The headliner, windshield, and backglass must be removed prior to the removal of the roof assembly. Protect the interior of the vehicle by covering it or removing it. Use care when working near the adjacent panels, glass, weather-strips and molding. It is recommended the seats be removed to avoid damage due to the overhead welding required to service the roof assembly.

Notice: Some vehicles equipped with sunroofs utilize drain tubes, routed through the upper body pillars, to prevent water from entering the vehicle. Use care not to damage the drain tubes, otherwise, damage to the interior of the vehicle may occur.

1. Remove all panels and components necessary to access the welds attaching the roof assembly to the vehicle.
2. 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. Note the number and location of welds for installation of the service panel.



5. Locate the factory weld joint at the sail panel.
6. Apply heat and wire brush to remove silicone-bronze material from area.
7. Separate the roof panel from the quarter sail panel.
8. Remove the damaged roof panel assembly.

1. Drill 8 mm (5/16 in) holes for plug welding at the sail panel over-lap joint, and around the perimeter of the panel as noted from the original roof panel.
2. Prepare all mating surfaces for welding as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.



4. Position the roof panel on the vehicle. Check fit and alignment.
5. When the service assembly is correctly positioned, plug weld accordingly.
6. Stitch weld the roof panel at the sail panel seam.
7. Clean and prepare all bare metal surfaces.
8. Apply the following as necessary:

•

Sealers.

•	Anti-corrosion materials.

•	Sound deadeners.

•	Two-part catalyzed primer.

•

Top coat.

Important: Do not combine paint systems. Refer to paint manufacturer's recommendations.

9. Apply GM Goodwrench structural bonding epoxy P/N 12345726 or equivalent, to the roof panel stiffener and position according to original roof panel.
10. Install the panels and components previously removed for access.