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Roof Outer Panel Replacement

Removal Procedure

This repair procedure includes an installation procedure for either metal-inert gas welding or adhesive bonding.

    Warning : Refer to Approved Equipment for Collision Repair Warning in the Preface section.

    Note : When replacing panels that involve servicing of stationary windows, refer to Full-Cut Method Description before performing any priming or refinishing.

  1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling .
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

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  4. Remove all related panels and components.
  5. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body : C105/Short Body  → C100/Long Body .
  6. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  7. Remove the windscreen. Refer to Windshield Replacement .
  8. Remove the liftgate. Refer to Liftgate Replacement .

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  10. Locate and drill out all factory welds. Note the number and location of welds for installation of the roof panel.

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  12. With the aid of an assistant, remove the roof panel.

Installation Procedure


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  1. Drill 8 mm (5/16 in) plug weld holes as necessary in locations noted from the original panel.
  2. Note : If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1½ in) apart.

  3. Prepare all mating surfaces as necessary.
  4. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces

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  6. With the aid of an assistant, position the roof panel to the body.

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  8. Plug weld accordingly.
  9. Clean and prepare all welded surfaces.

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  11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  12. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .
  13. Install the windscreen. Refer to Windshield Replacement .
  14. Install the liftgate. Refer to Liftgate Replacement .
  15. Install all related panels and components.
  16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  17. Enable the SIR system. Refer to SIR Disabling and Enabling .
   


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