Bubbles in the Paint Around the Perimeter of the Roof (Replace Roof)

This bulletin is being revised to correct a part number in the Parts Information section. Please discard Corporate Bulletin Number 03-08-98-001 (Section 08-Body and Accessories)

Implementation of this service bulletin by "GM of Canada" dealers requires prior District Service Manager approval.

Some customers may comment that there are bubbles in the paint around the perimeter of the roof.

Replace the outer roof panel with a new roof panel following the procedure below:

T-Top Vehicles

1. Clean the bottom of the panel with Naptha, then scuff the bottom and clean with Naptha again.
2. Paint and clearcoat the top of the panel. Refer to GM 4901M-2003 Refinish Approved Refinish Booklet, GM 4901 M-D-2003 (English) or 4901 M-D-F2003 (French).
3. Paint the bottom of the roof panel with an epoxy primer. Refer to GM 4901M-2003 Refinish Approved Refinish Booklet, GM 4901 M-D-2003 (English) or 4901 M-D-F2003 (French).
4. Remove the weatherstrip and the run channel retainer on the "B" pillar prior to removing the roof tape off or protect the back light reveal molding.
5. Use the wire method to cut the urethane around the perimeter of the roof. Refer to the above illustration for urethane location.
6. Remove any excess but not all of the urethane from the body.
7. Apply primer 76 mm (3 in) around the perimeter to the roof panel.
8. V cut the urethane tube and apply a 19 mm (3/4 in) high bead around the perimeter of the roof and the three dots across the back.
9. Install new applique to the roof.
10. Install the weatherstrip and the run channel retainer on the "B" pillar.

Hard Top Vehicles

1. Clean the bottom of the panel with Naptha, then scuff the bottom and clean with Naptha again.
2. Paint and clearcoat the top of the panel. Refer to GM 4901M-2003 Refinish Approved Refinish Booklet, GM 4901 M-D-2003 (English) or 4901 M-D-F2003 (French).
3. Paint the bottom of the roof panel with an epoxy primer. Refer to GM 4901M-2003 Refinish Approved Refinish Booklet, GM 4901 M-D-2003 (English) or 4901 M-D-F2003 (French).
4. Remove the weatherstrip and the run channel retainer on the "B" pillar and roof.

Notice: In steps five and six, be careful not to cut too deep or damage may occur to the head liner.

5. Cut through the roof from the front (at the windshield) to the rear (rear hatch opening).
6. Make a second cut starting at the upper rear corner of the door glass opening across the car.



7. Pull back or peel the roof or cut the urethane. Refer to the illustration above for urethane location.
8. Remove any excess but not all of the urethane from the body.
9. Apply primer 76 mm (3 in) around the perimeter to the roof panel
10. If the windshield molding was damaged during removal, replace it before the next step.
11. V cut the urethane tube and apply a 19 mm (3/4 in) high bead around the perimeter of the roof and the three dots across the back.
12. With an assistant, slide the front panel under the windshield molding and lay down the rear.
13. Press down on the roof and make sure the top is even, side to side at the "C" Pillar.
14. Install the weatherstrip and the run channel retainer on the "B" pillar and roof.

Parts are currently available from GMSPO.

The following urethanes are available from outside auto parts suppliers:

For vehicles repaired under warranty, use: