Hard Top Replacement
Hard Top Replacement
Removal Procedure
1. Remove the windshield reveal molding. Set the molding aside.
2. Remove the rear window.
3. Remove the 2 sun visors.
4. Remove the windshield side garnish moldings and retainers.
5. Remove 2 bolts and the seat belt guides from the roof bow.
6. Remove 3 headliner fasteners.
7. Remove the headliner.
8. Remove the roof weatherstrips and moldings.
9. Remove the side reveal molding.
10. Protect the interior of the vehicle with plastic sheeting.
11. Make a rough cut the width of the roof, 100 mm (4 in) from the windshield front edge (1) in order to gain access to the bonded areas. Refer to Roof Description.
12. Make a rough cut the width of the roof, 150 mm (6 in) forward of the rear glass (2) in order to gain access to the bonded areas. Do NOT cut into the roof bow (3).
13. Mark the location of 2 brackets (1) on the front edge of the roof bow, Remove the brackets.
14. Mark the location of 3 brackets (1) at the front edge of the surround panel (3). Remove the brackets.
15. Mark the location of 2 brackets on the opposite sides of the roof bow. Remove the brackets.
16. Use a heat gun to debond the roof panel along all remaining seams. If the outer panel is separating from the inner roof panel, apply more heat.
17. Use a pneumatic knife to cut the front edge of the roof from the windshield header and the rear edge of the roof at the surround panel.
Important: Use caution when prying off the panel to prevent the inner brace from separating.
18. Pry up the roof panel along the roof bow, along the windshield and the front edge of the deck lid.
19. Note the location of butyl and clean excess urethane from all panels to prepare for installation.
Installation Procedure
1. Prepare the mating surfaces.
2. Remove the tape and all tape residue from the service part along all bonded surfaces.
3. Install 3 rear brackets along the rear edge of the roof bow.
4. Prepare the bonding surfaces using a scuff pad. Clean the bond area with a lintfree rag, using a water-based cleaner.
Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do NOT combine paint systems. Refer to the paint manufacturer's recommendations.
5. Prime bare metal areas and the SMC bond areas using the urethane adhesive kit, GM P/N #12346284 (Canadian P/N 10952983).
* Prime the small bare metal areas along the windshield header and the roof bow with the pinch-weld flange primer.
* For large bare metal areas, larger than 4x4 in, use a 2-part catalyzed primer.
6. Apply a butyl sealer (1) to the service part as indicated.
7. Apply urethane (2) to the vehicle and in recommended locations along the service part.
Important: The quarter panels must be in the body position before you insert the roof panel. Place the deck lid in the open position.
8. With the aid of a helper, install the service part roof.
Notice: Refer to Fastener Notice in Service Precautions.
9. From the outside of the vehicle, push down on the top of the roof to create a flush fit with the surrounding panels. From the inside of the vehicle, tighten the fasteners.
10. Reinstall the hardware along the windows and along the windshield side pillar.
11. Install the side reveal molding.
12. Install new roof weatherstrip side retainers and replace the moldings.
13. Install the headliner through the rear window opening. Fasten the headliner in place.
14. Install 3 headliner fasteners.
15. Install the seat belt upper guides.
16. Install the windshield side garnish moldings and retainers.
17. Install 2 sun visors.
18. Install the rear window.
19. Install the window reveal molding.
20. Test the roof panel for water leaks.