Service Procedure
Inspection Procedure - Z06 Coupe1. Remove the driver and passenger side sun visor and sun visor clamp. Refer to the Sun Shade Replacement procedure in SI.
2. Disconnect the rear view mirror electrical connector. Refer to the Rear View Mirror Replacement procedure in SI.
3. Remove the windshield side garnish molding. Refer to the Windshield Side Garnish Molding Replacement procedure in SI.
Important:
The rear roof bow trim panel holds the rear of the headliner in place.
4. Remove the rear roof bow trim panel. Refer to the Rear Roof Bow Trim Panel Replacement procedure in SI.
5. Remove the headliner from the vehicle.
5.1 Ensure that the sunshade and rear view mirror electrical connectors have been disconnected.
5.2 Pry down on the edge of the headliner to loosen it from the vehicle roof panel.
5.3 Lower the headliner and route it through the rear hatch.
6. Remove the bolts on all four corners of the roof panel and the center rear bracket.
7. Remove the roof panel from the vehicle. Discard the 10 roof panel fasteners.
Important:
Note the orientation and number of shims on the driver and passenger side of the roof panel assembly contact points and the center rear bracket.
Notice:
Protect the painted surface of the roof panel from damage.
8. Place the roof panel, painted surface down, on a glass stand, bench, or other suitable area.
9. Inspect for proper adhesion by inserting a 0.254 mm (.010 in) feeler gage between the panel and the frame. If the feeler gage fits between the panel and the frame, and the depth is 19.05 mm (.750 in) or greater, the roof panel is separated from the frame.
^ If the feeler gage does not identify any area of the roof panel with separation, proceed to Step 4.
^ If LESS than 75 percent of the roof panel is separated from the frame, prepare the roof panel for the foam adhesive injection procedure. Refer to the section titled, Roof Panel Preparation for Roof Panels with Separation. This is a temporary repair that will prevent the separation of the roof panel. Submit the claim using labor code T5461, which will not close the program in GMVIS. When the roof panel is available, install the new roof panel and submit the claim using the appropriate V labor code, which will close the program in GMVIS.
Important:
Inspect all roof panels, including new roof panels, to determine if the foam fill procedure has been completed. Perform the foam adhesive injection procedure on new roof panels that have not been foam filled. Perform Steps 4-22 after removing the original roof panel.
^ If more than 75 percent of the roof panel is separated from the frame, replace the roof panel.
Roof Panel Preparation for Roof Panels with Separation - Z06
1. Mark the gaps or separation of the roof panel with tape.
2. Place a rubber-coated clamp (or equivalent) 102 mm (4 in) on either side of the separation. Ensure that a clamp is installed every 152 mm (6 in) along the gap or separation area. Refer to the illustration for clamp position.
Important:
If a bead of urethane is not applied to the gap or separation area, foam will ooze out of the gap or separation area during the foam adhesive injection process.
3. Apply a bead of urethane to the inner and the outer edge of any area of the roof panel with a gap or separation.
4. Prepare the roof panel for the foam adhesive injection.
Important:
Use tape with strong adhesion. It is difficult to clean the foam off of visible surfaces. Ensure that the tape covers holes 1, 2, and 3.
4.1 Cut four pieces of tape to cover holes 1, 2, and 3. Tape length: 76 mm (3 in); Tape width: 76 mm (3 in).
4.2 Place the tape near the roof panel holes 1, 2, and 3. Two pieces of tape are required for roof panel hole # 1.
4.3 Insert the two removed bolts from the rear center attachment into the holes (finger tight) until the washer is touching the roof inner panel. This is to prevent foam from filling the location where the bolts are to be when the roof is reinstalled.
4.4 Prepare a cartridge.
4.5 Remove the top plug. Insert a screwdriver into the end and rock it back and forth.
4.6 Install a reducer into the cartridge.
4.7 Insert a mixer nozzle through a nut.
4.8 Install the nozzle onto the cartridge.
4.9 Install the cartridge nozzle assembly to the BO 48206 applicator gun.
Important:
This is a two-part foam product that expands and sets very quickly. Once the mixing begins, the foam will be set in approximately 15 seconds. It is recommended that technicians wear disposable gloves while working with the foam adhesive. Steps 10, 12, and 14 must be performed with approximately 15 seconds from start to finish. Place one piece of tape over the bottom (smaller) hole (1) before injecting foam into the hole (1).
5. Place one piece of tape over the bottom (smaller) hole (1) before injecting foam into the hole (1).
6. Inject six pumps of adhesive foam into the rear slot or top hole (1) of the roof panel.
7. Tape over the top slot hole (1) to keep the foam from coming out.
8. Inject four pumps of adhesive foam into the outboard (left) side of the hole (2) and then turn the applicator to the inboard (right) side of the hole (2) and inject four pumps of adhesive foam into the hole (2).
9. Tape over the hole (2) to keep the foam from coming out.
10. Inject four pumps of adhesive foam into the outboard (left) side of the hole (3) and then turn the applicator to the inboard (right) side of the hole (3) and inject four pumps of adhesive foam into the hole (3).
11. Tape over the hole (3) to keep the foam from coming out.
12. Wait 60 seconds for the foam to set.
13. Remove the tape from holes 1, 2, and 3.
14. Look for any areas where the foam may have leaked out between the frame and the composite panel. Clean the areas where foam leaked out between the frame and the composite panel. Apply a bead of urethane to the inner and outer edge of any area of the roof panel where foam was present.
15. Inspect the roof panel bolt holes for foam or debris. Clean the bolt hole threads with a tap.
16. Install the roof panel shims to the roof panel assembly contact points. Verify fit of roof panel. Adjust shims as required.
Notice:
Discard the old roof panel fasteners and install new roof panel fasteners. Clean the 10 roof panel thread holes with a tap before installing the new roof panel fasteners to avoid damaging the bolt hole or fastener. This is required to clean the adhesive that was left from the original bolts on the threaded attachment holes.
17. Install the roof panel to the vehicle.
Tighten
Tighten the roof panel bolts to 9 Nm (10 lb-in).
18. Install the headliner in the vehicle.
18.1 Slide the headliner through the rear hatch and place it into position.
18.2 Align the headliner in the following locations:
^ Windshield side garnish moldings
^ Sun visor mounting bezel holes and sun visor clamp holes
^ Rear roof bow trim panel area
19. Connect the rear view mirror electrical connector. Refer to the Rear View Mirror Replacement procedure in SI.
20. Install the windshield side garnish moldings. Refer to the Windshield Side Garnish Molding Replacement procedure in SI.
21 Install the driver and passenger side sun visor and sun visor clamp. Refer to the Sun Shade Replacement procedure in SI.
22. Install the rear roof bow trim panel. Refer to the Rear Roof Bow Trim Panel Replacement procedure in SI.
Inspection Procedure - Standard Coupe (non-Z06)
Tools Required
BO-48206 Two-Part Applicator Gun
1. Remove the roof panel from the vehicle.
Notice:
Be sure to protect the painted surface of the panel from damage.
2. With the painted surface down, support the roof panel horizontally on a glass stand, bench, or other suitable area.
3. Lift the edge of the headliner in the areas indicated for inspection in the next step.
4. Inspect for proper adhesion by inserting a 0.254 mm (.010 in) feeler gage between the panel and the frame. Particular attention should be paid to the areas around the rear hatch and the front corners. If the feeler gage fits between the panel and the frame, and the depth is 19.05 mm (.750 in) or greater, the roof panel has some degree of separation.
^ If the feeler gage does not identify any area of the roof panel with separation, proceed to Step 5.
^ If less than 75 percent of the roof panel is separated from the frame, prepare the roof panel for the foam adhesive injection procedure. Refer to the section titled, Roof Panel Preparation for Roof Panels with Separation. This is a temporary repair that will prevent the separation of the roof panel. Submit the claim using labor code T5641, which will not close the program in GMVIS. When the roof panel is available, install the new roof panel and submit the claim using the appropriate V labor code, which will close the program in GMVIS.
Important:
Inspect all roof panels, including new roof panels, to determine if the foam fill procedure has been completed. Perform the foam adhesive injection procedure on new roof panels that have not been foam filled. Perform Steps 5-24 after removing the original roof panel and following the SI procedures listed in the table below.
^ If more than 75 percent of the roof panel is separated from the frame, replace the roof panel.
The SI procedures below may be used.
