Roof Panel Vehicles With: Sliding Roof Opening Panel

Trustmark Authoring Standards (TAS) Repair Procedures

NOTE: TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.

A TAS removal and installation procedure uses a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.

TAS Graphics

Colors used in the graphic are as follows:
- Blue - Component to be removed/installed or disassembled/assembled.
- Green and Brown - Additional components that need to be removed/installed or disassembled/assembled prior to the target component.
- Yellow - Component that is touched or affected in a way but remains in the vehicle. It may be detached, attached, moved, modified, checked, adjusted etc.
- Magenta - Electrical connectors and fasteners such as nuts, bolts, clamps and clips.
- Pale Blue - Special tool(s) and general equipment.

One illustration may have multiple steps assigned to it.

Numbered pointers are used to indicate the number of electrical connectors and fasteners such as nuts, bolts, clamps and clips.

Items in the illustration can be transparent or use cutouts to show hidden details.














TAS Symbols

Symbols are used inside the graphics and in the text area to enhance the information display.

Roof Sheet Metal Repairs - Roof Panel Vehicles With: Sliding Roof Opening Panel

Removal and Installation

Removal

1. NOTE: The roof panel is manufactured from mild steel.

The roof panel is serviced as a separate weld-on panel.







2. The roof panel is replaced in conjunction with:
- Headliner
- Windshield
- Rear window glass

3. For additional information relating to this repair procedure please see the following:
Refer to Service Precautions
Corrosion Protection
Body Dimensions

4. Remove both front seats.
5. Disconnect the battery ground cable.
6. Disconnect the generator electrical connectors.
7. Remove the windshield glass.
8. Remove the rear window glass.
9. Remove the roof opening panel frame.
10. Remove the driver and passenger side front scuff plate trim panels.
11. Remove the driver and passenger side rear scuff plate trim panels.
12. Remove the driver and passenger side air curtain modules.
13. Remove the rear seat backrest.
14. Remove the driver and passenger side rear safety belt retractors.
15. Remove the rear center safety belt retractor.
16. Remove the driver and passenger side RF filters.
17. Remove the diversity antenna module.
18. Remove the antenna.
19. Release and position the roof wiring harnesses to one side
20. Position the roof opening panel front and rear drain hoses to one side.
21. Remove the driver and passenger side roof mouldings.
22. Drill out the spot welds.







23. Separate the joints and remove the old panel.

Installation

1. NOTE: The slots should be made so that the new roof panel can be brazed to the A-Pillar outer and inner.

Cut 2 slots in the new roof panel.







2. Prepare the old and new panel joint surfaces.
3. Offer up the new panel and clamp into position. Check alignment, if correct, proceed to next step, if not rectify and recheck before proceeding.
4. Remove the new panel.

5. NOTE: Make sure the adhesive is kept away from the area of MIG brazed slots.

Apply adhesive to the areas indicated.







6. Offer up the new panel and clamp into position.
7. Spot weld.







8. MIG braze the slots.







9. Remove any excess adhesive and dress all welded/brazed joints.
10. Make sure the external areas around the MIG brazed slots are sealed as part of the paint preparation process as this cannot be performed satisfactorily during panel replacement.







11. Install NVH (noise, vibration and harshness) sound deadening pads.







12. The installation of associated panels and components is the reversal of removal procedure.