ROCKER PANEL CUT AND JOIN REPLACEMENT SECTIONS

Info Added 2016-03-29

A01Q0D0

  1. REMOVAL

    Symbol Meaning
    A01Q0FO Remove Weld Points
    A01Q0HQ Remove Weld Points
    A01Q0JR Cut with Disc Sander etc.
    A01Q0M9 Cut and Join Location
    A01Q0KD 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 front of the supplied part cut position.

      Tech Tips

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

      A01Q0KFC01
      *1 ROCKER PANEL SUB-ASSEMBLY OUTER - -
      *a 240 mm (9.45 in.) *b 160 mm (6.30 in.)
      A01Q0I3 Laser Screw Welding - -

    3. 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.

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

      A01Q0FDC01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY - -
      *a 265 mm (10.43 in.) - -
      A01XPT4 Adhesive A01Q0I3 Laser Screw Welding
      A01Q0MNC01
      *a 35 mm (1.38 in.) *b 25 mm (0.98 in.)
      *c 100 mm (3.94 in.) *d 20 mm (0.79 in.)
      A01Q0HVC01
      A01Q0I3 Laser Screw Welding - -

  2. INSTALLATION

    Symbol Meaning
    A01Q0FO Remove Weld Points
    A01Q0KH Spot Weld
    A01Q0J0 Plug Weld
    A01Q0E4 Plug Weld
    A01Q0M9 Cut and Join Location
    A01Q0DB Fillet Weld
    A01Q0HW Butt Weld
    A01Q0IW 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. If the entire supply part is not needed, remove the part of the supply part that is needed.

      Tech Tips

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

      A01Q0IRC01
      *1 ROCKER PANEL SUB-ASSEMBLY OUTER - -
      *a 60 mm (2.36 in.) *b 430 mm (16.93 in.)
      *c 35 mm (1.38 in.) - -

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

      Tech Tips

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

      A01Q0D9C01
      *1 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY *2 CENTER BODY PILLAR SUB-ASSEMBLY INNER
      *a 175 mm (6.89 in.) *b 50 mm (1.97 in.)

    5. 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.

      A01Q0HIC01
      A01XPT4 Adhesive - -

    6. Before temporarily installing the new parts, weld the rocker panel sub-assembly outer, center body pillar reinforcement sub-assembly and center body pillar sub-assembly inner with the standard number of welding points.

      A01Q0MDC01
      *1 ROCKER PANEL SUB-ASSEMBLY OUTER *2 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY
      *3 CENTER BODY PILLAR SUB-ASSEMBLY INNER - -
      *a Ultra High Strength Steel Welding Point *b 10 mm (0.39 in.)
      *c 20 mm (0.79 in.) - -
      A01Q0I3 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.

    7. 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.

      A01Q0FUC01
      A01XPT4 Adhesive - -

    8. Weld the rocker panel sub-assembly outer, center body pillar reinforcement sub-assembly and center body pillar sub-assembly inner to the vehicle side.

      A01Q0DDC01
      *1 ROCKER PANEL SUB-ASSEMBLY OUTER *2 CENTER BODY PILLAR REINFORCEMENT SUB-ASSEMBLY
      *a Ultra High Strength Steel Welding Point *b Ultra High Strength Steel Welding Point
      A01Q0I3 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: Spot weld Pressure 2940 N (300 kgf, 661 lbf)
        Weld current 10000 A
        Weld time 18 Cyc.(0.30 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.

      A01Q0DXC01
      *1 CENTER BODY PILLAR SUB-ASSEMBLY INNER - -
      *a Ultra High Strength Steel Welding Point *b 20 mm (0.79 in.)
      *c 15 mm (0.59 in.) - -
      A01Q0I3 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.

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

      Tech Tips

      Apply body sealer in an even, continuous bead.

      A01Q0EM

    10. 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.

      A01Q09FC01
      A01XPT4 Adhesive - -

    11. Weld the center body pillar outer and A to the vehicle side.

      A01Q0CIC01
      *1 CENTER BODY PILLAR OUTER - -
      *a Ultra High Strength Steel Welding Point - -
      A01Q0I3 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 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.

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

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

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