Lexus RX300 (MCU15). 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.
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