LEXUS SC400 1991 Service Repair Manual

REAR FLOOR REAR SIDE MEMBER (ASSY)
REMOVAL (With the rear floor No. 3 crossmember
removed.)
1. Replace the rear floor pan to quarter panelextension at the same time.
BODY PANEL REPLACEMENTRE-54
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INSTALLATION
Assembly Mark
1. When temporarily installing the new parts,determine the installation position by the
assembly mark. Then, measure each part
in accordance with the body dimension dia-
gram.
BODY PANEL REPLACEMENTRE-55
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REAR FLOOR NO. 1 CROSSMEMBER (ASSY),
REAR FLOOR NO. 2 CROSSMEMBER (ASSY)
REMOVAL (With the rear floor pan removed.)
1. After removing the rear floor No. 1 cross-member, disconnect the welding between
the rear floor crossmember reinforcement
and the rear floor side member.
BODY PANEL REPLACEMENTRE-56
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INSTALLATION
2. After welding the rear floor No. 2 cross-member, install the rear floor No. 1 cross-
member.
1. Temporarily install the new parts and mea-
sure each part in accordance with the body
dimension diagram.
BODY PANEL REPLACEMENTRE-57
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Manual NamePub. No.

SC400 Repair Manual

SC400 Electrical Wiring Diagrar's
Manual

Fundamental Painting Procedures

Fundamental Body Repair Procedures BRM019U
BRM020U
M/Y Version
M/Y Version
FOREWORD
This
repair manual has been prepared to provide information on
the repair methods (including cutting and welding operations,
but excluding painting) for collision- damaged body compo-
nents of the LEXUS SC400.
Applicable models: UZZ30 series
This manual consists of body repair methods, exploded dia-
grams and illustrations of the body components and other infor-
mation relating to body panel replacement such as handling
precautions, etc. However, it should be noted that the front fend-
ers of the LEXUS model is bolted on and require no welding.
For the repair procedures and specifications other than colli-
sion-damaged body components of the LEXUS SC400 refer to
the following repair manuals.
If you require the above manuals, please contact your LEXUS
Dealer.
All information contained in this manual is the most up-to-date
at the time of publication. However, specifications and proce-
dures are subject to change without prior notice.
TOYOTA MOTOR CORPORATION
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mm in.1
1.5
3.5
4
4.8
5
5.5
6 0.04
0.06
0.14
0.16
0.19
0.20
0.22
0.24
FIT STANDARDS
After doors and the engine hood are installed, be sure to perform flit a\
djustment to prevent abnormal wind
noise and ensure a good appearance.
APPENDIXAP-2
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mmin.
2.0
3.9
4.0 0.08
0.15
0.16
SILENCER SHEET INSTALLATION AREAS
4.0 mm
2.0 mm2.0 mm3.9 mm
3.9 mm
3.9 mm
3.9 mm
2.0 mm
2.0 mm 3.9 mm
2.0 mm
3.9 mm3.9 mm
2.0 mm
3.9 mm
2.0 mm
The figures in the illustration show the silencer sheet thickness.
APPENDIXAP-3
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FOAMED MATERIAL APPLICATION AREAS
The sections shown in the figure below are
filled with foamed material to provide noise
insullation.
After repairing these sections or their periph-
eries, refill with foamed material.
HINT:1. Use the service holes located on the reverse side of the body panel to refillwith foamed material.
2. When handling foamed material, follow the directions of the material's manufac-
turer.
APPENDIXAP-4
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1. WELD-THROUGH PRIMER (SPOT SEALER)APPLICATION
For anti-corrosion measures, always apply the
weld-through primer (spot sealer) to welding sur-
faces where the paint film has been removed.
HINT: Apply the weld-through primer (spot sealer)
so that it does not ooze out from the joining sur-faces.
GENERAL INFORMATION
Anti-rust treatment is necessary before welding and before and after the painting\
process.
ANTI-RUST TREATMENT BEFORE WELDING
Weld-Through Primer
(Spot Sealer)
WELD-THROUGH PRIMER (SPOT SEALER)
APPLICATION
ANTI-RUST TREATMENT BEFORE PAINTING PROCESS
Sealer Gun1. BODY SEALER APPLICATION
For water-proofing and anti-corrosion measures,
always apply the body sealer to the body panel
seams and hems of the doors, hoods, etc.
BODY SEALER APPLICATION
2. UNDERCOAT APPLICATION
To prevent corrosion and protect the body from dam-
age by flying stones, always apply sufficient undercoat
to the bottom surface of the under body and inside of
the wheel housings.
UNDERCOAT APPLICATION
ANTI-RUST TREATMENT
AR-2
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Steel MetalUndercoat (ED Primer) Anti-Chipping Paint
Second Coat
Steel Metal Undercoat (ED Primer) Second Coat Top Coat
REFERENCE: ANTI-RUST TREATMENT BY PAINTING
ANTI-RUST TREATMENT AFTER PAINTING PROCESS
1. ANTI-RUST AGENT (WAX) APPLICATION
To preserve impossible to paint areas from
corrosion, always apply sufficient anti-rust
agent (wax) to the inside of the hemming
areas of the doors and hoods, and around
the hinges, or the welded surfaces inside
the boxed cross-section structure of the
side member, body pillar, etc.
ANTI-RUST AGENT (WAX) APPLICATION
Painting prevents corrosion and protects the sheet metal from damage. In\
this section, anti-chipping paint
only for anti-corrosion purpose is described.
1. ANTI-CHIPPING PAINT
To prevent corrosion and protect the body from damage by flying stones, et\
c., apply anti-chipping
paint to the rocker panel, wheel arch areas, valance panel, etc.
HINT:
Depending on the model or the application area, there are cases where th\
e application of anti-chipping paint is necessary before the second coat or after the top coat\
.

Apply the anti-chipping paint
before the second coat.


Apply the anti-chipping paint
after the top coat.
Top Coat
Anti-Chipping Paint
ANTI-RUST TREATMENTAR-3
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