GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.


Object Number: 748677  Size: SH

Important: The radiator support assembly is made from mild steel hydroformed tube which is welded to the front structure. The radiator support assembly is serviced as a complete assembly. The bolt-on portion of the upper tie bar (1) as well as the left and the right fascia support brackets (2) are a part of the radiator assembly. If the damage is limited to these parts they can be ordered and replaced individually. Replacement of the radiator support assembly requires removal of the upper fender rails. Upper fender rail service extensions (3) are included with the radiator support assembly for efficient installation. If the damage permits, locate and cut off the front portion of the upper rails along the die mark indicators and install the replacement upper fender rail service extensions. This procedure must be performed on both sides of the vehicle. Left side only is shown.


    Object Number: 748679  Size: SH
  1. Remove all of the related panels and components.
  2. Restore as much of the damage as possible back to the factory specifications.
  3. Note the location and remove the following as necessary:
  4. • The sealers
    • The sound deadeners
    • The anti-corrosion materials

    Object Number: 748682  Size: SH
  5. Locate the 2 die-mark indicators on the upper fender rail.

  6. Object Number: 748684  Size: SH

    Important: The edge of the masking tape must line up with the point of each die-mark arrow.

  7. Apply the masking tape for the cut location over the die-marks and across the top of the upper rail.

  8. Object Number: 748687  Size: SH

    Important: The tape edge facing the front of the vehicle is the proper location.

  9. Cut the upper fender rail along the front edge of the tape line.

  10. Object Number: 748811  Size: SH
  11. Locate and drill out all of the factory welds in the upper fender rail in front of the cut location.

  12. Object Number: 748812  Size: SH
  13. If necessary, use a chisel in order to separate the upper fender rail extension from the radiator support.

  14. Object Number: 748814  Size: SH
  15. Remove the upper fender rail extension.

  16. Object Number: 748815  Size: SH
  17. Locate and drill out all of the factory welds in the upper wheelhouse area.

  18. Object Number: 748816  Size: SH
  19. Locate and drill out all of the factory welds along the wheelhouse extension.

  20. Object Number: 748817  Size: SH
  21. If necessary, use a chisel in order to separate the radiator support from the vehicle.

  22. Object Number: 748818  Size: SH
  23. Remove the damaged radiator support.

Installation Procedure


    Object Number: 748830  Size: SH

    Important: In any area with excessive damage, space the plug weld holes every 40 mm (1½ in) apart.

  1. Prepare all of the mating surfaces as necessary.
  2. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .

  3. Object Number: 748832  Size: SH
  4. Position and align the radiator support using 3-dimensional measuring equipment.

  5. Object Number: 748834  Size: SH
  6. Plug weld accordingly with the frequent measurements to ensure the proper positioning.

  7. Object Number: 748837  Size: SH
  8. Position and align the upper fender rail extension using the three-dimensional measuring equipment.

  9. Object Number: 748839  Size: SH
  10. Plug weld accordingly with frequent measurements to ensure the proper positioning.

  11. Object Number: 748840  Size: SH
  12. Clean and prepare all of the welded surfaces.

  13. Object Number: 748842  Size: SH
  14. Apply the following as necessary:
  15. • Apply the sound deadening materials.
    • Apply an approved anti-corrosion primer.
    • Apply the sealers and refinish as necessary.