roof LEXUS SC400 1991 Service Service Manual

INSTALLATION
Butt WeldButt Weld
Roof Drip Channel
Butt Weld
1. After installing the new parts, apply foamed material.
HINT: For the foamed material application areas,
refer to AP-4.
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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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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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mm in.45 1.77
QUARTER WHEEL HOUSING OUTER PANEL
(CUT)
45 mm
REMOVAL (With the quarter panel removed.)
Roof Side Outer Panel
Cut and Join Location
1. After removing the roof side outer panel, cutand join the quarter wheel housing outer panel
at the location shown above.
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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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BO6848
E-e
1,304
(51.34) 1,500
(69.06)F-fVehicle Dimensions Left
eRight
G-g
1,511
(59.49) H-h
1,511
(59.49) I-i
1,083
(42.64) 1,363
(53.66)J-j
1,503
(59.17)K-k
E-f
or
e-F
1,536
(60.47) 1,577
(62.09)E-g
or
e-G
1,694
(66.69)E-h
or
e-H
1,587
(62.48)E-j
or
e-J
1,909
(75.16)F-j
or
f-J
HINT: For symbols, Capital letters indicate
right side of vehicle, small letters indicate
left side of vehicle (See from rear).
F-k
or
f-K
1,945
(76.57) G-h
or
g-H
1,665
(65.55) H-i
or
h-I
1,568
(61.73) 1,595
(62.80)H-j
or
h-J
1,490
(58.66)
mm (in.)J-k
or
j-K
(Three-Dimensional Distance)
Hote dia.
Name
Rocker panel adjoining portion mark
Rocker panel adjoining portion mark
Roof side rail adjoining portion mark
Quarter panel adjoining portion mark
Quarter panel adjoining portion mark
Symbol
G, g
H, h
I, i
J, j
K, k
Hole dia.
10 (0.39) screw
10 (0.39) screw
Name
Roof panel/Front body pillar adjoining portion
Cowl top panel/Front body pillar adjoining portion
Front door hinge installation nut
D, d Front door hinge installation nut
Front body pillar adjoining portion mark
Front body pillar adjoining portion mark
Symbol
A, a
B, b
C, c
E, e
F, f
BODY OPENING AREAS (Side View)
BODY DIMENSIONSDI-8
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BO6849
mm (in.)
(Three-Dimensional Distance)
Hole dia.18 (0.71)
Name
Opening trough/Lower back panel adjoining portion
Upper back panel center mark
Rear floor side member standard hole
Symbol
P, pQ
R, r
Hole dia.
Name
Roof panel/Quarter panel adjoining portion
Quarter panel/Upper back panel adjoining portion
Quarter panel/Upper beck panel adjoining portion
Opening trough/Quarter panel adjoining portion
Symbol
L, l
M, m
N, n
O, o
BODY OPENING AREAS (Rear View)
BODY DIMENSIONSDI-9
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