Roof Panel Page 9–1
Page 9–1
Section 9
Roof Panel
ATTENTION
Before performing any Service Operation or other procedure described in this Section, refer to Section 00
Warnings, Cautions And Notes for correct workshop practices with regard to safety and/or property damage.
The Structure of the MY 2004 WK Series
vehicle body shell has been developed using
complex design and development techniques.
In addition to meeting all required standards,
the vehicle body is also a critical part of the
overall safety systems. It is therefore
imperative the repair procedures described
here are adhered to during all vehicle body
repairs.
1 General Information............................................................................................................................... 2
1.1 Roof Components..................................................................................................................................................2
2 Service Operations................................................................................................................................ 4
2.1 Roof Panel - Replace Without Sunroof.................................................................................................................4
Remove ...................................................................................................................................................................4
Replace ...................................................................................................................................................................6
2.2 Roof Panel - Replace With Sunroof......................................................................................................................8
Remove ...................................................................................................................................................................8
Replace .................................................................................................................................................................10
Roof Panel Page 9–2
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1 General Information
With the following exceptions, MY 2004 WK Series roof panel information carries over from MY 2003 VY Series vehicles.
For information not contained within this Section, refer to Section 9, Roof Panel, in the MY 2003 VY & V2 Series Service
Information Supplement, Body Structure Repair.
• Roof panel - without sunroof
• Roof panel - with sunroof
This Section describes repairs to the MY 2004 WK Series Vehicles Roof Panel. The repair procedures are limited to the
replacement of this pan el.
The roof panel is both spot welded and glued in place with metal adhesive. This material cannot be softened by heating
or other normal means and the panel can only be removed by cutting and/or grinding.
A sunroof option is available that is fitted on the production line. To cater for this option, a new roof structure has been
introduced which features a housing assembly in place of the roof bow panel. A stainless steel front drain tube is also
fitted within the hinge pillar cavity which effects the service procedures for the hinge pillar, refer to Section 7 Body Side.
When repairing the roof structure, care must be taken to ensure it is returned to its original production configuration.
NOTE
It is imperative that the correct body adhesives,
sealants, deadeners and cavity waxes are
used when repairing the body structure of
WK Series Vehicles. Refer to Section 3,
5 Body Sealing, Adhesives & Deadeners and
Section 3, 6 Cavity Wax for details of the correct
materials and their commercially available
equivalents.
1.1 Roof Components
The shaded components shown are those dealt with in this
Section.
The components and assemblies shown are the parts
serviced for this section of the WK Series Vehicles, refer to
Figure 9 – 2.
These components form the basis of the repair procedures.
Figure 9 – 1
Roof Panel Page 9–3
Page 9–3
Figure 9 – 2
Legend
1 Roof Panel
2 Roof Front Header Panel
3 Roof Bow Panel
4 Roof Bow Panel No. 2
5 Roof Rear Panel
6 Roof Panel Assembly (With Sunroof)
Roof Panel Page 9–4
Page 9–4
2 Service Operations
2.1 Roof Panel - Replace Without Sunroof
Remove
1 Remove the adjacent trim and components, refer to Section 1A8, Headlining and Interior Trim in the MY 2004 WK
Series Service Information.
2 Remove the front windshield and back window, refer to Section 1A6, Stationary Glass in the MY 2004 WK Series
Service Information.
3 Spot cut the welds attaching the roof panel to the
windshield header rail and rear roof frame.
Figure 9 – 3
4 Using a cutting tool such as an air chisel or angle
grinder, cut through the roof panel along the side of
the roof channel.
NOTE
As the roof panel is securely glued to the body
side panel along the channel it cannot be
removed by simply spot cutting the welds.
NOTE
If the header and support panels are to be
retained, take care not to cut them off with the
roof panel. Alternatively, if one or more are to be
replaced, it is easier to cut off those being
replaced along with the roof panel.
