FRONT BODY PILLAR CUT AND JOIN REPLACEMENT SECTIONS

A001ZVX


  1. REMOVAL

    Symbol Meaning
    A00206N Remove Weld Points
    A00205Y Remove Weld Points
    A002000 Cut with Disc Sander etc.
    A00200Q Cut and Join Location
    A001ZZ5 Cut Location for Supply Parts

      REMOVAL POINT

    1. *a in the illustration indicates the laser screw welding location.

    2. Reuse A, as the area of the outer panel that is cut and joined is to the rear of the supplied part cutposition.

    3. *b in illustration indicates where the adhesive is located.

    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.

    5. Carefully cut the rocker panel sub-assembly outer so not to damage B.

    6. C indicates the location of the foamed sealing material. Be careful when cutting as the foamed sealingmaterial is located near the cutting position.

    A00203AC01
    *1 ROCKER PANEL SUB-ASSEMBLY OUTER - -
    *c 170 mm (6.69 in.) *d 55 mm (2.17 in.)
    *e 80 mm (3.15 in.) *f 40 mm (1.57 in.)
    A00203C Laser Screw Welding - -
    A001ZZ1C01
    *c 140 mm (5.51 in.) *d 120 mm (4.72 in.)
    A00203C Laser Screw Welding - -

  2. INSTALLATION

    Symbol Meaning
    A00206N Remove Weld Points
    A001ZU3 Spot Weld
    A00200M Plug Weld
    A001ZVD Plug Weld
    A00200Q Cut and Join Location
    A002003 Fillet Weld
    A00201N Butt Weld
    A001ZXQ Body Sealer

      INSTALLATION POINT

    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. *a in the illustration indicates the laser screw welding location.

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

    5. A is reused.

    6. Carefully cut the rocker panel sub-assembly outer so not to damage B.

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

    8. Apply adhesive (3MTMAutomixTMPanel Bonding Adhesive #8115) to the area indicated by *c in the illustration.

      Tech Tips


      • Apply a light coat of adhesive around the plug welding points.

      • Apply enough adhesive to the panels.

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

      Tech Tips

      Apply body sealer in an even, continuous bead.

    10. C indicates the location of the foamed sealing material. Be careful when welding as the foamed sealing material is located near the area that is cut and joined together.

    11. After welding the rocker panel sub-assembly outer, front body pillar sub-assembly inner and front body pillar reinforce sub-assembly upper to the vehicle side, install the D.

    12. After welding the rocker panel sub-assembly outer, front body pillar sub-assembly inner, front body pillar reinforce sub-assembly upper and D to the vehicle side, install the front body pillar outer and E.

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

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

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

    A00202HC01
    *1 ROCKER PANEL SUB-ASSEMBLY OUTER *2 FRONT BODY PILLAR SUB-ASSEMBLY INNER
    *d 80 mm (3.15 in.) *e 135 mm (5.31 in.)
    *f 40 mm (1.57 in.) *g 120 mm (4.72 in.)
    A002051C01
    *1 FRONT BODY PILLAR REINFORCE SUB-ASSEMBLY UPPER - -
    *d 10 mm (0.39 in.) *e 20 mm (0.79 in.)
    *f 15 mm (0.59 in.) - -
    A00203C Laser Screw Welding - -
    A001ZY0C01
    *d 19 mm (0.75 in.) *e 15 mm (0.59 in.)
    A00203C Laser Screw Welding - -
    A002023C01
    *1 FRONT BODY PILLAR OUTER - -
    A00203C Laser Screw Welding - -
    A001ZUM