For 1990-2009 cars

## Roof Outer Panel Replacement Sedan

### Removal Procedure

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

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove all related panels and components.
4. Remone the windshield. Refer to Windshield Replacement in Stationary Windows.
5. Remone the rear window. Refer to Rear Window Replacement in Stationary Windows.
6. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
7. 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.

Important: Do not damage any inner panels or reinforcements.

8. Locate and drill out all factory welds. Note the number and location of the welds for installation of the roof panel.
9. Cut the adhesive on the roof panel bows.
10. Remove the damaged roof panel.

### Installation Procedure

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.

Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld.
1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all welded mating surfaces only.
4. Scuff the opposing mating surfaces of the roof panel to remove the gloss of the E-Coat.
5. Apply a 3-6 mm (1/8 to 1/4 in) bead of urethane adhesive GM P/N 12345633 or equivalent, to both of the mating surfaces (2).
6. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces to ensure corrosion protection.
7. Apply Fusor super flexible anti-flutter foam - fast set, Fusor P/N 121/124 or equivalent in evenly spaced locations (1).

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

8. Position the roof panel to the vehicle using 3-dimensional measuring equipment. Clamp the roof panel into place.
9. Plug weld accordingly.
10. Clean and prepare all welded surfaces.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
12. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
13. Install all related panels and components.
14. Install the windshield. Refer to Windshield Replacement in Stationary Windows.
15. Install the rear window. Refer to Rear Window Replacement in Stationary Windows.
16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
17. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.

## Roof Outer Panel Replacement Wagon

### Removal Procedure

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

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove all related panels and components.
4. Remone the windshield. Refer to Windshield Replacement in Stationary Windows.
5. Remone the lift gate. Refer to Liftgate Replacement in Body Rear End.
6. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
7. 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.

Important: Do not damage any inner panels or reinforcements.

8. Locate and drill out all factory welds. Note the number and location of the welds for installation of the roof panel.
9. Cut the adhesive on the roof panel bows.
10. Remove the damaged roof panel.

### Installation Procedure

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.

Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld.
1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all welded mating surfaces only.
4. Scuff the opposing mating surfaces of the roof panel to remove the gloss of the E-Coat.
5. Apply a 3-6 mm (1/8 to 1/4 in) bead urethane adhesive GM P/N 12345633 or equivalent, to both of the mating surfaces (2).
6. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces to ensure corrosion protection.
7. Apply Fusor super flexible anti-flutter foam - fast set, Fusor P/N 121/124 or equivalent in evenly spaced locations (1).

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

8. Position the roof panel to the vehicle using 3-dimensional measuring equipment. Clamp the roof panel into place.
9. Plug weld accordingly.
10. Clean and prepare all welded surfaces.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
12. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
13. Install all related panels and components.
14. Install the windshield. Refer to Windshield Replacement in Stationary Windows.
15. Remone the lift gate. Refer to Liftgate Replacement in Body Rear End.
16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
17. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.