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

A004D59


  1. REMOVAL

    Symbol Meaning
    A004D0P Remove Weld Points
    A004D62 Remove Weld Points
    A004CVQ Cut with Disc Sander etc.
    A004D1P Cut and Join Location

    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. 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.

      A004D2XC01
      A004D5G Adhesive - -

    3. Remove the rivets.

      A004CXWC01
      *1 RIVETS - -
      A004CYMC01
      A004D35 Laser Screw Welding - -
      A004D3HC01
      A004D35 Laser Screw Welding - -
      A004CVUC01
      *a 140 mm (5.51 in.) - -

    4. 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
    A004D0P Remove Weld Points
    A004D2M Plug Weld
    A004D7A Plug Weld
    A004D16 Butt Weld
    A004CZ4 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. Remove A from the new parts.

      A004CXBC02
      *1 FRONT BODY PILLAR REINFORCE SUB-ASSEMBLY UPPER - -

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

      Tech Tips

      Apply body sealer in an even, continuous bead.

      A004D63

    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.

      A004D0JC01
      A004D5G Adhesive - -

    6. After welding the A to the vehicle side, install the B.

      A004D2WC01
      *a Ultra High Strength Steel Welding Point *b Ultra High Strength Steel Welding Point
      *c 13 mm (0.51 in.) - -
      A004D35 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.

      A004D3PC03
      A004D35 Laser Screw Welding - -

    7. Install the rivets.

      A004CXWC01
      *1 RIVETS - -

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

      Tech Tips

      Apply body sealer in an even, continuous bead.

      A004D7L

    9. 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.

      A004D2QC01
      A004D5G Adhesive - -

    10. Weld the side panel outer No.2 to the vehicle side.

      A004D3NC01
      *1 SIDE PANEL OUTER NO.2 - -
      *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.

    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.