FRONT BODY PILLAR CUT AND JOIN REPLACEMENT SECTIONS (PATTERN 1)

B006JNP


  1. REMOVAL

    Symbol Meaning
    B006JOY Remove Weld Points
    B006JQU Remove Weld Points
    B006JPE Cut and Join Location

    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. Be careful when cutting as foamed sealing material is located near the cutting position.

      Tech Tips

      Remove the remaining foamed sealing material from the vehicles side.

      B006JOHC01
      B006JOS Foamed Sealing Material - -
      B006JR8C01
      *a 325 mm (12.80 in.) *b 760 mm (29.92 in.)
      *c 50 mm (1.97 in.) - -
      B006JOA

  2. INSTALLATION

    Symbol Meaning
    B006JTE Spot Weld
    B006JU9 Plug Weld
    B006JRV Plug Weld
    B006JPE Cut and Join Location
    B006JOP 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.

      B006JU7C03
      *1 ROCKER PANEL SUB-ASSEMBLY OUTER *2 FRONT BODY PILLAR UPPER INNER
      *a 173 mm (6.81 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.

      B006JQFC02
      B006JTL Adhesive - -

    5. Before temporarily installing the new parts, weld the rocker panel sub-assembly outer, front body pillar reinforce sub-assembly lower and front body pillar upper inner with the standard number of welding points.

      B006JOXC02
      *1 ROCKER PANEL SUB-ASSEMBLY OUTER *2 FRONT BODY PILLAR REINFORCE SUB-ASSEMBLY LOWER
      *3 FRONT BODY PILLAR UPPER INNER - -
      *a Ultra High Strength Steel Welding Point *b Ultra High Strength Steel Welding Point
      *c Ultra High Strength Steel Welding Point *d 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: Spot weld Pressure 2940 N (300 kgf, 661 lbf)
        Weld current 10000 A
        Weld time 18 Cyc.(0.30 Sec.)
        *c: Spot weld Pressure 2940 N (300 kgf, 661 lbf)
        Weld current 10000 A
        Weld time 24 Cyc.(0.40 Sec.)
        *d: 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. Weld the rocker panel sub-assembly outer, front body pillar reinforce sub-assembly lower and front body pillar upper inner to the vehicle side.

      B006JTJC01
      *1 ROCKER PANEL SUB-ASSEMBLY OUTER *2 FRONT BODY PILLAR REINFORCE SUB-ASSEMBLY LOWER
      *3 FRONT BODY PILLAR UPPER INNER - -
      *a Ultra High Strength Steel Welding Point *b Ultra High Strength Steel Welding Point
      *c 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: Spot weld Pressure 2940 N (300 kgf, 661 lbf)
        Weld current 10000 A
        Weld time 18 Cyc.(0.30 Sec.)
        *c: 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. Weld the front body pillar upper outer and rocker panel outer to the vehicle side.

      B006JT1C02
      *1 FRONT BODY PILLAR UPPER OUTER *2 ROCKER PANEL OUTER
      *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 3 panels or more 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.

      B006JU4C01
      *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 3 panels or more 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.

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

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

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