Lexus SC300 / Lexus SC400. Service manual — part 308

REFERENCE:

HIGH-STRENGTH STEEL (HSS) PARTS

Generally, High-Strength Steel (HSS) is that which has an intensity value of at least 35 kgf/mm

2

(343 MPa),

and distinguished from mild steel.

The handling of HSS is the same as for mild steel, but the following should 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 easily 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 the drill during use.

3.

Panel Welding: Panel welding procedures for HSS are exactly the same as for mild 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.

BODY PANEL CONSTRUCTION

CN-3

Ordinary Galvannealed
Steel Sheet

Zinc-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 metal 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. Excelite 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 according 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 steel sheet, but the following
should be observed.
1.

Panel welding: The paint as well as the zinc portion must be removed completely 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 CONSTRUCTION

CN-4

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 a
tracking 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 Hole

Tape Measure

Along Body
Surface

Front Suspension Member Rear Side
Upper Installation Hole

Master Gauge

Pointer

Pointer Looseness

Body 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 DIMENSIONS

DI-2

mm (in.)

BO6846
BO6860

1,218
(47.95)

392
(15.43)

H-U
h-u

K-o
k-O

1,186
(46.69)

H-T
h-t

393
(15.47)

D-U
D-u

379
(14.92)

G-U
g-u

1,158
(45.59)

D-T
D-t

G-T
g-t

366
(14.41)

1,299
(51.14)

D-S
D-s

151
(5.94)

1,260
(49.61)

D-R
D-r

J-S
j-s

187
(7.36)

1,215
(47.83)

D-Q
D-q

J-R
j-r

1,192
(45.92)

1,201
(47.28)

K-q
k-Q

D-P
D-p

1,033
(40.67)

1,143
(45.0)

K-p
k-P

D-O
D-o

Vehicle Dimensions

1,689
(66.50)

847
(33.35)

205
(8.19)

1,460
(57.48)

C-K, c-k

C-K, c-k

A-K, a-k

A-a

Vehicle Dimensions

*1 851 (33.50)

(Three-Dimensional Distance)

Symbol

Name

Hole dia.

Symbol

Name

Hole dia.

A, a

Front fender apron standard hole

10 (0.39)

L, l

Front fender installation nut

6 (0.24) nut

B, b

Front spring support hole-front

11 (0.43)

M, m

Hood hinge installation nut-rear

8 (0.31) nut

C, c

Cowl side panel standard hole

10 (0.39)

N, n

Front fender installation nut-rear

6 (0.24) nut

D

Cowl top panel center mark

O, o

Head light installation nut

6 (0.24) nut

E, e

Front side member working hole

18 (0.71)

P, p

Head light installation nut

6 (0.24) nut

F, f

Front side member working hole

18 (0.71)

Q, q

Head light installation nut

6 (0.24) nut

G, g

Radiator support standard hole

10 (0.39)

R, r

Head light installation nut

6 (0.24) nut

H, h

Radiator support standard hole

10 (0.39)

S, s

Head light installation hole

11 (0.43)

I, i

Front fender apron standard hole

10 (0.39)

T, t

Head light installation hole

10 (0.39)

J, j

Front side member standard hole

8 (0.31)

U, u

Head light installation hole

10 (0.39)

K, k

Front fender installation nut-front

6 (0.24) screw

BODY DIMENSION DRAWINGS

ENGINE COMPARTMENT

BODY DIMENSIONS

DI-3