Roof Panel Replacement (5-door) - Honda Civic FC/FK 2016-2021

Roof Panel Replacement

NOTE:

High-strength steel is defined as any steel with a tensile strength of 340 MPa or higher. If a part is constructed of, or includes high-strength steel observe the important guidelines.

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.	Mass Production Body Welding Positions and Numbers - Remove

Roof Panel

2.	Construction - Check

Roof Panel

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 complete, the roof arch gusset, and the rear roof rail complete to the body, and replace the roof panel.

Check the roof front rail complete, the roof arch gusset, and the rear roof rail complete 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.

Check the body dimensions:

Inner panel positions

Roof rail positions

Windshield and door openings

Tailgate openings

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 - Install

Weld the roof front rail complete (A), and the rear roof rail complete (B).

( )*: Welding positions with high-strength steel (except 1500 MPa) parts. Confirm the plug welding conditions.

(?)*: Welding positions with the front inner upper pillar (C), the ultra high-strength steel (1500 MPa) part. Confirm the MIG brazing specifications.

Apply a soft type sealer (A) to mating surfaces of the roof front rail complete (B) and the rear roof rail complete (C).

4.	Roof Panel - Install

Clamp the roof panel, and attach the roof arch gusset (A) on both sides with the mounting bolts.

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 complete.

( )*: 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