ROCKER PANEL CUT AND JOIN REPLACEMENT SECTIONS

A01MAQC

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

      A01MASNC01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a 300 mm (11.81 in.) *b 80 mm (3.15 in.)
      A01MAKV

    3. A indicates welds to remove for easier removal.

      A01MARMC01
      *a 80 mm (3.15 in.) *b 160 mm (6.30 in.)

  2. INSTALLATION

    Symbol Meaning
    A01MATN Remove Weld Points
    A01MALC Spot Weld
    A01MASW Plug Weld
    A01MAGF Plug Weld
    A01MASE Plug Weld
    A01MANE Cut and Join Location
    A01MAJL Fillet Weld
    A01MAN9 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. Due to production issues, there are weld marks where the roof side rail reinforcement outer and rocker reinforce sub-assembly outer contact the center body pillar reinforcement sub-assembly service part.

      A01MAMAC01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -

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

      A01MAINC01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY *2 CENTER BODY PILLAR REINFORCE SUB-ASSEMBLY LOWER
      *a 80 mm (3.15 in.) *b 160 mm (6.30 in.)

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

      A01MAK1C01
      *1 ROCKER REINFORCE SUB-ASSEMBLY OUTER *2 CENTER 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 20 Cyc.(0.34 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.

    6. Weld the rocker reinforce sub-assembly outer and center body pillar reinforce sub-assembly lower to the vehicle side.

      A01MAIVC01
      *1 ROCKER REINFORCE SUB-ASSEMBLY OUTER *2 CENTER BODY PILLAR REINFORCE SUB-ASSEMBLY LOWER
      *a Ultra High Strength Steel Welding Point *b Ultra High Strength Steel Welding Point
      *c 15 mm (0.59 in.) *d 20 mm (0.79 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: Spot weld Pressure 2940 N (300 kgf, 661 lbf)
        Weld current 10000 A
        Weld time 20 Cyc.(0.34 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.

      A01MARBC01
      *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 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.

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

      A01MAILC01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -

    8. Weld the rear pillar to the vehicle side.

      A01MANDC01
      *1 REAR PILLAR - -
      *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 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. After welding, apply the foamed sealing material to the corresponding parts. (See the painting/coating)

    10. After welding, apply body sealer 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.