Lexus - IS 250 - Workshop Manual - 2010 - 2010

L-SB-0149-10 November 16, 2010 Convertible Top Component Rattle Service Category Vehicle Exterior Section Sliding Roof/Convertible Market USA Applicability YEAR(S) MODEL(S) 2010 IS250C, IS350C ADDITIONAL INFORMATION Introduction Some 2010 model year IS 250C and IS 350C vehicles may exhibit a rattle noise condition from convertible top components. This condition may occur more frequently on rough driving surfaces. A comprehensive alignment and insulation procedure has been developed to improve this condition. Parts Information PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY 90201-11011 Same Washer, Plate (1.0 mm Shim) 4 08231-00810 Same Interior Noise Kit 1 Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 BD1095 Convertible Top Alignment and Insulation Procedure 8.6 63203-53030 91 43 APPLICABLE WARRANTY • This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle’s in-service date. • Warranty application is limited to occurrence of the specified condition described in this bulletin. © 2010 Lexus, a division of Toyota Motor Sales, USA Page 1 of 48 L-SB-0149-10 November 16, 2010 Page 2 of 48 Convertible Top Component Rattle Required Tools & Equipment PART NUMBER QTY 00002-06000-01 1 SPECIAL SERVICE TOOLS (SST) Plastic Pry Tool Set* * Essential SST. NOTE Additional SSTs may be ordered by calling 1-800-933-8335. REQUIRED MATERIAL QUANTITY Blackboard Chalk As Needed White Paper Correction Fluid As Needed Auto Refinish Masking Tape As Needed TSIB Overview This TSIB contains 4 procedures that must all be performed to correct the identified noises from the convertible top. A: Metal Top Roof Panel Alignment B: Package Tray Alignment & Insulation C: Interior Component Insulation D: Final Assembly & Repair Confirmation Preparation 1. Confirm condition. If possible, have customer fill out the “Interior Noise Concerns Questionnaire”. Refer to the Technical Information System (TIS), Reference Information – Technician Group – “Interior Noise Concerns Questionnaire” NOTICE If previous adjustments or repair attempts have been performed, the components need to be returned to their original position(s). This is extremely important for the header lock latch and header lock pin assembly. © 2010 Lexus, a division of Toyota Motor Sales, USA November 16, 2010 L-SB-0149-10 Page 3 of 48 Convertible Top Component Rattle Preparation (Continued) Figure 1. 3 2 1 4 1 Front Windshield Header 3 Roof Panel No. 1 to No. 2 Adjuster 2 Roof Panel No. 1 4 Header Lock NOTE Part descriptions in this TSIB may differ from the Repair Manual and Parts Catalog. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 4 of 48 Convertible Top Component Rattle Preparation (Continued) Figure 2. 4 1 3 2 5 1 Roof Panel No. 2 4 U-shaped Hook and Eccentric 2 Back Window Frame Assembly 5 Package Tray Assembly 3 2/3 Lock 2. Follow Repair Manual instructions to remove the components listed below. Refer to TIS, 2010 model year IS 250C/350C Repair Manual: A. Vehicle Exterior – Sliding Roof/Convertible – “Sliding Roof/Convertible: Metaltop Roof: Removal” B. Vehicle Interior – Seat – “Seat: Rear Seat Assembly: Removal” C. Vehicle Interior – Interior Panels/Trim – “Interior Panels/Trim: Roof Headlining (for Front Side): Removal” HINT A, B, and C above correspond to the sections cross referenced in the following table, “Components to Be Removed”. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 5 of 48 Convertible Top Component Rattle Preparation (Continued) COMPONENTS TO BE REMOVED REPAIR MANUAL SECTION CROSS REFERENCE (SEE PAGE 4) Under Package Tray Trim Cover A: Step 14 Package Tray Trim Cover A: Step 15 No. 1 Roof Side Rail Garnish LH A: Step 20 No. 1 Roof Side Rail Garnish RH A: Step 21 Roof Headlining Assembly (for Center) A: Step 22 Front Side Rail Spacer LH A: Step 23 Front Side Rail Spacer RH A: Step 24 No. 3 Roof Side Rail Garnish LH A: Step 32 No. 3 Roof Side Rail Garnish RH A: Step 33 Roof Headlining Assembly (for Rear Side) A: Step 34 Rear Side Rail Spacer LH A: Step 35 Rear Side Rail Spacer RH A: Step 36 Roof Side Inner Garnish LH A: Step 44 Roof Side Inner Garnish RH A: Step 45 Rear Roof Headlining Garnish A: Step 52 Tonneau Cover Assembly A: Step 65 NOTICE Temporarily reinstall the tonneau cover board in the sensor bracket so the top will operate. Tonneau Cover Hook Holder A: Step 66 Sliding Roof Guide Rail Stopper A: Step 67 NOTICE Reinstall 1 rubber stopper before opening roof to avoid damage to roof top components. Front Luggage Compartment Trim Cover A: Step 68 Roof Side Inner Garnish Cover LH A: Step 90 Roof Side Inner Garnish Cover RH A: Step 92 © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 6 of 48 Convertible Top Component Rattle Preparation (Continued) COMPONENTS TO BE REMOVED REPAIR MANUAL SECTION CROSS REFERENCE (SEE PAGE 4) Rear Roof Side Rail Garnish LH A: Step 91 Rear Roof Side Rail Garnish RH A: Step 93 Rear Seat