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Installation Procedure

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 Chevrolet Tahoe, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the horns onto the radiator support. Refer to HORN REPLACEMENT .
    2. Fig 1: Radiator Support & Bolt
    GM370884Courtesy of GENERAL MOTORS CORP.
  2. Position the radiator support (1) onto the frame.
  3. Install the radiator support baffle (2).
    4. Fig 2: Lower Radiator Support To Frame Nut & Bolt
    GM402774Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE .
  4. Install the lower radiator support nut and bolt at the frame (1).

    Tighten:  Tighten the nut to 70 N.m (52 lb ft).

    5. Fig 3: Front Upper & Lower Fender To Tie Bar/Radiator Support Bolts
    GM401168Courtesy of GENERAL MOTORS CORP.
  5. Install the front upper and lower fender bolts (1) to the tie bar/radiator support (2). The left fender is shown, the right is similar. Refer to Fender Replacement - Front - Left  and to Fender Replacement - Front - Right .

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

    6. Fig 4: Battery Tray Support
    GM401544Courtesy of GENERAL MOTORS CORP.
  6. Install the battery tray support and secure the support with bolts.

    Tighten:  Tighten the bolts to 9 N.m (80 lb in).

  7. Install the air cleaner mounting bracket. Refer to Mounting Bracket Replacement - Air Cleaner .

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

  8. Install the battery tray. Refer to BATTERY TRAY REPLACEMENT .
    9. Fig 5: Lower Washer Reservoir Bolt & Tie Bar
    GM401108Courtesy of GENERAL MOTORS CORP.
  9. Install the lower washer reservoir bolt (1) to the tie bar (2).

    Tighten:  Tighten the washer reservoir bolt to 9 N.m (80 lb in).

    10. Fig 6: Upper Washer Reservoir Bolt & Tie Bar
    GM370698Courtesy of GENERAL MOTORS CORP.
  10. Install the upper washer reservoir bolt (1) to the tie bar (2) and secure the reservoir with the bolt.

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

  11. Install the A/C condenser, if equipped. Refer to CONDENSER .
    12. Fig 7: Automatic Recirculation Switch Electrical Connector
    GM397231Courtesy of GENERAL MOTORS CORP.
  12. Connect the electrical connector to the automatic recirculation switch.
  13. Reposition the power steering cooler and install the mounting bolts.
  14. Install the air baffles. Refer to RADIATOR AIR BAFFLE ASSEMBLIES AND DEFLECTORS (SIDE) or RADIATOR AIR BAFFLE ASSEMBLIES AND DEFLECTORS (UPPER) .
  15. Install the auxiliary transmission oil cooler, if equipped. Refer to AUXILIARY OIL COOLER
  16. Install the radiator. Refer to RADIATOR REPLACEMENT .
  17. Connect the horn electrical connector. Refer to HORN REPLACEMENT .
    18. Fig 8: Headlamp Housing Support & Tie Bar
    GM370330Courtesy of GENERAL MOTORS CORP.
  18. Install the headlamp housing support (1) to the tie bar (2) with the screws. The 15 series lower mounting position is shown. The 25 series mounting position is similar.

    Tighten:  Tighten the screws to 9 N.m (80 lb in).

  19. Install the tie bar, if equipped. Refer to Tie Bar Replacement - Upper .
  20. Install the hood latch release bracket and cable. Refer to Hood Latch Replacement .
  21. Install the park/turn signal lamp assemblies. Refer to PARK/TURN SIGNAL LAMP REPLACEMENT (EXCEPT AVALANCHE) or PARK/TURN SIGNAL LAMP REPLACEMENT (AVALANCHE) .
  22. Install the headlamps. Refer to HEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT (EXCEPT AVALANCHE) or HEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT (AVALANCHE) or HEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT (ESCALADE) .
  23. Install the inflatable restraint front end discriminating sensor. Refer to FRONT END DISCRIMINATING SENSOR .
  24. Install the front bumper. Refer to BUMPER REPLACEMENT - FRONT (OLD STYLE) .
  25. For Avalanche only, install the grille reinforcement. Refer to Support Replacement - Radiator Grille Reinforcement  in Body Front End.
  26. Install the grille. Refer to GRILLE REPLACEMENT (CADILLAC) or GRILLE REPLACEMENT (AVALANCHE) .
  27. Install the air cleaner assembly.
  28. Install the air intake duct.
  29. Enable the SIR. Refer to ACTIVATING SYSTEM .
  30. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (SINGLE BATTERY) or BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (AUXILIARY BATTERY) .
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