GM S-Series Pick-ups and SUV's 1994-1999 Repair Guide

Radiator

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REMOVAL & INSTALLATION



See Figures 1 through 12


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.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system.
  4.  



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Fig. Fig. 1: Place a suitable container beneath the radiator petcock and open the petcock to drain the coolant



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Fig. Fig. 2: Exploded view of a common radiator and shroud assembly

  1. If equipped, remove the air inlet duct.
  2.  
  3. Disconnect the overflow hose from the radiator, then disconnect the upper and lower radiator hoses.
  4.  
  5. If equipped with A/C, it may be necessary to remove the A/C hose retaining clip and reposition the hose for shroud and/or radiator removal. DO NOT disconnect any refrigerant fittings.
  6.  

If equipped with a 1 piece shroud, then shroud may be unbolted from the radiator support and pushed back over the cooling fan instead of removing it completely.

  1. If equipped with a 2 piece radiator/fan shroud, remove the upper fan shroud-to-radiator support bolts and the upper fan shroud-to-lower fan shroud retainers. Remove the upper shroud from the vehicle.
  2.  
  3. If equipped with an A/T, disconnect and plug the fluid cooler lines at the radiator. Plug all openings to prevent system contamination or excessive fluid loss.
  4.  
  5. If equipped with a factory engine oil cooler which is integral to the radiator, disconnect and plug the oil cooler lines at the radiator. Plug all openings to prevent system contamination or excessive fluid loss. Plug all openings to prevent system contamination or excessive fluid loss.
  6.  
  7. If equipped, remove the lower fan shroud.
  8.  
  9. Lift the radiator straight upward from the supports and from the vehicle. Be careful to lift the radiator straight upward and not to tilt it excessively as the radiator will still contain a significant amount of coolant and, if applicable, transmission fluid/engine oil.
  10.  



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Fig. Fig. 3: Use pliers to remove the upper radiator hose clamp and then disconnect the hose from the radiator



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Fig. Fig. 4: The air inlet duct assembly is retained by plastic pins.



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Fig. Fig. 5: Remove the upper air duct assembly



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Fig. Fig. 6: Remove the upper shroud bolts



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Fig. Fig. 7: The upper shroud is attached to the lower shroud with bolts



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Fig. Fig. 8: After unfastening the bolts, separate the upper shroud from the lower shroud



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Fig. Fig. 9: The top of the lower shroud will have to be tilted inward to clear the cooling fan to remove the shroud



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Fig. Fig. 10: The lower shroud clips into the bottom of the radiator



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Fig. Fig. 11: Disconnect the lower hose from the radiator



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Fig. Fig. 12: Remove the radiator from the engine compartment

To install:
  1. Lower the radiator into position on the supports.
  2.  
  3. If equipped, install the lower fan shroud.
  4.  
  5. If equipped, remove the plugs, then connect the engine oil cooler lines and tighten the fittings.
  6.  
  7. If equipped with an A/T, remove the plugs, then connect the transmission fluid cooler lines and tighten the fittings.
  8.  
  9. Install the upper fan shroud and secure using the support and lower shroud retainers.
  10.  
  11. If applicable, reposition the A/C refrigerant hose and secure using the retaining clip.
  12.  
  13. Connect the overflow hose, upper and lower radiator hoses.
  14.  
  15. If equipped, install the air inlet duct.
  16.  
  17. Properly refill the engine cooling system.
  18.  

 
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