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

Important: This adhesive bonding procedure represents one manufacturer's installation application. Other manufacturers' procedures may vary, including MIG welding in some areas of the repair. Always follow the system manufacturer's instructions for application, handling, and curing.

Important: Before you begin the repair, refer to Metal Panel Bonding for proper adhesive preparations and general information.

The roof panel is attached to the steel roof structure with beads of adhesive on the sides and spot-welds on the side rail, windshield and back-glass flanges. Replacement of the roof panel can be performed using conventional procedures, however, the windshield and back glass must be removed. Factory roof panel is attached with spot welds on the side rails, the service part will use adhesive only on both side rails.

Important: Use care when cutting to protect adjacent panels. Cut inboard of the roof structure.

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 .
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 .
6. Locate and mark all factory welds.



7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.
8. Cut the adhesive with an appropriate tool after removing the panel.
9. Remove the remaining portion of the original panel.

1. Clean and prepare the attaching surfaces for welding.
2. Drill 8 mm (5/16 in) for plug welding along the windshield and back glass edges of the service panel as noted from the original panel.
3. Grind the surface of the body side mating flanges to bare steel. Do not damage the corners or thin the metal during the grinding process.
4. Grind the mating flanges of the service roof panel to remove the e-coating. Do not damage the corners or thin the metal during the grinding process.
5. Clean the mating surfaces.

Important: Do not allow the adhesive to cure prior to installing the service panel

6. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive to both of the mating surfaces.
7. Using a small acid brush, spread a coat of adhesive to both of the mating surfaces. Cover all the bare metal surfaces to ensure corrosion protection.
8. Apply a 9-13 mm (3/8 to 1/2 in) bead of metal panel bonding adhesive to the mating surface of the service roof panel.

Important: DO NOT pull the panels apart after being joined together. Slide the panels against each other to realign the panels.

9. Install the service roof panel.
10. Clamp the service roof panel into position



11. Plug weld accordingly.
12. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
13. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
14. Install all related panels and components.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
16. Enable the SIR system. Refer to SIR Disabling and Enabling .