Coolant Reservoir: Service and Repair

REMOVAL

WARNING: To avoid the danger of being burned, do not remove the cap while the engine, radiator, and surge tank are still hot. scalding fluid and steam can be blown out under pressure.

1. Drain the cooling system by opening the drain valve at the bottom of the radiator. Collect the fluid in a container.





2. Remove the pressure cap.





3. Remove surge tank screws. Move washer fluid bottle off to the side.
4. Disconnect the electrical harness from the low coolant sensor.





5. Remove the clamps from the vent hose and the heater return pipe hose. Disconnect hoses.
6. Remove coolant bottle and drain out any remaining fluid.

INSTALLATION

NOTE: Check low coolant sensor float by shaking bottle. Float should rattle.

1. Connect electrical harness.
2. Connect the heater return pipe hose and then the vent hose. Install pipe hose clamp at 3 o'clock position.
3. Position the surge tank and the washer bottle through holes in the body. Install and tighten screws.
4. Close the radiator drain plug. Fill the cooling system with the coolant meeting Saturn specification. Fill the coolant bottle to the FULL COLD mark.
5. Block the drive wheels and firmly apply the parking brake. Shift an automatic transaxle to P (Park), or a manual transaxle to neutral. Run the engine until the upper radiator hose is hot. Check for leaks and level of coolant in tank. Add coolant if necessary.
6. Install pressure cap.