Radiator Support Replacement for Chevrolet Malibu 2001

Important: The front end structure consists of six resistance-welded components. The upper tie bar and upper reinforcement panel are serviced as individual components. The brace, (front-end lower structure), includes rail reinforcement gussets, which provide cross-car alignment of the service assembly. The left and right impact bar brackets are serviced separately and must be installed using three-dimensional coordinates.

1. Remove all related panels and components.
2. Visually inspect and restore as much of the damage as possible to factory specifications.
3. Remove sealers and anti-corrosion materials as necessary.
4. Locate, mark and drill out all factory welds as necessary. Note the number of welds for installation of the service panels.
5. Remove the damaged panels in the upper tie bar assembly and the front end lower brace, as necessary.

1. Prepare mating surfaces and check for proper fit of the service panels.
2. Drill 8 mm (5/16 in) plug weld holes in the locations noted from the original assembly on the service panels.

Important: If original components are damaged beyond recognition, place plug weld holes every 40 mm (1 ½ in) apart.

3. Position the service panels.
4. Check fit using body dimensions.
5. Plug weld accordingly with frequent measurements to ensure proper fit.
6. Clean and prepare welded surfaces.

Important:  Do not combine paint systems. Prior to refinishing, refer to GM P/N 4901MD-99 Refinish Manual for recommended products. Refer to paint manufacturer's recommendations.

7. Apply approved anti-corrosion primer.
8. Apply sealers and refinish as necessary.

Important: Upper tie-bar service parts do not have mounting location for the three center latch support holes. Use threaded inserts such as Riv-nuts, available through Kent-Moore™ tools Riv-nut Kit  P/N  42151-8 MS.

9. Install all related panels and components.