ROCKER PANEL CUT AND JOIN REPLACEMENT SECTIONS

A01CSJT


  1. REMOVAL

    Symbol Meaning
    B002GA9 Remove Weld Points
    B002GBL Remove Weld Points
    B002G8M Remove Weld Points
    A01CSNX Cut with Disc Sander etc.
    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. Remove the front body pillar upper outer.

      A01CSSPC01
      *A LH - -
      *1 FRONT BODY PILLAR UPPER OUTER - -
      *a 430 mm (16.93 in.) - -
      A01CSK4 Laser Screw Welding - -
      A01CSK6C01
      *A LH - -
    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.

      A01CSN4C01
      *A LH - -
      A01H2DV Adhesive - -
    4. Remove the A.

      A01CSOPC01
      *A LH - -
      A01CSK4 Laser Screw Welding - -
    5. 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.

      A01CSPZC01
      *A LH - -
      A01H2DV Adhesive - -
    6. Carefully cut the center body pillar reinforcement sub-assembly so as not to damage A.

      A01CSUGC01
      *A LH - -
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a 290 mm (11.42 in.) *b 180 mm (7.09 in.)
      A01CSK4 Laser Screw Welding - -
      A01CSU6C01
      *A LH - -
      *a 145 mm (5.71 in.) *b 145 mm (5.71 in.)
    7. 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.

      A01CSMOC01
      *A LH - -
      A01H2DV Adhesive - -
    8. Carefully cut the center body pillar reinforcement sub-assembly so as not to damage A.

      A01CSS2C01
      *A RH - -
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a 290 mm (11.42 in.) *b 180 mm (7.09 in.)
      A01CSK4 Laser Screw Welding - -
      A01CSUOC01
      *A RH - -
      *a 35 mm (1.38 in.) - -
      A01CSRXC01
      *A RH - -
      *a 145 mm (5.71 in.) *b 145 mm (5.71 in.)
    9. 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.

      A01CSJ5C01
      *A RH - -
      A01H2DV Adhesive - -
  2. INSTALLATION

    Symbol Meaning
    B002GA9 Remove Weld Points
    A01CSK1 Spot Weld
    B002GBI Plug Weld
    B002G9Z Plug Weld
    B002GAP Plug Weld
    A01CSQ1 Cut and Join Location
    B002G9N Fillet Weld
    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.

      A01CSLMC01
      *A LH - -
      *1 FRONT PILLAR REINFORCEMENT SUB-ASSEMBLY LOWER - -
    4. If the entire supply part is not needed, remove the part of the supply part that is needed.

      A01CSQXC01
      *A LH - -
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY *2 CENTER BODY PILLAR SUB-ASSEMBLY INNER
      *a 130 mm (5.12 in.) *b 35 mm (1.38 in.)
      *c 30 mm (1.18 in.) - -
    5. 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.

      A01CST1C01
      *A LH - -
      A01H2DV Adhesive - -
    6. Before temporarily installing the new parts, weld the center body pillar reinforcement sub-assembly, center body pillar sub-assembly inner and rocker panel sub-assembly outer with the standard number of welding points.

      A01CSRAC01
      *A LH - -
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY *2 CENTER BODY PILLAR SUB-ASSEMBLY INNER
      *3 ROCKER PANEL SUB-ASSEMBLY OUTER - -
      *a Ultra High Strength Steel Welding Point *b Ultra High Strength Steel Welding Point

        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: Spot weld Pressure 2940 N (300 kgf, 661 lbf)
        Weld current 10000 A
        Weld time 16 Cyc. (0.27 Sec.)
        *b: 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.

    7. 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.

      A01CSIKC01
      *A LH - -
      A01H2DV Adhesive - -
    8. Weld the center body pillar reinforcement sub-assembly, center body pillar sub-assembly inner and rocker panel sub-assembly outer to the vehicle side.

