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Roof Outer Panel Replacement (5-Door Wagon 35)

Removal Procedure

Warning:  Refer to Approved Equipment for Collision Repair Warning .

1. Disable the SIR System. Refer to SIR Disabling and Enabling .
2. Disconnect the battery negative 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.

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6. Drill all factory welds of the roof outer panel (1). Note the number and location of welds for installation of the service assembly.
7. Cut the adhesive with an appropriate tool.

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8. Remove the damaged roof outer panel (1).

Installation Procedure


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1. Cut the lifting lugs (1).
2. Clean and prepare attaching surfaces for spot welding.

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3. Apply one-part urethane adhesive (1) as noted from the original panel.

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4. Apply structural adhesive (1).

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5. Position the roof outer panel (1).
6. Verify the fit of the panel.
7. Clamp the panel into position.

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8. Spot weld the roof outer panel (1) accordingly.
9. Apply the sealers and anti-corrosion materials to the repair area as necessary.
10. Paint the repaired area.
11. Install all related panels and components.
12. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
13. Enable the SIR System. Refer to SIR Disabling and Enabling .

Body Repair > Collision Repair > Repair Instructions > Roof Outer Panel Replacement - 5-Door Estate 35

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