For 1990-2009 cars only
Removal Procedure
- Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Remove all related panels and components.
- Repair as much of the damage as possible, to factory specifications. Refer to Dimensions - Body .
- Note the location, and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
- Remove the windshield. Refer to Windshield Replacement in Stationary Windows.
- Remove the rear window. Refer to Rear Window Replacement in Stationary Windows.
- Locate and drill out all factory welds. Note the number and location of welds for installation of the roof panel.
- With an assistant remove the roof panel.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: When replacing panels that involve servicing of stationary windows, refer to Adhesive Installation of Stationary Windows in Stationary Windows, before performing any priming or refinishing.
Installation Procedure
- Drill 8 mm (5/16 in) plug weld holes, as necessary, in locations noted from the original panel.
- Prepare all mating surfaces, as necessary.
- Apply 3M® Weld-Thru coating P/N 05916, or equivalent, to all mating surfaces.
- With the aid of an assistant, position the roof panel to the body.
- Plug weld accordingly.
- Clean and prepare all welded surfaces.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
- Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
- Install the windshield. Refer to Windshield Replacement in Stationary Windows.
- Install the rear window. Refer to Rear Window Replacement in Stationary Windows.
- Install all related panels and components.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.
Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1½ in) apart.
