For 1990-2009 cars

### Removal Procedure

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

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling .

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the front doors. Refer to Front Side Door Replacement .
4. Remove the front seats. Refer to Front Seat Replacement - Bucket .
5. Remove the front seat belts. Refer to Front Seat Belt Replacement .
6. Remove the headliner. Refer to Headlining Trim Panel Replacement .
7. Remove the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement .
8. Remove the remote function actuator. Refer to Remote Control Door Lock Receiver and Theft Deterrent Module Replacement .
9. Remove the positive battery cable from the vehicle. Refer to Battery Positive Cable Replacement .
10. Remove the roof weld joint reveal moulding. Refer to Roof Weld Joint Reveal Molding Replacement .
11. Remove the windshield pillar garnish. Refer to Windshield Pillar Garnish Molding Replacement .
12. Remove the windshield. Refer to Windshield Replacement .
13. Remove the rear window. Refer to Rear Window Replacement .
14. Remove the rear header trim. Refer to Roof Panel Rear Applique Replacement .
15. Remove the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement .
16. Remove the rear body rail cover. Refer to Body Side Rear Trim Panel Stowage Compartment Outer Cover Replacement .
17. Remove the roof panel. Refer to Roof Outer Replacement .
18. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Clean all the adhesives mating surfaces in accordance with the adhesive manufacturer's specifications.

19. Locate, mark and drill out the factory welds attaching the roof front header panel to the body side (1).

### Installation Procedure

Important: Spot welding is the preferred method for attaching panels and should be used whenever possible. A plug weld should only be performed where spot welding is not possible.

Important: If the location of the original plug weld holes cannot be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).

Important: Follow the adhesive manufacturer's instructions during the assembly process. Heat must be applied as per the manufacturer's specifications to cure the adhesives and to expand the sealing baffles.

Important: Secondary sealer must be applied to the perimeter of all flanges and over all joints.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted when dissembling.
2. Clean and prepare the mating surfaces of the body side and the roof front header panel.
3. Apply an approved structural adhesive (1) to the roof front header panel lower surface.

Important: As the front roof header panel is installed to the vehicle, structural adhesive should be visible on the outside edges of both surfaces (squeezed out when pushed together).

4. Install the roof front header panel (1) to the body side.
5. Weld the front roof header panel to the body side (1).
6. Install the rear body rail cover. Refer to Body Side Rear Trim Panel Stowage Compartment Outer Cover Replacement .
7. Install the roof panel. Refer to Roof Outer Replacement .
8. Install the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement .
9. Install the rear header trim. Refer to Roof Panel Rear Applique Replacement .
10. Install the windshield. Refer to Windshield Replacement .
11. Install the windshield pillar garnish moulding. Refer to Windshield Pillar Garnish Molding Replacement .
12. Install the rear window. Refer to Rear Window Replacement .
13. Install the roof weld joint reveal moulding. Refer to Roof Weld Joint Reveal Molding Replacement .
14. Install the positive battery cable to the vehicle. Refer to Battery Positive Cable Replacement .
15. Install the remote function actuator. Refer to Remote Control Door Lock Receiver and Theft Deterrent Module Replacement .
16. Install the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement .
17. Install the headliner. Refer to Headlining Trim Panel Replacement .
18. Install the front seat belts. Refer to Front Seat Belt Replacement .
19. Install the front seats. Refer to Front Seat Replacement - Bucket .
20. Install the front doors. Refer to Front Side Door Replacement .
21. Enable the SIR system. Refer to SIR Disabling and Enabling .
22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .