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Home >> Pontiac >> 2001 >> Aztek Base, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 969 (Body Front End) >> Repair Instructions >> Radiator Support Replacement >> Removal Procedure
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Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  2. Disable the supplemental inflatable restraint (SIR). Refer to SIR Disabling and Enabling Zone 1 in SIR.
  3. Remove the air intake duct. Refer to Air Cleaner Resonator Outlet Duct Replacement in Engine Controls - 4.3L, 5.3L and 6.0L.
  4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.8L, 5.3L and 6.0L.
  5. Remove the grille. Refer to Grille Replacement (GMC) or Grille Replacement (Chevrolet) in Exterior Trim.
  6. Remove the front bumper. Refer to Bumper Replacement - Front (Old Style) in Bumpers.
  7. Remove the inflatable restraint front end discriminating sensor. Refer to Inflatable Restraint Front End Sensor Replacement in SIR.
  8. Remove the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Old Style) in Lighting Systems.
  9. Remove the park/turn signal lamp assemblies. Refer to Park/Turn Signal Lamp Replacement (Old Style) in Lighting Systems.
  10. Remove the hood latch release bracket and reposition the release cable. Refer to Hood Latch Replacement .
  11. Remove the tie bar, if equipped. Refer to Tie Bar Replacement - Upper .
  12. Unscrew the headlamp housing support (1) from the tie bar (2). The 15 series lower mounting position is shown. The 25 series mounting position is similar.
    13. Fig 1: Headlamp Housing Support & Tie Bar
    GM370330Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the horn electrical connector.
  14. Remove the radiator. Refer to Radiator Replacement (EXC 8.1L) or Radiator Replacement (8.1L) in Engine Cooling.
  15. Remove the auxiliary transmission oil cooler (if equipped). Refer to Transmission Fluid Auxiliary Cooler Replacement in Automatic Transmission-4L80E.
  16. Remove the upper air baffles. Refer to Radiator Air Baffle and Deflector Replacement - Upper in Engine Cooling.
  17. Remove the side air baffle. Refer to Radiator Air Baffle and Deflector Replacement - Side in Engine Cooling.
  18. Remove the power steering cooler mounting bolts and reposition the cooler.
  19. Disconnect the electrical connector from the automatic recirculation switch.
    20. Fig 2: Automatic Recirculation Switch Electrical Connector
    GM397231Courtesy of GENERAL MOTORS CORP.
  20. Remove the A/C condenser, if equipped. Refer to Condenser Replacement in Heating, Ventilation, and Air Conditioning.
  21. Remove the upper washer reservoir bolt (1) from the tie bar (2).
    22. Fig 3: Upper Washer Reservoir Bolt & Tie Bar
    GM370698Courtesy of GENERAL MOTORS CORP.
  22. Remove the battery tray. Refer to Battery Tray Replacement in Engine Electrical.
  23. Remove the lower washer reservoir bolt (1) from the tie bar (2).
    24. Fig 4: Lower Washer Reservoir Bolt & Tie Bar
    GM401108Courtesy of GENERAL MOTORS CORP.
  24. Remove the battery tray support.
    25. Fig 5: Battery Tray Support
    GM401544Courtesy of GENERAL MOTORS CORP.
  25. Remove the air cleaner mounting bracket. Refer to Mounting Bracket Replacement - Air Cleaner .
  26. Remove the front upper and lower fender bolts (1) from 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 .
    Fig 6: Front Upper & Lower Fender To Tie Bar/Radiator Support Bolts
    GM401168Courtesy of GENERAL MOTORS CORP.
  27. Remove the lower radiator support nut and bolt at the frame (1).
    28. Fig 7: Lower Radiator Support To Frame Nut & Bolt
    GM402774Courtesy of GENERAL MOTORS CORP.
  28. Remove the radiator support baffle (2).
  29. Remove the radiator support (1) from the frame.
    30. Fig 8: Radiator Support & Baffle
    GM370884Courtesy of GENERAL MOTORS CORP.
  30. Remove the horn(s) from the radiator support. Refer to Horn Replacement - Left or to Horn Replacement - Right in Horns.
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