GM Service Manual Online
For 1990-2009 cars
Makes 🢒 Chevrolet 🢒 2004 🢒 Tahoe - 2WD 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Radiator Support Replacement

Removal Procedure

  1. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Disable the supplemental inflatable restraint (SIR). Refer to SIR Disabling and Enabling in SIR.
  3. Remove the air intake duct. Refer to Air Cleaner Resonator Outlet Duct Replacement in Engine Controls - 4.8L, 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 in Exterior Trim.
  6. For the Avalanche only, remove the grille reinforcement. Refer to Radiator Grille Reinforcement Support Replacement .
  7. Remove the front bumper. Refer to Front Bumper Replacement in Bumpers.
  8. Remove the inflatable restraint front end discriminating sensor. Refer to Inflatable Restraint Front End Sensor Replacement in SIR.
  9. Remove the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement in Lighting Systems.
  10. Remove the park/turn signal lamp assemblies. Refer to Parking and Turn Signal Lamp Replacement in Lighting Systems.
  11. Remove the hood latch release bracket and reposition the release cable. Refer to Hood Primary and Secondary Latch Replacement .
  12. Remove the tie bar, if equipped. Refer to Front End Upper Tie Bar Replacement .

    13. Object Number: 370330 Size: SH
  13. 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.
  14. Disconnect the horn electrical connector.
  15. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
  16. Remove the auxiliary transmission oil cooler, if equipped. Refer to Transmission Fluid Auxiliary Cooler Replacement in Automatic Transmission 4L80-E.
  17. Remove the upper air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement in Engine Cooling.
  18. Remove the side air baffle. Refer to Radiator Air Side Baffle and Deflector Replacement in Engine Cooling.
  19. Remove the mounting bolts from the power steering cooler and reposition the cooler.

    20. Object Number: 397231 Size: SH
  20. Disconnect the electrical connector from the automatic recirculation switch.
  21. Remove the A/C condenser, if equipped. Refer to Condenser Replacement in Heating, Ventilation, and Air Conditioning.

    22. Object Number: 370698 Size: SH
  22. Remove the upper washer reservoir bolt (1) from the tie bar (2).
  23. Remove the battery tray. Refer to Battery Tray Replacement in Engine Electrical.

    24. Object Number: 401108 Size: SH
  24. Remove the lower washer reservoir bolt (1) from the tie bar (2).

    25. Object Number: 401544 Size: SH
  25. Remove the battery tray support.
  26. Remove the air cleaner mounting bracket. Refer to Air Cleaner Bracket Replacement .

    27. Object Number: 401168 Size: SH
  27. 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 Front Fender Replacement - Left Side and to Front Fender Replacement - Right Side .

    28. Object Number: 402774 Size: SH
  28. Remove the lower radiator support nut and the bolt at the frame (1).

    29. Object Number: 370884 Size: SH
  29. Remove the radiator support baffle (2).
  30. Remove the radiator support (1) from the frame.
  31. Remove the left horn from the radiator support. Refer to Horn Replacement - Left Side in Horns.
  32. Remove the right horn from the radiator support. Refer to Horn Replacement - Right Side in Horns.

Installation Procedure

  1. Install the right horn to the radiator support. Refer to Horn Replacement - Right Side in Horns.
  2. Install the horns onto the radiator support. Refer to Horn Replacement - Left Side in Horns.

    3. Object Number: 370884 Size: SH
  3. Position the radiator support (1) onto the frame.
  4. Install the radiator support baffle (2).

    5. Object Number: 402774 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  5. Install the lower radiator support nut and bolt at the frame (1).

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


    Object Number: 401168 Size: SH
  6. 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 Front Fender Replacement - Left Side and to Front Fender Replacement - Right Side .

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


    Object Number: 401544 Size: SH
  7. Install the battery tray support and secure the support with bolts.

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

  8. Install the air cleaner mounting bracket. Refer to Air Cleaner Bracket Replacement .

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

  9. Install the battery tray. Refer to Battery Tray Replacement in Engine Electrical.

    10. Object Number: 401108 Size: SH
  10. Install the lower washer reservoir bolt (1) to the tie bar (2).

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


    Object Number: 370698 Size: SH
  11. Install the upper washer reservoir bolt (1) to the tie bar (2) and secure the reservoir with the bolt.

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

  12. Install the A/C condenser, if equipped. Refer to Condenser Replacement in Heating, Ventilation, and Air Conditioning.

    13. Object Number: 397231 Size: SH
  13. Connect the electrical connector to the automatic recirculation switch.
  14. Reposition the power steering cooler and install the mounting bolts.
  15. Install the side air baffle. Refer to Radiator Air Side Baffle and Deflector Replacement in Engine Cooling.
  16. Install the air baffles. Refer to Radiator Air Upper Baffle and Deflector Replacement .
  17. Install the auxiliary transmission oil cooler, if equipped. Refer to Transmission Fluid Auxiliary Cooler Replacement in Automatic Transaxle 4T65-E.
  18. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
  19. Connect the horn electrical connector. Refer to Horn Replacement - Left Side and Horn Replacement - Right Side in Horns.

    20. Object Number: 370330 Size: SH
  20. 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.

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

  21. Install the tie bar, if equipped. Refer to Front End Upper Tie Bar Replacement .
  22. Install the hood latch release bracket and cable. Refer to Hood Primary and Secondary Latch Replacement .
  23. Install the park/turn signal lamp assemblies. Refer to Parking and Turn Signal Lamp Replacement in Lighting Systems.
  24. Install the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement in Lighting Systems.
  25. Install the inflatable restraint front end discriminating sensor. Refer to Inflatable Restraint Front End Sensor Replacement in SIR.
  26. Install the front bumper. Refer to Front Bumper Replacement in Bumpers.
  27. For Avalanche only, install the grille reinforcement. Refer to Radiator Grille Reinforcement Support Replacement .
  28. Install the grille. Refer to Grille Replacement in Exterior Trim.
  29. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls -- 4.8L, 5.3L and 6.0L.
  30. Install the air intake duct. Refer to Air Cleaner Resonator Outlet Duct Replacement in Engine Controls - 4.8L, 5.3L and 6.0L.
  31. Enable the SIR. Refer to SIR Disabling and Enabling in SIR.
  32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .