Body - BO1 BODY BO2 BODY GENERAL INFORMATION GENERAL...

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Unformatted text preview: BO1 BODY BO2 BODY GENERAL INFORMATION GENERAL INFORMATION HANDLING PRECAUTIONS BO01M0D Taping When it is possible that the body or parts may be scratched during the operation, apply protective tape before starting work. Example: 1. Before starting work, apply protective tape to body surfaces around parts to be removed and installed. 2. Before prying parts loose with a screwdriver or scraper etc., apply protective tape to the tip of the tool to avoid scratching parts or painted surfaces of the body. Battery In order to prevent a short circuit while doing work on the electrical circuit such as disconnecting a connector, first turn off the ignition switch and disconnect the negative () terminal cable from the battery before starting work. HINT: When battery voltage is required for operation of a functioning part, connect the cable to the battery when needed, and promptly disconnect it when no longer necessary. CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the "LOCK" position and the negative () terminal cable is disconnected from the battery. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. Fitting Adjustments When removing and installing body panels which have a preload value, after installation refer to the page containing the installation adjustment methods, and make adjustments according to the required specifications. HINT: When making adjustments, do not completely loosen the bolts and nuts of the part being adjusted. Tighten them appropriately, and move the panels by hand to align them. BO3 BODY GENERAL INFORMATION ANTIRUST TREATMENT BO01N0B Antirust treatment used on the vehicle body includes body sealer, undercoat, rust inhibitor and paint. HINT: Refer to the Body Collision Damage Repair Manual for details of which parts have received antirust treatment. Body Sealer If the body sealer is damaged (peeling, cracks, etc.) during the operation, replace it with new body sealer. HINT: If body sealer gets on other parts, promptly wipe it off with a clean cloth dipped in a grease, wax and silicone remover. Undercoat If the undercoat is damaged during the operation, apply new undercoat. HINT: Cover the surrounding area with masking paper to avoid applying undercoat where it is not needed. Do not apply undercoat to high temperature parts such as the tailpipe, or to drive parts such as the drive shaft. Rust Inhibitor After removing and reinstalling hinges and outer panel parts, apply rust inhibitor to the parts. HINT: If rust inhibitor gets spilled on other parts, promptly wipe it off with a clean cloth dipped in a grease, wax and silicon remover. TouchUp Paint If a small scratch is made in the body surface, correct the scratch using touchup paint the same color as the body color. BO4 BODY GENERAL INFORMATION CLIPS BO01P0C The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If the clip is damaged during the operation, always replace it with a new clip. BO5 BODY GENERAL INFORMATION CLIPS (Cont'd) BO6 BODY GENERAL INFORMATION SRS (Supplemental Restraint System) BO01Q0E The LEXUS GS300 is equipped with an SRS (Supplemental Restraint System). Failure to carry out service operations in the correct sequence could cause the SRS to operate, possibly leading to a serious accident. When removing or installing of SRS parts and the yellow wire harness and connector for the airbag is necessary, refer to the precautionary notices in the RS section before performing the operation. S Work must be started after 90 seconds from the time the ignition switch is set to the LOCK position and the negative () terminal cable is disconnected from the battery. (The SRS is equipped with a backup power source so that if work is started within 90 seconds of dis connecting the negative () terminal cable from the battery, the SRS may deploy.) S To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. S Before repairs, remove