ROOF PANEL(for Sliding Roof) ASSEMBLY REPLACEMENT

A001ZU7

  1. LASER BRAZED ROOF PANEL REPLACEMENT USING ADHESIVE


    1. The laser brazed roof panel is repaired using a roof panel reinforcement bracket, roof panel reinforcement plate and adhesive.

      A001ZTLC01
      *1 Roof Panel *2 Roof Panel Reinforcement Bracket
      *3 Roof Panel Reinforcement Plate *4 Adhesive
      *5 Bolt *6 Roof Drip Moulding Sub-Assembly
      *a Laser Brazing *b Adhesive and Sealer

    2. Roof panel rough cutting.

      Note

      Carefully cut the roof panel so not to damage the internal reinforcement.

    3. Sand the roof panel and brazing filler metal left on the vehicle using a belt grinder to make them smooth.

      A00202VN01

      Tech Tips


      • Do not damage the area above *a (brazing filler metal part) of the roof side outer upper No.1 rail.

      • All of the brazing filler metal does not need to be sanded.

    4. Roof panel reinforcement bracket installation.


      1. Remove the paint film where the adhesive will be applied for the roof panel and roof panel reinforcement bracket.

        Tech Tips

        On the roof panel side, remove the paint film from the roof panel reinforcement bracket installation area only.

      2. Place marks to indicate the roof panel reinforcement bracket installation position.

        A00202YC01
        *A Front - -
        *1 NO.1 *2 NO.2
        *3 NO.3 *4 NO.4
        *5 NO.5 - -

        Tech Tips

        Perform the measurement along the roof panel surface.

      3. A00204MC01
        4. *1 Roof Panel
        *2 Roof Panel Reinforcement Bracket
        *a Adhesive
        *b Protrusions

Apply adhesive in the positions shown in the illustration and place the roof panel reinforcement bracket at the marked positions on the roof panel.

Tech Tips


  • A001ZYBC01
    *A RH
    *B Front
    *b 20 mm (0.79 in.)

    Adjust the clearance of *a using an adjustmentbolt to the value shown below.

    No.1 No.2 No.3 No.4 No.5
    A 9.3 mm(0.366 in.) 9.5 mm(0.374 in.) 9.4 mm(0.370 in.) 9.5 mm(0.374 in.) 9.3 mm(0.366 in.)
    B 9.3 mm(0.366 in.) 9.5 mm(0.374 in.) 9.5 mm(0.374 in.) 9.5 mm(0.374 in.) 9.5 mm(0.374 in.)

    Tech Tips

    Use an M6 adjustment bolt or higher with a pitch of 1.0 mm (0.039 in.) or more and a grip length of 20 mm (0.787 in.) or more.

  • Weld the roof panel reinforcement bracket after adjusting the clearance.

    Note

    In order to prevent heat deformation to the roof panel, perform welding while cooling the area.

  • Drying.

    Tech Tips


  • roof panel reinforcement plate installation.


    1. Temporarily place the roof panel on the vehicle and fix the front and back in place using locking pliers.

      Tech Tips

      Make sure to balance the roof panel lengthwise and widthwise.

    2. Place marks on the roof side outer upper No.1 rail after aligning it with the roof panel reinforcement bracket.

    3. Remove the roof panel.

    4. Align the roof panel reinforcement plate with the marks and perform welding.

      Tech Tips

      Push the protrusions against the roof side outer upper No.1 rail.

  • A00202JN01

    Adjust the clearance between the roof panel reinforcement bracket and roof panel reinforcement plate.


    1. Temporarily place the roof panel on the vehicle and fix the front and back in place using locking pliers.

    2. Make sure that A (welded area) of the roof panel and roof panel reinforcement bracket do not interfere with the vehicle.

    3. Visually make sure there is a clearance between the roof panel reinforcement bracket and roof panel reinforcement plate.

    4. Visually make sure the clearance between the roof panel reinforcement bracket and roof panel reinforcement plate is parallel.

      Tech Tips

      If the clearance is not parallel with the roof panel reinforcement plate, lightly tap the roof panel reinforcement plate until it is parallel.

    5. Measure the clearance labeled *a, and choose shims according to the chart.

      Tech Tips

      There are two types of shims: 0.5 mm and 1.0 mm

      Clearance Shim
      0.5 mm (0.020 in.) or less -
      0.6 to 1.0 mm (0.024 to 0.039 in.) 0.5 mm (0.020 in.)
      1.1 to 1.5 mm (0.043 to 0.059 in.) 1.0 mm (0.024 in.)
      1.6 to 2.0 mm (0.063 to 0.079 in.) 0.5 + 1.0 mm (0.020 + 0.024 in.)
      2.1 to 2.5 mm (0.083 to 0.098 in.) 1.0 + 1.0 mm (0.024 + 0.024 in.)
      2.6 to 3.0 mm (0.102 to 0.118 in.) 0.5 + 1.0 + 1.0 mm (0.020 + 0.024 + 0.024 in.)
      3.1 to 3.5 mm (0.122 to 0.138 in.) 1.0 + 1.0 + 1.0 mm (0.024 + 0.024 + 0.024 in.)

