LEXUS SC400 1991 Service Repair Manual

BODY PANEL SEALING AREAS
HINT:1. Prior to applying body sealer, clean the area with a rag soaked in a grease, wax and silicone remover\
.
2. If weld-through primer was used, first wipe off any excess and coat with\
anticorrosion primer before applying body sealer.
3. Wipe off any excess body sealer with a rag soaked in a grease, wax and si\
licone remover.
4. If body sealer is damaged by peeling, cracks, etc., be sure to repair as\
necessary.
Flat surfacing
Flat surfacing
Flat surfacing
Flat surfacingFlat surfacing
Flat surfacing Flat surfacing
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Flat Surfacing
Flat Surfacing
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Flat
SurfacingFlat Surfacing
Flat Surfacing
Flat Surfacing
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Flat Surfacing (All Around)
Hood Luggage Compartment Door
Front Door
Flat Surfacing
Flat Surfacing (All Around)
Flat Surfacing Flat Surfacing
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BODY PANEL UNDERCOATING AREAS
HINT:1. First wipe off any dirt, grease or oil with a rag soaked in a grease, wa\
x and silicone remover.
2. Cover the surrounding areas with masking paper to avoid coating unnecess\
ary areas. If other areas are accidently coated, wipe off the coating immediately.
3. Apply the first coating of undercoat to all welded areas and panel joint\
s, then apply a second coat over the entire area.
4. Do not coat parts which become hot, such as the tailpipe, or moving part\
s, such as the propeller shaft.
5. Besides the locations described below, apply undercoating to all weld points under the body to insure corrosion prevention.
6. Be sure to seal the edge of the flange of the member and bracket with un\
dercoating. 7. If undercoat is damaged by peeling, cracks, etc, be sure to repair as ne\
cessary.
REFERENCE: Referring to the notes above, undercoating should be applied \
according to the specifications
for your country.
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BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION
AREAS
HINT:1. Whenever adjusting the doors and hoods, apply anti-rust agent (wax) ar\
ound the hinges.
2. Even if partially repairing a part, apply anti-rust agent (wax) over t\
he entire application area of the part.3. Wipe off the anti-rust agent immediately with a rag soaked in a grease, w\
ax and silicone remover, if accidently applied to other areas.
Luggage Compartment Door
Hood Front DoorFront Door Hinge
Front Body Pillar
A-A
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HINT: Apply anti-chipping paint to a thickness of about 300 microns.
BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS
HINT:1. Anti-chipping paint should be applied to some areas before the second coat and to oth\
ers after the top coat.
2. If other areas are accidentally coated, wipe of the paint immediately wi\
th a rag soaked in a grease, wax and silicone remover.
Urethane Bumper
Urethane Bumper
Anti-Chipping PaintUrethane Bumper
Extension
Door Panel
Protector Anti-Chipping Paint
A-A ' Cross Section B-B' Cross Section
Apply anti-chipping paint after the top coat.
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mm in. 2
10
13
15
18 0.08
0.39
0.51
0.59
0.71
10
f
18f
18f
Assembly Mark Assembly
Mark
STANDARD BODY MARKS
Center Mark
(15
f)
Assembly Mark Center Mark
2R
18
f
Assembly Mark
18
f
13f
Assembly Mark
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REFERENCE:
HIGH-STRENGTH STEEL (HSS) PARTS
Generally, High-Strength Steel (HSS) is that which has an intensity value of at\
least 35 kgf/mm2 (343 MPa),
and distinguished from mild steel.
The handling of HSS is the same as for mild steel, but the following sho\
uld be observed.
1. Panel Hammering: Because HSS is thinner than mild steel, care should be \
taken to avoid warping during hammering operations.
2. Removing Spot Welds: Because HSS is tougher than mild steel, damage will occur more eas\
ily to a regular drill. Therefore, an HSS Spot Cutter is recommended.
Also, use a high-torque drill at low speed, and supply grinding oil to t\
he drill during use.
3. Panel Welding: Panel welding procedures for HSS are exactly the same as for mil\
d steel. Plug welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at
areas other than specified.
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Ordinary Galvannealed
Steel SheetZinc-Iron Alloy Double-
Layer Galvannealed
Steel Sheet
REFERENCE:
RUST-RESIST ANT STEEL SHEET PARTS
Rust-Resistant Steel Sheets have zinc, tin or aluminum etc, plating over the base meta\
l surface in order
to improve the corrosion resistance of the sheet metal. For the vehicle'\
s body panels, galvanized steel
sheet is widely used.
Body panel on LEXUS models are made of two different galvanized steel sheet. The ordinary galvanized
steel sheet has a zinc-iron alloy plating over the base metal surface. E\
xcelite II has zinc-iron alloy plating
on both the outside and the back surface, plus a further iron-rich zinc-\
iron alloy plating which good paint
adherence. These two galvanized steel sheets are used selectively accord\
ing to need.
Zinc-Iron Alloy
Zinc-Iron Alloy Iron-rich Zinc-Iron alloy
Base Metal
Base Metal
Excelite II
Ordinary Galvanized Steel Sheet
The handling of Rust-Resistant Steel Sheet is the same as for ordinary s\
teel sheet, but the following
should be observed.
1. Panel welding: The paint as well as the zinc portion must be removed com\
pletely from the welding
area to guarantee good welding integrity.
2. Anti-rust treatment: Since the zinc plating is lost after welding, anti-\
rust treatment of the welded area must be thoroughly performed (refer to section AR).
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