ROCKER PANEL CUT AND JOIN REPLACEMENT SECTIONS

A01FK12


  1. REMOVAL

    Symbol Meaning
    A01FJXV Remove Weld Points
    A01FK35 Remove Weld Points
    A01FJUY Remove Weld Points
    A01FJX6 Cut with Disc Sander etc.
    A01FK1Z Cut and Join Location
    A01FJU5 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)

      A01FJYC
      A01FK4P

    2. A is reused.

      A01FK3GC01
      *a 70 mm (2.76 in.) - -

    3. Carefully cut the center body pillar reinforcement sub-assembly so as not to damage A.

      A01FJZFC01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a 255 mm (10.04 in.) - -
      A01FK5L

    4. 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.

      A01FJW8C01
      A01FK0W Adhesive - -

    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.

      A01FJTZC01
      A01FK0W Adhesive - -

  2. INSTALLATION

    Symbol Meaning
    A01FK6Y Plug Weld
    A01FK5C Plug Weld
    A01FJU6 Plug Weld
    A01FK24 Fillet Weld
    A01FK45 Butt Weld

    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.

      A01FK0GC01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a 255 mm (10.04 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.

      A01FK2IC01
      A01FK0W Adhesive - -

    5. Weld the rocker panel sub-assembly outer to the vehicle side.

      A01FJWRC01
      *1 ROCKER PANEL SUB-ASSEMBLY OUTER - -
      *a Ultra High Strength Steel Welding Point - -
      A01FK71 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.

      A01FK1OC01
      *a 15 mm (0.59 in.) - -

    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.

      A01FJVJC01
      A01FK0W Adhesive - -

    7. Weld the center body pillar reinforcement sub-assembly to the vehicle side.

      A01FK6RC01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a 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 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 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.

    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.

      A01FK4EC01
      A01FK0W Adhesive - -

    9. Weld the rocker panel outer and A to the vehicle side.

      A01FJWMC01
      *1 ROCKER PANEL OUTER - -
      *a Ultra High Strength Steel Welding Point - -
      A01FK71 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 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.

      A01FJYK

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

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