Flex-a-Lite 57291 Radiator & Fan GM Truck/SUV - Manual

Note: To view these instructions or to view a video of this product installation, visit
www.flex-a-lite.com or call 1-800-851-1510 for assistance. It is HIGHLY recommended to
read and review these instructions prior to installation.
Removal of Old Radiator and Fan (if needed):
1. As a safety precaution, be sure the vehicle is COOL enough to work on; also disconnect the negative (-)
battery cable.
2. Open the radiator fill cap. Locate the radiator drain and drain the radiator fluid into a spill-resistant
container.
3. Remove the plastic cover from the top of the radiator that covers the front support. Use a flat-head
screwdriver to pop and release the push-clips.
4. For ease of removal and installation, remove the air intake box and tube. This will be re-installed after
final installation.
5. Remove the upper fan shroud: The fan shroud is made of a top half and a lower half. Remove the
upper hose from the radiator inlet. Release the plastic hose clamp securing upper hose routed along
top of upper shroud. Pop the push-clips that hold the upper half to the lower half. Remove the 2 upper
bolts that hold the upper shroud to the top cross member. At this point, this upper half should be free.
Remove this upper shroud from the vehicle, save the plastic factory hose clamp by removing it from
the shroud. This will be used later to re-secure the upper hose.
6. Remove the clutch fan: Support the clutch face and/or fan while spinning the nut of the fan counter-
clockwise with a 1-3/8” open-end wrench. Spin completely off and remove the fan from the vehicle.
7. Remove the lower shroud: Pull up on the lower shroud which sits in saddles with tabs.
8. Disconnect the rest of the radiator hoses: The overflow tank and steam hose will come off. Then
remove the transmission hoses (if applicable) by pulling the retaining ring away from the tank
connection and pulling the “C” clip off of the connection by pulling up with a scribe or small flat-end
screwdriver. Finally, disconnect the main outlet hose at the bottom of the radiator over the drain
container. Use a rag or plug for these ports as they may leak upon removal.
9. Remove the radiator: Remove the 2 bolts from the top flanges located at both sides of the radiator.
This will free the radiator. Tilt the radiator towards the engine and lift slowly as to not damage the
radiator or any other components. Note: Save the 4 rubber bushings from the factory radiator (2 at top
and 2 at bottom. These will be used later in the install of the new radiator.)
Installation of the New Radiator and Fan (if required):
1. Placing the radiator: Place the factory lower bushings in the lower radiator support on the vehicle. The
driver’s side may have 2 locations for placement. Use the nearest location to the center of the vehicle.
Once these are in place, lower the radiator into place as the guide pins of the new radiator seat into
the bushings.
2. Upper Radiator Mounts: Find the left and right upper mounting brackets and slide on the factory upper
bushings. Loosely mount the brackets to the left and right on the top/engine side of the radiator
utilizing the supplied T-bolts, washers and nylock nuts. Use the upper factory bolts to mount the
radiator to the original support locations. Tighten those first, then snug up the nuts on the T-bolts of
the radiator.
3. Connect Hoses: Place the hose nipples to the tanks if necessary for the overflow and the steam port
with thread tape. Do not over-tighten! Then, connect the overflow and steam port hoses. Bolt the
short side of the tube support bracket to the inside drivers side threaded insert in the shroud. Connect
Note: always read instructions and verify kit contents prior to installation.
Radiator ............................................... 1ea. Electrical Connector Kit ........................ 1ea.
Pre-Mounted Fan ................................. 1ea. VSC Controller Kit ................................ 1ea.
Bracket, Top Rad. Mount Left Hand ...... 1ea. Wire Bundle ........................................ 1ea.
Bracket, Top Rad. Mount Right Hand .... 1ea. Instruction Sheet ................................. 1ea.
Mounting Hardware Kit ........................ 1ea. Flex-a-lite Decal ................................... 1ea.
Installation Instructions For:
#57001 Radiator GM Truck/SUV
#57291 Radiator & Fan GM Truck/SUV
Fits MOST 1999-2012 Vehicles
(Vehicles with automatic transmission will require cooler kit #4118GMT,
sold separately, prior to installation)
Rev. 04-01-13 #99291 Page #1 of 6