Orlando

Roof Front Header Panel Replacement — Welding

Note : According to different corrosion warranties, only the regional mandatory joining methods are allowed.

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

Warning : Refer to Collision Sectioning Warning in the Preface section.

Warning : Refer to Glass and Sheet Metal Handling Warning in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling .
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
3. Remove all related panels and components.
4. Visually inspect the damage. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .



6. Locate and mark all the necessary factory welds of the roof panel front bracket right (1).
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



8. Remove the roof panel front bracket right (1).
9. Proceed the same way with the roof panel front bracket left.



10. Create cut lines on the roof front header panel (1).



11. Cut the roof front header panel (1) where sectioning is to be performed.



12. Remove the damaged roof front header panel (1).

1. Cut the roof front header panel (1) in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.
2. Prepare all mating surfaces as necessary.
3. Align roof front header panel.
4. Clean and prepare the attaching surfaces for welding.



5. Position the roof front header panel (1) on the vehicle.
6. Verify the fit of the roof front header panel.
7. Clamp the roof front header panel into position.



8. Weld the roof front header panel (1) accordingly.
9. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch weld.



10. Drill 8 mm (5/16 in) for plug welding along the edges of the roof panel (1) front bracket right as noted from the original panel.
11. Clean and prepare the attaching surfaces for welding.



12. Position the roof panel front bracket right (1) on the vehicle.
13. Verify the fit of the roof panel front bracket.
14. Clamp the roof panel front bracket right into position.



15. Weld the roof panel front bracket right (1) accordingly.



16. Spotweld roof the panel front bracket right (1) accordingly.
17. Proceed the same way with the roof panel front bracket left.
18. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
19. Paint the repaired area.
20. Install all related panels and components.
21. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
22. Enable the SIR system. Refer to SIR Disabling and Enabling .