Orlando

Roof Rear Inner 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 Glass and Sheet Metal Handling Warning in the Preface section.

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 : 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 factory welds.



7. Create cut lines on the roof rear inner panel (1).



8. Cut the roof rear inner panel (1) where sectioning is to be performed.



9. Drill all factory welds of the roof rear inner panel (1).



10. Remove the damaged roof rear inner panel (1).

1. Cut the roof rear inner 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 the roof rear inner panel.
4. Clean and prepare the attaching surfaces for welding.



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



8. Plug weld the roof rear inner panel (1) accordingly.



9. Plug weld the roof rear inner panel (1) accordingly.
10. Apply the sealers and anti-corrosion materials to the repair area as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
11. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
14. Enable the SIR system. Refer to SIR Disabling and Enabling .