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 .
- Take note of the gap sizes along the perimeter of the roof panel to the headers, the glass, and the doors.
- Remove all related panels and components.
- Repair as much of the damaged area 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 windshield. Refer to Windshield Replacement .
- Remove the liftgate. Refer to Liftgate Replacement
- Locate and drill out all factory welds. Note the number and locations of the welds for installation of the roof panel.
- With the aid of an assistant, remove the damaged roof panel.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: When replacing panels that involve servicing of stationary windows, refer to Adhesive Installation of Windshields before performing any priming or refinishing.
Important: Do not damage any inner panels or reinforcements. Drill through the roof panel only.
Installation Procedure
- Drill 8 mm (5/16 in) plug weld holes as necessary in 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
- Apply Fusor super flexible anti-flutter foam fast set, Fusor P/N 121/124, or equivalent, with the bead placed as shown.
- With the aid of an assistant, position the roof panel on the vehicle.
- Plug weld accordingly.
- 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 the repair area. Refer to Basecoat/Clearcoat Paint Systems .
- Install the liftgate. Refer to Liftgate Replacement
- Install the windshield. Refer to Windshield Replacement .
- 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 40 mm (1 1/2 in) apart.
