GM Full Size Vans 1987-1997 Repair Guide

Radiator

Print

REMOVAL & INSTALLATION



See Figures 1 through 12


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

Gasoline Engines


Click image to see an enlarged view

Fig. Fig. 1: Drain the cooling system using the radiator draincock - a tube on the outlet may prevent a mess



Click image to see an enlarged view

Fig. Fig. 2: On some models, you must remove the hood latch - start by matchmarking it ...



Click image to see an enlarged view

Fig. Fig. 3: ... then loosen the retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 4: ... and remove the latch assembly from the radiator support

  1. Drain the cooling system.
  2.  
  3. Remove the coolant recovery reservoir, if applicable.
  4.  
  5. If necessary, remove the air cleaner assembly.
  6.  
  7. If necessary, remove the hood latch.
  8.  
  9. If there is a fan shroud, remove the shroud or shroud halves (upper and lower) attaching retainers.
  10.  
  11. Disconnect the radiator upper and lower hoses and, if applicable, the transmission coolant lines.
  12.  
  13. If applicable, remove the oil cooler lines from the radiator.
  14.  
  15. Remove the radiator upper panel if so equipped.
  16.  
  17. Disengage any electrical connections from the radiator.
  18.  
  19. On 1996-97 models, remove the fan and clutch assembly.
  20.  
  21. Remove the radiator attaching bolts and remove the radiator.
  22.  



Click image to see an enlarged view

Fig. Fig. 5: Loosen the retainers for the upper fan shroud ...



Click image to see an enlarged view

Fig. Fig. 6: ... being careful not to miss any (a long extension is handy for the upper-to-lower shroud bolts)



Click image to see an enlarged view

Fig. Fig. 7: With the retainers removed, carefully lift the upper fan shroud from the engine compartment:



Click image to see an enlarged view

Fig. Fig. 8: Loosen and disconnect any threaded transmission or oil cooler lines



Click image to see an enlarged view

Fig. Fig. 9: An open-end line wrench is well suited for this purpose



Click image to see an enlarged view

Fig. Fig. 10: Disengage the overflow hose from the radiator



Click image to see an enlarged view

Fig. Fig. 11: Loosen the clamps and disconnect the remaining radiator hoses ...



Click image to see an enlarged view

Fig. Fig. 12: ... then carefully lift the radiator from the engine compartment

To install:
  1. Install the radiator.
  2.  
  3. Install the upper panel, if removed.
  4.  
  5. Connect the engine oil cooler and transmission oil cooler lines.
  6.  
  7. Engage the electrical connections to the radiator.
  8.  
  9. Connect the upper and lower radiator hoses.
  10.  
  11. Install and the shroud.
  12.  
  13. If removed., install the air cleaner assembly and coolant recovery reservoir.
  14.  
  15. Fill the cooling system and check for leaks.
  16.  

Diesel Engines
  1. Drain the cooling system.
  2.  
  3. Remove the air intake snorkel.
  4.  
  5. Remove the windshield washer bottle.
  6.  
  7. Remove the hood release cable.
  8.  
  9. Remove the upper fan shroud.
  10.  
  11. Disconnect the upper radiator hose.
  12.  
  13. Disconnect the transmission cooler lines.
  14.  
  15. On the 6.2L diesel engine, unplug the low coolant sensor wire.
  16.  
  17. Disconnect the overflow hose.
  18.  
  19. Disconnect the engine oil cooler lines.
  20.  
  21. Disconnect the lower radiator hose.
  22.  
  23. On the 6.2L diesel engine, remove the brake master cylinder. see Brakes .
  24.  
  25. Remove the fasteners securing the radiator, then remove the radiator from the vehicle.
  26.  

To install:
  1. Position the radiator at its mounting points and install its retainers. Tighten to 71 inch lbs. (9 Nm).
  2.  
  3. If removed, install the brake master cylinder.
  4.  
  5. Connect the lower radiator hose.
  6.  
  7. Connect the engine oil cooler lines.
  8.  
  9. Connect the overflow hose.
  10.  
  11. If removed, engage the low coolant sensor wire.
  12.  
  13. Connect the transmission cooler lines.
  14.  
  15. Connect the upper radiator hose.
  16.  
  17. Install the upper fan shroud.
  18.  
  19. Install the hood release cable.
  20.  
  21. Install the windshield washer bottle.
  22.  
  23. Install the air intake snorkel.
  24.  
  25. Fill the cooling system.
  26.  

 
label.common.footer.alt.autozoneLogo