Roof Panel Replacement
1. Mass Production Body Welding Positions and Numbers - Remove

Roof Panel (With moonroof)






Roof Panel (With panoramic glass roof)






Roof Panel (Normal roof)






Roof Rail and Roof Arch





2. Construction - Remove

NOTE:
This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual.
The component replacement procedure described here is only for new genuine supplied parts, as needed, according to the area and the degree of damage on the body.
With moonroof or panoramic glass roof: Remove the mounting bolts, leave the front roof rail, the roof stiffener gussets, and the rear roof rail to the body, and replace the roof panel.
Normal roof: Leave the front roof rail, roof arch A, and the rear roof rail to the body, and replace the roof panel.
Check the front roof rail, roof arch A (normal roof), and the rear roof rail positions for damage. If necessary, replace them.
With moonroof


With panoramic glass roof


Normal roof



NOTE:
Position the replacement parts.
Before doing the main welding, check the body dimensions:
?
Inner panel positions
?
Rear pillar gutter and rear panel positions
?
Windshield and door openings
?
Tailgate opening
Temporarily install the related parts, then check for differences in level and clearance.
Check the external parts fitting positions. Make sure the body lines flow smoothly.
Confirm the sheet thickness, tensile strength, and existence of the zinc treatment of both sides, and set the welder to conform to the welding conditions by referring to Roof and Side Panel Construction.
Welding symbols (The welding symbols with dashed lines have a meaning of the spot welding of the part which is not visible)
( ) and ( )*: The number of welds

1. Roof Rails and Roof Arch A - Weld
1.
Weld the front roof rail (A) to the roof side rail (B).
( )*: Welding positions with high-strength steel parts. Confirm the plug welding conditions.
2.
Normal roof: Weld roof arch A to the roof side rail (B) and the center inner pillar (C).
( )*: Welding positions with high-strength steel parts. Confirm the plug welding conditions.
3.
Weld the rear roof rail (A) to the rear inner upper pillar (B) and the rear pillar upper stiffener (C).

2. Roof Panel - Weld
1.
Apply adhesive (A) on the flanges of the roof panel (B) and the roof gutter areas (C) of the body as shown.

Adhesive: 3M AUTO MIX Panel Bonding 8115, or equivalent, commercially available
NOTE: See the adhesive manufacturer's instructions for details.
2.
Apply a soft type sealer (B) to the mating surfaces of the front roof rail (C) and roof arch A.
3.
Apply a soft type sealer (A) to the mating surfaces of the rear roof rail (B).
4.
With moonroof: Clamp the roof panel (A), attach the front roof rail (B) with the moonroof mounting bolts (C).
5.
With moonroof or panoramic glass roof: Attach the roof stiffener gussets (A) to the roof panel stiffeners (B) with the mounting bolts.




With moonroof

With panoramic glass roof

Normal roof
6.
Weld the front and rear flanges of the roof panel (A).
7.
Weld the side flanges of the roof panel (A).
(?)*: Welding positions with the front pillar upper stiffener (B), include ultra high-strength steel (1500 MPa) parts. Perform the spot welding on the conditions of No. 30 in the table shown below.
Spot welding conditions
No. 30
8500 A
1200 ms
3432 N (350 kgf)