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Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the horn (s) onto the radiator support. Refer to HORN REPLACEMENT .
  2. Position the radiator support (1) onto the frame.
  3. Install the radiator support baffle (2).
    Fig 1: Installing Radiator Support Baffle
    G01579041Courtesy 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 radiator support nut to 70 N.m (52 lb ft).

    Fig 2: Installing Lower Radiator Support Nut & Bolt
    G01579042Courtesy 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 - Left Front (Old Style)   or Fender Replacement - Left Front (New Style GMC)   or Fender Replacement-Front-Left (New Style Chevrolet)   and Fender Replacement-Front-Right (Old Style)   or Fender Replacement-Front-Right (New Style GMC)   or Fender Replacement-Front-Right (New Style Chevrolet)   .

    Tighten 

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

    Fig 3: Fender Bolts & Tie Bar/Radiator Support
    G01579043Courtesy of GENERAL MOTORS CORP.
  6. Install the battery tray support.

    Tighten 

    Tighten the battery tray support bolts to 9 N.m (80 lb in).

  7. Install the battery tray. Refer to BATTERY TRAY REPLACEMENT .
    Fig 4: Installing Battery Tray Support
    G01579044Courtesy of GENERAL MOTORS CORP.
  8. Install the air cleaner mounting bracket. Refer to Mounting Bracket Replacement-Air Cleaner   .
  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).

    Fig 5: Installing Lower Washer Reservoir Bolt
    G01579045Courtesy of GENERAL MOTORS CORP.
  10. Install the upper washer reservoir bolt (1) to the tie bar (2).

    Tighten 

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

  11. Install the A/C condenser, if equipped. Refer to CONDENSER REPLACEMENT .
    Fig 6: Installing Upper Washer Reservoir Bolt To Tie Bar
    G01579046Courtesy 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 side air baffles. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT-SIDE .
  15. Install the upper air baffles. Refer to RADIATOR AIR BAFFLE AND DEFLECTOR REPLACEMENT-UPPER
  16. Install the auxiliary transmission oil cooler (if equipped). Refer to TRANSMISSION FLUID AUXILIARY COOLER REPLACEMENT .
  17. Install the radiator. Refer to RADIATOR REPLACEMENT .
  18. Connect the horn electrical connector, Refer to HORN REPLACEMENT .
    Fig 7: Connecting Electrical Connector
    G01579047Courtesy of GENERAL MOTORS CORP.
  19. Install the headlamp housing support (1) to the tie bar 92). The 15 Series lower mounting position is shown. The 25 series mounting position is similar.

    Tighten 

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

  20. Install the tie bar, if equipped. Refer to Tie Bar Replacement-Upper   in Engine Controls.
  21. Install the hood latch release bracket and cable. Refer to Hood Latch Replacement   .
  22. Install the park/turn signal lamp assemblies, Refer to PARK/TURN SIGNAL LAMP REPLACEMENT (OLD STYLE) or PARK/TURN SIGNAL LAMP REPLACEMENT (NEW STYLE) .
    Fig 8: Installing Headlamp Housing Support
    G01579048Courtesy of GENERAL MOTORS CORP.
  23. Install the headlamps. Refer to HEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT (OLD STYLE) or HEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT (NEW STYLE GMC) or HEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT (NEW STYLE CHEVY) .
  24. Install the inflatable restraint front end discriminating sensor. Refer to ELECTRONIC FRONTAL SENSOR (EFS) (PASSENGER-SIDE) .
  25. Install the front bumper. Refer to BUMPER REPLACEMENT-FRONT (OLD STYLE) or BUMPER REPLACEMENT-FRONT (NEW STYLE GMC) or BUMPER REPLACEMENT-FRONT (NEW STYLE CHEVROLET) .
  26. Install the grille. Refer to GRILLE REPLACEMENT (OLD STYLE) or GRILLE REPLACEMENT (NEW STYLE GMC) or GRILLE REPLACEMENT (NEW STYLE CHEVROLET) .
  27. Install the air cleaner assembly. Refer to one of the following procedures:AIR CLEANER ASSEMBLY .
  28. Install the air intake duct. Refer to one or the following procedures: AIR CLEANER RESONATOR OUTLET DUCT
  29. Enable the SIR, Refer to DISABLING & ACTIVATING AIR BAG 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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