Figure 9 – 4
Roof Panel Page 9–5
Page 9–5
5 Use a heat gun to soften the anti-flutter adhesive
between the roof panel and headers, and roof panel
and support panel, by heating the areas shown.
Figure 9 – 5
6 Cut through the softened adhesive between the roof
panel and headers, using a suitable tool.
7 Remove the roof panel from the vehicle.
Figure 9 – 6
8 Using an angle grinder, air chisel or other suitable tool,
remove the remaining strip of roof panel from the body
side panel, along with the adhesive beneath the strip.
9 Repair any damage to adjacent parts.
10 Check and repair, if necessary, the alignment of the
body shell. Refer to the dimensions available in
Section 3, Body Construction.
Figure 9 – 7
Roof Panel Page 9–6
Page 9–6
Replace
The same number and position of spot welds
(or plug welds) should be used when
replacing the panel, as was used during
manufacture, in order to maintain the original
structural strength of the vehicle.
When welding a relatively flat panel such as
the roof panel, due care must be taken to
minimise the heat absorbed by the panel
which could lead to panel distortion.
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment
available to the repairer will not access the
required weld position, a plug weld should be
performed.
1 Clean the remaining anti-flutter adhesive from the surfaces of the header rail, roof rear frame and support panel.
2 Prepare the mating surface areas for welding. Dress the channel flange area, the windshield header rail and the
roof rear frame, so they are flat and free from imperfections.
3 Treat the front and rear mating surfaces with Weld Through Primer (Item 1) as required. Refer to Section 3, 5 Body
Sealing, Adhesives & Deadeners.
4 Mark the new roof panel with drilling locations, where plug welding is necessary. Drill holes as required.
5 Apply Structural adhesive (Item 6) (1) to the mating
surfaces of the roof panel and door opening frame.
Refer to Section 3, 5 Body Sealing, Adhesives &
Deadeners.
6 Apply a bead of Anti-flutter adhesive (Item 5) to the full
length of the groove in the windshield header (section
A-A) and the groove in the rear roof frame (section C-
C), refer to Figure 9 – 9. Refer to Section 3, 5 Body
Sealing, Adhesives & Deadeners.
7 Apply two full length beads of Anti-flutter adhesive to
the grooves in the roof supports (section B-B).
Figure 9 – 8
Roof Panel Page 9–7
Page 9–7
Figure 9 – 9
8 Position the roof panel on the vehicle and clamp in place.
Take care to minimise the heat absorbed by
the panel in order to reduce heat distortion.
In some cases, especially if plug welding, it
may be advantageous to begin welding from
the middle of the run and weld alternatively
to the front and rear. This may reduce panel
distortion.
9 Spot or plug weld the roof panel to the door opening
frame on both sides of the vehicle using the sa me
number of welds as per original build.
Figure 9 – 10
10 Spot or plug weld the roof panel to the windshield
header rail and the rear roof frame using the same
number of welds as per original build.
11 Apply Joint Sealer (Item 3) as required. Refer to
Section 3.5, Body Sealing, Adhesives & Deadeners.
12 Refinish and paint panels and other components as
required. Refer to Sect ion 3, 7 Paint Refini shing in the
MY 2003 VY & V2 Series Service Information
Supplement, Body Structure Repair.
13 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint. Refer
to Sect ion 3, 6 Cavit y Wax.
14 Replace the front and rear windscreens as described
in Section 1A6, Stationary Glass in the MY 2004 WK
Series Service Information.
15 Replace the adjacent trim and components as
described in the appropriate Section of the MY 2004
WK Series Service Information. Figure 9 – 11
Roof Panel Page 9–8
Page 9–8
2.2 Roof Panel - Replace With Sunroof
Remove
1 Remove the adjacent trim and components as described in the appropriate Section of the MY 2004 WK Series
Service Information.
2 Remove the front windshield and back window as described in Section 1A6, Stationary Glass in the MY 2004 WK
Series Service Information.
3 Spot cut the welds attaching the roof panel to the
windshield header rail and rear roof frame.
