Lexus RX300 (MCU15). Manual - part 21

1.

Cut the new parts for the rocker panel No.1 re-
inforcement at the location shown above.

2.

Before temporarily installing the new parts.
Weld the rocker panel No.1 reinforcement,
rocker panel No.3 reinforcement, inner pillar
and center body pillar reinforcement with
standard points.

3.

Temporarily install the new parts and mea-
sure each part in accordance with the body di-
mension diagram.

4.

Before welding the new parts, check the fit of
the front door and rear door.

Rocker Panel No.1 Reinforcement

580 mm

Cut Location

Rocker Panel No.3 Reinforcement

Rocker Panel No.1 Reinforcement

Center Body
Pillar
Reinforcement

Inner Pillar

Butt Weld

Butt Weld

— 4

— 4

— 28

— 26

— 11

— 6

— 3

— 12

BODY PANEL REPLACEMENT

RE-30

INSTALLATION

mm

in.

580

22.83

5.

After welding the inner pillar, center body pil-
lar reinforcement and rocker panel No.1 rein-
forcement to the vehicle install the outer pil-
lar.

6.

Apply framd material to the pillar section.

A – A
[Foamed Material
Application Areas]

— 40

Butt Weld

— 41

— 1

— 1

A

A

Butt Weld

Butt Weld

Butt Weld

— 21

— 2

— 3

— 3

— 11

BODY PANEL REPLACEMENT

RE-31

FRONT DOOR OUTER PANEL (ASSY)

REMOVAL

1.

Before removing the outer panel, make the
installation position with a tape.

2.

After grinding off the hemming location, re-
move the outer panel.

Hemming Location

Disc Sander

Braze

Installation
Position

Braze

Positioning Tape

BODY PANEL REPLACEMENT

RE-32

1.

Before temporarily installing the new parts,
apply body sealer to the reinforcement, side
impact protection beam and back side of the
new parts.

HINT:
1)

Apply just enough sealer for the reinforce-
ment and side impact beam to touch the new
panel. Apply sealer evenly around the flange
area, about 10 mm (0.39 in.) from the edge, as
shown.

2)

For other sealing points, refer to section AR.

2.

Bend the flange hem about 30

_ with a hem-

mer and dolly, then fasten tightly with a hem-
ming tool.

HINT:
1)

Perform hemming 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.

Body Sealer

about 10 mm

Do not close the
drain hole.

Cloth Tape

30

_

Hemming Tool

Braze

Body Sealer

Positioning
Tape

Braze

Body Sealer

— 4

— 4

— 4

— 4

BODY PANEL REPLACEMENT

RE-33

INSTALLATION

mm

in.

10

0.39