Lexus RX300 (MCU15). Manual — part 22

REAR 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

Positioning
Tape

Installation
Position

Braze

Braze

BODY PANEL REPLACEMENT

RE-34

1.

Bofore 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

Positioning
Tape

Body Sealer

Braze

Braze

Body Sealer

— 4

— 4

— 4

— 4

BODY PANEL REPLACEMENT

RE-35

INSTALLATION

mm

in.

10

0.39

ROCKER OUTER PANEL (ASSY)

REMOVAL

1.

Cut and join the parts at the locations as
shown above.

HINT:

Take care not to damage the internal rein-

forcement of the center body pillar.

2.

Remove the remaining foamed material from
the vehicles side.

70 mm

Cut and Join Location

Cut and Join Location
(Cut Location for
Supply Parts)

Cut and Join Location
(Cut Location for
Supply Parts)

[Cut and Join Location]

[Cut and Join Location]

[Cut and Join Location]

— 16

— 24

— 2

— 9

BODY PANEL REPLACEMENT

RE-36

mm

in.

70

2.76

1.

Temporarily install the new parts and check
the fit of the front door and rear door.

2.

After installing the new parts, apply foamed
materials.

A – A
[Foamed Material
Application Areas]

Butt Weld

A

A

Butt Weld

Butt Weld

— 21

— 12

— 2

— 32

BODY PANEL REPLACEMENT

RE-37

INSTALLATION