ROCKER PANEL CUT AND JOIN REPLACEMENT SECTIONS

A018MJW

  1. REMOVAL

    Symbol meaning
    A002667 Remove Weld Points
    A00265J Remove Weld Points
    A00265D Remove Weld Points
    A00266X Cut with Disc Sander etc.
    A00264B Cut and Join Location
    A00265G Cut Location for Supply Parts
    A00266P Cut Location

      REMOVAL POINT

    1. Do not butt weld or heat repair because the heat decreases the strength of areas where ultra high strength steel is used. (See the introduction)

    2. *a is reused.

    3. Reuse *b, as the area of the outer panel that is cut and joined is in front of the supplied part cut position.

    4. *c indicates the location of the foamed sealing material. Be careful when cutting as the foamed sealing material is located near the cutting position.

    A018MLXC01
    *c Foamed Sealing Material *d mm (in.)
    A018MP7C01
    *b Reused *e mm (in.)
    A018MQDC01
    *f mm (in.) - -
    A018MPWC01
    *a Reused - -

  2. INSTALLATION

    Symbol meaning
    A018MJA Spot Weld
    A00266T Plug Weld
    A00266S Plug Weld
    A002652 Plug Weld
    A00264B Cut and Join Location
    A00265P Fillet Weld
    A002641 Butt Weld
    A00265Q Body Sealer
    Weld work for 980 MPa ultra high strength steel
    Follow the welding conditions below when welding ultra high strength steel to assure sufficient weld strength. (When repairing this model)

    • *a: When welding 2 panels together including 980 MPa ultra high strength steel.

      Spot weld Pressure 2940 N (300 kgf, 661 lbf)
      Weld current 10000 A
      Weld time 16 Cyc. (0.27 Sec.)
      Plug weld Plug diameter 10 mm (0.39 in.)
      Wire type AWS A5.18 ER70S-3
      Shield gas Metal active gas

    • *b: When welding more than 3 panels together including 980 MPa ultra high strength steel. (When plug welding a third panel to 2 panels which are welded under the conditions described above.)

      Plug weld Plug diameter Same as the standard method (See the introduction)
      Wire type AWS A5.18 ER70S-3
      Shield gas Metal active gas

    Note

    Be sure to use Metal active gas (Ar 80% + CO220%) as the shield gas when plug welding. Sufficient weld strength cannot be assured when using 100% CO2shield gas.


      INSTALLATION POINT

    1. Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.

    2. Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimensions)

    3. If the entire supply part is not needed, remove the part of the supply part that is needed.

    4. Before installing a new part, apply body sealer.

      Tech Tips

      Apply body sealer in an even, continuous bead.

    5. Follow the welding conditions when welding *a and *b to assure sufficient weld strength. (See the introduction)

    6. Before temporarily installing the new parts, weld the rocker panel sub-assembly outer and NO.2 inner pillar sub-assembly with the standard number of welding points.

    7. When welding *c, make a hole on a new part for plug welding and weld the panel with the panel behind completely.

    8. After welding the rocker panel sub-assembly outer and NO.2 inner pillar sub-assembly to the vehicle side, install the center body pillar sub-assembly and *d.

    9. After welding the rocker panel sub-assembly outer, NO.2 inner pillar sub-assembly, center body pillar sub-assembly and *d to the vehicle side, install the rear body front outside panel and *e.

    10. After welding, apply the foamed sealing material to the corresponding parts. (See the painting / coating)

    11. After welding, apply body sealer and undercoating to the corresponding parts. (See the painting / coating)

    12. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.

    A018MJ7C01
    *1 CENTER BODY PILLAR SUB-ASSEMBLY *2 NO.2 INNER PILLAR SUB-ASSEMBLY
    *f mm (in.) - -
    A018MLGC01
    *3 ROCKER PANEL SUB-ASSEMBLY OUTER - -
    *a Ultra High Strength Steel Welding Point *g mm (in.)
    A018MMMC01
    *a Ultra High Strength Steel Welding Point *h mm (in.)
    A018MNJC01
    *i mm (in.) - -
    A018MNY
    A018MP6C01
    *4 REAR BODY FRONT OUTSIDE PANEL - -
    *b Ultra High Strength Steel Welding Point - -
    A018MIX