Roof Rear Header Panel Replacement 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 Anti-Corrosion Treatment and Repair.




Important: Do not damage any other panels or reinforcements.

Important: The roof rear header panel asm consists of an inner and outer panel which are joined to the body structure with both spotwelds and adhesive.

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



26. Mark cut lines  (1) on the inner roof rear header panel inboard of the body side assembly.

Important: Only cut through the inner roof rear header panel. Do not damage any other panels or reinforcements.

27. Cut along the cut lines  (1) on the inner roof rear header panel.



28. Mark cut lines  (1) along the outer roof rear header panel inboard of the body side assembly.

Important: Use a suitable device to support the roof rear header panel assembly.

Important: Only cut through the outer roof rear header panel. Do not damage any other panels or reinforcements.

29. Cut along the cut lines  (1) on the outer roof rear header panel.
30. Remove the centre section of the roof rear header panel assembly from the vehicle.

Important: Only remove the remaining portions of the roof rear header panel. Do not damage any other panels or reinforcements.

31. Using a suitable tool, remove the remaining outer portions of both the inner and outer roof rear header panel from the vehicle. Ensure that 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 roof rear header panel assembly.



3. The roof rear header panel is supplied as separate inner and outer panels which must be welded together by the repairer. Align the inner and outer panels as shown in the diagram. Align the inner roof rear header panel, D, and the outer roof rear header panel, B, hard up against each other at locations C and E. The panels must be aligned to achieve the required gap where dimension A = 4.56mm (0.180in). This gap must be achieved symmetrically across the assembly.




Important: For weld locations, refer to the damaged rear roof header panel.

4. Weld (1) the roof rear header inner and outer panels together prior to installation to the vehicle. The welds (2) should be done when the outer roof panel is replaced. Refer to Roof Outer Replacement



5. Apply an approved structural adhesive (1) GM6449G or equivalent to the mating surface between the inner roof rear header panel and the body side assembly.
6. Apply an approved structural adhesive  (2) GM6449G or equivalent to the mating surface between the outer roof rear header panel and the body side assembly.

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

7. Install the roof rear header panel (1) to the body side.



8. Weld the roof rear header panel to the body side (1).
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.