For 1990-2009 cars

### Removal Procedure

This repair procedure includes an installation procedure for either metal-inert gas welding or adhesive bonding.

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

Note: When replacing panels that involve servicing of stationary windows, refer to Adhesive Installation of Encapsulated Stationary Windows before performing any priming or refinishing.

1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove all related panels and components.
4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
6. Remove the windshield. Refer to Windshield Replacement.
7. Remove the liftgate. Refer to Liftgate Replacement.
8. Locate and drill out all factory welds. Note the number and location of welds for installation of the roof panel.
9. With the aid of an assistant, remove the roof panel.

### Installation Procedure

1. Drill 8 mm (5/16 in) plug weld holes as necessary in locations noted from the original panel.

Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1½ in) apart.

2. Prepare all mating surfaces as necessary.
3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.
4. With the aid of an assistant, position the roof panel to the body.
5. Plug weld accordingly.
6. Clean and prepare all welded surfaces.
7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
8. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
9. Install the windshield. Refer to Windshield Replacement.
10. Install the liftgate. Refer to Liftgate Replacement.
11. Install all related panels and components.
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
13. Enable the SIR system. Refer to SIR Disabling and Enabling.