Roof Bow Panel Replacement - Outer for Chevrolet Corvette 2003

The roof bow outer panel is made of Sheet Molded Compound (SMC) and is bonded to the mild steel hydroformed roof bow with structural adhesive.

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

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove all related panels and components.
4. Remove the quarter panels. Refer to Rear Quarter Panel Replacement in Body Rear End.



5. Remove the screws (1) attaching the weatherstrip (2) to the roof bow outer panel (3).
6. Remove the weatherstrip (2).



7. Remove the screws (1) attaching the center weatherstrip retainer (2) to the outer panel.
8. Remove the center weatherstrip retainer (2).



9. Remove the screws (1) attaching the left and right weatherstrip retainers (2) to the outer panel.
10. Remove the left and right weatherstrip retainers (2).



11. Remove the screws (1) attaching the outer panel to the roof bow.



12. Remove the outer panel by applying heat (1). Pry (2) the outer panel to break loose along the bonding surface (3).



13. Note the location of the adhesive and remove all remaining adhesive (1).

1. Before applying adhesive dry fit the outer panel for proper fit and alignment.

Important: Do NOT top coat any bonding surface.

2. Prime all bare metal surfaces. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coating.



3. Apply 2 beads of sealer (1), Kent Products P/N 10552, 10 mm (3/8 in) in diameter and 50 mm (2 in) in length, to the left and right side inner surfaces of the outer panel (2).
4. Apply a sealant patch (3), GM P/N 14064578, to the left and right top inner surfaces of the outer panel.
5. Scuff all bonding surfaces.
6. Clean all bonding surfaces with a lint-free rag using a naptha solvent.




Important: Bonding surfaces must be dry before applying adhesive.

7. Apply a consistent bead of structural adhesive (1) GM P/N 89020330 or GM P/N Canada 8902332, 10 mm (3/8 in) in diameter, to the roof bow to mate with the inner surface of the outer panel .



8. Install the outer panel (1) to the roof bow (2).



9. Apply pressure to the top and the side surfaces of the outer panel to set the adhesive.

Notice: Refer to Fastener Notice in the Preface section.




10. Install the screws that attach the outer panel to the roof bow.

Tighten
Tighten the screws to 2 N·m (18 lb in).

11. Remove any excess adhesive.
12. Allow the adhesive to cure according to the adhesive manufacturer's recommendations.



13. Install the left and right weatherstrip retainers (2) to the outer panel.
14. Install the screws (1) attaching the left and right weatherstrip retainers (2).

Tighten
Tighten the screws to 2 N·m (18 lb in).




15. Install the center weatherstrip retainer (2) to the outer panel.
16. Install the screws (1) attaching the center weatherstrip retainer (2).

Tighten
Tighten the screws to 2 N·m (18 lb in).




17. Apply a bead of sealer (1), Kent Products P/N 10552, 6 mm (¼ in), in diameter and 100 mm (2 in) in length, to the left and right upper B-pillar corners of the outer panel (2).



18. Apply a bead of sealer (1), Kent Products P/N 10552, 6 mm (¼ in) in diameter and 100 mm (2 in) in length, to the left and right lower B-pillar corners of the outer panel (2).



19. Install the weatherstrip (2) to the roof bow outer panel (3).
20. Install the screws (1) attaching the weatherstrip (2).

Tighten
Tighten the screws to 2 N·m (18 lb in).

21. Install all related panels and components.
22. Install the quarter panels. Refer to Rear Quarter Panel Replacement in Body Rear End.
23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
24. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.