the airbag sensors if shocks are likely to be applied to the sensors during repairs. S The front airbag sensor set bolt has been antirust treated. When the sensor is removed, always replace the set bolt with a new one. S If the front airbag sensors, center airbag sensor assembly, steering wheel pad or front passenger airbag assembly have been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. S Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. S Do not expose the front airbag sensors, center airbag sensor assembly, steering wheel pad or front passenger airbag assembly directly to hot air or flames. S The SRS wire harness is integrated with the cowl wire harness assembly. The wires for the SRS wire harness are encased in a yellow corrugated tube. All the connectors for the system are also a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it. (See RS section) S The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position; otherwise, cable disconnection and other troubles may result. Refer to RS section of this manual concerning correct steering wheel installation. S When removing or handling the steering wheel pad or front passenger airbag assembly, it should be placed with them top surface facing up. In this case, the twinlock type connector lock lever should be in the locked state and care should be taken to place it so the connector will not be damaged. (Storing the pad with its metallic surface up or the front passenger airbag assembly with the airbag door facing down may lead to a serious accident if the airbag inflates for some reason.) S Grease should not be applied to the steering wheel pad or the front passenger airbag assembly, and they should not be cleaned with detergents of any kind. S Store the steering wheel pad or the front passenger airbag assembly where the ambient temperature remains below 93C (200F), without high humidity and away from electrical noise. S Information labels are attached to the periphery of the SRS components. Follow the notices. S When the ignition switch is at ACC or ON and the SRS warning light remains on, the center airbag sensor assembly has detected a malfunction code. (See RS section) EQUIPMENT Cleaner Tape Drill Adhesive Doublestick tape Adhesive tape Hand riveter Torx driver Clip remover Hog ring pliers Torque wrench Drill bit, diam. 3.2mm (0.126in.) Hexagon wrench (6 mm) To avoid surface damage To avoid surface damage BO04W06 RECOMMENDED TOOLS SST (SPECIAL SERVICE TOOLS) PREPARATION BODY PREPARATION BO7 BO01R04 BO04V04 SSM (SPECIAL SERVICE MATERIALS) LUBRICANT MP grease Plastic sheet Item Capacity To avoid surface damage Classification BO01S0B EQUIPMENT (Cont'd) BO8 Wooden block or similar object Glass plate or similar object Putty spatula Brush Sealer gun Knife Shop rag BODY PREPARATION 0885000051 Adhesive (Super Special) or equivalent 0883300030 Three cement black or equivalent 0885000090 Windshield glass adhesive set No.45 or equivalent 0885000080 Windshield glass adhesive set No.35 or equivalent 0885000070 Windshield glass adhesive set No.15 or equivalent 0883300070 Adhesive 1324, THREE BOND 1324 or equivalent For tying both piano wire ends For mixing the adhesive on Outside moulding Windshield Moulding Back Window Moulding Windshield Back Window Glass Windshield Back Window Glass (3545C or 95113F) Windshield Back Window Glass (1535C or 5995F) Windshield Back Window Glass (015C or 3259F) Front Door Rear Door Luggage Compartment BO0SA03 BO9 BODY Ambient temperature 015C (3259F) 1535C (5995F) 3545C (95113F) Part No. 0885000070 0885000080 0885000090 Part Name Windshield glass adhesive set No. 15 Windshield glass adhesive set No. 35 Windshield glass adhesive set No. 45 V00250 PREPARATION 1. CHOOSE SUITABLE ADHESIVE SET BO0SB03 Use an adhesive set suitable for the ambient temperature. 2. CHECK ADHESIVE USABLE TIME After mixing main and hardening agents, finish glass installation within the specified time, as shown. Example: For glass installation in an ambient temperature of 25C (77F), apply adhesive set No. 35 within 45 minutes. 