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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 191 (FOLDING TOP SYSTEM)REPAIR INSTRUCTIONSHARD TOP REPLACEMENTREMOVAL PROCEDURE
2001 Chevrolet Cavalier LS, 2.4 T

Removal Procedure

2001 Chevrolet Cavalier LS, 2.4 TSECTION Removal Procedure
WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the windshield reveal molding. Set the molding aside.
  2. Remove the rear window. Refer to REAR WINDOW REPLACEMENT in Stationary Windows.
  3. Remove the 2 sun visors. Refer to SUNSHADE REPLACEMENT in Interior Trim.
  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. Refer to HARD TOP HEADLINER REPLACEMENT in Interior Trim.
    Fig 1: Windshield Reveal Molding
    G01451528Courtesy of GENERAL MOTORS CORP.
  8. Remove the roof weatherstrips and moldings. Refer to WEATHERSTRIP SIDE RETAINER REPLACEMENT (COUPE AND CONVERTIBLE) or WEATHERSTRIP SIDE RETAINER REPLACEMENT (HARDTOP in Stationary Windows.
  9. Remove the side reveal molding. Refer to SIDE REVEAL MOLDING REPLACEMENT (COUPE AND CONVERTIBLE) or SIDE REVEAL MOLDING REPLACEMENT (HARDTOP) in Stationary Windows.
  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).
    Fig 2: Making A Rough Cut On Forward Of Rear Glass In Order To Gain Access To Bonded Areas
    G01451529Courtesy of GENERAL MOTORS CORP.
  13. Mark the location of 2 brackets (1) on the front edge of the roof bow. Remove the brackets.
    Fig 3: Brackets
    G01451530Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 4: Brackets
    G01451531Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.