Front Pillar Outer Panel Replacement
1. Mass Production Body Welding Positions and Numbers - Remove

Front Pillar Outer Panel



3. Mass Production Body Welding Positions and Numbers - Remove

Front Pillar Lower Stiffener



4. Construction - Remove

NOTE:
This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual.
The component replacement procedure described here is only for new genuine supplied parts, as needed, according to the area and the degree of damage on the body.
Cut and pry off the outer panel at the front pillar and side sill portions.
NOTE: Select the sectioning location in consideration of the front side outer panel repair part.
Check the front pillar lower stiffener position for damage. If necessary, replace it.
Replace the front pillar upper outer separator, the lower outer separator, and the lower inner separator.



NOTE:
Position the replacement parts.
Before doing the main welding, check the body dimensions:
?
Front wheelhouse lower member position
?
Door hinge positions
?
Windshield and door openings
?
Inside sill positions
Temporarily install the related parts, then check for differences in level and clearance.
Check the external parts fitting positions. Make sure the body lines flow smoothly.
Confirm the sheet thickness, tensile strength, and existence of the zinc treatment of both sides, and set the welder to conform to the welding conditions by referring to Front Body Construction.
Welding symbols (The welding symbols with dashed lines have a meaning of the spot welding of the part which is not visible)
( ) and ( )*: The number of welds

1. Front Pillar Lower Stiffener - Weld
1.
Install the new front pillar lower inner separator (A) to the front pillar lower stiffener (B). Apply the sealer (C) without gaps all the way around the separator and the front inner lower pillar (D).
2.
Weld the front pillar lower stiffener (A) to the front pillar upper stiffener (B), the side sill reinforcement (C), the front inner lower pillar (D), the hood hinge bracket (E), and the dashboard upper side member extension (F).
(?)*: Welding positions with the front pillar upper stiffener and the side sill reinforcement, include ultra high-strength steel (1500 MPa) parts. Perform the spot welding on the conditions of No. 15 in the table shown below. Confirm the MIG brazing conditions.
Spot welding conditions
No. 15
9000 A
600 ms
3432 N (350 kgf)

Welding positions (G): Must be welded according to the following conditions.
Plug hole diameter: ?10 mm (0.39 in)
Welding wire: Must use wire with a tensile strength of 980 MPa or higher (142 ksi or higher).
( )*: Welding positions with high-strength steel parts. Confirm the plug welding conditions.

2. Outer Panel Repair Part - Weld
1.
Install the new front pillar outer upper separator (A) and the outer lower separator (B) on the front pillar upper stiffener (C) and the front pillar lower stiffener (D). Apply the sealer (E) without gaps all the way around the separator and inside the outer panel repair part (F).
2.
Apply the adhesive (A) to areas around holes on the inside of the outer panel repair part (B) and the outside of the front pillar lower stiffener (C) as shown.
Adhesive: 3M AUTO MIX Panel Bonding 8115, or equivalent, commercially available
NOTE: See the adhesive manufacture's instructions for details.
3.
Weld the outer panel repair part (A).
(?)*: Welding positions with the front pillar upper stiffener (B), the front inner upper pillar (C), and the side sill reinforcement (D), include ultra high-strength steel (1500 MPa) parts. Perform the spot welding on the conditions of No. 26, 30, and 31 in the table shown below.
Spot welding conditions
No. 26
8000 A
800 ms
3432 N (350 kgf)
No. 30
8500 A
1200 ms
3432 N (350 kgf)
No. 31
9000 A
1200 ms
3432 N (350 kgf)