Radiator Support

Assembly
The radiator support assembly is made from 2
mild steel hydroformed tube which is welded
1
to the front structure. The Radiator Support
Assembly is serviced as a complete assembly. 2
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
3
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.
Removal Procedure
1. Remove all of the related panels and
components.
2. Restore as much of the damage as
possible back to factory specifications.
3. Note the location and remove the
following as necessary:
• Sealers
• Sound deadeners
• Anti-corrosion materials

4. Locate the two die-mark indicators on

the upper fender rail.
—continued

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Radiator Support Assembly
Removal Procedure con't
IMPORTANT: The edge of the
masking tape must line up with the
point of each die-mark arrow.
5. Apply the masking tape for the cut
location over the die-marks and
across the top of the upper rail.

IMPORTANT: The tape edge facing

the front of the vehicle is the proper
cut location.
6. Cut the upper fender rail along the
front edge of the tape line.

7. Locate and drill out all of the

factory welds in the upper fender
rail in front of the cut location.

8. If necessary, use a chisel in order to

separate the upper fender rail
extension from the Radiator
Support.
—continued

2002 S/T Sport Utility Vehicles 2-7

Radiator Support Assembly
Removal Procedure con't
9. Remove the upper fender rail
extension.

10. Locate and drill out all of the

factory welds in the upper
wheelhouse area.

11. Locate and drill out all of the

factory welds along the wheelhouse
extension.
—continued

2-8 2002 S/T Sport Utility Vehicles

Radiator Support Assembly
Removal Procedure con't
12. If necessary, use a chisel in order to
separate the Radiator Support from
the vehicle.

13. Remove the damaged Radiator

Support.

2002 S/T Sport Utility Vehicles 2-9

Radiator Support
Assembly
Installation Procedure
IMPORTANT: In any area damaged
beyond recognition, space the plug weld
holes every 40 mm (1-1/2 in.) apart.
1. Prepare all of the attachment surfaces
as necessary.
2. Apply a weld-thru primer to all of the
bare metal surfaces.

3. Position and align the radiator support

using three-dimensional measuring
equipment.

4. Plug weld accordingly with frequent

measurements to ensure proper
positioning.

5. Position and align the upper fender

rail extension using three-dimensional
measuring equipment.
—continued

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Radiator Support Assembly
Installation Procedure con't
6. Plug weld accordingly with frequent
measurements to ensure the proper
positioning.

7. Clean and prepare all welded

surfaces.

IMPORTANT: Prior to refinishing,

refer to publication GM4901M-D-
01 GM Approved Refinish Materials
for recommended products. Do not
combine the paint systems. Refer to
the paint manufacturer’s
recommendation.
8. Apply sound deadening materials.
9. Apply an approved anti-corrosion
primer.
10. Apply sealers and refinish as
necessary.
11. Install all of the related panels and
components.

2002 S/T Sport Utility Vehicles 2-11