Page 2577 of 3229

Publ is hed: 11-May-2011
Front End Sheet Metal Repairs - Fender Apron Panel Front Reinforcement
Removal and Installation
Removal
• NOTE: The fender apron panel front reinforcement has to be removed from the fender apron panel service panel; it is not
available as a separate panel.
• NOTE: The panel is serviced less its weld studs
1. The front side member and fender apron panel is replaced in
conjunct ion wit h:
Front bumper cover
Front bumper
Hood
Hood lat ch panel
Both front fenders
Fender apron l ower panel
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Remove t he fender apron l ower panel .
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Fender Apron Lower Panel
(501-27 Front End Sheet Met al Re pai rs , Removal and
Installation).
4. Mill out the spot welds.
5. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.
Page 2578 of 3229
2. Drill holes in the new panel ready for MIG plug welding.
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. MIG P l ug we l d.
5. Install weld studs.
6. Dress all welded joints.
7. The installation of associated panels and mechanical
components is the reverse of removal.
Page 2579 of 3229
Publ is hed: 11-May-2011
Roof Sheet Metal Repairs - Roof
Description and Operation
Roof service panels
Ite m De scription
1Roof panel
2 Roof rear panel
3 Roof front panel
Time schedules, roof panels
The following times relate to the replacement of the roof panels as single panels. The published times include the removal
of Mechanical, Electrical and Trim, (MET), items, plus paint times based on Metallic Clear Over Base Paint, (blends to
adjacent panel s are not i ncl ude d). A corros i on prot ect i on t i me i s i ncl ude d where appropri at e .
The times were generated by Thatcham, (the Motor Insurance Repair Research Centre), and are to be used as a guide only,
based on new undamaged panels. Job allowances are not included, as a guide Thatcham recommend 0.3 hours to be added
to single panel times.
Single panel timesP a n e l D e s c r ip t io n T ime s
Roof panel20.3
Roof rear panel16.4
Roof front panel14.4
Page 2580 of 3229

Publ is hed: 11-May-2011
Roof Sheet Metal Repairs - Roof PanelVehicles Without: Sliding Roof
Opening Panel
Removal and Installation
Removal
• NOTE: The roof is serviced as a separate weld on panel, less its reinforcements.
• NOTE: Along the RH and LH sides of the panel, spot welds should be installed adjacent to the originals and not in the
same locations.
1. The roof panel is replaced in conjunction with:
Liftgate
Windshield
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Disconnect both battery cables.
4. Remove the liftgate.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Liftgate
(501-03 Body
Closures, Removal and Installation).
5. Remove the windshield glass.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Windshield Glass
(501-11
Glass, Frames and Mechanisms, Removal and Installation).
6. Remove both front seats.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Seat
(501-10
Seating, Removal and Installation).
7. Remove the rear seat.
8. Remove bot h side air curt ain modules.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Side Air Bag Module
(501-20B Suppl ement al Res t rai nt Sys t em, Removal and
Installation).
9. Remove both front safety belt retractors.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Safety Belt Retractor
(501-20A Safe t y Bel t Sys t em, Removal and Ins t al l at i on).
10. Remove both rear safety belt retractors.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Safety Belt Retractor
(501-20A Safe t y Bel t Sys t em, Removal and Ins t al l at i on).
11. Release and lay aside the wiring harness.
Page 2581 of 3229
12. Re move 10 21mm he a de d bo l t s .
13. Mill out the spot welds.
Page 2582 of 3229
14. Cut t hro ug h t he a d he s i ve t o s e p a ra t e t he re i nf o rce me nt s
from the roof panel.
15. Se p a ra t e t he re ma i ni ng j o i nt s a nd re mo ve t he o l d p a ne l .
Installation
1. Prepare the old and new panel joint surfaces.
2. Apply adhesive, in the areas illustrated.
3. Offer up the new panel and clamp into position. Check
Page 2583 of 3229
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
4. Ins t all 10 21mm bol t s .
5. NOTE: Along the RH and LH sides of the panel, spot welds
should be installed adjacent to the originals and not in the
same locations.
Sp o t w e l d .
6. Dress all welded joints.
7. The installation of associated panels and mechanical
components is the reverse of removal.
Page 2584 of 3229

Publ is hed: 11-May-2011
Roof Sheet Metal Repairs - Roof Front PanelVehicles With: Sliding Roof
Opening Panel
Removal and Installation
Removal
• NOTE: The roof front panel is serviced as a separate weld-on panel.
1. The roof front panel is replaced in conjunction with:
Windshield
Roof opening panel
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Disconnect both battery cables.
4. Remove the windshield glass.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Windshield Glass
(501-11
Glass, Frames and Mechanisms, Removal and Installation).
5. Remove both front seats.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Seat
(501-10
Seating, Removal and Installation).
6. Remove the roof opening panel.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Roof Opening Panel
(501-17 Roof O peni ng Panel , Removal and Ins t al l at i on).
7. Remove bot h side air curt ain modules.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Si d e A i r Curt a i n Mo d ul e
(501-20B Suppl ement al Res t rai nt Sys t em, Removal and
Installation).
8. Remove both front safety belt retractors.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Safety Belt Retractor
(501-20A Safe t y Bel t Sys t em, Removal and Ins t al l at i on).
9. Remove both rear safety belt retractors.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Safety Belt Retractor
(501-20A Safe t y Bel t Sys t em, Removal and Ins t al l at i on).
10. Release and lay aside the wiring harness.
11. Re mo ve 2 21mm he a de d bo l t s , 1 e a ch s i de .