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

K138026

  • With the cowl top side upper panel assembly and roof panel assembly removed.

  1. REMOVAL

    Symbol Meaning
    K108818

    Remove Weld Points
    K108819

    Remove Weld Points
    K108820

    Remove Weld Points
    K108827

    Cut and Join Location
    K108828

    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.

      Tip:

      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.

      K137842C01
      K108837

      Adhesive

      -

      -

    3. A is reused.

      K137843C02

      *a

      90 mm (3.54 in.)

      -

      -
      K137844
      K137845
      K137846

    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
    K108823

    Plug Weld
    K108824

    Plug Weld
    K108825

    Plug Weld
    K108831

    Butt Weld
    K108834

    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. Apply adhesive (3MTM AutomixTM Panel Bonding Adhesive #8115).

      Tip:

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

      • Apply enough adhesive to the panels.

      K137842C01
      K108837

      Adhesive

      -

      -

    4. Weld the roof side rail sub-assembly and front pillar reinforcement sub-assembly lower to the vehicle side.

      K137847C01

      *1

      ROOF SIDE RAIL 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% + CO2 20%) as the shield gas when plug welding.Sufficient weld strength cannot be assured when using 100% CO2 shield gas.

      K137848C01

      *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 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% + CO2 20%) as the shield gas when plug welding.Sufficient weld strength cannot be assured when using 100% CO2 shield gas.

      K137849C01

      *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% + CO2 20%) as the shield gas when plug welding.Sufficient weld strength cannot be assured when using 100% CO2 shield gas.

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

      Tip:

      Apply body sealer in an even, continuous bead.

      K137850

    6. Apply adhesive (3MTM AutomixTM Panel Bonding Adhesive #8115).

      Tip:

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

      • Apply enough adhesive to the panels.

      K137963C01
      K108837

      Adhesive

      -

      -

    7. Weld the side panel sub-assembly inner and A to the vehicle side.

      K137851C01

      *1

      SIDE PANEL 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 more than 3 panels 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% + CO2 20%) as the shield gas when plug welding.Sufficient weld strength cannot be assured when using 100% CO2 shield gas.

      K137852C01

      *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 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% + CO2 20%) as the shield gas when plug welding.Sufficient weld strength cannot be assured when using 100% CO2 shield gas.

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

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

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