For 1990-2009 cars

### Removal Procedure

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 Windshields before performing any priming or refinishing.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
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 to factory specifications. 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. Remove the windshield. Refer to Windshield Replacement.
8. Remove the liftgate. Refer to Liftgate Replacement

Note: Do not damage any inner panels or reinforcements. Drill through the roof panel only.

9. Locate and drill out all factory welds. Note the number and locations of the welds for installation of the roof panel.
10. With the aid of an assistant, remove the damaged roof panel.

### Installation Procedure

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

Note: 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 40 mm (1 1/2 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. Apply Fusor super flexible anti-flutter foam fast set, Fusor P/N 121/124, or equivalent, with the bead placed as shown.
5. With the aid of an assistant, position the roof panel on the vehicle.
6. Plug weld accordingly.
7. Clean and prepare all welded surfaces.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
10. Install the liftgate. Refer to Liftgate Replacement
11. Install the windshield. Refer to Windshield Replacement.
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
14. Enable the SIR system. Refer to SIR Disabling and Enabling.