Figure 9 – 12
If the header and support panels are to be
retained, take care not to cut them off with
the roof panel. Alternatively, if one or more
are to be replaced, it is easier to cut off those
being replaced along with the roof panel.
4 Using a cutting tool such as an air chisel or angle
grinder, cut through the roof panel along the side of
the roof channel.
NOTE
As the roof panel is securely glued to the body
side panel along the channel it cannot be
removed by simply spot cutting the welds.
Figure 9 – 13
Roof Panel Page 9–9
Page 9–9
5 Use a heat gun to soften the anti-flutter adhesive
between the roof panel, headers and roof panel
by heating the areas shown.
Figure 9 – 14
6 Cut through the softened adhesive between the roof
panel, roof front header panel and roof rear panel
using a suitable tool.
7 Remove the roof panel from the vehicle.
Figure 9 – 15
8 Using an angle grinder, air chisel or other suitable tool,
remove the remaining strip of roof panel from the body
side panel, along with the adhesive beneath the strip.
9 Repair any damage to adjacent parts.
10 Check and repair, if necessary, the alignment of the
body shell. Refer to the dimensions available in
Section 3, Body Construction.
Figure 9 – 16
Roof Panel Page 9–10
Page 9–10
Replace
The same number and position of spot welds
(or plug welds) should be used when
replacing the panel, as was used during
manufacture, in order to maintain the original
structural strength of the vehicle.
When welding a relatively flat panel such as
the roof panel, due care must be taken to
minimise the heat absorbed by the panel
which could lead to panel distortion.
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment
available to the repairer will not access the
required weld position, a plug weld should be
performed.
1 Clean the remaining Anti-flutter adhesive from the surfaces of the header rail and the roof rear frame.
2 Prepare the mating surface areas for welding. Dress the windshield header rail and the roof rear frame, so they are
flat and free from imperfections.
3 Treat the front and rear mating surfaces with Weld Through Primer (Item 1) as required. Refer to Section 3, 5 Body
Sealing, Adhesives & Deadeners.
4 Mark the new roof panel with drilling locations, where plug welding is necessary. Drill holes as required.
5 Apply a bead of Anti-flutter adhesive (Item 5) to the full length of the groove in the windshield header (section A-A)
and the groove in the rear roof frame (section B-B), refer to Figure 9 - 17. Refer to Section 3, 5 Body Sealing,
Adhesives & Deadeners.
Figure 9 – 17
Roof Panel Page 9–11
Page 9–11
6 Apply Structural adhesive (Item 6) (1) to the mating
surfaces of the roof panel and door opening frame.
Refer to Section 3, 5 Body Sealing, Adhesives &
Deadeners.
7 Position the roof panel on the vehicle and clamp in
place.
Figure 9 – 18
Take care to minimise the heat absorbed by
the panel in order to reduce heat distortion.
In some cases, especially if plug welding, it
may be advantageous to begin welding from
the middle of the run and weld alternatively
to the front and rear. This may reduce panel
distortion.
8 Spot or plug weld the roof panel to the door opening
frame on both sides of the vehicle using the sa me
number of welds as per original build.
Figure 9 – 19
9 Spot or plug weld the roof panel to the windshield
header rail and the rear roof frame using the same
number of welds as per original build.
10 Apply Joint Sealer (Item 3) as required. Refer to
Section 3, 5 Body Sealing, Adhesives & Deadeners.
11 Refinish and paint panels and other components as
required. Refer to Section 3, 1.3 Paint Refinishing in
the MY 2003 VY & V2 Series Service Information
Supplement, Body Structure Repair.
12 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint. Refer
to Section 3.6, Cavity Wax.
13 Replace the front and rear windscreens as described
in Section 1A6, Stationary Glass in the MY 2004 WK
Series Service Information.
14 Replace the adjacent trim and components as
described in the appropriate Section of the MY 2004
WK Series Service Information.
Figure 9 – 20