FRONT BODY PILLAR CUT AND JOIN REPLACEMENT SECTIONS

A01MAR2


  1. REMOVAL

    Symbol Meaning
    A01MATN Remove Weld Points
    A01MANR Remove Weld Points
    A01MAH4 Remove Weld Points
    A01MALE Cut with Disc Sander etc.
    A01MANE Cut and Join Location
    A01MAJ0 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. Reuse A, as the area of the outer panel that is cut and joined is to the rear of the supplied part cut position.

      A01MAHAC01
      *a 40 mm (1.57 in.) - -

    3. A indicates welds to remove for easier removal.

      A01MAS5
      A01MAQY
      A01MAGE
      A01MAP0C01
      *a 55 mm (2.17 in.) - -

  2. INSTALLATION

    Symbol Meaning
    A01MALC Spot Weld
    A01MASW Plug Weld
    A01MAGF Plug Weld
    A01MASE Plug Weld
    A01MAJL Fillet Weld
    A01MAN9 Butt Weld
    A01MAHG 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. Before installing a new part, apply body sealer.

      Tech Tips

      Apply body sealer in an even, continuous bead.

      A01MAOK

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

      A01MAMDC01
      *1 FRONT BODY PILLAR SUB-ASSEMBLY INNER - -
      *a Ultra High Strength Steel Welding Point *b 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 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.

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

      Tech Tips

      Apply body sealer in an even, continuous bead.

      A01MAM3

    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.

      A01MAJ9C01
      A01MARO Adhesive - -

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

      A01MALFC01
      *1 FRONT BODY PILLAR REINFORCE SUB-ASSEMBLY LOWER - -
      *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 18 Cyc.(0.30 Sec.)

      • When welding 2 panels together including 1500 MPa or 980 MPa ultra high strength steel.

        *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.

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

      Tech Tips

      Apply body sealer in an even, continuous bead.

      A01MAJJ

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

      A01MAOSC01
      *1 FRONT BODY PILLAR UPPER 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: Plug weld Plug diameter 10 mm (0.39 in.)
        Wire type AWS A5.18 ER70S-3
        Shield gas Metal active gas

      • When welding more than 3 panels together including 1500 MPa or 980 MPa ultra high strength steel. (When plug welding a third panel to 2 panels which are welded under the conditions described above.)

        *b: 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.

    10. Weld the A to the vehicle side.

      A01MAMLC01
      *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 1500 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.

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

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

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