      A01CSTMC01
      *A LH - -
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY *2 ROCKER PANEL SUB-ASSEMBLY OUTER
      *a Ultra High Strength Steel Welding Point *b 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: Spot weld Pressure 2940 N (300 kgf, 661 lbf)
        Weld current 10000 A
        Weld time 16 Cyc. (0.27 Sec.)
        *b: 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.

      A01CSN3C01
      *A LH - -
      *1 CENTER BODY PILLAR SUB-ASSEMBLY INNER - -
      *a Ultra High Strength Steel Welding Point *b 15 mm (0.59 in.)
      *c 10 mm (0.39 in.) *d 10 mm (0.39 in.)

        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.

    9. 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.

      A01CSKCC01
      *A LH - -
      A01H2DV Adhesive - -
    10. Weld the A to the vehicle side.

      A01CSIZC01
      *A LH - -
      A01CSK4 Laser Screw Welding - -
    11. 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.

      A01CSRVC01
      *A LH - -
      A01H2DV Adhesive - -
    12. Weld the rocker panel outer to the vehicle side.

      A01CSHTC01
      *A LH - -
      *1 ROCKER PANEL OUTER - -
      *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.

    13. 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.

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

      Tech Tips

      Apply body sealer in an even, continuous bead.

      A01CSL9C01
      *A LH - -
      A01H2DV Adhesive - -
    15. Weld the front body pillar upper outer to the vehicle side.

      A01CST5C01
      *A LH - -
      *1 FRONT BODY PILLAR UPPER OUTER - -
      *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.

      A01CSMTC01
      *A LH - -
    16. If the entire supply part is not needed, remove the part of the supply part that is needed.

      A01CSR8C01
      *A RH - -
      *1 ROCKER REINFORCE SUB-ASSEMBLY OUTER *2 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY
      *3 CENTER BODY PILLAR SUB-ASSEMBLY INNER - -
      *a 200 mm (7.87 in.) *b 130 mm (5.12 in.)
      *c 30 mm (1.18 in.) *d 35 mm (1.38 in.)
    17. 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.

      A01CSOHC01
      *A RH - -
      A01H2DV Adhesive - -
    18. Before temporarily installing the new parts, weld the center body pillar reinforcement sub-assembly, rocker reinforce sub-assembly outer and center body pillar sub-assembly inner with the standard number of welding points.

      A01CSSBC01
      *A RH - -
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY *2 ROCKER REINFORCE SUB-ASSEMBLY OUTER
      *3 CENTER BODY PILLAR SUB-ASSEMBLY INNER - -
      *a Ultra High Strength Steel Welding Point *b Ultra High Strength Steel Welding Point

        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: Spot weld Pressure 2940 N (300 kgf, 661 lbf)
        Weld current 10000 A
        Weld time 16 Cyc. (0.27 Sec.)
        *b: 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.

    19. 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.

      A01CSRNC01
      *A RH - -
      A01H2DV Adhesive - -
    20. Weld the center body pillar reinforcement sub-assembly, center body pillar sub-assembly inner and rocker reinforce sub-assembly outer to the vehicle side.

      A01CSN7C01
      *A RH - -
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY *2 ROCKER REINFORCE SUB-ASSEMBLY OUTER
      *a Ultra High Strength Steel Welding Point *b 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: Spot weld Pressure 2940 N (300 kgf, 661 lbf)
        Weld current 10000 A
        Weld time 16 Cyc. (0.27 Sec.)
        *b: 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.

      A01CSPRC01
      *A RH - -
      *1 CENTER BODY PILLAR SUB-ASSEMBLY INNER - -
      *a Ultra High Strength Steel Welding Point *b 15 mm (0.59 in.)
      *c 10 mm (0.39 in.) *d 10 mm (0.39 in.)

        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.

    21. 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.

      A01CSPBC01
      *A RH - -
      A01H2DV Adhesive - -
    22. Weld the rocker panel outer to the vehicle side.

      A01CSLVC01
      *A RH - -
      *1 ROCKER PANEL OUTER - -
      *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.

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

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