FRONT BODY PILLAR CUT AND JOIN REPLACEMENT SECTIONS (PATTERN 2)

A01P8PH


  1. REMOVAL

    Symbol Meaning
    B00550I Remove Weld Points
    B00558K Remove Weld Points
    B00555W Remove Weld Points
    B0054YZ Cut with Disc Sander etc.
    B00554K Cut and Join Location
    B0054ZR 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. Remove the front body pillar upper outer.

      A01P8P8C01
      *1 FRONT BODY PILLAR UPPER OUTER - -
      B00552Z Laser Screw Welding - -
      A01P8JE

    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.

      A01P8P3C01
      B00550G Adhesive - -

    4. 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.

    5. A is reused.

      A01P8G2C01
      *a 35 mm (1.38 in.) *b 190 mm (7.48 in.)
      B00552Z Laser Screw Welding B00552V Foamed Sealing Material
      A01P8ECC01
      *A for Standard Roof - -
      A01P8NXC01
      *A for Sliding Roof - -
      A01P8NGC01
      *A for Glass Roof - -
      A01P8ME

    6. Remove the front body pillar reinforce sub-assembly lower.

      A01P8JRC01
      *1 FRONT BODY PILLAR REINFORCE SUB-ASSEMBLY LOWER - -
      B00552Z Laser Screw Welding - -

    7. A indicates welds to remove for easier removal.

      A01P8PU

    8. 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.

      A01P8DVC01
      B00550G Adhesive - -

    9. A indicates welds to remove for easier removal.

    10. Remove the front body pillar sub-assembly inner.

      A01P8QJC01
      *1 FRONT BODY PILLAR SUB-ASSEMBLY INNER - -
      A01P8PM
      A01P8MYC01
      *A w/o Glass Roof *B w/ Glass Roof
      B00552Z Laser Screw Welding - -

    11. When replace only the outer panel, please cut off a necessary range depending on a damage range.


      1. Carefully cut the outer panel so not to damage the reinforcement.

      2. Make sure that butt welding does not heat-affect the reinforcement when welding the outer panel.

  2. INSTALLATION

    Symbol meaning
    B005513 Spot Weld
    B005570 Plug Weld
    B00558E Plug Weld
    B005527 Plug Weld
    B005515 Fillet Weld
    B005529 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. Weld the front body pillar sub-assembly inner to the vehicle side.

      A01P8PPC01
      *1 FRONT BODY PILLAR SUB-ASSEMBLY INNER - -
      *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 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.

      A01P8JYC01
      *a 10 mm (0.39 in.) - -
      A01P8JWC01
      *A w/o Glass Roof *B w/ Glass Roof
      B00552Z Laser Screw Welding - -

    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.

      A01P8DVC02
      B00550G Adhesive - -

    5. Weld the front body pillar reiforce sub-assembly lower to the vehicle side.

      A01P8QAC01
      *1 FRONT BODY PILLAR REINFORCE SUB-ASSEMBLY LOWER - -
      *a Ultra High Strength Steel Welding Point - -
      B00552Z 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 1500 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.

      A01P8GEC01
      *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 1500 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.


        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.

    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.

      A01P8KYC01
      B00550G Adhesive - -

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

      A01P8DXC01
      *1 FRONT BODY PILLAR UPPER OUTER - -
      *a Ultra High Strength Steel Welding Point - -
      B00552Z 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 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.

      A01P8NQC01
      *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.

    8. Weld the A to the vehicle side.

      A01P8I3C01
      *a Ultra High Strength Steel Welding Point - -
      B00552Z 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 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.

      A01P8N8C01
      *A for Standard Roof - -
      *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.

      A01P8K0C01
      *A for Sliding Roof - -
      *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.

      A01P8FPC01
      *A for Glass Roof - -
      *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.

    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.