ect LEXUS SC300 1991 Service Repair Manual

mm in.5 0.20
INSTALLATION
Butt Weld
LiningBody Sealer
Butt Weld Braze
Body Sealer
about 5 mm
1. Before temporarily installing the new parts, ap- ply body sealer to the wheel arch.
HINT:
1) Apply body sealer about 5 mm (0.20 in.) from the flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4 mm (0.12 - 0.16 in.) diameter.
3) For other sealing points, refer to section AR.
2. Temporarily install the new parts and check the fit of the luggage compartment door and
rear combination light.
3. Before welding, cut the lining away from the weld seams a little.
BODY PANEL REPLACEMENTRE-45
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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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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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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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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.
ANTI-RUST TREATMENTAR-10
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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).
BODY PANEL CONSTRUCTIONCN-4
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GENERAL INFORMATION
1. BASIC DIMENSIONS
(a) There are two types of dimensions in the diagram.(Three-dimensional distance)

Straight-line distance between the centers of two
measuring points.
(Two-dimensional distance)

Horizontal distance in forward/rearward between
the centers of two measuring points.

The height from an imaginary standard line.
(b) In cases in which only one dimension is given, left and right are symmetrical.
(c) The dimensions in the following drawing indicate actual distance. Therefore, please use the dimen-
sions as a reference.
2. MEASURING
(a) Basically, all measurements are to be done with atracking gauge. For portions where it is not possible
to use a tracking gauge, a tape measure should be
used.
(b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers.
HINT:
1. The height of the left and right pointers must be equal.
2. Always calibrate the tracking gauge before measuring or after adjusting the pointer height.
3. Take care not to drop the tracking gauge or otherwise shock it.
4. Confirm that the pointers are securely in the holes.
(c) When using a tape measure, avoid twists and bends in the tape.
(d) When tracking a diagonal measurement from the front spring support inner hole to the suspension
member upper rear installation hole, measure
along the front spring support panel surface.
Center-to-center
straight-line
distance
Three-dimensional
distance
Front Spring Support Inner HoleTape Measure
Along Body
Surface Front Suspension Member Rear Side
Upper Installation Hole Master Gauge
Pointer
Pointer LoosenessBody Looseness
Plate Looseness
Two-dimensional
distance
Center-to-center
Horizontal distance in
forward/rearward
Vertical distance
in lower surface
Vertical distance
in center
Imaginary Standard Line
Wrong Correct
Pointer
BODY DIMENSIONSDI-2
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BO6847
NOTICE: True up the mounting section ofthe front airbag sensor very carefully and
accurately so that the sensor can bemounted at the correct angle.
Imaginary
Standard
Line
mm (in.)
(Two-Dimensional Distance)
Hote dia.
10 (0.39) nut
10 (0.33) nut
18 (0.71)
14 (0.55) nut 9 (0.35)
Name
Engine rear mounting member installation nut-front Propeller shaft center support bearing installation nut
Front floor reinforcement standard hole
Rear suspension member installation nut Rear spring support hole-front
Symbol
J, j
K, k
L, l
N, n
O, o
Hole dia.
9 (0.35)
9 (0.35)
8 (0.31) nut
13 y11 (0.51 y0.43)14 (0.55) nut
Name
Front crossmember working hole
Airbag front sensor installation hole
Airbag front sensor installation nut Front spring support hole = outer
Front suspension crossmember installation nut
Symbol
B, b
C, c
E, e
G, g H, h
UNDER BODY (Cont'd)
BODY DIMENSIONSDI-7
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