GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2002 🢒 Envoy - 4WD 🢒 Body and Accessories 🢒 Collision Repair 🢒 Roof Panel Replacement

Removal Procedure

    Object Number: 742019 Size: SH
  1. Remove all of the related panels and components.
  2. Restore as much of the damage as possible to the factory specifications.
  3. Note the location and remove the following as necessary:
    4. • The sealers
    • The sound deadeners
    • The anti-corrosion materials

    Object Number: 742020 Size: SH

    Important: Do not damage any inner panels or reinforcements. Drill through roof panel only.

  4. Locate and drill out all factory welds. Note the number and location of welds for installation of the service part.

    5. Object Number: 742021 Size: SH
  5. Remove the damaged roof panel.

Installation Procedure

    Object Number: 742024 Size: SH

    Important: In any area damaged beyond recognition, space the plug weld holes every 40 mm (1-1/2 in) apart.

  1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.

    2. Object Number: 742025 Size: SH
  2. Prepare all of the attachment surfaces as necessary.
  3. Position the roof panel.

    4. Object Number: 742027 Size: SH
  4. Plug weld accordingly.

    5. Object Number: 742028 Size: SH
  5. Clean and prepare all of the welded surfaces.

    6. Important: Prior to refinishing, refer to publication GM 4901M-2001 GM Approved Refinish Materials for recommended products. Do not combine the paint systems. Refer to the paint manufacturer's recommendation.

  6. Apply the following as necessary:
    7. • Apply the sound deadening materials.
    • Apply an approved anti-corrosion primer.
    • Apply the sealers and refinish as necessary.
  7. Install all of the related panels and components.