Roof Panel Replacement. Chevrolet PJJ 2000

For 1990-2009 cars

### Removal Procedure

The roof is made of steel and welded to the steel roof structure. The roof panel is supplied as part of an assembly that includes the center roof support. The roof assemblies are unique to the coupe and the sedan models.

Important: Remove the following components before removing the roof assembly.

• | The headliner

• | The windshield

• | The backglass

Protect the interior of the vehicle by covering the vehicle with blankets (J 41156) and use care when working near the following adjacent components:

• | The exterior panels

• | The glass

• | The weatherstrips

• | The moldings

1. Remove all of the related panels and components in order to gain proper access to the welds attaching the roof assembly to the vehicle.
2. Remove the following components as necessary.

• | Windshield

• | Backlight

• | Left and right quarter glass appliques (on coupe models)

3. Locate and mark the factory welds. Note the number and location of welds for installation of the service part.
4. Drill out the factory welds.
5. Remove both the roof panel and the center roof support.

### Installation Procedure

1. Prepare mating surfaces and inspect for proper fit of the roof assembly.
2. Apply urethane memory tape to the front and rear roof bows before installing the roof panel.
3. Position the roof panel. Inspect the fit using body dimensions and plug weld accordingly with frequent measurements in order to ensure proper fit.
4. Clean and prepare the welded surfaces.

Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. For further information or to order manual, please call 1-800-269-5100.

Do not top-coat any windshield bonding surface. When replacing panels that involve servicing stationary glass, refer to GM Service Bulletin P/N 43-10-48.
5. Prime with two-part catalyzed primer.
6. Apply the sealers and the corrosion protection materials.
7. Reinstall all of the related panels and components.