FRONT BODY PILLAR CUT AND JOIN REPLACEMENT SECTIONS

A01CSNE


  1. REMOVAL

    Symbol Meaning
    B002GA9 Remove Weld Points
    B002GBL Remove Weld Points
    B002G8M Remove Weld Points
    A01CSQ1 Cut and Join Location
    A01CSI7 Cut Location for Supply Parts

    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 indicates welds to remove for easier removal.

      A01CSRDC01
      *A LH - -
      A01CSK4 Laser Screw Welding - -
      A01CSHKC01
      *A LH - -
      *a 50 mm (1.97 in.) - -
      A01CSRZC01
      *A LH - -
      A01CSPQC01
      *A LH - -
      *a 170 mm (6.69 in.) *b 250 mm (9.84 in.)
      A01CSK4 Laser Screw Welding - -

    3. Roughly cut open the panel so that the adhesive can be reached. Cut through the adhesive with a cut chisel to remove the panel.

      Tech Tips

      In cases where the adhesive cannot be removed with a cut chisel, heat the adhesive with an industrial heater gun or gas burner taking care not to cause panel deformation by overheating.

      A01CSKMC02
      *A LH - -
      A01H2DV Adhesive - -

    4. A is reused.

      A01CSMUC01
      *A RH - -
      A01CSK4 Laser Screw Welding - -
      A01CSKPC01
      *A RH - -
      *a 50 mm (1.97 in.) *b 40 mm (1.57 in.)
      *c 70 mm (2.76 in.) - -
      A01CSPEC01
      *A RH - -
      *a 170 mm (6.69 in.) *b 250 mm (9.84 in.)
      A01CSK4 Laser Screw Welding - -

  2. INSTALLATION

    Symbol Meaning
    B002GBI Plug Weld
    B002G9Z Plug Weld
    B002GAP Plug Weld
    A01CSQ1 Cut and Join Location
    A01CSRT Butt Weld
    A01CSJQ Body Sealer

    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.

      A01CSISC01
      *A LH - -
      *1 FRONT BODY PILLAR SUB-ASSEMBLY INNER - -
      *a 170 mm (6.69 in.) - -

    4. Apply adhesive (3MTMAutomixTMPanel Bonding Adhesive #8115).

      Tech Tips


      • Apply a light coat of adhesive around the plug welding points.

      • Apply enough adhesive to the panels.

      A01CSPMC01
      *A LH - -
      A01H2DV Adhesive - -

    5. Weld the front body pillar sub-assembly inner to the vehicle side.

      A01CSS7C01
      *A LH - -
      *1 FRONT BODY PILLAR SUB-ASSEMBLY INNER - -
      *a Ultra High Strength Steel Welding Point - -
      A01CSK4 Laser Screw Welding - -

        Follow the welding conditions below when welding ultra high strength steel to assure sufficient weld strength. (When repairing this model)

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

        *a: Plug weld Plug diameter 10 mm (0.39 in.)
        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.

    6. Apply adhesive (3MTMAutomixTMPanel Bonding Adhesive #8115).

      Tech Tips


      • Apply a light coat of adhesive around the plug welding points.

      • Apply enough adhesive to the panels.

      A01CSSEC01
      *A LH - -
      A01H2DV Adhesive - -

    7. Weld the front pillar reinforcement sub-assembly lower to the vehicle side.

      A01CSNPC01
      *A LH - -
      *1 FRONT PILLAR REINFORCEMENT SUB-ASSEMBLY LOWER - -
      *a Ultra High Strength Steel Welding Point - -
      A01CSK4 Laser Screw Welding - -

        Follow the welding conditions below when welding ultra high strength steel to assure sufficient weld strength. (When repairing this model)

      • 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.)

        *a: 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.

      A01CSQFC01
      *A LH - -

    8. Apply adhesive (3MTMAutomixTMPanel Bonding Adhesive #8115).

      Tech Tips


      • Apply a light coat of adhesive around the plug welding points.

      • Apply enough adhesive to the panels.

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

      Tech Tips

      Apply body sealer in an even, continuous bead.

      A01CSV5C01
      *A LH - -
      A01H2DV Adhesive - -

    10. Weld the front body pillar upper outer to the vehicle side.

      A01CSOUC01
      *A LH - -
      *1 FRONT BODY PILLAR UPPER OUTER - -
      A01CSK4 Laser Screw Welding - -

        Follow the welding conditions below when welding ultra high strength steel to assure sufficient weld strength. (When repairing this model)

      • 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.)

        *a: 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.

      A01CSQNC01
      *A LH - -

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

      A01CSRHC01
      *A RH - -
      *1 FRONT BODY PILLAR SUB-ASSEMBLY INNER *2 ROCKER REINFORCE SUB-ASSEMBLY OUTER
      *a 170 mm (6.69 in.) *b 200 mm (7.87 in.)

    12. Before temporarily installing the new parts, weld the front pillar reinforcement sub-assembly lower and rocker reinforce sub-assembly outer with the standard number of welding points.

      A01CSOKC01
      *A RH - -
      *1 FRONT PILLAR REINFORCEMENT SUB-ASSEMBLY LOWER *2 ROCKER REINFORCE SUB-ASSEMBLY OUTER

    13. Weld the front body pillar sub-assembly inner to the vehicle side.

      A01CSNSC01
      *A RH - -
      *1 FRONT BODY PILLAR SUB-ASSEMBLY INNER - -
      A01CSK4 Laser Screw Welding - -

    14. Apply adhesive (3MTMAutomixTMPanel Bonding Adhesive #8115).

      Tech Tips


      • Apply a light coat of adhesive around the plug welding points.

      • Apply enough adhesive to the panels.

      A01CSMMC01
      *A RH - -
      A01H2DV Adhesive - -

    15. Weld the front pillar reinforcement sub-assembly lower and rocker reinforce sub-assembly outer to the vehicle side.

      A01CSN6C01
      *A RH - -
      *1 FRONT PILLAR REINFORCEMENT SUB-ASSEMBLY LOWER *2 ROCKER REINFORCE SUB-ASSEMBLY OUTER
      A01CSK4 Laser Screw Welding - -

    16. Apply adhesive (3MTMAutomixTMPanel Bonding Adhesive #8115).

      Tech Tips


      • Apply a light coat of adhesive around the plug welding points.

      • Apply enough adhesive to the panels.

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

      Tech Tips

      Apply body sealer in an even, continuous bead.

      A01CSHQC01
      *A RH - -
      A01H2DV Adhesive - -

    18. Weld the front body pillar upper outer and A to the vehicle side.

      A01CSU7C01
      *A RH - -
      *1 FRONT BODY PILLAR UPPER OUTER - -
      A01CSK4 Laser Screw Welding - -
      A01CSJGC01
      *A RH - -

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

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

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