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

B0054VL


  1. REMOVAL

    Symbol Meaning
    B0054Y8 Remove Weld Points
    B0054WD Remove Weld Points
    B0054TV Cut and Join Location
    B0054Y4 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. 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.

      B0054XXC01
      B0054VN Adhesive - -

    3. Remove the front body pillar outer.

      B0054W9C01
      *1 FRONT BODY PILLAR OUTER - -
      B0054UR Laser Screw Welding - -
      B0054VB
      B0054VF

    4. Remove the A.

      Tech Tips

      A is reused.

      B0054V6C01
      *a 165 mm (6.50 in.) - -
      B0054UR Laser Screw Welding - -
      B003HVC

    5. Remove the A.

      Tech Tips

      A is reused.

      B0054W7C01
      B0054UR Laser Screw Welding - -

    6. 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.

      B0054X4C01
      B0054VN Adhesive - -

    7. Remove the cowl side panel sub-assembly and front pillar reinforcement sub-assembly lower.

      B0054XJC01
      *1 COWL SIDE PANEL SUB-ASSEMBLY *2 FRONT PILLAR REINFORCEMENT SUB-ASSEMBLY LOWER
      B0054UR Laser Screw Welding - -
      B0054YE

    8. 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
    B0054VX Spot Weld
    B0054U5 Plug Weld
    B0054U8 Plug Weld
    B0054V1 Butt Weld
    B0054Y3 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. Before temporarily installing the new parts, weld the cowl side panel sub-assembly and front pillar reinforcement sub-assembly lower with the standard number of welding points.

      B0054VWC01
      *1 COWL SIDE PANEL SUB-ASSEMBLY *2 FRONT PILLAR REINFORCEMENT SUB-ASSEMBLY LOWER
      *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 1500 MPa or 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.

    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.

      B0054X4C01
      B0054VN Adhesive - -

    5. Weld the cowl side panel sub-assembly and front pillar reinforcement sub-assembly lower to the vehicle side.

      B0054YBC01
      *1 COWL SIDE PANEL SUB-ASSEMBLY *2 FRONT PILLAR REINFORCEMENT SUB-ASSEMBLY LOWER
      *a Ultra High Strength Steel Welding Point *b Ultra High Strength Steel Welding Point
      B0054UR 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

        When welding 2 panels together including 1500 MPa ultra high strength steel.

        *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.

      B0054TUC01
      *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 1500 MPa or 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. Weld the A to the vehicle side.

      B0054WLC01
      *a Ultra High Strength Steel Welding Point - -
      B0054UR 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.

    7. Weld the A to the vehicle side.

      B0054WWC01
      *a Ultra High Strength Steel Welding Point - -
      B0054UR 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 3 panels or more 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.

      B0054TKC02
      *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 3 panels or more 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. Before installing a new part, apply body sealer.

      Tech Tips

      Apply body sealer in an even, continuous bead.

      B0054TQ

    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.

      B0054XXC01
      B0054VN Adhesive - -

    10. Weld the front body pillar outer to the vehicle side.

      B0054W2C01
      *1 FRONT BODY PILLAR OUTER - -
      *a Ultra High Strength Steel Welding Point - -
      B0054UR 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 3 panels or more together including 1500 MPa or 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.

      B0054WUC02
      *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 3 panels or more 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.

    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.