Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Removal & Installation

Print


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

4.8L, 5.3L And 8.1L Engines



  1. Drain the cooling system.
  2.  
  3. Remove the radiator inlet hose.
  4.  
  5. Remove the radiator outlet hose.
  6.  
  7. Remove the fan shroud.
  8.  
  9. Remove the engine vent hose (4.8L, 5.3L, 6.0L engines).
  10.  
  11. Disconnect the engine oil cooler lines.
  12.  
  13. Disconnect the transmission oil cooler lines.
  14.  
  15. Remove the radiator mounting bolts.
  16.  
  17. Tilt the radiator towards the engine
  18.  
  19. Remove the radiator by pulling the radiator from the support.
  20.  

To install:

  1. Install the radiator by pushing the radiator and the rubber mounts into the radiator support .
  2.  
  3. Install the radiator mounting bolts. Tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the outlet heater hose.
  6.  
  7. Connect the engine oil cooler lines.
  8.  
  9. Install the fan shroud.
  10.  
  11. Install the engine vent hose (4.8L, 5.3L, 6.0L engines).
  12.  
  13. Install the radiator outlet hose.
  14.  
  15. Install the radiator inlet hose.
  16.  
  17. Fill the cooling system and test the cooling system for leaks.
  18.  

5.7L, 6.5L And 7.4L Engines



  1. Drain the coolant from the cooling system.
  2.  
  3. Remove the upper fan shroud.
  4.  
  5. Remove the upper insulators and brackets.
  6.  
  7. Disconnect the upper and lower radiator hoses.
  8.  
  9. Remove the transmission fluid cooler pipes.
  10.  
  11. Remove the engine oil cooler pipes.
  12.  
  13. Remove the lower fan shroud bolts and the lower fan shroud.
  14.  
  15. Disconnect the coolant recovery reservoir/surge tank hose. On diesel equipped vehicles, remove surge tank.
  16.  
  17. Remove the radiator from the lower insulators and brackets.
  18.  
  19. Inspect all of the parts and connections for leaks and wear.
  20.  
  21. Replace the parts and/or connections, as necessary.
  22.  

To install:

  1. Install the radiator on the lower insulators.
  2.  
  3. Install the coolant recovery reservoir/surge tank hose.
  4.  
  5. Install the lower fan shroud bolts and the lower fan shroud. Tighten the bolts to 71 inch lbs. (9 Nm).
  6.  
  7. Install the engine oil cooler pipes. Tighten the fittings to 18 ft. lbs. (24 Nm).
  8.  
  9. Install the transmission fluid cooler pipes. Tighten the fittings to 19 ft. lbs. (26 Nm).
  10.  
  11. Install the upper and lower radiator hoses.
  12.  
  13. Install the upper insulators.
  14.  
  15. Install the upper fan shroud and the upper fan shroud bolts. Tighten the bolts to 71 inch lbs. (9 Nm).
  16.  
  17. Refill the cooling system and check for leaks.
  18.  

Diesel Engines



  1. Drain the cooling system.
  2.  
  3. Unfasten the upper fan shroud bolts and remove the upper fan shroud.
  4.  
  5. If equipped, remove the upper panel fasteners and the panel.
  6.  
  7. If equipped, remove the upper insulators and brackets.
  8.  
  9. Disconnect the radiator upper and lower hoses and, if applicable, the transmission coolant lines.
  10.  
  11. Remove the coolant recovery system line, if so equipped.
  12.  
  13. Remove the oil coolant lines, if equipped.
  14.  
  15. Remove the lower fan shroud bolts and the lower fan shroud.
  16.  
  17. Remove radiator from the lower brackets and insulators.
  18.  

To install:

  1. Install the radiator on the lower brackets and insulators.
  2.  
  3. Install the lower fan shroud and its retaining bolts. Tighten the shroud bolts to 71 inch lbs. (9 Nm).
  4.  
  5. Attach and tighten the engine oil cooler pipe bolts to 18 ft. lbs. (24 Nm) and the transmission oil cooler bolts to 19 ft. lbs. (26 Nm).
  6.  
  7. Attach the lower and upper radiator hoses..
  8.  
  9. Install the upper insulators, the upper fan shroud and fan shroud bolts. Tighten the shroud bolts to 71 inch lbs. (9 Nm).
  10.  
  11. Attach the coolant recovery system line, if so equipped.
  12.  
  13. If equipped, install the upper panel fasteners.
  14.  
  15. Refill the cooling system.
  16.  

