Roof Panel Bow Replacement Front - Sportwagon

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

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the front doors. Refer to Front Side Door Replacement.
4. Remove the front seats. Refer to Front Seat Replacement - Bucket.
5. Remove the front seat belts. Refer to Front Seat Belt Replacement.
6. Remove the rear doors. Refer to Rear Door Replacement.
7. Remove the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement.
8. Remove the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
9. Remove the load floor stationary panel carpet. Refer to Load Floor Stationary Panel Carpet Replacement.
10. Remove the load floor front panel carpet. Refer to Load Floor Front Panel Carpet Replacement.
11. Remove the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
12. Remove the headlining rear trim panel retainer. Refer to Headlining Rear Trim Panel Retainer Replacement.
13. Remove the body side window rear garnish moulding. Refer to Body Side Window Rear Garnish Molding Replacement.
14. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement.
15. Remove the rear seat back. Refer to Rear Split Folding Seat Back Replacement.
16. Remove the headliner. Refer to Headlining Trim Panel Replacement.
17. Remove the roof weld joint reveal moulding. Refer to Roof Weld Joint Reveal Molding Replacement.
18. Remove the windshield pillar garnish moulding. Refer to Windshield Pillar Garnish Molding Replacement.
19. Remove the windshield. Refer to Windshield Replacement.
20. Remove the liftgate. Refer to Liftgate Replacement.
21. Remove the liftgate hinges. Refer to Liftgate Hinge Replacement.
22. Remove the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement.
23. Remove the roof panel. Refer to Roof Outer Replacement.
24. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Approved Equipment for Collision Repair Caution.




Important: Do nor damage any inner panels or reinforcements.

Important: The front roof bow panel is attached to the upper body sides with beads of adhesive and spot-welds at each end.

Important: Note the number and location of factory welds for installation of the new front roof panel bow.

25. Locate, mark and drill out the factory welds  (1) attaching the front roof panel bow to the body side.



26. Mark a cut line (1) on the front roof bow panel  (2) inboard of the body side assembly.

Important: Cut through the front roof bow panel only. Do not damage any other panels or reinforcements.

27. Using a suitable tool, cut along the cut line  (1) on the front roof bow panel  (2).
28. Remove the centre portion of the front roof bow panel  (2) from the vehicle.
29. Using a suitable tool, remove the remaining portions of the front roof bow panel from the vehicle. Ensure all traces of old adhesive are removed.

Important: Spot welding is the preferred method for attaching panels and should be used whenever possible. A plug weld should only be performed where spot welding is not possible.

Important: If the location of the original plug weld holes cannot be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).

Important: Ensure that all factory welds are replaced in their original locations.

Important: Ensure that all structural adhesives and sealers are replaced in their original locations.

Important: Follow the adhesive manufacturer's instructions during the assembly process. Heat must be applied as per the manufacturer's specifications to cure the adhesives and to expand the sealing baffles.

Important: Secondary sealer must be applied to the perimeter of all flanges and over all joints.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted when dissembling.
2. Clean and prepare the mating surfaces of the body side and the front roof bow panel. Ensure all traces of old adhesive are removed.
3. Verify that the vehicle body structure alignment is correct. Refer to Dimensions - Body.



4. Apply a  13mm wide bead of approved structural adhesive  (1) (GM6449G or equivalent) between the front roof bow and body side outer panel.
5. Apply approved structural adhesive  (2) (GM6449G or equivalent) between the front roof bow and the centre pillar upper reinforcement.

Important: As the front roof bow panel is installed to the vehicle, structural adhesive should be visible on the outside edges of both surfaces (squeezed out when pushed together).

6. Install the front roof bow panel  (1) to the body side.



7. Weld the front roof bow panel  (1) to the body side.
8. Apply any sealers and anti-corrosion materials to the repair area noted on disassembly. Refer to Anti-Corrosion Treatment and Repair.
9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
10. Install the roof outer panel. Refer to Roof Outer Replacement.
11. Install the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement.
12. Install the liftgate hinges. Refer to Liftgate Hinge Replacement.
13. Install the liftgate. Refer to Liftgate Replacement.
14. Install the windshield. Refer to Windshield Replacement.
15. Install the windshield pillar garnish moulding. Refer to Windshield Pillar Garnish Molding Replacement.
16. Install the roof weld joint reveal moulding. Refer to Roof Weld Joint Reveal Molding Replacement.
17. Install the headliner. Refer to Headlining Trim Panel Replacement.
18. Install the rear seat back. Refer to Rear Split Folding Seat Back Replacement.
19. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement.
20. Install the body side window rear garnish moulding. Refer to Body Side Window Rear Garnish Molding Replacement.
21. Install the headlining rear trim panel retainer. Refer to Headlining Rear Trim Panel Retainer Replacement.
22. Install the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
23. Install the load floor front panel carpet. Refer to Load Floor Front Panel Carpet Replacement.
24. Install the load floor stationary panel carpet. Refer to Load Floor Stationary Panel Carpet Replacement.
25. Install the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
26. Install the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement.
27. Install the rear doors. Refer to Rear Door Replacement.
28. Install the front seat belts. Refer to Front Seat Belt Replacement.
29. Install the front seats. Refer to Front Seat Replacement - Bucket.
30. Install the front doors. Refer to Front Side Door Replacement.
31. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
32. Enable the SIR system. Refer to SIR Disabling and Enabling.

