GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2005 🢒 TopKick C-Series (Crew) C4/C5 🢒 Engine 🢒 Engine Cooling 🢒 Radiator Support Replacement

Removal Procedure
  1. Remove the front wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  2. Remove the surge tank. Refer to Radiator Surge Tank Replacement .
  3. Remove the charged air cooler hoses from the charged air cooler. Refer to appropriate procedure:
    4. •  Charge Air Cooler Replacement in Engine Controls - 6.6L
    •  Charge Air Cooler Replacement in Engine Controls - 7.2L
    •  Charge Air Cooler Replacement in Engine Controls - 7.8L
  4. Remove the condenser. Refer to Condenser Replacement .
  5. Remove the radiator support braces. Refer to Radiator Support Diagonal Brace Replacement in Body Front End.
  6. Remove the vacuum pump. Refer to Vacuum Pump Assembly Replacement in HVAC Systems - Manual.
  7. Remove the vacuum tank. Refer to Vacuum Tank Replacement in HVAC Systems - Manual.
  8. Remove the fan shroud. Refer to Fan Shroud Replacement .
  9. Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement .
  10. Remove the side radiator air baffles. Refer to Radiator Air Side Baffle and Deflector Replacement .
  11. Remove the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement .

    12. Object Number: 816439 Size: SH
  12. Remove the upper radiator support bracket bolts.
  13. Remove the upper radiator support (1).
  14. Remove the radiator. Refer to Radiator Replacement .
  15. Remove the lower radiator support bracket bolts.
  16. Remove the side radiator support brackets (2, 4).
  17. Remove the lower radiator support bracket (3).

Installation Procedure

    Object Number: 816439 Size: SH
  1. Install the lower radiator support bracket (3).
  2. Install the side radiator support brackets (2, 4).

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the lower radiator support bracket bolts.

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

  4. Install the radiator. Refer to Radiator Replacement .
  5. Install the upper radiator support (1).
  6. Install the upper radiator support bracket bolts.

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

  7. Install the fan shroud. Refer to Fan Shroud Replacement .
  8. Install the side radiator air baffles. Refer to Radiator Air Side Baffle and Deflector Replacement .
  9. Install the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement .
  10. Install the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement .
  11. Install the vacuum tank. Refer to Vacuum Tank Replacement in HVAC Systems - Manual.
  12. Install the vacuum pump. Refer to Vacuum Pump Assembly Replacement in HVAC Systems - Manual.
  13. Install the radiator support braces. Refer to Radiator Support Diagonal Brace Replacement in Body Front End.
  14. Install the condenser. Refer to Condenser Replacement .
  15. Install the charged air cooler hoses from the charged air cooler. Refer to the appropriate procedure:
    16. •  Charge Air Cooler Replacement in Engine Controls - 6.6L
    •  Charge Air Cooler Replacement in Engine Controls - 7.2L
    •  Charge Air Cooler Replacement in Engine Controls - 7.8L
  16. Install the surge tank. Refer to Radiator Surge Tank Replacement .
  17. Install the front wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.