Radiator Support Replacement General

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.

1. Disconnect the negative battery cable(s).
2. Disable the supplemental inflatable restraint (SIR). Refer to Disabling the SIR System in SIR.
3. Remove the air intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls -4.8L, 5.3L, 6.0L or Air Cleaner Assembly Replacement in Engine Controls-4.3L.
4. Remove the front bumper. Refer to Front Bumper Replacement in Bumpers.
5. Remove the inflatable restraint front end discriminating sensor. Refer to Inflatable Restraint Front End Discriminating Sensor Replacement in SIR.
6. Remove the headlamps. Refer to Headlamp Replacement in Lighting Systems.
7. Remove the park/turn signal lamp assemblies. Refer to Parking and Turn Signal Lamp Replacement in Lighting Systems.
8. Remove the hood latch release bracket and reposition the release cable. Refer to Hood Primary and Secondary Latch Replacement in Body Front End.



9. Unscrew the headlamp housing support (1) from the radiator support (2). The 15 series lower mounting position is shown. The 25 series mounting position is similar.
10. Disconnect the horn electrical connector. Refer to Horn Replacement in Horns.
11. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
12. Remove the auxiliary transmission oil cooler (if equipped). Refer to Transmission Oil Cooler Replacement Transmission Oil Cooler Replacement in Automatic Transmission 4L60E or Transmission Fluid Auxiliary Cooler Replacement Transmission Oil Cooler Replacement in Automatic Transmission 4L80E.
13. Remove the air baffles. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine Cooling.
14. Remove the power steering cooler mounting bolts and reposition the cooler. Refer to Power Steering Fluid Cooler Replacement in Power Steering Systems.



15. Disconnect the electrical connector from the automatic recirculation switch.
16. Remove the a/c condenser, if equipped. Refer to Condenser Replacement Condenser Replacement in HVAC systems - Manual.



17. Remove the upper washer reservoir bolt (1) from the radiator support (2).
18. Remove the battery tray. Refer to Battery Tray Replacement in Engine Electrical.



19. Remove the lower washer reservoir bolt (1) from the radiator support (2).



20. Remove the battery tray support.



21. Remove the front upper and lower fender bolts (1) from the radiator support (2). The left fender is shown, the right is similar.



22. Remove the lower radiator support nut and bolt at the frame (1).



23. Remove the radiator support baffle (2).
24. Remove the radiator support (1) from the frame.
25. Remove the horn(s) from the radiator support. Refer to Horn Replacement in Horns.

1. Install the horn(s) onto the radiator support. Refer to Horn Replacement in Horns.



2. Position the radiator support (1) onto the frame.
3. Install the radiator support baffle (2).



4. 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).




5. Install the front upper and lower fender bolts (1) to the radiator support (2). The left fender is shown, the right is similar.

Tighten
Tighten the front fender bolts to 25 N·m(18 lb in).




6. Install the battery tray support.

Tighten
Tighten the battery tray support bolts to 9 N·m(80 lb in).




7. Install the lower washer reservoir bolt (1) to the radiator support (2).

Tighten
Tighten the bolt to 9 N·m(80 lb in).

8. Install the battery tray. Refer to Battery Tray Replacement in Engine Electrical.



9. Install the upper washer reservoir bolt (1) to the radiator support (2).

Tighten
Tighten the reservoir bolt to 9 N·m(80 lb in).

10. Install the a/c condenser, if equipped. Refer to Condenser Replacement in HVAC systems - Manual.



11. Connect the electrical connector to the automatic recirculation switch.
12. Reposition the power steering cooler and install the mounting bolts. Refer to Power Steering Fluid Cooler Replacement in Power Steering Systems.
13. Install the air baffles. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine Cooling.
14. Install the auxiliary transmission oil cooler (if equipped). Refer to Transmission Oil Cooler Replacement in Automatic Transmission 4L60E or Transmission Fluid Auxiliary Cooler Replacement in Automatic Transmission 4L80E.
15. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
16. Connect the horn electrical connector. Refer to Horn Replacement in Horns.



17. Install the headlamp housing support (1) to the radiator support (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).

18. Install the hood latch release bracket and cable. Refer to Hood Primary and Secondary Latch Replacement in Body Front End.
19. Install the park/turn signal lamp assemblies. Refer to Parking and Turn Signal Lamp Replacement in Lighting Systems.
20. Install the headlamps. Refer to Headlamp Replacement in Lighting Systems.
21. Install the inflatable restraint front end discriminating sensor. Refer to Inflatable Restraint Front End Discriminating Sensor Replacement in SIR.
22. Install the front bumper. Refer to Front Bumper Replacement in Bumpers.
23. Install the air intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls -4.8L, 5.3L, 6.0L or Air Cleaner Assembly Replacement in Engine Controls-4.3L.
24. Enable the SIR. Refer to Enabling the SIR System in SIR.
25. Connect the negative battery cable. Perform the Idle Learn Procedure for 4.8L, 5.3L, and 6.0L engines only. Refer to PCM Idle Learn Procedure in Engine Controls-4.8L, 5.3L, 6.0L.

Radiator Support Replacement Upper

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.

1. Disconnect the negative battery cable.
2. Remove the upper radiator baffle. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine Cooling.
3. Remove the headlamps. Refer to Headlamp Replacement in Lighting.



4. Remove the upper condenser mounting bolts.



5. Remove the front end diagonal brace.
6. Remove the fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.



7. Remove the radiator support to the radiator brace bolts (1). Access the bolts from the rear of the upper radiator support using an extension.



8. Remove the radiator mounting bolts from the rear side of the upper radiator support.



9. Remove the upper radiator support bolts.



10. Remove the upper headlamp housing support screws.
11. Remove the upper radiator support.

1. Position the upper radiator support onto the lower radiator support. Install the upper radiator support bolts hand tight.

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.

2. Assure that the alignment is proper. Tighten the upper radiator support bolts.

Tighten
Tighten the bolts to 9 N·m (80 lb in).




3. Install the upper headlamp housing support screws.

Tighten
Tighten the screws to 9 N·m (80 lb in).




4. Install the radiator mounting bolts onto the rear side of the upper radiator support.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).




5. Install the radiator support to the radiator brace bolts (1). Access the bolts from the rear of the upper radiator support using an extension.

Tighten
Tighten the bolts to 9 N·m (80 lb in).

6. Install the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.



7. Install the front end diagonal brace.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).




8. Install the upper condenser mounting bolts.

Tighten
Tighten the bolts to 9 N·m (80 lb in).

9. Install the headlamps. Refer to Headlamp Replacement in Lighting.
10. Install the upper radiator baffle. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine Cooling.
11. Connect the negative battery cable.