Lexus RX300 (MCU15). Service manual — part 5

INTRODUCTION –

General Repair Instructions

IN-13

WRONG

OKAY

WRONG

Safety Glass

2. Plug welding should be done

with a MIG (Metal Inert Gas)
welder. Do not gas weld or
braze panels at areas other
than specified.

PRE-WELDING MEASUREMENTS
Always take measurements
before installing underbody or
engine components to insure
correct assembly. After installation,
confirm proper fit.

WELDING PRECAUTIONS
1. The number of welding spots

should be as follows.
Spot weld:

1.3 x No. of

manufacturer’s spots.
Plug weld:

More than No.

of manufacturer’s plugs.

POST-WELDING REFINISHING
1. Always check the welded

spots to insure they are
secure.

2. When smoothing out the

weld spots with a disc
grinder, be careful not to
grind off too much as this
would weaken the weld.

Body
Measurement
Diagrams

SPOT WELD LOCATIONS
Try to avoid welding over
previous spots.

New Spot
Locations

Old
Spot
Locations

Tip Cutter

SPOT WELDING PRECAUTIONS
1. The shape of the welding

tip point has an effect on
the strength of the weld.

2. Always insure that the

seams and welding tip are
free of paint.

INSTALLATION

INTRODUCTION –

General Repair Instructions

IN-14

Apply body sealer to the
required areas.

Apply anti-rust agent to
following sections.

D Inside of the hems of the

doors and hood.

D Around the hinges of the

doors and hood.

D Inside of the welded parts

with boxed cross-section.

UNDERCOAT
Apply undercoat to the underbody and
wheel housings.

Cartridge Type

Tube Type

Spray Gun

Undercoating
(Oil base)

Undercoating
(Water base)

Body Sealer, White (Cartridge Type)

Body Sealer, White (Tube Type)

Body Sealer, Black (Cartridge Type)

Parts Name

Parts Number

08839-00020

08839-00030

08839-00040

Rustop W (Aerosol)

Rustop W (1

ȏ Milky White)

Rustop W (18

ȏ Milky White)

Rustop B (1

ȏ Black)

Rustop B (18

ȏ Black)

Parts Name

Parts Number

08860-00200

08860-00210

08860-00230

08860-00220

08860-00240

Pastar UC (Oil Base)

Pastar UW (Water Base)

Pastar Gun (For thick application)

Parts Name

Parts Number

08836-00155

08836-00115

08836-00091

The above SSM or equivalent

The above SSM or equivalent

The above SSM or equivalent

ANTI-RUST TREATMENT

When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the re-
quirements of your country.

HINT:

For further details, see the description given in Section AR of this manual.

BODY SEALER

ANTI-RUST AGENT (WAX)

INTRODUCTION

– Rivet Removal and Installation

IN-15

Mandrel

Flange

øX mm
Rivet Size

Outer

Inner

Outer

Inner

Outer

Inner

Outer

Inner

Waterproof Seal

Mandrel

Charac-

teristics

External Appearance

Rivet size

Blade size

ø4 mm

ø4 mm

ø4.8 mm

ø5 mm

ø6.4 mm

ø6.5 mm

RIVET REMOVAL AND INSTALLATION

PARTS NAME AND VARIETY OF RIVET

Aluminum-Rivet

Steel-Rivet

Waterproof-Rivet

T-Rivet

Before installation

After installation

Before installation

After installation

Before installation

After installation

Before installation

After installation

D Small nonwaterproof

rivet

D No magnetic

adherence

D Small nonwaterproof

rivet

D Magnetic adherence

D Small waterproof

rivet

D Waterproof seal

D Large waterproof

rivet

D Mandrel sticks out

after installation

RIVET REMOVAL

1.

SELECTION OF CUTTING TOOL

Cutting tool

Note

Aluminum-Rivet
Steel-Rivet
T-Rivet

with ø6.4 mm

Drill blade

D Cutting can be done with drill blade or

rivet cutter for an aluminum-rivet with
ø4.8 mm.

D When a rivet cutter is used for an

aluminum-rivet (except ø4.8 mm), a
steel-rivet, or a T-rivet with ø6.4 mm, it is
possible that the drill will spin abnormally
damaging the rivet hole and breaking the

i

Waterproof special-Rivet

with ø4.0 mm

Drill blade with ø4.0 mm

rivet cutter.

Aluminum-Rivet

with ø4.8 mm

Waterproof-Rivet
with ø4.8 mm or ø6.0 mm

Rivet Cutter (P / N 09060-60350)

D When a ordinary cutter is used for a

waterproof-rivet with ø4.8 mm or
ø6.0 mm, the rivet can not be cut as it
spins with the cutter.

INTRODUCTION

– Rivet Removal and Installation

IN-16

Ponch (ø5 mm)

Mandrel

Drill

5 mm (0.20 in.)

Tape

Vacuum Hose

Tape

Continue drilling until taking away

2.

RIVET REMOVAL

(1)

T-Rivet with ø6.4 mm:
Using a ponch with ø5 mm, stamp out the mandrel.

(2)

Put tape around the drill blade 5 mm (0.20 in.) from
the tip to prevent damage to the rivet hole.

NOTE: Use of tape or a vacuum hose prevents damage to

the rivet hole.

(3)

Attach the drill blade or a rivet cutter to the drill.

(4)

Gently and vertically put the drill to the rivet, and cut
the rivets flange.

NOTE:
D While upward drilling, wear a protective glasses.
D If a drill is strongly pushed deeply in to a rivet, the

rivet can’t be cut as it spins together with the drill.

D Prizing the hole with a drill can lead to damage to

the rivet hole or the breaking of the rivet cutter.

D Take care as the cut rivet is hot.

(5)

Aluminum-Rivet and Waterproof-Rivet with ø4.8
mm or ø6.0 mm:
Even if flange is taken off, continue drilling and push
out remaining fragments with the drill.

(6)

Steel-Rivet:
If the flange is taken off, stop drilling and pull out the
remaining fragments with a pliers.

(7)

T-Rivet with ø6.4 mm:
If the flange is taken off, stop drilling and push out
the remaining fragments with a ponch with ø5 mm
or pull out the remaining fragments with pliers.