  1. Drain the cooling system.
  2.  
  3. Unfasten the upper fan shroud bolts and remove the upper fan shroud.
  4.  
  5. If equipped, remove the upper panel fasteners and the panel.
  6.  
  7. If equipped, remove the upper insulators and brackets.
  8.  
  9. Disconnect the radiator upper and lower hoses and, if applicable, the transmission coolant lines.
  10.  
  11. Remove the coolant recovery system line, if so equipped.
  12.  
  13. Remove the oil coolant lines, if equipped.
  14.  
  15. Remove the lower fan shroud bolts and the lower fan shroud.
  16.  
  17. Remove radiator from the lower brackets and insulators.

    Click image to see an enlarged view

    Fig. Exploded view of the radiator mounting-diesel engines

  18.  

To install:

  1. Install the radiator on the lower brackets and insulators.
  2.  
  3. Install the lower fan shroud and its retaining bolts. Tighten the shroud bolts to 71 inch lbs. (9 Nm).
  4.  
  5. Attach and tighten the engine oil cooler pipe bolts to 18 ft. lbs. (24 Nm) and the transmission oil cooler bolts to 19 ft. lbs. (26 Nm).
  6.  
  7. Attach the lower and upper radiator hoses..
  8.  
  9. Install the upper insulators, the upper fan shroud and fan shroud bolts. Tighten the shroud bolts to 71 inch lbs. (9 Nm).
  10.  
  11. Attach the coolant recovery system line, if so equipped.
  12.  
  13. If equipped, install the upper panel fasteners.
  14.  
  15. Refill the cooling system.
  16.  

  1. Drain the cooling system.
  2.  
  3. Unfasten the upper fan shroud bolts and remove the upper fan shroud.
  4.  
  5. If equipped, remove the upper panel fasteners and the panel.
  6.  
  7. If equipped, remove the upper insulators and brackets.
  8.  
  9. Disconnect the radiator upper and lower hoses and, if applicable, the transmission coolant lines.
  10.  
  11. Remove the coolant recovery system line, if so equipped.
  12.  
  13. Remove the oil coolant lines, if equipped.
  14.  
  15. Remove the lower fan shroud bolts and the lower fan shroud.
  16.  
  17. Remove radiator from the lower brackets and insulators.

    Click image to see an enlarged view

    Fig. Exploded view of the radiator mounting-diesel engines

  18.  

To install:

  1. Install the radiator on the lower brackets and insulators.
  2.  
  3. Install the lower fan shroud and its retaining bolts. Tighten the shroud bolts to 71 inch lbs. (9 Nm).
  4.  
  5. Attach and tighten the engine oil cooler pipe bolts to 18 ft. lbs. (24 Nm) and the transmission oil cooler bolts to 19 ft. lbs. (26 Nm).
  6.  
  7. Attach the lower and upper radiator hoses..
  8.  
  9. Install the upper insulators, the upper fan shroud and fan shroud bolts. Tighten the shroud bolts to 71 inch lbs. (9 Nm).
  10.  
  11. Attach the coolant recovery system line, if so equipped.
  12.  
  13. If equipped, install the upper panel fasteners.
  14.  
  15. Refill the cooling system.
  16.  

Gasoline Engines



  1. Drain the cooling system.
  2.  
  3. Unfasten the upper fan shroud bolts and remove the upper fan shroud.
  4.  
  5. If equipped, remove the upper panel fasteners and the panel.
  6.  
  7. If equipped, remove the upper insulators and brackets.
  8.  
  9. Disconnect the radiator upper and lower hoses and, if applicable, the transmission coolant lines.
  10.  
  11. Remove the coolant recovery system line, if so equipped.
  12.  
  13. Remove the oil coolant lines, if equipped.
  14.  
  15. Remove the lower fan shroud bolts and the lower fan shroud.
  16.  
  17. Remove radiator from the lower brackets and insulators.

    Click image to see an enlarged view

    Fig. Remove the radiator upper panel fasteners



    Click image to see an enlarged view

    Fig. Remove the radiator upper panel



    Click image to see an enlarged view

    Fig. Disconnect the transmission cooler lines

  18.  

