LEXUS SC400 1991 Service Repair Manual

ROOF PANEL (ASSY): w/o Moon Roof
REMOVAL
Braze
(both sides)
1. Heat the brazed area of the quarter panel andscrape off the brazing with a wire brush.
NOTICE: Be careful not to overheat the quarter
panel.
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INSTALLATION
Body Sealer
Body Sealer Braze
(both sides)
2. Braze the quarter panel connection.
NOTICE: Before performing these operations,place a wet rag on the roof panel to protect it fromdamage.
1. Before temporarily installing the new parts, apply body sealer to the windshield header
panel and the back window upper frame.
HINT: Apply just enough sealer for the new parts
to make contact.
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ROOF PANEL (ASSY): w/ Moon Roof
REMOVAL
Braze
(both sides)
1. Heat the brazed area of the quarter paneland scrape off the brazing with a wire brush.
NOTICE: Be careful not to overheat the quarter
panel.
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INSTALLATION
Body Sealer
Body Sealer Braze (both sides)
2. Braze the quarter panel connection.
NOTICE: Before performing these operations,place a wet rag on the roof panel to protect it fromdamage.
1. Before temporarily installing the new parts, apply body sealer to the windshield header
panel and back window upper frame.
HINT: Apply just enough sealer for the new parts
to make contact.
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FRONT DOOR PANEL (CUT)
REMOVAL
Cut and Join
LocationCut and Join Location
Heat Slightly Hemming Location
Disc Sander
1. Cut and join the parts at the location shown above.
2. After grinding off the hemming location, remove the outer panel.
HINT: Slightly heating the outer panel will soften thesealer and make removal easier.
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INSTALLATION
Butt WeldButt Weld
Body Sealer
Body Sealer
about 10 mmDo not close the
drain hole.
Body Sealer
Cloth Tape
30
°
Hemming Tool
1. Before temporarily installing the new parts, apply body sealer to the back side of the new
parts.
HINT: 1) Apply sealer evenly about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diame-
ter.
2) For other sealing-points, refer to section AR.
2. Bend the flange hem about 30 ° with a ham-
mer and dolly, then fasten tightly with a hem-
ming tool.
HINT:
1) Perform hemm ing in three steps, being care-
ful not to warp the panel.
2) If a hemming tool cannot be used, hem with
a hammer and dolly.
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mm in.150
200
300 5.91
7.87
11.81
QUARTER PANEL (CUT)
REMOVAL
Cut and Join Location
200 - 300 mm
150 - 200 mm
[Cut and Join Location]
Cut and Join Location
(Cut Location for Supply Parts)
1. Cut and join the parts at the location shown
above.
HINT: Make incision and bend the roof drip channel
at the upper part of the cut and join location.
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Make incision
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mm in.5 0.20
INSTALLATION
Butt Weld
Body Sealer
Butt Weld
Body Sealer
about 5 mm
1. Before temporarily installing the new parts, apply 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.) in diameter.
3) For other sealing points, refer to section AR.
2. Temporarily install the new parts and check the fit of the front door, luggage compartment
door and rear combination light.
3. Apply foamed material to the pillar section.
HINT: For the foamed material application areas, refer to page AP-4.
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Butt Weld
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