Options to deal with surge tank interference? - it has to go.

[WarWagon]

Need some ideas to deal with the 1995 suburban surge tank. I don't have much room under the hood with a K47 air cleaner, ABS under the hood, etc. (Surge tanks are NOT overflow bottles.)

It has to go to make room for performance parts... :Justwait2:

Extreme option is to remove the radiator and lower radiator hose and replace it with a 1993 type setup with a overflow bottle and real radiator cap on the radiator. The low coolant light system would be a factor to figure out. (Running green coolant so the 1995 design need is no longer relevant.)

Next option is to find a different surge tank that is smaller.

I can't think of anywhere to relocate the surge tank and battery move ideas make it more trouble than it is worth.

 

[THEFERMANATOR]

Some of the DURAMAX guys have swapped in a 05 CAVALIER surge tank. It is pretty small and mounts along the fender well. Or you could get a moroso expansion tank and mount on the firewall. The other option would be to put a MOROSO filler in your upper hose and block off the hoses to the current surge tank.

 

[Mike K3500]

If you did the 93 style aluminum radiator, they do have a low coolant sensor port hole. At least mine did.

 

[WarWagon]

The 1993 sensor is current to ground. The 1995's are switches by a float.

 

[WarWagon]

Another option as given above:
In line radiator hose filler on the top hose.
1993 lower hose while plugging off the surge tank vent line to the radiator. Only 1 hose to plug off. Maybe just splice then together?
Add external recovery tank.

http://www.jegs.com/p/Moroso/Moroso-Radiator-Hose-Fillers-and-Drains/744355/10002/-1

 

[WarWagon]

I take that back.
The upper radiator hose on the 1995 is 2.25".
Gas engines (454) are small vs. IDI diesel cooling systems. The largest available hose filler is 1.5".