Radiator: Service and Repair

Radiator Replacement (Gas)

Special Tools

J 38185 Hose Clamp Pliers

Removal Procedure

Note: 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 (Service and Repair) for the 4.8L, 5.3L, 6.0L, 6.2L, 7.0L engines or Air Cleaner Assembly Replacement (Service and Repair) for the 4.3L engine.
2. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement (Service and Repair).




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 (Service and Repair) for the 4L60-E/4L65-E/4L70-E transmission or Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (Service and Repair) for the 4L80-E/4L85-E transmission.
8. Remove the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement (Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement).




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.

Installation Procedure




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





Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the fan shroud bolts (1) to the top of the radiator support and tighten to 6 Nm (53 lb in).
4. Install the fan shroud bolts (3) to the sides of the fan shroud and tighten to 6 Nm (53 lb in).
5. Install the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement (Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement).
6. Install the automatic transmission oil cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (Service and Repair) for the 4L60-E/4L65-E/4L70-E transmission or Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (Service and Repair) 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 (Service and Repair).
12. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) for the 4.8L, 5.3L, 6.0L, 6.2L, 7.0L engines or Air Cleaner Assembly Replacement (Service and Repair) for the 4.3L engine.
13. Inspect the automatic transmission fluid level. Refer to Approximate Fluid Capacities (Service Intervals).
14. Inspect the engine oil level. Refer to Approximate Fluid Capacities (Service Intervals).