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Roof Outer Panel Replacement

Roof Outer Panel Replacement


Special Tools

BO-49383 Flexible Weights

For 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 .

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

3. Remove the headlining trim panel. Refer to Headlining Trim Panel Replacement (Without Sunroof) Headlining Trim Panel Replacement (With Sunroof) .

4. Visually inspect the damage. Repair as much of the damage as possible.

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.

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) .

7. Locate and mark all factory welds.

8. Drill all factory welds (1). Note the number and location of welds for installation of the service assembly.


9. Remove carefully the sealant from the roof outer panel channel (wire brush).


10. Cut the roof frames adhesive with an appropriate tool.


11. Grind carefully the laser weld seam (1) in the roof outer panel channel.


12.
Note

Do not apply pressure via contact surface.


When grinding through the laser weld seam on the roof outer panel, preliminary tension must be generated between the roof outer panel and roof frame using a chisel/lever.


13.
Note

Do not use cutting discs. Only wide grinding discs.


Grind carefully through the laser weld.


14. Remove the damaged roof outer panel (1).



Installation Procedure


1. Clean and prepare the attaching surfaces (1) for welding.


2. Apply one-part windshield urethane adhesive as noted from the original roof outer panel.

3. Apply bodywork structural adhesive on the roof outer panel channel (1).


4. Position the roof outer panel on the vehicle.

5. Verify the fit of the roof outer panel.

6. Clamp the roof outer panel into position.

7. Put weights (1) on both sides of the roof outer panel with BO-49383 flexible weights.


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.


9.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


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 (Without Sunroof) Headlining Trim Panel Replacement (With 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 .