Lexus RX300 (MCU15). Service manual - part 13

BODY PANEL CONSTRUCTION 

– High-Strength Steel Parts

CN-2

: High Strength Sheet Steel

HIGH-STRENGTH STEEL (HSS) PARTS

Generally, High-Strength Steel (HSS) is that which has an intensity value of at 35 kgf / mm

2

 (343 MPa), and

distinguished from mild steel.

The handling of HSS is the same as for mild steel, but the following should 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 easily 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 the drill use.

3.

Panel Welding:

Panel welding procedures for HSS are exactly the same as for mild steel. Plug weld-

ing should be done with MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other
than specified.

Fe-Zn Alloy (Iron Rich) improves
paint quality

Zn-Fe Alloy (Zinc Rich) improves
rust-resistant performance

Base
Metal

Double Layered Zinc-Iron Galvannealed Sheet Steel

Zn-Fe Alloy
(Zinc-Rich)

Base Metal

Galvannealed Sheet Steel

BODY PANEL CONSTRUCTION –

Rust-Resistant Sheet Steel Parts

CN-3

RUST-RESISTANT SHEET STEEL PARTS

Rust-Resistant Sheet Steel have zinc, tin or aluminum etc, plating over the base metal surface in order to
improve the corrosion resistance of the sheet metal. This sheeting is used on areas that require anti-corro-
sive abilities but there is no need to distinguish the differences between rust resistant sheet steel and ordi-
nary sheet steel in body repair.
Body panels on TOYOTA models are made of two different melted galvannealed sheet steel. The ordinary
melted galvannealed sheet has a zinc plating over the base metal surface and when heated a zinc-iron alloy
plating. The zinc-iron double layered galvannealed sheet has a iron rich and another zinc-rich layer above
the sheet steel. These 2 layers improve paint adhesion. These two melted galvannealed sheet steels are
used selectively according to need.

The handling of Rust-Resistant Sheet Steel is the same as for ordinary sheet steel, but the following should
be observed.

1.

Panel Welding:

The paint as well as the zinc portion must be removed completely 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).

 : Galvannealed Sheet Steel

BODY PANEL CONSTRUCTION –

Rust-Resistant Sheet Steel Parts

CN-4

RE

RE-1

BODY PANEL
REPLACEMENT

Page

RADIATOR UPPER SUPPORT (ASSY)

RE-2

. . . . . . . . . . . . . . . . . . 

RADIATOR SIDE SUPPORT (ASSY)

RE-4

. . . . . . . . . . . . . . . . . . . . 

RADIATOR SUPPORT UPPER BRACE (ASSY)

RE-6

. . . . . . . . . . . 

FRONT CROSSMEMBER (ASSY)

RE-8

. . . . . . . . . . . . . . . . . . . . . . 

RADIATOR SUPPORT (ASSY)

RE-10

. . . . . . . . . . . . . . . . . . . . . . . . . 

FRONT FENDER FRONT APRON (ASSY)

RE-12

. . . . . . . . . . . . . . . 

FRONT APRON TO COWL SIDE UPPER

MEMBER (ASSY)

RE-14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

FRONT FENDER APRON (ASSY)

RE-16

. . . . . . . . . . . . . . . . . . . . . . 

FRONT PANEL UPPER RENFORCEMENT

BRACE (ASSY)

RE-18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

FRONT SIDE MEMBER (CUT-P)

RE-20

. . . . . . . . . . . . . . . . . . . . . . . . 

FRONT SIDE MEMBER (ASSY)

RE-22

. . . . . . . . . . . . . . . . . . . . . . . . 

FRONT BODY PILLAR (CUT)

RE-24

. . . . . . . . . . . . . . . . . . . . . . . . . . 

CENTER BODY PILLAR (CUT)

RE-29

. . . . . . . . . . . . . . . . . . . . . . . . . 

FRONT DOOR OUTER PANEL (ASSY)

RE-32

. . . . . . . . . . . . . . . . . . 

REAR DOOR OUTER PANEL (ASSY)

RE-34

. . . . . . . . . . . . . . . . . . . 

ROCKER OUTER PANEL (ASSY)

RE-36

. . . . . . . . . . . . . . . . . . . . . . . 

QUARTER PANEL (CUT)

RE-38

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

QUARTER PANEL (CUT-P)

RE-42

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

QUARTER WHEEL HOUSING OUTER PANEL (ASSY):

Right Side

RE-44

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Left Side

RE-46

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

BODY LOWER BACK PANEL (ASSY)

RE-48

. . . . . . . . . . . . . . . . . . . 

BACK DOOR OPENING TROUGH, REAR

BODY REAR SIDE CORNER PANEL (ASSY)

RE-50

. . . . . . . . . . 

ROOF SIDE INNER REAR PANEL (ASSY)

RE-52

. . . . . . . . . . . . . . . 

ROOF SIDE INNER LOWEL PANEL, ROOF SIDE

INNER FRONT PANEL (ASSY)

RE-54

. . . . . . . . . . . . . . . . . . . . . . 

REAR FLOOR CENTER CROSSMEMBER (ASSY)

RE-56

. . . . . . . . 

REAR FLOOR PAN (ASSY)

RE-58

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

REAR FLOOR SIDE PANEL (ASSY)

RE-60

. . . . . . . . . . . . . . . . . . . . . 

REAR FLOOR SIDE REAR MEMBER (ASSY)

RE-62

. . . . . . . . . . . . 

REAR FLOOR NO.2 CROSSMEMBER (ASSY)

RE-64

. . . . . . . . . . . 

ROOF PANEL (ASSY)

RE-66

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .