For 1990-2009 cars

## Roof Panel Replacement Wagon

### Removal Procedure

Caution: When using tools that may create smoke when cutting urethane sealant, work should be done in a well ventilated area and/or with a NIOSH/MSHA approved air supplied respirator to prevent possible harmful exposure. When the urethane adhesive is heated enough to give off smoke, high levels of methylene diisocyanate (MDI) may be present. Unprotected exposure to methylene diisocyanate may result in severe, chronic, debilitating respiratory problems.

1. Remove the headliner.
2. Remove the front windshield. Refer to Windshield Replacement .
3. Remove the rear lift gate.
4. Cut openings in the roof panel as shown above. DO NOT damage the crossmembers and structural components.
5. Remove the 8 attaching nuts securing the roof.
6. Using piano wire with handles, cut the roof off and remove.
7. With the aid of an assistant, remove the roof from the the vehicle.

### Installation Procedure

Notice: Loose urethane and/or rough surfaces may cause sealing problems during installation. For cars with a sunroof, it is important to install the fasteners to the new roof assembly before the roof is installed in place.

1. Using a razor knife, remove loose urethane. Also trim the high spots in the remaining urethane to provide for an even application of new urethane.

Important: If there is any exposed bare metal, it must be primed with 3M® Windo Weld primer P/N 08693, or equivalent.

2. Clean all of the weld seams with a wire brush.
3. Prime and seal all repair areas.
4. Apply a permanent underbody sealant.

Important: Ensure that proper corrosion protection processes are used on all repair areas.

5. Prime with a 2-part catalyzed primer.
6. Apply sealers and corrosion protection materials according to the information in the Body Paint section of this service manual or the paint manufacturer's recommendations.
7. Clean the entire roof with a clean lint-free cloth dampened with alcohol and allow to dry.
8. With the liftgate installed, place the roof panel on the vehicle and mark for proper location.
9. Apply the urethane P/N 12345633 by repeating the pattern on the removed roof.
10. Apply the urethane to the roof panel. The urethane bead, 8 mm (5/16 in) minimum, must cover the entire flange in the corner to ensure a proper seal.

Notice: Refer to Fastener Notice in the Preface section.

11. Position the roof panel onto the spaceframe. Attach the 8 fasteners.

Tighten
Tighten the roof panel fasteners to 10 N·m (89 lb in).

## Roof Panel Replacement Sedan/Coupe

### Removal Procedure

Caution: When using tools that may create smoke when cutting or heating urethane adhesive, work should be done in a well ventilated area and/or with a NIOSH/MSHA approved air supplied respirator to prevent possible harmful exposure. When the urethane adhesive is heated enough to give off smoke, high levels of methylene diisocyanate may be present. Unprotected exposure to methylene diisocyanate may result in severe, chronic, debilitating respirator problems.

1. Remove the headliner.
2. Remove the sunroof, if equipped. Cut the opening in the roof as shown in the illustration.
3. Remove the front windshield. Refer to Windshield Replacement in Stationary Windows.
4. Remove the backglass. Refer to Rear Window Replacement in Stationary Windows.
5. Remove the 6 attaching nuts securing the roof.
6. Using piano wire with handles, cut the roof off and remove.
7. With the aid of an assistant, remove the roof from the vehicle.

### Installation Procedure

Notice: Loose urethane and/or rough surfaces may cause sealing problems during installation. For cars with a sunroof, it is important to install the fasteners to the new roof assembly before the roof is installed in place.

1. Using a razor knife, remove the loose urethane. Also, trim the high spots in the remaining urethane to provide for an even application of the new urethane.
2. Clean the entire roof with a clean lint-free cloth dampened with alcohol and allow to air dry.
3. If installing a new roof, remove all 4 roof tabs.
4. Clean all of the weld seams with a wire brush.
5. Prime and seal all repair areas.
6. Apply a permanent underbody sealant.

Important: Ensure that proper corrosion protection processes are used on all repair areas.

7. Prime with a 2-part catalyzed primer.
8. Apply sealers and corrosion protection materials according to the information in the Body Paint section of this service manual or the paint manufacturer's recommendations.
9. If there is any exposed bare metal, prime with 3M® Windo-Weld, P/N 08693, or equivalent.
10. Place the roof on the vehicle and mark for proper location. Ensure that the roof shim blocks are in place (Sedan).
11. Apply the urethane, P/N 12345633, by repeating the pattern on the removed roof panel.

11.1. | Apply urethane bead, 8 mm (5/16 in) minimum, to the roof panel.

11.2. | The urethane bead must cover the entire flange in the corner to ensure a proper seal.

Notice: Refer to Fastener Notice in the Preface section.

12. Position the roof panel onto the spaceframe. Attach the 6 fasteners and tighten to specification.

Tighten
Tighten the roof panel fasteners to 10 N·m (89 lb in).