GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Caprice WM 🢒 Body Repair 🢒 Collision Repair 🢒 Roof Front Header Panel Replacement

Removal Procedure

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

    Caution: Refer to Safety Glasses Caution in the Preface section.

    Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling.

    2. Caution: Refer to Battery Disconnect Caution in the Preface section.

  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  3. Remove the front doors. Refer to Front Side Door Replacement.
  4. Remove the front seats. Refer to Front Seat Replacement - Bucket.
  5. Remove the front seat belts. Refer to Front Seat Belt Replacement.
  6. Remove the rear doors. Refer to Rear Door Replacement.
  7. Remove the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement.
  8. Remove the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
  9. Remove the load floor stationary panel carpet. Refer to Load Floor Stationary Panel Carpet Replacement.
  10. Remove the load floor front panel carpet. Refer to Load Floor Front Panel Carpet Replacement.
  11. Remove the liftgate weatherstrip. Refer to Liftgate Weatherstrip Replacement.
  12. Remove the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
  13. Remove the headlining rear trim panel retainer. Refer to Headlining Rear Trim Panel Retainer Replacement.
  14. Remove the body side window rear garnish moulding. Refer to Body Side Window Rear Garnish Molding Replacement.
  15. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement.
  16. Remove the rear seat back. Refer to Rear Split Folding Seat Back Replacement.
  17. Remove the headliner. Refer to Headlining Trim Panel Replacement.
  18. Remove the roof weld joint reveal moulding. Refer to Roof Weld Joint Reveal Molding Replacement.
  19. Remove the windshield pillar garnish moulding. Refer to Windshield Pillar Garnish Molding Replacement.
  20. Remove the windshield. Refer to Windshield Replacement.
  21. Remove the liftgate. Refer to Liftgate Replacement.
  22. Remove the liftgate hinges. Refer to Liftgate Hinge Replacement.
  23. Remove the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement.
  24. Remove the roof panel. Refer to Roof Outer Replacement.
  25. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.

    26. Object Number: 2063090 Size: SH

    Important: The roof front header panel is attached to the upper body sides with beads of adhesive and spot-welds at each end.

    Important: Note the number and location of factory welds (1) for installation of the new roof front header panel.

  26. Locate, mark and drill out the factory welds  (1) attaching the roof front header panel to the upper body side.

    27. Object Number: 2096401 Size: SH
  27. Mark a cut line (1) on the front roof bow panel inboard of the body side assembly.

    28. Important: Cut through the roof header panel only. Do not damage any other panels or reinforcements.

  28. Using a suitable tool, cut through the roof front header panel  (1) inboard of the upper body side. Remove the centre portion of the roof front header panel from the vehicle.
  29. Using a suitable tool remove the remaining end portions of the front roof header panel from the upper body side. Ensure all traces of old adhesive are removed.

Installation Procedure

    Important: Spot welding is the preferred method for attaching panels and should be used whenever possible. A plug weld should only be performed where spot welding is not possible.

    Important: Ensure that all factory welds are replaced in their original locations.

    Important: Ensure that all structural adhesives and sealers are replaced in their original locations.

    Important: If the location of the original plug weld holes cannot be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).

    Important: Follow the adhesive manufacturer's instructions during the assembly process. Heat must be applied as per the manufacturer's specifications to cure the adhesives and to expand the sealing baffles.

    Important: Secondary sealer must be applied to the perimeter of all flanges and over all joints.

  1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted when dissembling.
  2. Clean and prepare the mating surfaces of the body side and the roof front header panel. Ensure all traces of old adhesive are removed.
  3. Verify that the vehicle body structure alignment is correct. Refer to Dimensions - Body.

    4. Object Number: 2063091 Size: SH
  4. Apply of approved structural adhesive  (1) (GM6449G or equivalent) to the roof front header panel lower surface.

    5. Important: As the front roof header panel is installed to the vehicle, structural adhesive should be visible on the outside edges of both surfaces (squeezed out when pushed together).

  5. Position the roof front header panel to the body sides.
  6. Align the front roof header panel using three dimensional measuring equipment. Refer to Dimensions - Body.

    7. Object Number: 2063092 Size: SH
  7. Weld the front roof header panel to the body sides (1).
  8. Apply any sealers and anti-corrosion materials to the repair area noted on disassembly. Refer to Anti-Corrosion Treatment and Repair.
  9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
  10. Install the roof outer panel. Refer to Roof Outer Replacement.
  11. Install the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement.
  12. Install the liftgate hinges. Refer to Liftgate Hinge Replacement.
  13. Install the liftgate. Refer to Liftgate Replacement.
  14. Install the windshield. Refer to Windshield Replacement.
  15. Install the windshield pillar garnish moulding. Refer to Windshield Pillar Garnish Molding Replacement.
  16. Install the roof weld joint reveal moulding. Refer to Roof Weld Joint Reveal Molding Replacement.
  17. Install the headliner. Refer to Headlining Trim Panel Replacement.
  18. Install the rear seat back. Refer to Rear Split Folding Seat Back Replacement.
  19. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement.
  20. Install the body side window rear garnish moulding. Refer to Body Side Window Rear Garnish Molding Replacement.
  21. Install the headlining rear trim panel retainer. Refer to Headlining Rear Trim Panel Retainer Replacement.
  22. Install the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
  23. Install the liftgate weatherstrip. Refer to Liftgate Weatherstrip Replacement.
  24. Install the load floor front panel carpet. Refer to Load Floor Front Panel Carpet Replacement.
  25. Install the load floor stationary panel carpet. Refer to Load Floor Stationary Panel Carpet Replacement.
  26. Install the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
  27. Install the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement.
  28. Install the rear doors. Refer to Rear Door Replacement.
  29. Install the front seat belts. Refer to Front Seat Belt Replacement.
  30. Install the front seats. Refer to Front Seat Replacement - Bucket.
  31. Install the front doors. Refer to Front Side Door Replacement.
  32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  33. Enable the SIR system. Refer to SIR Disabling and Enabling.