Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to
the vehicle or its components.
- Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Disable the supplemental inflatable restraint (SIR). Refer to
Disabling the SIR System
in SIR.
- Remove the air intake duct. Refer to one of the following procedures:
- Remove the air cleaner assembly. Refer to
Air Cleaner Assembly Replacement
in Engine Controls 4.8L, 5.3L and 6.0L.
- Remove the grille. Refer to
Grille Replacement
in Exterior Trim.
- Remove the front bumper. Refer to
Front Bumper Replacement
in Bumpers.
- Remove the inflatable restraint front end discriminating sensor. Refer
to
Inflatable Restraint Front End Discriminating Sensor Replacement
in SIR.
- Remove the headlamps. Refer to
Headlamp Assembly or Headlamp Bulb Replacement
in Lighting Systems.
- Remove the park/turn signal lamp assemblies. Refer to
Parking and Turn Signal Lamp Replacement
in Lighting Systems.
- Remove the hood latch release bracket and reposition the release cable.
Refer to
Hood Primary and Secondary Latch Replacement
.
- Remove the tie bar, if equipped. Refer to
Front End Upper Tie Bar Replacement
.
- Unscrew the headlamp housing support (1) from the tie bar (2). The 15 series
lower mounting position is shown. The 25 series mounting position is similar.
- Disconnect the horn electrical connector.
- Remove the radiator. Refer to
Radiator Replacement
in Engine Cooling.
- Remove the auxiliary transmission oil cooler (if equipped). Refer to
Transmission Fluid Auxiliary Cooler Replacement
in Automatic
Transmission-4L80-E.
- Remove the air baffles. Refer to
Radiator Air Baffle Assemblies and Deflectors
in Engine Cooling.
- Remove the power steering cooler mounting bolts and reposition the cooler.
- Disconnect the electrical connector from the automatic recirculation switch.
- Remove the A/C condenser, if equipped. Refer to
Condenser Replacement
in Heating, Ventilation, and Air Conditioning.
- Remove the upper washer reservoir bolt
(1) from the tie bar (2).
- Remove the battery tray. Refer to
Battery Tray Replacement
in Engine Electrical.
- Remove the lower washer reservoir bolt
(1) from the tie bar (2).
- Remove the battery tray support.
- Remove the air cleaner mounting bracket. Refer to
Air Cleaner Bracket Replacement
.
- Remove the front upper and lower fender
bolts (1) from the tie bar/radiator support (2). The left fender is shown,
the right is similar. Refer to
Front Fender Replacement - Left Side
and to
Front Fender Replacement - Right Side
.
- Remove the lower radiator support nut
and bolt at the frame (1).
- Remove the radiator support baffle (2).
- Remove the radiator support (1) from the frame.
- Remove the horn(s) from the radiator support. Refer to
Horn Replacement
in Horns.
Installation Procedure
- Install the horn(s) onto the radiator support. Refer to
Horn Replacement
in Horns.
- Position the radiator support (1) onto
the frame.
- Install the radiator support baffle (2).
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the lower radiator support nut and bolt at the frame (1).
Tighten
Tighten the radiator support nut to 70 N·m (52 lb ft).
- Install the front upper and lower fender
bolts (1) to the tie bar/radiator support (2). The left fender is
shown, the right is similar. Refer to
Front Fender Replacement - Left Side
and
Front Fender Replacement - Right Side
.
Tighten
Tighten the front fender bolts to 25 N·m (18 lb ft).
- Install the battery tray support.
Tighten
Tighten the battery tray support bolts to 9 N·m (80 lb in).
- Install the battery tray. Refer to
Battery Tray Replacement
in Engine Electrical.
- Install the Air Cleaner Mounting Bracket. Refer to
Air Cleaner Bracket Replacement
.
- Install the lower washer reservoir bolt
(1) to the tie bar (2).
Tighten
Tighten the washer reservoir bolt to 9 N·m (80 lb in).
- Install the upper washer reservoir bolt
(1) to the tie bar (2).
Tighten
Tighten the reservoir bolt to 9 N·m (80 lb in).
- Install the A/C condenser, if equipped. Refer to
Condenser Replacement
in Heating, Ventilation, and Air Conditioning.
- Connect the electrical connector to the automatic recirculation switch.
- Reposition the power steering cooler and install the mounting bolts.
- Install the air baffles. Refer to
Radiator Air Baffle Assemblies and Deflectors
.
- Install the auxiliary transmission oil cooler (if equipped). Refer
to
Transmission Fluid Auxiliary Cooler Replacement
in Automatic Transmission-4L80-E.
- Install the radiator. Refer to
Radiator Replacement
in Engine Cooling.
- Connect the horn electrical connector. Refer to
Horn Replacement
in Horns.
- Install the headlamp housing support (1) to the tie bar (2). The 15 series
lower mounting position is shown. The 25 series mounting position is similar.
Tighten
Tighten the screws to 9 N·m (80 lb in).
- Install the tie bar, if equipped. Refer to
Front End Upper Tie Bar Replacement
.
- Install the hood latch release bracket and cable. Refer to
Hood Primary and Secondary Latch Replacement
.
- Install the park/turn signal lamp assemblies. Refer to
Parking and Turn Signal Lamp Replacement
in Lighting Systems.
- Install the headlamps. Refer to
Headlamp Assembly or Headlamp Bulb Replacement
in Lighting Systems.
- Install the inflatable restraint front end discriminating sensor. Refer
to
Inflatable Restraint Front End Discriminating Sensor Replacement
in SIR.
- Install the front bumper. Refer to
Front Bumper Replacement
in Bumpers.
- Install the grille. Refer to
Grille Replacement
in Exterior Trim.
- Install the air cleaner assembly. Refer to one of the following procedures:
- Install the air intake duct. Refer to one of the following procedures:
- Enable the SIR. Refer to
Enabling the SIR System
in SIR.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.