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Removal Procedure

WARNING: This page is about a different car, the 2006 GMC Sierra and 2006 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Refer to BATTERY DISCONNECT CAUTION .
  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) .
  2. Disable the supplemental inflatable restraint (SIR). Refer to SIR Disabling and Enabling Zone 1 .
  3. Remove the air intake duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (4.3L, 5.3L and 6.0L).
  4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  5. Remove the grille. Refer to Grille Replacement (GMC) or Grille Replacement (Chevrolet) .
  6. Remove the front bumper. Refer to Bumper Replacement - Front (Old Style) .
  7. Remove the inflatable restraint front end discriminating sensor. Refer to Inflatable Restraint Front End Sensor Replacement .
  8. Remove the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Old Style) .
  9. Remove the park/turn signal lamp assemblies. Refer to Park/Turn Signal Lamp Replacement (Old Style) .
  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.
    Fig 1: Removing Headlamp Housing Support
    GM370330Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the horn electrical connector.
  14. Remove the radiator. Refer to Radiator Replacement (4.3, 4.8, 5.3, and 6.0L) or Radiator Replacement (Diesel) or Radiator Replacement (8.1L) .
  15. Remove the auxiliary transmission oil cooler (if equipped). Refer to Transmission Fluid Auxiliary Cooler Replacement (4L80E).
  16. Remove the upper air baffles. Refer to Radiator Air Baffle and Deflector Replacement - Upper .
  17. Remove the side air baffle. Refer to Radiator Air Baffle and Deflector Replacement - Side .
  18. Remove the power steering cooler mounting bolts and reposition the cooler.
  19. Disconnect the electrical connector from the automatic recirculation switch.
    Fig 2: Disconnecting Automatic Recirculation Switch Electrical Connector
    GM397231Courtesy of GENERAL MOTORS CORP.
  20. Remove the A/C condenser, if equipped. Refer to Condenser Replacement .
  21. Remove the upper washer reservoir bolt (1) from the tie bar (2).
    Fig 3: Removing Upper Washer Reservoir Bolt
    GM370698Courtesy of GENERAL MOTORS CORP.
  22. Remove the battery tray. Refer to Battery Tray Replacement .
  23. Remove the lower washer reservoir bolt (1) from the tie bar (2).
    Fig 4: Removing Lower Washer Reservoir Bolt
    GM401108Courtesy of GENERAL MOTORS CORP.
  24. Remove the battery tray support.
    Fig 5: Removing 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: Removing Front Upper & Lower Fender Bolts
    GM401168Courtesy of GENERAL MOTORS CORP.
  27. Remove the lower radiator support nut and bolt at the frame (1).
    Fig 7: Removing Lower Radiator Support Nut & Bolt
    GM402774Courtesy of GENERAL MOTORS CORP.
  28. Remove the radiator support baffle (2).
    Fig 8: Removing Radiator Support & Baffle
    GM370884Courtesy of GENERAL MOTORS CORP.
  29. Remove the radiator support (1) from the frame.
  30. Remove the horn(s) from the radiator support. Refer to Horn Replacement - Left or to Horn Replacement - Right .
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