Page 1225 of 4087

BODY PANEL UNDERCOATING AREAS
HINT:1. First wipe off any dirt, grease or oil with a rag soaked in a grease, wa\
x and silicone remover.
2. Cover the surrounding areas with masking paper to avoid coating unnecess\
ary areas. If other areas are accidently coated, wipe off the coating immediately.
3. Apply the first coating of undercoat to all welded areas and panel joint\
s, then apply a second coat over the entire area.
4. Do not coat parts which become hot, such as the tailpipe, or moving part\
s, such as the propeller shaft.
5. Besides the locations described below, apply undercoating to all weld points under the body to insure corrosion prevention.
6. Be sure to seal the edge of the flange of the member and bracket with un\
dercoating. 7. If undercoat is damaged by peeling, cracks, etc, be sure to repair as ne\
cessary.
REFERENCE: Referring to the notes above, undercoating should be applied \
according to the specifications
for your country.
ANTI-RUST TREATMENTAR-8
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Page 1226 of 4087
BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION
AREAS
HINT:1. Whenever adjusting the doors and hoods, apply anti-rust agent (wax) ar\
ound the hinges.
2. Even if partially repairing a part, apply anti-rust agent (wax) over t\
he entire application area of the part.3. Wipe off the anti-rust agent immediately with a rag soaked in a grease, w\
ax and silicone remover, if accidently applied to other areas.
Luggage Compartment Door
Hood Front DoorFront Door Hinge
Front Body Pillar
A-A
ANTI-RUST TREATMENTAR-9
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Page 1227 of 4087
HINT: Apply anti-chipping paint to a thickness of about 300 microns.
BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS
HINT:1. Anti-chipping paint should be applied to some areas before the second coat and to oth\
ers after the top coat.
2. If other areas are accidentally coated, wipe of the paint immediately wi\
th a rag soaked in a grease, wax and silicone remover.
Urethane Bumper
Urethane Bumper
Anti-Chipping PaintUrethane Bumper
Extension
Door Panel
Protector Anti-Chipping Paint
A-A ' Cross Section B-B' Cross Section
Apply anti-chipping paint after the top coat.
ANTI-RUST TREATMENTAR-10
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Page 1228 of 4087
mm in. 2
10
13
15
18 0.08
0.39
0.51
0.59
0.71
10
f
18f
18f
Assembly Mark Assembly
Mark
STANDARD BODY MARKS
Center Mark
(15
f)
Assembly Mark Center Mark
2R
18
f
Assembly Mark
18
f
13f
Assembly Mark
BODY PANEL CONSTRUCTIONCN-2
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Page 1229 of 4087
REFERENCE:
HIGH-STRENGTH STEEL (HSS) PARTS
Generally, High-Strength Steel (HSS) is that which has an intensity value of at\
least 35 kgf/mm2 (343 MPa),
and distinguished from mild steel.
The handling of HSS is the same as for mild steel, but the following sho\
uld 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 eas\
ily 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 t\
he drill during use.
3. Panel Welding: Panel welding procedures for HSS are exactly the same as for mil\
d 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 CONSTRUCTIONCN-3
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Page 1230 of 4087

Ordinary Galvannealed
Steel SheetZinc-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 meta\
l 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. E\
xcelite 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 accord\
ing 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 s\
teel sheet, but the following
should be observed.
1. Panel welding: The paint as well as the zinc portion must be removed com\
pletely 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 CONSTRUCTIONCN-4
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Page 1231 of 4087

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 atracking 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 HoleTape Measure
Along Body
Surface Front Suspension Member Rear Side
Upper Installation Hole Master Gauge
Pointer
Pointer LoosenessBody 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 DIMENSIONSDI-2
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Page 1232 of 4087

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-s187
(7.36)
1,215
(47.83)
D-Q
D-q
J-R
j-r1,192
(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, oHead light installation nut
6 (0.24) nut
E, e Front side member working hole
18 (0.71)P, pHead light installation nut
6 (0.24) nut
F, f Front side member working hole
18 (0.71)Q, qHead light installation nut
6 (0.24) nut
G, g Radiator support standard hole
10 (0.39)R, rHead light installation nut
6 (0.24) nut
H, h Radiator support standard hole
10 (0.39)S, sHead 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 DIMENSIONSDI-3
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