1991 LEXUS SC300 roof

BO6848
E-e
1,304
(51.34) 1,500
(69.06)F-fVehicle Dimensions Left
eRight
G-g
1,511
(59.49) H-h
1,511
(59.49) I-i
1,083
(42.64) 1,363
(53.66)J-j
1,503
(59.17)K-k
E-f
or
e-F
1,536
(60.47) 1,577
(62.09)E-g
or
e-G
1,694
(66.69)E-h
or
e-H
1,587
(62.48)E-j
or
e-J
1,909
(75.16)F-j
or
f-J
HINT: For symbols, Capital letters indicate
right side of vehicle, small letters indicate
left side of vehicle (See from rear).
F-k
or
f-K
1,945
(76.57) G-h
or
g-H
1,665
(65.55) H-i
or
h-I
1,568
(61.73) 1,595
(62.80)H-j
or
h-J
1,490
(58.66)
mm (in.)J-k
or
j-K
(Three-Dimensional Distance)
Hote dia.
Name
Rocker panel adjoining portion mark
Rocker panel adjoining portion mark
Roof side rail adjoining portion mark
Quarter panel adjoining portion mark
Quarter panel adjoining portion mark
Symbol
G, g
H, h
I, i
J, j
K, k
Hole dia.
10 (0.39) screw
10 (0.39) screw
Name
Roof panel/Front body pillar adjoining portion
Cowl top panel/Front body pillar adjoining portion
Front door hinge installation nut
D, d Front door hinge installation nut
Front body pillar adjoining portion mark
Front body pillar adjoining portion mark
Symbol
A, a
B, b
C, c
E, e
F, f
BODY OPENING AREAS (Side View)
BODY DIMENSIONSDI-8
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BO6849
mm (in.)
(Three-Dimensional Distance)
Hole dia.18 (0.71)
Name
Opening trough/Lower back panel adjoining portion
Upper back panel center mark
Rear floor side member standard hole
Symbol
P, pQ
R, r
Hole dia.
Name
Roof panel/Quarter panel adjoining portion
Quarter panel/Upper back panel adjoining portion
Quarter panel/Upper beck panel adjoining portion
Opening trough/Quarter panel adjoining portion
Symbol
L, l
M, m
N, n
O, o
BODY OPENING AREAS (Rear View)
BODY DIMENSIONSDI-9
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mm in.150
200
300 5.91
7.87
11.81
Replacement parts
QUARTER PANEL
HOW TO USE THIS MANUAL
Each repair method description provided in Section RE of this manual com\
prises two pages, divided into
2 blocks (REMOVAL AND INSTALLATION) and includes illustrations to facilitate body repair.
BODY PANEL REPLACEMENT-Rear Body Components
RE-40
QUARTER PANEL (CUT)REMOVAL Cut and Join Location
200 - 300 mm
150 - 200 mm
[Cut and Join Location]
Cut and Join Location
(Cut Location for Supply Parts)
1. Cut and join the parts at the location shown above.
HINT: Make incision and bend the roof drip channel at the upper part of the cur and join location.
REPLACEMENT PARTS AND METHOD
(CUT)
Replacement method(ASSY) Assembly replacement . . . . .
(CUT) Major cutting (less than 1/2 of parts used) . . . . . .
(CUT-H) Half cutting (about 1/2 of parts used) . . . .
(CUT-P) Partial cutting (most of parts used) . . . .
PARTS LOCATION
REMOVAL DIAGRAM
Describes in detail removal of the damaged parts involving repair by cut\
ting.
REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
INTRODUCTIONIN-2
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Front
Fender Area
Area from the Front Fender Apron
to the Cowl Side Member


Before repairing the body, remove the airbag sensors if, during repair, shocks are likely to, be applied
to the sensors due to vibrations of the body or direct tapping with tool\
s or other parts.

Do not expose the airbag sensors or the steering wheel pad directly to h\
ot air or flames.
NOTICE:
1) The maximum ambient temperature tolerance is 120
°C (248°F) for the front airbag sensor, 105°C
(221
°F) for the center airbag sensor assembly and 93°C (200°F) for the steering wheel pad. If it is
possible that the ambient temperature may reach or exceed the temperatur\
e limit, remove the sen- sors and the steering wheel pad from the vehicle or protect them with a \
hot insulation material be-fore starting work.
2) Prior to welding, remove adjacent airbag sensors or the steering wheel p\
ad from the vehicle or protect them with fire-proof covers.

If the front fender or periphery of the vehicle is damaged, visually ins\
pect for damage to the front air-
bag sensor using the inspection procedures described in section AB of th\
e repair manual for the rele-
vant model year.
Also check that the dimensions of the body where the front airbag sensor\
is installed match those in
the body dimension drawings.
(The airbag may malfunction; or may not work, if the mounting angle or \
dimensions of the sensor
mount are not correct.)

If the vehicle is damaged, visually inspect for damage to the steering w\
heel pad using the inspection
procedures described in section AB of the repair manual for the relevant\
model year.

When removing the steering wheel pad or handling a new steering wheel pa\
d, keep the pad upper
surface facing upward. Also, lock the lock lever of the twin lock type c\
onnector at the rear of the pad
and take care not to damage the connector.
(Storing the pad with its metallic surface up may lead to a serious acc\
ident if the airbag inflates for
some reason.)

Store the steering wheel pad where the ambient temperature remains below\
93 °C (200 °F), without
high humidity and away from electrical noise.

Be careful not to let painting materials contact the airbag sensors.

Information labels are attached to the periphery of the airbag component\
s. Follow the NOTICES.
INTRODUCTIONIN-7
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Fuel Pump ECUAuto Antenna Motor and Relay
Power Seat ECU
(For Passenger's Seat)
Power Seat ECU
(For Driver's Seat) CD Automatic Changer
Wireless Door Lock ECU
Moon Roof Control Relay
Locations of ECUs (Cont'd)
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to th\
e ECUs.


Before starting electric welding operations, disconnect the negative (-\
) terminal cable from the battery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the\
contents memorized by each
memory system. Then when work is finished, reset the clock and audio sys\
tems as before.
When the vehicle has tilt and telescopic steering, power seat and outsid\
e rear view mirror, which are all
equipped with memory function, it is not possible to make a record of th\
e memory contents.
So when the operation is finished, it will be necessary to explain this \
fact to the customer, and request
the customer to adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80 °C (176 °F).
NOTICE: If it is possible the ambient temperature may reach 80°C (176°F) or, more, remove the ECUs
from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them\
.
5. COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to\
the body panels.
Strictly observe the following precautions to prevent damaging these com\
ponents and the body panels
during handling.

Before repairing the body panels, remove their adjacent components or ap\
ply protective covers over
the components.

Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body to
ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, \
hoses, etc., on the reverse side.
INTRODUCTIONIN-9
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GENERAL REPAIR INSTRUCTIONS
Work Precautions
SAFETY
1. Before performing repair work, checkfor fuel leaks. If a leak is found, be sure
to close the opening totally.
2. If it is necessary to use a frame in the area of the fuel tank, first remove the
tank and plug the fuel line.
VEHICLE PROTECTION
When welding, protect the
painted surfaces, windows,
seats and carpet with heat
resistant, fire-proof covers.
SAFETY
Never stand in direct
line with the chain when
using a puller on the
body or frame, and be
sure to attach a safety
cable.
WRONG
Glass Cover
Safety Cable Seat Cover
WRONG
SAFETY WORK CLOTHES
HAND TOOLS
Keeping your hand tools in
neat order improve your
work efficiency.
In addition to the usual mechanic's wear, cap and safety shoes,
the appropriate gloves, head protector, glasses, ear plugs, face
protector, dust-prevention mask, etc. should be worn as, the
situation demands.
Dust-
Prevention
Mask Welder's
Glasses
Ear
Plugs Body
Mechanic
Stand
Face
Protector
Head
Protector
Eye
Protector
Welder's
Gloves
Safety
Shoes
INTRODUCTIONIN-10
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The 1 UZ±FE engine has 8±cylinders in a V±arrangement at a bank an\
gle of 905. From the front of the RH
bank cylinders are numbered 2 ± 4 ± 6 ± 8, and from the front of t\
he LH bank cylinders are 1 ± 3 ± 5 ± 7.
The crankshaft is supported by 5 bearings inside the crankcase. These beari\
ngs are made of a copper and
lead alloy.
The crankshaft is integrated with 8 weights for balance. Oil holes are plac\
ed in the center of the crankshaft
to supply oil to the connecting rods, bearing, pistons and other component\
s.
The ignition order is 1 ± 8 ± 4 ± 3 ± 6 ± 5 ± 7 ± 2. T\
he cylinder head is made of alminum alloy, with a cross
flow type intake and exhaust layout and with pent±roof type combustion chambers. The spark plugs are
located in the center of the combustion chambers.
At the front and rear of the intake manifold, a water passage has been p\
rovided which connects the RH
and LH cylinder heads.
Exhaust and intake valves are equipped with irregular pitch springs made\
of special valve spring carbon
steel which are capable of functioning at all engine speeds.
The RH and LH intake camshaft are driven by a timing belt, and a gear on\
the intake camshaft engages
with a gear on the exhaust camshaft to drive it. The cam journal is supp\
orted at 5 (intake) or 4 (exhaust)
places between the valve lifters of each cylinder and on the front end o\
f the cylinder head. Lubrication of
the cam journals and gears is accomplished by oil being supplied through th\
e oiler port in the center of the
camshaft.
Adjustment of the valve clearance is done by means of an outer shim type\
system, in which valve adjusting
shims are located above the valve lifters. This permits replacement of the sh\
ims without removal of the
camshafts.
Pistons are made of high temperature±resistant aluminum alloy, and a depression is built into the piston
head to prevent interference with the valves.
Piston pins are the full±floating type, with the pins fastened to neither the piston boss nor the connecting
rods. Instead, snap rings are fitted on both ends of the pins, preventing the\
pins from falling out.
The No.1 compression ring is made of steel and the No.2 compression ring\
is made of cast iron. The oil
ring is made of a combination of steel and stainless steel. The outer diamet\
er of each piston ring is slightly
larger than the diameter of the piston and the flexibility of the rings allows them to hug the cylinder walls
when they are mounted on the piston. Compression rings No.1 and No.2 work to\
prevent gas leakage from
the cylinder and the oil ring works to scrape oil off the cylinder walls to prevent it from entering the combus-
tion chambers.
The cylinder block is made of aluminum alloy with a bank of 90 5. Cast iron cylinders are installed inside
the cylinder block. It has 8 cylinders which are approximately twice the le\
ngth of the piston stroke. The top
of each cylinder is closed off by the cylinder head and the lower end of the cylinders becomes the crank-
case, in which the crankshaft is installed. In addition, the cylinder block c\
ontains a water jacket, through
which coolant is pumped to cool the cylinders.
The No.1 and No.2 oil pans are bolted onto the bottom of the cylinder bl\
ock. The No.1 oil pan is made of
