For 1990-2009 cars only
Removal Procedure
- Disable the SIR system. Refer to SIR Disabling and Enabling .
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Remove all related panels and components.
- Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
- Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
- Remove the roof panel. Refer to Roof Outer Panel Replacement .
- Locate and drill out all factory welds. Note the number and location of welds for installation of the service part.
- Remove the damaged roof header panel.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: Do not damage any inner panels or reinforcements.
Installation Procedure
- Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
- Prepare all mating surfaces as necessary.
- Apply GM-approved Weld-Thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .
- Position the roof header panel.
- Align the roof header panel over the locator tabs (1).
- Plug weld accordingly.
- Install the roof panel. Refer to Roof Outer Panel Replacement .
- Clean and prepare all welded surfaces.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
- Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems .
- Install all related panels and components.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Enable the SIR system. Refer to SIR Disabling and Enabling .
Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1½ in) apart.
