GM Service Manual Online
For 1990-2009 cars only

Radiator Replacement Gas

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure

Important: Always install a new set of insulators when replacing a radiator. Used insulators may be worn or too large for the new radiator. These conditions may cause the new radiator to be loose.

  1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 4.8L, 5.3L, 6.0L engines or Air Cleaner Assembly Replacement for the 4.3L engine.
  2. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .

  3. Object Number: 834215  Size: SH
  4. Remove the clamp at the radiator inlet using the J 38185 .
  5. Remove the radiator inlet hose (5) from the radiator.
  6. Remove the outlet heater hose clamp at the radiator using the J 38185 .
  7. Remove the outlet heater hose (2) from the radiator.
  8. Remove the automatic transmission cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L60-E/4L65-E/4L70-E transmission or Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L80-E/4L85-E transmission.
  9. Remove the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting .

  10. Object Number: 834218  Size: SH
  11. Remove the fan shroud bolts (1) from the top of the radiator support.
  12. Remove the fan shroud bolts (3) from the sides of the fan shroud.

  13. Object Number: 814407  Size: SH
  14. Remove the radiator (2).
  15. Remove the radiator insulators (1, 3).
  16. Inspect the following components:
  17. • The radiator
    • The insulators
    • The hoses and clamps
    • The mounting hardware
    • Replace the components as necessary.

Installation Procedure


    Object Number: 814407  Size: SH
  1. Install the radiator insulators (1, 3).
  2. Install the radiator (2).

  3. Object Number: 834218  Size: SH

    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.

  4. Install the fan shroud bolts (1) to the top of the radiator support.
  5. Tighten
    Tighten the bolts to 6 N·m (53 lb in).

  6. Install the fan shroud bolts (3) to the sides of the fan shroud.
  7. Tighten
    Tighten the bolts to 6 N·m (53 lb in).

  8. Install the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting .
  9. Install the automatic transmission oil cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L60-E/4L65-E/4L70-E transmission or Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L80-E/4L85-E transmission.

  10. Object Number: 834215  Size: SH
  11. Install the radiator inlet hose (5) to the radiator.
  12. Install the hose clamp at the radiator inlet housing using the J 38185 .
  13. Install the outlet heater hose (2).
  14. Install the outlet heater hose clamp using the J 39529 .
  15. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
  16. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 4.8L, 5.3L, 6.0L engines or Air Cleaner Assembly Replacement for the 4.3L engine.
  17. Inspect the automatic transmission fluid level. Refer to Approximate Fluid Capacities .
  18. Inspect the engine oil level. Refer to Approximate Fluid Capacities .

Radiator Replacement Diesel

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure

Important: Always install a new set of insulators when replacing a radiator. Used insulators may be worn or too large for the new radiator. These conditions may cause the new radiator to be loose.


    Object Number: 1726280  Size: SH
  1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  2. Remove the upper radiator baffle.
  3. Remove the surge tank. Refer to Radiator Surge Tank Replacement .
  4. Remove battery. Refer to Battery Replacement .
  5. Remove the charged air cooler inlet hose/pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement .

  6. Object Number: 834215  Size: SH
  7. Remove the clamp at the radiator inlet using the J 38185 .
  8. Remove the radiator inlet hose (5) from the radiator.
  9. Remove the outlet heater hose clamp at the radiator using the J 38185 .
  10. Remove the outlet heater hose (2) from the radiator.
  11. Remove the automatic transmission cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L60-E/4L65-E/4L70-E transmissions or Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L80-E/4L85-E transmissions.
  12. Remove the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting .
  13. Remove the engine oil fill tube. Refer to Oil Filler Tube Replacement .
  14. Remove intake manifold tube. Refer to Intake Manifold Tube Replacement .

  15. Object Number: 834218  Size: SH
  16. Remove the upper radiator baffle.
  17. Remove the fan shroud bolts (1) from the top of the radiator support.

  18. Remove the fan shroud bolts (3) from the sides of the fan shroud.

  19. Object Number: 1726332  Size: SH
  20. Remove the radiator mounting bolts from the charged air cooler.
  21. Remove the charge air cooler bolts to core support.
  22. Remove the radiator and charge air cooler as assembly.
  23. Remove radiator bolts to charge air cooler.
  24. Remove the radiator insulators.
  25. Inspect the following components:
  26. • The radiator
    • The insulators
    • The hoses and clamps
    • The mounting hardware
    • Replace the components as necessary.

Installation Procedure


    Object Number: 1726332  Size: SH
  1. Install the radiator insulators.
  2. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the radiator to the charge air cooler.
  4. Tighten
    Tighten the bolts to 6 N·m (53 lb in).

  5. Install the radiator and charge air cooler as an assembly.
  6. Install the radiator mounting bolts to the charged air cooler.
  7. Tighten
    Tighten the bolts to 6 N·m (53 lb in).


    Object Number: 834218  Size: SH
  8. Install the fan shroud bolts (1) to the top of the radiator support.
  9. Tighten
    Tighten the bolts to 6 N·m (53 lb in).

  10. Install the fan shroud bolts (3) to the sides of the fan shroud.
  11. Tighten
    Tighten the bolts to 6 N·m (53 lb in).

  12. Install the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting .
  13. Install the automatic transmission oil cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L60-E/4L65-E/4L70-E transmissions or Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L80-E/4L85-E transmissions.

  14. Object Number: 834215  Size: SH
  15. Install the radiator inlet hose (5) to the radiator.
  16. Install the hose clamp at the radiator inlet housing using the J 38185 .
  17. Install the outlet heater hose (2).
  18. Install the outlet heater hose clamp using the J 39529 .
  19. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement .
  20. Install oil fill tube. Oil Filler Tube Replacement .
  21. Install the upper radiator baffle.
  22. Install the battery. Refer to Battery Replacement .
  23. Install the charged air cooler hose/pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement .
  24. Install the surge tank assembly. Refer to Radiator Surge Tank Replacement .
  25. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

  26. Object Number: 1726280  Size: SH
  27. Install the upper radiator baffle.
  28. Inspect the automatic transmission fluid level. Refer to Approximate Fluid Capacities .
  29. Inspect the engine oil level. Refer to Approximate Fluid Capacities .