For 1990-2009 cars

### Removal Procedure

Important: Deformation of the roof panel is highly noticeable in terms of the vehicle's outer appearance. Before replacing the roof, make sure that the body is horizontal.

Before welding the roof panel, adjust the frame door opening flanges so that they contact the roof panel. Pay particular attention to twists and parallelism.

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

1. Disable the SIR system. Refer to SIR Disabling and Enabling .
2. Disconnect the negative battery cable.
3. Take note of the gap sizes along the perimeter of the roof panel to the headers, the glass, and the doors.
4. Remove all related panels and components.
5. Repair as much of the damaged area as possible. Refer to Dimensions - Body .
6. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
7. Locate and drill out all he necessary factory welds.
8. Locate and drill out all he necessary factory welds surrounding the sunroof area opening, if equipped.

Important: Do not damage any inner panels or reinforcements.

9. Cut the roof weld flanges with a hand saw and snips at the roof panel and roof frames.
10. Using a chisel, pry off the roof panel along the bold lines (1).
11. Using a chisel and a disc sander, pry off the welded flange from the front, rear body pillar and roof panel.
12. Level and finish the burrs of the welded flanges.
13. Remove the sealer at the welding areas of the frame door opening.
14. Remove the damaged roof panel.

### Installation Procedure

Important: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1½ in) apart.

1. Drill 8-mm (5/16-in) plug weld holes along the service part as necessary in the corresponding locations noted on the original panel.
2. Apply sealer to the roof frames.
3. Apply sealer to one groove of the rail windshield header, two grooves of the support roof panel and one groove of the frame rear roof panel.
4. Position and the roof panel to the vehicle.
5. Verify the fit of the roof panel to the front edge of the front header panel and to the rear edge of the rear header panel.
6. Verify the fit of the roof panel at the gap along the top of the door frame to the roof panel. Adjust the panel if necessary.
7. Clamp the roof panel in position once adjusted.
8. Prepare all mating surfaces for welding as necessary.
9. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair
10. Plug weld accordingly.
11. Plug weld accordingly around the sunroof opening, if equipped.
12. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .
13. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair
14. Install all related panels and components.
15. Connect the negative battery cable.
16. Enable the SIR system. Refer to SIR Disabling and Enabling .