GM Service Manual Online
For 1990-2009 cars only

Installation Procedure

  1. Follow the Wiring Systems sub-section for splicing wires using splice sleeves. Refer to Splicing Copper Wire Using Splice Sleeves .
  2. Remove the ground terminal of the battery. Refer to Battery Negative Cable Disconnection and Connection .
  3. Ensure the vehicle is in the park position.
  4. Apply park brake.

  5. Object Number: 1609354  Size: SH
  6. Center the template provided (1) on the roof between the two A-pillars. Position the template so that the front edge rests against the rear edge of the windshield reveal molding and tape in place.
  7. Mark the 6 hole locations with a trip punch or center punch.

  8. Object Number: 1609356  Size: SH
  9. Before drilling, add several wraps of tape (1) around end of drill bit to prevent the drill bit from penetrating through the roof into the headliner.
  10. Drill pilot holes with 2 mm (3/32 in) drill bit.
  11. Expand the holes with 6 mm (1/4 in) drill bit.
  12. Drill 9 mm holes in the 6 hole locations using the bit supplied within the kit.
  13. Clear all the metal shavings from around the holes with a magnet or vacuum.
  14. Apply GM Super Lube with PTFE, GM P/N 12371287, to the lower half of the rivnut and between the washer and hex body of rivnut tool prior to inserting the rivnut into the hole.

  15. Object Number: 1609357  Size: SH
  16. Ensure that the Star washer (1) is positioned on top of the rivnut tool (2).
  17. Notice: Refer to Fastener Notice in the Preface section.

    Important: Do not overtighten the rivnuts.

  18. Using a 5/16 inch box wrench in conjunction with a 1/2 inch open end wrench, secure the rivnuts to the roof panel.
  19. Tighten
    Tighten the rivnuts to 7 N·m (45 lb in).

  20. Secure each rivnut to the roof panel.

  21. Object Number: 1609359  Size: SH
  22. Remove the air inlet covers (1) on both driver and passenger sides by gently pulling upward to release the clips.

  23. Object Number: 1609360  Size: SH
  24. Open both front doors.
  25. Remove the exterior trim on both driver and passenger A-pillars by first peeling back the weatherstrip (3) to expose 2 screws (4).
  26. Using a Phillips head screwdriver, remove the screws.
  27. Pull the lower end of the A-pillar trim to unsnap the clips (1).
  28. Disengage the A-pillar trim from the front end of the luggage rack/siderail (2) and remove.

  29. Object Number: 1609362  Size: SH
  30. Using diagonal cutters, clip a notch (c) in both A-pillars (1) as shown for the wire pass through.

  31. Object Number: 1609379  Size: SH
  32. Drill 3 holes in both A-pillar trim pieces for clearance lamp installation. On the backside of the A-pillar trim, locate the 3 circles and center points which are molded into the trim.
  33. Using a 2 mm drill bit, pre-drill (1) all 3 holes.
  34. Using a 2 inch holesaw, drill the middle hole (2).
  35. Using a ½ inch drillbit, drill the forward hole (3).

  36. Object Number: 1609363  Size: SH
  37. Place the lightbar (1) and electrical harness assembly (2) upside down on the roof.
  38. Route the harness down the driver side A-pillar, placing it near the windshield glass interference to A-pillar and spot tape in 3 places.
  39. Ensure the harness lies flat and does not interfere with snap locations for A-pillar trim.

  40. Object Number: 1609364  Size: SH
  41. Loosen the 2 screws (2) at the fender flange under the air inlet cover to allow the electrical harness (1) to pass underneath.
  42. Move the black foam out of the way.
  43. Tighten the fender flange attaching screws.
  44. Tighten
    Tighten the fender flange screws to 7 N·m (45 lb in).

  45. Reposition the black foam under fender flange.
  46. Rotate the lightbar to the correct orientation.
  47. Position the front edge of light bar approximately 3 mm (1/8 in) rearward from the front edge of the windshield reveal molding. Using the 6 fasteners provided, and T25® Torx driver, install the lightbar to the roof.
  48. Important: Ensure the wiring is not trapped beneath the fasteners.

  49. Maintain a parallel gap to the windshield reveal molding and luggage rack side rails.
  50. Tighten
    Tighten the fasteners to 4.5 N·m (30 lb in).

  51. Ensure the lightbar is centered between A-pillars, adjust if necessary.

  52. Object Number: 1609381  Size: SH
  53. Install the 6  fastener covers (1) by aligning the cover's tab to the driver's side and gently pressing in place.
  54. Mount the clearance lamps to A-pillars by sliding hook at front edge into 1/2 inch hole. Secure the rear edge with T20® torx driver and screw provided.
  55. Ensure left hand lamp is on the driver side A-pillar and right hand lamp is on the passenger side A-pillar.
  56. Plug in the bulb and socket on clearance lamps by pressing the socket in and turning ¼ turn clockwise.
  57. Reinstall the A-pillar trim on both driver and passenger sides by hooking rear edge under tab at luggage rack siderail and pressing the clips into place.
  58. Install the 2 screws behind the weatherstrip.
  59. Tighten
    Tighten the screws to 2 N·m(18 lb in).

  60. Reposition the weatherstrip.

  61. Object Number: 1609369  Size: SH
  62. Locate the 6 blunt wiring cuts (1) in the engine compartment behind the driver's side wheelhouse. The engine compartment blunt cuts have seals on them that must be removed prior to using the splice sleeve.
  63. Carefully remove some of the seal on the appropriate wire using a wiring stripping tool.
  64. Using the splice sleeve provided, splice the blunt black cut wire to the black wire in the electrical harness.
  65. Replace the conduit over the splice and tape the wiring in position.

  66. Object Number: 1609371  Size: SH
  67. Remove the battery vent tube (1) in order to access the bussed electrical center (BEC) .

  68. Object Number: 1609373  Size: SH
  69. Release the BEC cover (1) by depressing the locks (2) on both sides of cover simultaneously.

  70. Object Number: 1609375  Size: SH
  71. Press the tabs (2) on the right and left sides.
  72. Pull up on the BEC using both hands.

  73. Object Number: 1609377  Size: SH
  74. Locate the red harness wire with a connector at the end.
  75. Plug the 8-way electrical connector (2) into the bottom of BEC (1) as shown.
  76. Reassemble the BEC by ensuring the 2 47-way connectors are in the upright and locked position. Ensure the locking fingers are engaged under the mating lock lug.
  77. Press downward and listen for an audible snap.

  78. Object Number: 1609373  Size: SH
  79. Position the cover (1) over the 4 lock tabs (2). Ensure the appropriate wire routing to avoid trapping wires.
  80. Press down and listen for an audible snap.
  81. Install the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  82. Verify the marker lamps come on with the other exterior lamps.
  83. Place the vehicle in park transmission position.
  84. Disengage the park brake.