LEXUS SC400 1991 Service Repair Manual

mm in.50
70 1.97
2.76
FRONT SIDE MEMBER (CUT-P)
REMOVAL (With the radiator upper support and front
crossmember removed.)
70 mm
Cut and Join Location
(Inner Member and Reinforcement)
50 mm
Cut and Join Location
(Outer Plate)
1. Cut and join the parts at the location shown above.
HINT: Shift the cut and join location of the outer plate,
inner member and the reinforcement.
BODY PANEL REPLACEMENTRE-14
WhereEverybodyKnowsYourName

mm in.10 0.39
INSTALLATION
Butt Weld
(Inner Member)
Outer Plate
New Parts
about 10 mm
Flange Butt Weld
(Reinforcement)
Continuous
MIG Weld
Front Side Member
Plate
Continuous
MIG Weld
(Outer Plate)
1. Temporarily install the new parts and mea- sure each part in accordance with the body
dimension diagram. 2. After butt welding the inner member and the
reinforcement, install the outer plate.
HINT: Provide a flange of about 10 mm (0.39 in.) on
the new outer plate, then overlap it with the vehicleside panel and weld them with a continuous MIGweld to the edge.
BODY PANEL REPLACEMENTRE-15
WhereEverybodyKnowsYourName

MEMORE-16
WhereEverybodyKnowsYourName

FRONT SIDE MEMBER (ASSY)
REMOVAL (With the front crossmember and the front
fender apron removed.)
LH:
1. Replace the front side member No. 3 reinforce-ment at the same time.
BODY PANEL REPLACEMENTRE-17
WhereEverybodyKnowsYourName

INSTALLATION
Front Side
MemberFront Side Member
No. 3 Reinforcement
Front Side Member
Plate
1. Before temporarily installing the new front side member, weld the front side member
No. 3 reinforcement with standard points. 2. Temporarily install the new parts and measure
each part in accordance with the body dimen-
sion diagram.
NOTICE: Make sure each measurement is correct,
as this part affects the front wheel alignment.
BODY PANEL REPLACEMENTRE-18
WhereEverybodyKnowsYourName

INSTALLATION
BODY PANEL REPLACEMENTRE-19
WhereEverybodyKnowsYourName

mm in.10 0.39
COWL SIDE OUTER PANEL UPPER (ASSY)
REMOVAL
Cut with disc
sander etc.
INSTALLATIONTack Weld
(10 mm each)
1. Temporarily install the new parts and mea-
sure each part in accordance with the body
dimension diagram.
BODY PANEL REPLACEMENTRE-20
WhereEverybodyKnowsYourName

mm in.10 0.39
COWL TOP TO APRON BRACE (ASSY):
Right Side
REMOVAL (With the cowl side outer panel upper removed.)
Cut with disc
sander etc.
Cut with disc
Sander etc.
INSTALLATIONTack Weld (10 mm each)
Tack Weld
(10 mm each)
BODY PANEL REPLACEMENTRE-21
WhereEverybodyKnowsYourName

mm in.10 0.39
COWL TOP TO APRON BRACE (ASSY):
Left Side
REMOVAL (With the cowl side outer panel upper removed.)
Cut with disc sander etc.
Cut with disc sander etc.
INSTALLATIONTack Weld (10 mm)Tack Weld (10 mm each)
BODY PANEL REPLACEMENTRE-22
WhereEverybodyKnowsYourName

mm in.10 0.39
COWL TOP SIDE PANEL (ASSY)
REMOVAL (With the cowl top to apron brace removed.)
Cut with disc sander etc.
INSTALLATIONTack Weld (10 mm)
BODY PANEL REPLACEMENTRE-23
WhereEverybodyKnowsYourName