aluminum alloy. The No.2 oil pan is an oil reservoir made of pressed steel sheet. An o\
il level sensor is
installed in the No.1 oil pan (If oil level drops below a set level, a warning light\
s up.). And oil pan baffle plate
keeps sufficient oil in the bottom of the No.2 oil pan even when the vehicle is t\
ilted. This dividing plate also
prevents the oil from marking waves when the vehicle is stopped suddenly\
and the oil shifts away from the
oil pump suction pipe.
Plastic region tighten bolts are used for the cylinder head, main bearin\
g cap and connecting rod.
EG±4
±
1UZ±FE ENGINE ENGINE MECHANICAL
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The 1 UZ±FE engine has 8±cylinders in a V±arrangement at a bank an\
gle of 905. From the front of the RH
bank cylinders are numbered 2±4±6±8, and from the front of the LH b\
ank cylinders are numbered 1 ±3±5±7.
The crankshaft is supported by 5 bearings specified by the inside of the cr\
ankcase. These bearings are made
of a copper and lead alloy. The crankshaft is integrated with 8 weights which are cast along with it\
for balancing. Oil holes are built
into the center of the crankshaft for supplying oil to the connecting ro\
ds, pistons and other components. The ignition order is 1±8±4±3±6±5±7±2. The cylinder\
head is made of aluminum alloy, with a cross flow
type intake and exhaust layout and with pent±roof type combustion chambers. The spark plugs are loca\
ted in
the center of the combustion chambers.
At the front and rear of the intake manifold, a water passage has been p\
rovided which connects the RH
and LH cylinder heads. Exhaust and intake valves are equipped with irregular pitch springs made\
of special valve spring carbon
steel which are capable of following no matter what the engine speed.
The RH and LH intake camshafts are driven by a single timing belt, and a ge\
ar on the intake camshaft en-
gages with a gear on the exhaust camshaft to drive it. The camshaft jour\
nal is supported at 5 (intake) or 4 (ex-
haust) places between the valve lifters of each cylinder and on the front end of the cylinder \
head. Lubrication
of the cam journal gear is accomplished by oil being supplied through the \
oiler port in the center of the camshaft. Adjustment of the valve clearance is done by means of an outer shim type\
system, in which valve adjusting
shims are located above the valve lifters. This permits replacement of the sh\
ims without removal of the cam-
shafts. Pistons are made of high temperature±resistant aluminum alloy, and a depression is built into the piston
head to prevent interference with valves.
Piston pins are the full±floating type, with the pins fastened to neither the piston boss nor the connecting
rods. Instead, snap rings are fitted on both ends of the pins, preventing the\
pins from falling out. The No.1 compression ring is made of steel and the No.2 compression ring\
is made of cast iron. The oil
ring is m ade of a combination of steel and stainless steel. The outer diameter of\
each piston ring is slightly larger
than the diameter of the piston and the flexibility of the rings allows them\
to hug the cylinder walls when they
are mounted on the piston. Compression rings No.1 and No.2 work to prevent \
the leakage of gas from the cylin-
der and the oil ring works to scrape oil off the cylinder walls to prevent it from entering the combustion chamber. The cylinder block is made of aluminum alloy with a bank angle of 90 5. Cast iron cylinders are installed
inside the cylinder block. It has 8 cylinders which are approximately twice the length of th\
e piston stroke. The
top of each cylinder is closed off by the cylinder heads and the lower end of the cylinders becomes the crank-
case, in which the crankshaft is installed. In addition, the cylinder bl\
ock contains a water jacket, through which
coolant is pumped to cool the cylinders. The No.1 and No.2 oil pans are bolted onto the bottom of the cylinder block\
. The No.1 oil pan is made of
aluminum alloy. The No.2 oil pan is an oil reservoir made of pressed steel sheet. An o\
il level sensor is installed
in the No.1 oil pan (If the oil level drops below a set level, a warnin\
g light lights up.). A oil pan baffle plate keeps
sufficient oil in the bottom of the No.2 oil pan even when the vehicle is tilted. \
This dividing plate also prevents
the oil from making waves when the vehicle is stopped suddenly and the oil \
shifts away from the oil pump suction
pipe. Plastic region tightening bolts are used for the cylinder head, main bearing ca\
p and connecting rod.
EM±4
±
ENGINE MECHANICAL Operation
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