GM 25769371
Reservoir Tank

Drain all coolant from the vehicle to start the Coolant Reservoir (LP1, LY7) replacement process. Begin by draining coolant and then remove clutch master cylinder reservoir bolts on cars with manual transmissions before moving the reservoir aside. Install j 38185 hose clamp pliers (J 38185) to detach the Coolant Reservoir inlet hose clamp before disconnecting the hose. Follow the same hose outlet procedure for the Coolant Reservoir. Separate the master cylinder from the Brake Booster by removing each nut so you can reposition the cylinder gently aside. First remove the two bolts securing the Coolant Reservoir and the bolt securing the Coolant Reservoir nut before you gently lift the air inlet grille panel to remove the device. After disconnecting the low coolant sensor's electrical connection you can proceed to remove the Coolant Reservoir. The installation process begins with plugging in the low coolant sensor electrical connection and installing the Coolant Reservoir which must have its tab facing behind the air inlet grille screen. Use the j 38185 to position the inlet grille aside before connecting the Coolant Reservoir outlet hose through its clamp installation. Fasten the Coolant Reservoir installing nut to 9 nm (80 inch lbs.) specifications. Use j 38185 to position the clamp which will secure the Coolant Reservoir inlet hose. Affix the two Coolant Reservoir bolts while tightening them to 9 nm torque (80 inch lbs). Screw in place the vacuum booster to the master cylinder before tightening the nuts to 25 nm (18 ft. Lbs.). After filling the cooling system personnel should install the clutch master cylinder reservoir to its bracket and bolt down the clutch master cylinder reservoir using 50 nm (37 ft. Lbs.) of torque.

Service procedures on the Coolant Reservoir (LHD M 35) start with coolant draining. First disconnect the Coolant Reservoir inlet hose and then remove its upper bolt. First clear the necessary area by unscrewing clutch master cylinder reservoir bolts then move the reservoir to a safe location. Remove the master cylinder nuts so you can move the cylinder away from the vacuum Brake Booster without breaking the brake lines. Loosen and slide the clamp on the Coolant Reservoir outlet hose using hose clamp pliers (J38185) before disconnecting the outlet hose. To access the Coolant Reservoir you must first remove the lower tank bolt and the air inlet grille bolt which enables lifting the panel out of the way for Coolant Reservoir removal. The following procedure involves removing both the Coolant Reservoir along with disconnecting its low coolant sensor electrical connector. During the mounting process, position the Coolant Reservoir behind the air inlet grille screen while connecting the low coolant sensor electrical connector. Set the air inlet grille into its final position before fastening the Coolant Reservoir nut to a torque of 9 nm (80 inch lbs.). Secure the Coolant Reservoir outlet hose with hose clamp pliers (J38185) before relocating the hose clamp. Connect the Coolant Reservoir inlet hose then install its lower bolt with 9 nm (80 inch lbs.) of torque. Screw and tighten the Coolant Reservoir bolt to 9 nm (80 inch lbs.). Fasten the clutch master cylinder reservoir bolts where they require a torque of 50 nm (37 ft. Lbs.). Secure the master cylinder to the vacuum Brake Booster then torque its nuts to 25 nm (18 ft. Lbs.). Finally, fill the cooling system.

Disconnect the low coolant sensor electrical connector.

Fill the cooling system, and if equipped with a manual transmission, position the clutch master cylinder reservoir to the bracket and install the clutch master cylinder reservoir bolts, tightening them to 50 N.m (37 lb ft).