Roof Panel Replacement
1. Mass Production Body Welding Positions and Numbers - Remove

Roof Panel (Without Moonroof)






Roof Panel (With Moonroof)



2. Construction - Check

Roof Panel (Without Moonroof)

NOTE:
This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual.
The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to the area and the degree of damage on the body.
Check the roof front rail, the roof arch A, and the rear roof rail positions for damage. If necessary, replace them.




Roof Panel (With Moonroof)

NOTE:
This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual.
The component replacement procedure described here is only for new Honda-supplied parts, as needed, according to the area and the degree of damage on the body.
Remove the mounting bolts, leave the roof front rail, the roof arch gusset, and the rear roof rail to the body, and replace the roof panel.
Check the roof front rail, the roof arch gusset, and the rear roof rail positions for damage. If necessary, replace them.


NOTE:
Confirm the sheet thickness, tensile strength, and existence of the zinc treatment of both sides, and set the welder to conform to the welding conditions by referring to Roof and Side Panel Construction.
Welding symbols (The welding symbols with dashed lines have a meaning of the spot welding of the part which is not visible)
( ) and ( )*: The number of welds

1. Body Dimensions - Check

Positioning the replacement parts.
Clamp or tack weld the new parts into position.

2. External Parts Fitting Positions - Check

Temporarily install the related parts, then check for differences in level and clearance. Check the external parts fitting positions. Make sure the body lines flow smoothly. Remove the clamped part.

3. Roof Rails and Roof Arch A (Without Moonroof)/Roof Arch A Gusset (With Moonroof) - Install

Without Moonroof



With Moonroof
1.
Weld the roof front rail (A), the roof arch A (without moonroof) (B), and the rear roof rail (C).
( )*: Welding positions with high-strength steel (except 1500 MPa) parts. Confirm the plug welding conditions.
(?)*: Welding positions with the roof front rail and the front inner upper pillar, the ultra high-strength steel (1500 MPa) part. Confirm the MIG brazing specifications.




Without Moonroof


With Moonroof
2.
Apply a soft type sealer (A) to mating surfaces of the roof front rail (B), the roof arch A (without moonroof) (C), and the rear roof rail (D).

4. Roof Panel - Install
1.
With moonroof: Clamp the roof panel (A), and attach the roof arch gusset (B) on both sides with the mounting bolts.
2.
Do the main welding.
Weld the front, rear, and side flanges of the roof panel (A) and both sides edge of the rear roof rail.
( )*: Welding positions with high-strength steel (except 1500 MPa) parts. Confirm the plug welding conditions.
(?)*: Welding positions with the roof front rail (B) and the roof side stiffener (C), the ultra high-strength steel (1500 MPa) part. Perform the spot welding on the conditions of No. 12, No. 26 and No. 30 in the table shown below. Confirm the spot welding specifications.
(?)*: Welding positions with the roof front rail and the roof side stiffener, the ultra high-strength steel (1500 MPa) part. Confirm the MIG brazing specifications.
Spot Welding Conditions
Condition
No.
Welding
current (A)
Welding
time (ms)
Applied force
(N (kgf))
No. 12
7500
600
3432 (350)
No. 26
8000
800
3432 (350)
No. 30
8500
1200
3432 (350)
Front Area

Rear Area

Side Area