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Installation Procedure

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, 2003 Chevrolet RV Cutaway, and 2003 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the braces to the radiator support with the bolts.
    CAUTION: Refer to FASTENER NOTICE .
  2. Place the top of the left brace between the support and the right brace (3).

    Tighten 

    Tighten the brace to the radiator support bolts (1) to 25 N.m (18 lb ft).

  3. Install the radiator support (4) into the vehicle.
    Fig 1: Installing Braces & Radiator Support
    G02422943Courtesy of GENERAL MOTORS CORP.
  4. Install the upper mounting cushion and the shims between the support and the bracket on the frame.
    • Level the radiator support by placing the shims (8) below the support.
    • Do not exceed 11 mm (0.43 in) in height.
    • Do not exceed 5 mm (0.19 in) between the left shim and the right shim pack height.
  5. Install the bolt through the following components:
    • The shims (8)
    • The upper cushion (7)
    • The frame bracket
    • The lower cushion (4)
    • The retainer (5)
    • The nut (6)

      Tighten 

      Tighten the radiator support mounting nut to 57 N.m (42 lb ft).

    Fig 2: Installing Radiator Support Bolt & Components
    G02422944Courtesy of GENERAL MOTORS CORP.
  6. Install the air cleaner inlet to the right side of the radiator support.
  7. Install the fender to the radiator support bolts.

    Tighten 

    Tighten the fender to the support bolts to 25 N.m (18 lb ft).

    Fig 3: Installing Fender
    G02422945Courtesy of GENERAL MOTORS CORP.
  8. Install the wheelhouse to the radiator support bolts (4).

    Tighten 

    Tighten the wheelhouse to the support bolts to 25 N.m (18 lb ft).

  9. Install the air conditioning condenser and the lines, if equipped.
  10. Install the horn to the sheet metal support. Refer to HORN REPLACEMENT .
  11. Install the auxiliary transmission and the engine oil coolers, if equipped. Refer to ENGINE OIL COOLER REPLACEMENT - AUXILIARY .
  12. Install the fuel vapor canister and the lines to the radiator support.
  13. Install the sheet metal support to the front of the radiator support with the bolts.

    Tighten 

    Tighten the sheet metal support to the radiator support bolts to 25 N.m (18 lb ft).

    Fig 4: Installing Wheelhouse To Radiator Support Bolts
    G02422946Courtesy of GENERAL MOTORS CORP.
  14. Install the headlamps. Refer to HEADLAMP REPLACEMENT - SEALED BEAM .
  15. Install the primary hood latch bracket to the sheet metal support. Refer to Hood Latch Replacement .
  16. Install the ground wires to the support.
  17. Install the wiring harnesses into the clips on the front and the back of the support.
  18. Install the headlamp connectors and the parking lamp connectors to the lamps.
  19. Install the grille. Refer to GRILLE REPLACEMENT (UPLEVEL) or GRILLE REPLACEMENT (BASE) .
  20. Install the radiator. Refer to RADIATOR REPLACEMENT .
  21. Install the engine cooling fan shroud. Refer to FAN SHROUD REPLACEMENT .
  22. Install the battery tray to the wheelhouse.

    Tighten 

    Tighten the battery tray to the wheelhouse bolts to 25 N.m (18 lb ft).

  23. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
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