- Headliner Replacement - Roof Lift Off panel
- Roof Lift Off Panel Rear Latch Replacement
- Roof Lift Off Panel Front Latch Handle Replacement
- Roof Lift Off Panel Molding Replacement
- Roof Lift Off Panel Rear Locator Pin Replacement
- Roof Lift Off Panel Adjustment
Roof Panel Preparation for Roof Panels with Separation
1. Mark gaps or separation of the roof panel with tape.
2. Place a rubber-coated clamp (or equivalent) 102 mm (4 in) on either side of the separation. Ensure a clamp is installed every 152 mm (6 in) along the gap or separation area. Refer to the illustration for clamp position.
Important:
If a bead of urethane is not applied to the gap or separation area, foam will ooze out of the gap or separation area during the foam adhesive injection process.
3. Add a bead of urethane to the inner and outer edge of any area of the roof panel with a gap or separation.
4. Proceed to Step 5.
5. Remove the rear hatch trim screws (1) and the trim (2).
6. Remove the rear hatch attaching bolts (3) and the rear hatch assembly (4).
Important:
Perform Step 7 if no gap or separation was identified in Step 4. Proceed to Step 8 if a gap or separation was identified in Step 4. If installing a new roof panel, proceed to Step 8.
7. Inspect the area underneath the latch for foam.
^ If foam is present, the foam adhesive injection process has been completed. No further action is required.
^ If foam is not present, proceed to Step 8.
8. Install the rear latch attaching bolts (3) to the frame.
9. Remove the front corner brackets (5).
10. Tape off the rear latch and the front bracket areas.
Important:
Cover the area completely with tape that has strong adhesion. It is difficult to clean the foam off of visible surfaces.
11. Using a pen or small knife, cut holes in the tape to inject foam.
Important:
This is a two-part foam product that expands and sets very quickly. Once the mixing begins, the foam will be set in approximately 15 seconds. It is recommended that technicians wear disposable gloves while working with foam.
12. Prepare a cartridge.
12.1 Remove a portion of the label.
12.2 Measure the length of the tubes containing the foam product. Divide the length and mark the cartridge into four equal parts.
12.3 Remove the top plug. Insert a screwdriver into the end and rock it back and forth.
12.4 Install a reducer into the cartridge.
12.5 Insert a mixer nozzle through a nut.
12.6 Install the nozzle onto the cartridge.
12.7 Install the cartridge nozzle assembly to the BO 48206 applicator gun.
12.8 Prepare a piece of tape to cover the hole in each front corner after the foam is injected.
Important:
The following steps must be performed within approximately 15 seconds from start to finish.
13. Inject the one half of the cartridge of foam into the right rear latch area (1) of the panel and the other half of the cartridge into the left latch area (1) of the panel.
14. Tape over the holes to keep the foam from coming out.
15. Prepare a second cartridge.
15.1 Remove a portion of the label.
15.2 Measure the length of the tubes containing the foam product. Divide the length and mark the cartridge into four equal parts.
15.3 Remove the top plug.
15.4 Install a reducer into the cartridge.
15.5 Insert a mixer nozzle through a nut.
15.6 Install the nozzle onto the cartridge.
15.7 Install the cartridge nozzle assembly to the BO-48206 applicator gun.
15.8 Prepare a piece of tape to cover the hole in each front corner after the foam is injected.
Important:
The following steps must be performed within approximately 15 seconds from start to finish.
16. Insert the cartridge approximately 25 mm (1 in) into the hole.
Important:
Use one-quarter of the cartridge in each of the next four steps.
16.1 While watching the cartridge, inject one quarter of the foam in one front corner, pointing front to back.
16.2 In the same corner, turn the applicator and inject one quarter of the foam, pointing the applicator from side to side.
16.3 Tape the hole closed.
16.4 Repeat for the other front corner.
17. Wait 60 seconds for the foam to set.
18. Remove all of the tape.
19. Look for any areas where the foam may have leaked out between the frame and the composite panel. If required, clean the area where foam leaked out between the frame and the composite panel. Apply a bead of urethane around the entire perimeter of the roof panel to improve the appearance of the roof panel edge. Apply the bead of urethane between the frame and composite panel.
20. Install the front corner brackets. A sharp knife or small screwdriver may be needed to remove just enough foam to install the brackets.
21. Remove the latch bolts.
22. Install the latch and bolts. A sharp knife or small screwdriver may be needed to remove just enough foam to install the latch and latch trim cover.
23. Install the rear latch trim cover and screws.
24. Install a new headliner, if required.
25. Install the top to the vehicle.