3. CHECK ADHESIVE HARDENING TIME After main and hardening agents are mixed, leak tests should be made only after the hardening time has elapsed. Example: The hardening time for adhesive set No. 35 with an ambient temperature of 25C (77F) is 2 1/2 hours. NOTICE: Do not drive the vehicle until at least double the hardening time has elapsed. BO88 BODY FRONT SEAT FRONT SEAT COMPONENTS BO0Q003 BO89 BODY FRONT SEAT COMPONENTS (Cont'd) BO90 BODY FRONT SEAT COMPONENTS (Cont'd) BO91 BODY FRONT SEAT FRONT SEAT REMOVAL BO1JZ01 Installation is in the reverse order of removal. 1. REMOVE THESE PARTS: (a) Front door scuff plate (b) Rear door scuff plate (c) Center pillar lower garnish (d) Front seat belt shoulder anchor Torque: 43 Nm (440 kgfcm, 32 ftlbf) 2. REMOVE FRONT SEAT BELT RETRACTOR (a) Disconnect the connectors. (b) Remove the 2 bolts and the retractor. Torque: Upper side: 19 Nm (195 kgfcm, 14 ftlbf) Lower side: 43 Nm (440 kgfcm, 32 ftlbf) 3. REMOVE HEADREST While pushing the lock button, pull up the headrest to remove it. 4. REMOVE SEAT TRACK COVERS HINT: Tape the screwdriver tip before use. Using a screwdriver, pry out 4 covers. 5. REMOVE FRONT SEAT (a) Remove the 4 bolts. Torque: 37 Nm (370 kgfcm, 27 ftlbf) (b) Disconnect the connector. (c) Remove the front seat with the seat belt. FRONT SEAT DISASSEMBLY BO10H03 1. REMOVE POWER SEAT SWITCH KNOB HINT: Tape the screwdriver tip before use. (a) Using a screwdriver, remove the slide knob. (b) Using a screwdriver, remove the reclining knob. 2. REMOVE FRONT SEAT CUSHION SHIELD (a) Remove the 5 screws. (b) Disconnect the connector. BO92 BODY FRONT SEAT (c) Remove the 2 screws and the seat belt guide. (d) Remove the shield. 3. REMOVE FRONT SEAT OUTER BELT (a) Remove the nut and the outer belt anchor. Torque: 43 Nm (440 kgfcm, 32 ftlbf) (b) Remove the outer belt. 4. REMOVE FRONT SEAT INNER BELT (a) Disconnect the connector and clamps. (b) Remove the bolt and the inner belt. Torque: 43 Nm (440 kgfcm, 32 ftlbf) 5. REMOVE FRONT SEAT CUSHION SHIELD NO. 1 Remove the 3 screws and the shield. 6. REMOVE FRONT SEATBACK BOARD (a) Remove the 2 screws. (b) Slide the board downward to remove it. BO93 BODY FRONT SEAT 7. REMOVE FRONT SEAT REGULATOR (a) Disconnect the connectors. (b) Remove the 4 bolts and the regulator. Torque: 18 Nm (185 kgfcm, 13 ftlbf) 8. (a) (b) (c) 9. REMOVE WIRE HARNESS Disconnect the connectors. Using a clip remover, remove the clamps. Remove the wire harness. REMOVE FRONT SEATBACK Remove the 4 bolts and the seatback. Torque: 18 Nm (185 kgfcm, 13 ftlbf) 10. REMOVE SEAT CUSHION COVER HINT: Tape the screwdriver tip before use. (a) Using a screwdriver, remove the hog rings. (b) Using a screwdriver, remove the hog rings. (c) Remove seat cushion cover. (d) w/ Seat Heater: Remove the seat heater. 11. REMOVE POWER SEAT SWITCH (a) Using a clip remover, remove the clamp. (b) Remove the 2 screws and the switch. BO94 BODY FRONT SEAT 12. REMOVE HEADREST SUPPORT Pull the headrest support to remove it. 13. REMOVE SEATBACK COVER HINT: Tape the screwdriver tip before use. (a) Using a screwdriver, remove the hog rings. (b) Remove the seatback cover. (c) w/ Seat Heater: Remove the seat heater. 14. REMOVE LUMBAR SUPPORT ADJUSTER Remove the 2 bolts and the adjuster. Torque: 18 Nm (185 kgfcm, 13 ftlbf) 15. REMOVE RECLINING ADJUSTER Remove the 3 bolts and the adjuster. Torque: 18 Nm (185 kgfcm, 13 ftlbf) 16. REMOVE RECLINING MOTOR (a) Remove the 3 screws and the motor with the hinge cover. (b) Remove the 3 screws and the motor from the hinge cover. BO95 BODY FRONT SEAT POWER SEAT REGULATOR DISASSEMBLY BO10J02 1. REMOVE SLIDE SCREW COVER LH HINT: Tape the screwdriver tip before use. (a) Remove the screw. (b) Using a screwdriver, remove the cover. (c) Remove the screw and the seat track cover LH. 2. REMOVE SLIDE SCREW COVER RH HINT: Tape the screwdriver tip before use. (a) Remove the screw. (b) Using a screwdriver, remove the cover. (c) Pull the seat track cover RH to remove it. 3. REMOVE SLIDE SCREW BRACKET Remove the 2 bolts and the bracket. Torque: 25 Nm (260 kgfcm, 19 ftlbf) 4. REMOVE FRONT VERTICAL MOTOR (a) Remove the 2 screws and the screw support bush. (b) Slide the seat track rearward. (c) Remove the bolt. Torque: 19 Nm (195 kgfcm, 14 ftlbf) (d) Remove the 2 nuts. Torque: 19 Nm (195 kgfcm, 14 ftlbf) BO96 BODY FRONT SEAT (e) Remove the nut and the front vertical motor support bracket. Torque: 4.4 Nm (45 kgfcm, 39 inlbf) (f) Using a hexagon wrench, remove the bolt. (g) Remove the motor from the support bracket. 