM873719Courtesy of GENERAL MOTORS CORP.
  5. Remove the underhood junction block bracket nuts (1,2).
    6. Fig 2: View Of Engine Compartment Component Locations
    GM889782Courtesy of GENERAL MOTORS CORP.
  6. Remove the underhood junction block bracket bolt (3).
  7. Lift the underhood junction block bracket and position away from the surge tank.
  8. Remove surge tank bolt. Lift surge tank and reposition the surge tank outlet hose clamp using SA9111E  . See Special Tools .
  9. Remove surge tank outlet hose.
    10. Fig 3: View Of Surge Tank & Surge Tank Outlet Hose
    GM873720Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the coolant level sensor electrical connector.
    11. Fig 4: View Of Coolant Level Sensor Electrical Connector
    GM873721Courtesy of GENERAL MOTORS CORP.
  11. Remove surge tank.
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