Removal and Installation - Rear Roof Frame

Special Service Tools / General Equipment

Materials

Removal

NOTICE: Battery electric vehicles (BEV), hybrid electric vehicles (HEV) and plug-in hybrid electric vehicles (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery, it must be removed to prevent damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. Temperatures in the paint booths of some body shops may exceed 60 °C. Therefore, during paint work the paint booth temperature must be set to 60 °C or lower, with a bake time of 45 minutes or less. A temperature above 60 °C or a bake longer than 45 minutes requires removing the high-voltage battery from the vehicle before placing it in the paint booth.

NOTICE: If the paint curing temperature exceeds 60 °C, the charge port indicator ring on plug-in vehicles must be removed.

1. 1
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High-Voltage Systems Health and Safety Precautions — Overview (100-00 General Information, Description and Operation).
2. 2
   Remove the roof or roof opening panel.
   Refer to: Roof Panel (501-28 Roof Sheet Metal Repair, Removal and Installation).
   Refer to: Roof Opening Panel Frame (501-17 Roof Opening Panel, Removal and Installation).
3. 3
   Set aside the wiring harness and washer hose on the rear roof frame.
4. 4
   Both sides:
   Remove the welds.
   Use common equipment: spot weld drill bit

   

5. 5
   Remove the rear roof frame.

   

Installation

NOTICE: Battery electric vehicles (BEV), hybrid electric vehicles (HEV) and plug-in hybrid electric vehicles (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery, it must be removed to prevent damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. Temperatures in the paint booths of some body shops may exceed 60 °C. Therefore, during paint work the paint booth temperature must be set to 60 °C or lower, with a bake time of 45 minutes or less. A temperature above 60 °C or a bake longer than 45 minutes requires removing the high-voltage battery from the vehicle before placing it in the paint booth.

NOTICE: If the paint curing temperature exceeds 60 °C, the charge port indicator ring on plug-in vehicles must be removed.

1. 1
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High-Voltage Systems Health and Safety Precautions — Overview (100-00 General Information, Description and Operation).
2. 2
   Drill the plug weld holes.
   Use common equipment: 8 mm drill bit.

   

3. 3
   Both sides:
   Grind to remove old adhesive and sealer, and clean the rear roof bow bonding surface on the body.

   

4. 4
   Both sides:
   Apply adhesive.
   Material: Metal adhesive / TA-1, TA-1-B, 3M™ 08115, LORD Fusor® 108B, Henkel Teroson EP 5055

   

5. 5
   Install, position and secure the rear roof bow.
   Use common equipment: locking pliers

   

6. 6
   Both sides:
   Install the welds.
   Use common equipment: MIG/MAG welding equipment

   

7. 7
   Metal finish all welds as necessary using standard metal finishing methods.
8. 8
   Position the wiring harness and washer hose to their original location.
9. 9
   Install the roof or sunroof panel.
   Refer to: Roof Panel (501-28 Roof Panel Sheet Metal Repairs, Removal and Installation).
   Refer to: Sunroof Opening Panel Frame (501-17 Sunroof Opening Panel, Removal and Installation).
   Refer to: Sunroof Opening Panel Fixed Glass (501-17 Sunroof Opening Panel, Removal and Installation).
   Refer to: Sunroof Opening Panel Glass (501-17 Sunroof Opening Panel, Removal and Installation).