Radiator Replacement Gas

Tools Required

J 38185 Hose Clamp Pliers

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. Remove the clamp at the radiator inlet using the J 38185 .
4. Remove the radiator inlet hose (5) from the radiator.
5. Remove the outlet heater hose clamp at the radiator using the J 38185 .
6. Remove the outlet heater hose (2) from the radiator.
7. 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.
8. Remove the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting .



9. Remove the fan shroud bolts (1) from the top of the radiator support.
10. Remove the fan shroud bolts (3) from the sides of the fan shroud.



11. Remove the radiator (2).
12. Remove the radiator insulators (1, 3).
13. Inspect the following components:

•	The radiator

•	The insulators

•	The hoses and clamps

•	The mounting hardware

•	Replace the components as necessary.

1. Install the radiator insulators (1, 3).
2. Install the radiator (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.

3. Install the fan shroud bolts (1) to the top of the radiator support.

Tighten
Tighten the bolts to 6 N·m (53 lb in).

4. Install the fan shroud bolts (3) to the sides of the fan shroud.

Tighten
Tighten the bolts to 6 N·m (53 lb in).

5. Install the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting .
6. 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.



7. Install the radiator inlet hose (5) to the radiator.
8. Install the hose clamp at the radiator inlet housing using the J 38185 .
9. Install the outlet heater hose (2).
10. Install the outlet heater hose clamp using the J 39529 .
11. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
12. 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.
13. Inspect the automatic transmission fluid level. Refer to Approximate Fluid Capacities .
14. Inspect the engine oil level. Refer to Approximate Fluid Capacities .