Roof Panel Bow Replacement Rear - Sportwagon

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

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the front doors. Refer to Front Side Door Replacement.
4. Remove the front seats. Refer to Front Seat Replacement - Bucket.
5. Remove the front seat belts. Refer to Front Seat Belt Replacement.
6. Remove the rear doors. Refer to Rear Door Replacement.
7. Remove the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement.
8. Remove the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
9. Remove the load floor stationary panel carpet. Refer to Load Floor Stationary Panel Carpet Replacement.
10. Remove the load floor front panel carpet. Refer to Load Floor Front Panel Carpet Replacement.
11. Remove the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
12. Remove the headlining rear trim panel retainer. Refer to Headlining Rear Trim Panel Retainer Replacement.
13. Remove the body side window rear garnish moulding. Refer to Body Side Window Rear Garnish Molding Replacement.
14. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement.
15. Remove the rear seat back. Refer to Rear Split Folding Seat Back Replacement.
16. Remove the headliner. Refer to Headlining Trim Panel Replacement.
17. Remove the roof weld joint reveal moulding. Refer to Roof Weld Joint Reveal Molding Replacement.
18. Remove the windshield pillar garnish moulding. Refer to Windshield Pillar Garnish Molding Replacement.
19. Remove the windshield. Refer to Windshield Replacement.
20. Remove the liftgate. Refer to Liftgate Replacement.
21. Remove the liftgate hinges. Refer to Liftgate Hinge Replacement.
22. Remove the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement.
23. Remove the roof panel. Refer to Roof Outer Replacement.
24. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Approved Equipment for Collision Repair Caution.




Important: The rear roof bow panel is attached to the upper body sides with beads of adhesive and spot-welds at each end.

Important: Note the number and location of factory welds for installation of the new rear roof bow panel.

25. Locate, mark and drill out the factory welds  (1) attaching the rear roof panel bow to the body side.




Important: Cut through the rear roof bow panel only. Do not damage any other panels or reinforcements.

26. Mark a cut line  (1) on the rear roof bow panel  (2) inboard of the body side assembly.
27. Cut along the cut line  (1) on the rear roof bow panel  (2) with a suitable cutting tool.
28. Remove the centre portion of the rear roof bow panel  (2) from the vehicle.
29. Using a suitable tool, remove the remaining portions of the rear roof bow panel from the vehicle. Ensure all traces of old adhesive are removed.

Important: Spot welding is the preferred method for attaching panels and should be used whenever possible. A plug weld should only be performed where spot welding is not possible.

Important: Ensure that all factory welds are replaced in their original locations.

Important: Ensure that all structural adhesives and sealers are replaced in their original locations.

Important: If the location of the original plug weld holes cannot be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).

Important: Follow the adhesive manufacturer's instructions during the assembly process. Heat must be applied as per the manufacturer's specifications to cure the adhesives and to expand the sealing baffles.

Important: Secondary sealer must be applied to the perimeter of all flanges and over all joints.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted when dissembling.
2. Clean and prepare the mating surfaces of the body side and the rear roof bow panel. Ensure all traces of old adhesive are removed.
3. Verify that the vehicle body structure alignment is correct. Refer to Dimensions - Body.




Important: Clean all the adhesives mating surfaces in accordance with the adhesive manufacturer's specifications.

4. Apply a  13mm wide bead of approved structural adhesive  (1) (GM6449G or equivalent) to the rear roof bow panel lower surface. On assembly, the adhesive should be between the rear roof bow panel and the body side outer panel.

Important: As the rear roof bow panel is installed to the vehicle, structural adhesive should be visible on the outside edges of both surfaces (squeezed out when pushed together).

5. Install the rear roof bow panel  (1) to the body side.



6. Weld the rear roof bow panel  (1) to the body side.
7. Apply any sealers and anti-corrosion materials to the repair area noted on disassembly. Refer to Anti-Corrosion Treatment and Repair.
8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
9. Install the roof panel. Refer to Roof Outer Replacement.
10. Install the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement.
11. Install the liftgate hinges. Refer to Liftgate Hinge Replacement.
12. Install the liftgate. Refer to Liftgate Replacement.
13. Install the windshield. Refer to Windshield Replacement.
14. Install the windshield pillar garnish moulding. Refer to Windshield Pillar Garnish Molding Replacement.
15. Install the roof weld joint reveal moulding. Refer to Roof Weld Joint Reveal Molding Replacement.
16. Install the headliner. Refer to Headlining Trim Panel Replacement.
17. Install the rear seat back. Refer to Rear Split Folding Seat Back Replacement.
18. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement.
19. Install the body side window rear garnish moulding. Refer to Body Side Window Rear Garnish Molding Replacement.
20. Install the headlining rear trim panel retainer. Refer to Headlining Rear Trim Panel Retainer Replacement.
21. Install the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
22. Install the load floor front panel carpet. Refer to Load Floor Front Panel Carpet Replacement.
23. Install the load floor stationary panel carpet. Refer to Load Floor Stationary Panel Carpet Replacement.
24. Install the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
25. Install the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement.
26. Install the rear doors. Refer to Rear Door Replacement.
27. Install the front seat belts. Refer to Front Seat Belt Replacement.
28. Install the front seats. Refer to Front Seat Replacement - Bucket.
29. Install the front doors. Refer to Front Side Door Replacement.
30. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
31. Enable the SIR system. Refer to SIR Disabling and Enabling.