GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 VUE - FWD 🢒 Body and Accessories 🢒 Collision Repair 🢒 Roof Outer Panel Replacement

Removal Procedure

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


    Object Number: 925565 Size: SH
  1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  2. Remove the headliner. Refer to Headlining Trim Panel Replacement in Interior Trim.
  3. Remove the sunroof. Refer to Sunroof Module Assembly Replacement in Roof.
  4. Remove the windshield. Refer to Windshield Replacement in Stationary Windows.
  5. Remove the lift gate. Refer to Liftgate Replacement in Body Rear End.
  6. Remove the luggage carrier. Refer to Luggage Carrier Replacement in Roof.
  7. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
  8. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.

    9. Important: Do not damage any inner panels or reinforcements.

  9. Cut openings in roof panel as shown.
  10. Remove the nuts that attach the roof.
  11. Cut the adhesive around the roof panel and bows.
  12. Remove the damaged roof panel.

Installation Procedure

    Object Number: 926581 Size: SH
  1. Using a razor knife, remove the loose urethane and trim high spots in the remaining urethane to provide for an even application of new urethane.
  2. Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a 50/50 mixture by volume of isopropyl alcohol and water to remove the adhesive.
  3. Install the lift gate. Refer to Liftgate Replacement in Body Rear End.
  4. Prepare all mating surfaces as necessary.
  5. Apply a 8 mm (0.31 in) minimum bead urethane adhesive GM P/N 12345633 or equivalent to the roof panel. Urethane bead must cover the entire flange in order to ensure proper seal.

    6. Important: Do NOT pull the panels apart after joined together. Slide the panels against each other to realign the panels.


    Object Number: 925565 Size: SH
  6. Position the roof panel onto the spaceframe.

    7. Notice: Refer to Fastener Notice in the Preface section.

  7. Install the roof nuts.

    8. Tighten
    Tighten the nuts to 10 N·m (89 lb in).

  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  10. Install the luggage carrier. Refer to Luggage Carrier Replacement in Roof.
  11. Install the windshield. Refer to Windshield Replacement in Stationary Windows.
  12. Install the sunroof, if equipped. Refer to Sunroof Module Assembly Replacement in Roof.
  13. Install the headliner. Refer to Headlining Trim Panel Replacement in Interior Trim.
  14. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.