  • Place shims in the clearance between the roof panel and roof panel reinforcement plate and tighten the bolts.

    A00207A
    Torque:
    5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    Tech Tips

    Be sure to tighten the bolts in diametric order.

  • A001ZX4C01
    *a Thickness Gauge

    After tightening all the bolts, check the contact points between the roof panel and roof side outer upper rail with a thickness gauge.

    Tech Tips


    • If there is a difference between the left and right sides, confirm the roof panel installation and perform adjustment when necessary.

    • Change to a thinner shim if the roof panel changes when it is lightly pushed.

  • Remove the paint film where the adhesive will be applied for the roof panel and roof side outer upper No.1 rail.

    Tech Tips

    Do not remove the paint film where the roof drip moulding sub-assembly is installed.


    1. Install the roof drip moulding sub-assembly.

      A001ZWSC01
      *1 Roof Drip Moulding Sub-Assembly - -
      *a Area to remove paint. - -

      Tech Tips

      Do not install the roof drip moulding sub-assembly where the roof panel reinforcement plate is installed.

    2. Apply adhesive.

      A00206WC01
      *A w/o ROOF PANEL REINFORCEMENT PLATE *B w/ ROOF PANEL REINFORCEMENT PLATE
      *C ROOF PANEL *D ROOF PANEL REINFORCEMENT BRACKET
      *1 Roof Drip Moulding Sub-Assembly - -
      *a Adhesive - -

    3. Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel reinforcement and back window frame.

      Tech Tips

      Apply just enough body sealer for the new parts to make contact.

  • Roof panel installation.


    1. Insert the shims selected during adjustment and install the bolts.

      A00207A
      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Tech Tips

      Be sure to tighten the bolts in diametric order.

    2. Remove any protruding adhesive with a spatula.

      Note

      Do not remove too much adhesive.

    3. Remove adhesive applied outside the application area before it hardens.

    4. Before temporarily installing the new parts, weld the windshield header panel, roof panel reinforcement and back window frame with the standard number of welding points.

    5. A00203HC01
      *a Adhesive

      Apply adhesive inside the roof panel reinforcement bracket.

  • Dry the adhesive areas of the new roof panel.

    Tech Tips


  • A001ZWA

    Finishing.


    1. Make a U shape using sand paper after the adhesive hardens.

    2. Apply a small amount of sealer after making a U.

      Tech Tips

      If the adhesive finish looks good, it is not necessary to apply sealer.

  • REMOVAL

    Symbol Meaning
    A00206N Remove Weld Points

      REMOVAL POINT

    1. If reusing the roof panel reinforcement, trim the hemming location using a disc sander, etc.

    2. *a in the illustration indicates the laser Brazing location.

    3. *b in illustration indicates where the adhesive is located.

    4. Roughly cut open the panel so that the adhesive can be reached. Cut through the adhesive with a cut chisel to remove the panel.

      Tech Tips

      In cases where the adhesive cannot be removed with a cut chisel, heat the adhesive with an industrial heater gun or gas burner taking care not to cause panel deformation by overheating.

    A001ZW1C01
    *a Laser Brazing *c Disc Sander

  • INSTALLATION

    Symbol Meaning
    A001ZU3 Spot Weld
    A00200M Plug Weld
    A002003 Fillet Weld
    A001ZXQ Body Sealer

      INSTALLATION POINT

    1. Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.

    2. Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimensions)

    3. *g in the illustration indicates the bolts.

    4. Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel reinforcement and back window frame.

      Tech Tips

      Apply just enough body sealer for the new parts to make contact.

    5. Apply adhesive (3MTMAutomixTMPanel Bonding Adhesive #8115) to the area indicated by *h in the illustration.

      Tech Tips


      • Apply a light coat of adhesive around the plug welding points.

      • Apply enough adhesive to the panels.

    6. Apply adhesive (3MTMAutomixTMPanel Bonding Adhesive #8115) to the area indicated by *i in the illustration.

      Tech Tips

      Apply enough adhesive to the panels.

    7. Bend the flange hem with a wooden hammer and dolly.

      Tech Tips

      Perform hemming three steps, being careful not to warp the panel.

    8. After welding, apply the foamed sealing material to the corresponding parts. (See the painting / coating)

    9. After welding, apply body sealer to the corresponding parts. (See the painting / coating)

    10. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.

    A001ZWFC01
    *A Lower Face *B Front
    *a 111 mm (4.37 in.) *b 295 mm (11.61 in.)
    *c 371 mm (14.61 in.) *d 167 mm (6.57 in.)
    *e 168 mm (6.61 in.) *f 351 mm (13.82 in.)
    A002021C01
    *A Upper Face *B Front
    *a 5 mm (0.20 in.) *b 10 mm (0.39 in.)
    A001ZVF
    A00201YC01
    *1 ROOF DRIP MOULDING SUB-ASSEMBLY - -
    A00200JC01
    *1 ROOF PANEL - -
    *a Dolly *b Cloth Tape
    *c Wooden Hammer - -
    A002042 N*m (kgf*cm, ft.*lbf): Specified torque - -