5. REMOVE REAR VERTICAL MOTOR (a) Remove the 2 screws and the screw support bush. (b) Using a hexagon wrench, remove the bolt. Torque: 2.5 Nm (25 kgfcm, 22 in.lbf) (c) Remove the nut and the motor. Torque: 4.4 Nm (45 kgfcm, 39 in.lbf) 6. REMOVE SLIDE MOTOR (a) Using a hexagon wrench, remove the 4 bolts. Torque: 2.5 Nm (25 kgfcm, 22 in.lbf) (b) Remove the 2 nuts. Torque: 4.4 Nm (45 kgfcm, 39 in.lbf) (c) Slide the seat track rearward. (d) Remove the 3 bolts and the slide motor support bracket. Torque: Bolt A: 13 Nm (130 kgfcm, 9 ftlbf) Bolt B: 19 Nm (195 kgfcm, 14 ftlbf) (e) Remove the motor. BO97 BODY FRONT SEAT POWER SEAT REGULATOR ASSEMBLY BO10K02 Assembly is in the reverse order of disassembly. HINT: Before installing parts, coat them with MP grease while referring to the components. When installing the slide motor, tighten both the left and right seat slide screws equally. Torque the bolts while referring to the components. FRONT SEAT ASSEMBLY BO0QA04 Assembly is in the reverse order of disassembly. HINT: Using hog ring pliers, install the new hog ring. Before installing the reclining adjuster, align the matchmarks. If creases occur in the front seat, stretch out the creases by heating them with a dryer, etc. If the creases still cannot be removed, spray them lightly with a vaporizer before applying the hair dryer again. BO98 BODY REAR SEAT REAR SEAT COMPONENTS BO0QF02 BO99 BODY REAR SEAT COMPONENTS (Cont'd) BO100 BODY REAR SEAT REAR SEAT REMOVAL BO0QH04 1. REMOVE REAR SEAT CUSHION Pull up the front portion of the rear seat cushion. 2. (a) (b) (c) REMOVE REAR SEATBACK Disconnect the seat belt from the belt guide. Remove the 4 bolts. Pull up the seat back to remove it. REAR SEAT DISASSEMBLY BO10R02 1. 2. REMOVE HEADREST While pushing the lock button, pull up the headrest to remove it. REMOVE HEADREST SUPPORT Pull the headrest to remove it. 3. REMOVE SHOULDER BELT GUIDE Remove the 2 nuts and the guide. 4. REMOVE CENTER ARMREST HINT: Tape the screwdriver tip before use. (a) Using a screwdrier, remove 2 hog rings. (b) Remove the 2 nuts and the armrest. BO101 BODY REAR SEAT 5. REMOVE SEAT CUSHION COVER HINT: Tape the screwdriver tip before use. (a) Using a screwdriver, remove the hog rings. (b) Remove the seat cushion cover. 6. REMOVE SEATBACK COVER HINT: Tape the screwdriver tip before use. (a) Using a screwdriver, remove the hog rings. (b) Remove the seatback cover. REAR SEAT ASSEMBLY BO10S02 Assembly is in the reverse order of disassembly. HINT: Using hog ring pliers, install the new hog ring. If creases occur in the front seat, stretch out the creases by heating them with a dryer, etc. If the creases still cannot be removed, spray them lightly with a vaporizer before applying the hair dryer again. REAR SEAT INSTALLATION BO10T02 1. INSTALL REAR SEATBACK (a) Push down the seatback and install 4 bolts. Torque: 18 Nm (185 kgfcm, 13 ftlbf) (b) Connect the seat belt to the belt guide. 2. INSTALL REAR SEAT CUSHION HINT: Before installation, confirm that the rear seat belts are positioned. (a) Pass the seat cushion wire to seatback. (b) Push down the cushion to install the hook to the body panel. HINT: Confirm that the seat is installed firmly. ...
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This note was uploaded on 05/03/2010 for the course BUSINESS econ203 taught by Professor Shivaggo during the Spring '10 term at Columbia College.

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