Roof Outer Panel Replacement
Roof Outer Panel Replacement |
Special Tools
BO-49383 Flexible WeightsFor equivalent regional tools, refer to Special Tools .
Removal Procedure |
Refer to Approved Equipment for Collision Repair Warning .
Refer to Collision Sectioning Warning .
Refer to Glass and Sheet Metal Handling Warning .
1. |
Disable the SIR system. Refer to
SIR Disabling and Enabling
.
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2. |
Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
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3. |
Remove the headlining trim panel. Refer to
Headlining Trim Panel Replacement (With Sunroof)
Headlining Trim Panel Replacement (Without Sunroof)
.
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4. |
Visually inspect the damage. Repair as much of the damage as possible.
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5. |
Before cutting out the roof outer panel, apply a double layer of masking tape around the perimeter of the upper side panel painted surfaces.
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6. |
Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to
Anti-Corrosion Treatment and Repair (Base)
Anti-Corrosion Treatment and Repair (Corrosion Protection)
.
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7. |
Locate and mark all factory welds.
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8. |
Drill all factory welds (1). Note the number and location of welds for installation of the service assembly.
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9. |
Remove carefully the sealant from the roof outer panel channel (wire brush).
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10. |
Cut the roof frames adhesive with an appropriate tool.
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11. |
Grind carefully the laser weld seam (1) in the roof outer panel channel.
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13. |
Grind carefully through the laser weld. |
14. |
Remove the damaged roof outer panel (1).
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Installation Procedure |
1. |
Clean and prepare the attaching surfaces (1) for welding.
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2. |
Apply one-part windshield urethane adhesive as noted from the original roof outer panel.
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3. |
Apply bodywork structural adhesive on the roof outer panel channel (1).
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4. |
Position the roof outer panel on the vehicle.
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5. |
Verify the fit of the roof outer panel.
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6. |
Clamp the roof outer panel into position.
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7. |
Put weights (1) on both sides of the roof outer panel with
BO-49383
flexible weights.
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8. |
Spread surplus bodywork structural adhesive (1) on the roof outer panel channel as a seam sealant and corrosion protection with a spatula or flat paintbrush. Sand down the bodywork structural adhesive after it has cured. To smooth out the surface on the roof outer panel channel, use a liquid filler. Refer to paint systems, paint repair KTA-2207/3.
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9. |
Spot weld (1) the roof outer panel accordingly. |
10. |
Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to
Anti-Corrosion Treatment and Repair (Base)
Anti-Corrosion Treatment and Repair (Corrosion Protection)
.
|
11. |
Install the headlining trim panel. Refer to
Headlining Trim Panel Replacement (With Sunroof)
Headlining Trim Panel Replacement (Without Sunroof)
.
|
12. |
Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
|
13. |
Enable the SIR system. Refer to
SIR Disabling and Enabling
.
|