To install:

  1. Install the radiator on the lower brackets and insulators.
  2.  
  3. Install the lower fan shroud and its retaining bolts. Tighten the shroud bolts to 71 inch lbs. (9 Nm).
  4.  
  5. Attach and tighten the engine oil cooler pipe bolts to 18 ft. lbs. (24 Nm) and the transmission oil cooler bolts to 19 ft. lbs. (26 Nm).
  6.  
  7. Attach the lower and upper radiator hoses..
  8.  
  9. Install the upper insulators, the upper fan shroud and fan shroud bolts. Tighten the shroud bolts to 71 inch lbs. (9 Nm).
  10.  
  11. Attach the coolant recovery system line, if so equipped.
  12.  
  13. If equipped, install the upper panel fasteners.
  14.  
  15. Refill the cooling system.

    Click image to see an enlarged view

    Fig. After the fasteners are removed, lift the radiator from the vehicle

  16.  

  1. Drain the cooling system.
  2.  
  3. Unfasten the upper fan shroud bolts and remove the upper fan shroud.
  4.  
  5. If equipped, remove the upper panel fasteners and the panel.
  6.  
  7. If equipped, remove the upper insulators and brackets.
  8.  
  9. Disconnect the radiator upper and lower hoses and, if applicable, the transmission coolant lines.
  10.  
  11. Remove the coolant recovery system line, if so equipped.
  12.  
  13. Remove the oil coolant lines, if equipped.
  14.  
  15. Remove the lower fan shroud bolts and the lower fan shroud.
  16.  
  17. Remove radiator from the lower brackets and insulators.

    Click image to see an enlarged view

    Fig. Exploded view of the radiator mounting-gasoline engines

  18.  

To install:

  1. Install the radiator on the lower brackets and insulators.
  2.  
  3. Install the lower fan shroud and its retaining bolts. Tighten the shroud bolts to 71 inch lbs. (9 Nm).
  4.  
  5. Attach and tighten the engine oil cooler pipe bolts to 18 ft. lbs. (24 Nm) and the transmission oil cooler bolts to 19 ft. lbs. (26 Nm).
  6.  
  7. Attach the lower and upper radiator hoses..
  8.  
  9. Install the upper insulators, the upper fan shroud and fan shroud bolts. Tighten the shroud bolts to 71 inch lbs. (9 Nm).
  10.  
  11. Attach the coolant recovery system line, if so equipped.
  12.  
  13. If equipped, install the upper panel fasteners.
  14.  
  15. Refill the cooling system.
  16.  

  1. Drain the cooling system.
  2.  
  3. Unfasten the upper fan shroud bolts and remove the upper fan shroud.
  4.  
  5. If equipped, remove the upper panel fasteners and the panel.
  6.  
  7. If equipped, remove the upper insulators and brackets.
  8.  
  9. Disconnect the radiator upper and lower hoses and, if applicable, the transmission coolant lines.
  10.  
  11. Remove the coolant recovery system line, if so equipped.
  12.  
  13. Remove the oil coolant lines, if equipped.
  14.  
  15. Remove the lower fan shroud bolts and the lower fan shroud.
  16.  
  17. Remove radiator from the lower brackets and insulators.

    Click image to see an enlarged view

    Fig. Exploded view of the radiator mounting-gasoline engines



    Click image to see an enlarged view

    Fig. Remove the radiator upper panel fasteners



    Click image to see an enlarged view

    Fig. Remove the radiator upper panel



    Click image to see an enlarged view

    Fig. Disconnect the transmission cooler lines

  18.  

To install:

  1. Install the radiator on the lower brackets and insulators.
  2.  
  3. Install the lower fan shroud and its retaining bolts. Tighten the shroud bolts to 71 inch lbs. (9 Nm).
  4.  
  5. Attach and tighten the engine oil cooler pipe bolts to 18 ft. lbs. (24 Nm) and the transmission oil cooler bolts to 19 ft. lbs. (26 Nm).
  6.  
  7. Attach the lower and upper radiator hoses..
  8.  
  9. Install the upper insulators, the upper fan shroud and fan shroud bolts. Tighten the shroud bolts to 71 inch lbs. (9 Nm).
  10.  
  11. Attach the coolant recovery system line, if so equipped.
  12.  
  13. If equipped, install the upper panel fasteners.
  14.  
  15. Refill the cooling system.

    Click image to see an enlarged view

    Fig. After the fasteners are removed, lift the radiator from the vehicle

  16.  

 
label.common.footer.alt.autozoneLogo