Cushion Assembly LH A: Step 94 Rear Seat Cushion Assembly RH A: Step 95 Rear Seatback Assembly With Rear Console Box Assembly A: Step 96 Door Scuff Plate Assembly LH A: Step 97 Door Scuff Plate Assembly RH A: Step 101 Lap Belt Outer Anchor Cover RH A: Step 102 Lap Belt Outer Anchor Cover LH A: Step 98 Package Tray Trim Garnish LH B: Step 2 Package Tray Trim Garnish RH B: Step 3 Front Door Opening Trim Cover LH C: Step 3 Front Pillar Garnish LH C: Step 4 Front Door Opening Trim Cover RH C: Step 6 Front Pillar Garnish RH C: Step 7 Map Light Assembly C: Step 8 © 2010 Lexus, a division of Toyota Motor Sales, USA November 16, 2010 L-SB-0149-10 Page 7 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment 1. Completely close the roof. 2. Loosen the set screw holding the panel No. 1 to panel No. 2 adjustment screw on the left and right side of the roof. Figure 3. Figure 4. 2 4 1 Front 2 Roof Panel No. 2 3 Roof Panel No. 1 4 Adjustment Screw 5 Measurement Point 6 Set Screw 5 1 6 3 3. Loosen the roof panel No. 1 to panel No. 2 adjustment screw until the adjustment screw is not contacting the roof panel. Figure 5. . © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 4. Open the roof halfway. Figure 6. . 5. Remove the rubber stoppers on both sides. Figure 7. 1 1 Rubber Stopper 6. Completely close the roof. © 2010 Lexus, a division of Toyota Motor Sales, USA Page 8 of 48 L-SB-0149-10 November 16, 2010 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 7. Manually release the 2/3 Lock (turn counterclockwise approx. 360◦). Click Here to Watch Supplemental Video Figure 8. 8. Manually release the header lock (turn counterclockwise approx. 360◦). Figure 9. © 2010 Lexus, a division of Toyota Motor Sales, USA Page 9 of 48 L-SB-0149-10 November 16, 2010 Page 10 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 9. Attach tape on the roof panels (between the roof header and roof panel No. 1) and make a mark on each piece to measure the distance (in mm) between each panel (A). Driver Side: A = _________ mm Passenger Side: A = ________ mm Figure 10. A A Measure in mm for Driver and Passenger Side 10. Manually lock the header lock (turn clockwise approx. 360◦). Click Here to Watch Supplemental Video Figure 11. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 11 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 11. Manually lock the 2/3 Lock (turn clockwise approx. 360◦). Figure 12. 12. Measure the same location as in step 9 on both sides to get measurement B. Figure 13. B B Measure in mm for Driver and Passenger Side 13. Using the formula below, insert the measurements from steps 9 and 12 to determine the header latch distance adjustment or C. Driver Side: 1.5 mm – (A ______ – B _______) = C_______ Passenger Side: 1.5 mm – (A ______ – B _______) = C_______ © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 12 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 14. Open the roof halfway. Figure 14. . 15. Mark (with white paper correction fluid) around the three header lock receiver bolts and scribe lines to indicate the distance the receiver needs to move (towards the front of the vehicle [C mm] and towards the outside of the vehicle [1 mm]). Figure 15. . C HINT 1 Use a feeler gauge to help scribe the movement distance. Click Here to Watch Supplemental Video 1 1 mm C Header Latch Distance Adjustment © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 13 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) Figure 16. 1 . 1 mm C Header Latch Distance Adjustment NOTICE Do NOT twist when adjusting the header lock receiver. 16. Loosen the header lock receiver bolts and adjust the brackets position in accordance with the lines scribed. Click Here to Watch Supplemental Video 17. Tighten the header lock catch bolts. Torque: 12 N*m (122 kgf*cm, 9 ft*lbf) 18. Completely close the roof. 19. Measure the cinch dimension using steps 7 – 12 to get measurements A and B. Driver Side: A – B = D Passenger Side: A – B = D Header Lock Cinch Dimension (D) = 1.5 – 2.0 mm • If D is NOT between 1.5 – 2.0 mm, return to step 7. • D must be within 0.5 mm between driver and passenger side. If out of specification, return to step 7. © 2010 Lexus, a division of Toyota Motor Sales, USA November 16, 2010 L-SB-0149-10 Page 14 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 20. Measure the gap between the front window header and front roof panel No. 1. Figure 17. Measurement Points. Tolerance: ±1.5 mm AREA MEASUREMENT A 7.0 mm (0.276 in.) B 7.0 mm (0.276 in.) C 7.0 mm (0.276 in.) A B C Figure 18. A Area A B Area B C Area C . a a Measurement Location © 2010 Lexus, a division of Toyota Motor Sales, USA November 16, 2010 L-SB-0149-10 Page 15 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 21. Tighten the roof panel No. 1 to panel No. 2 adjustment screw until it contacts the No. 2 roof panel, then rotate the screw clockwise 90◦ to 135◦ (90+45◦) on both sides until roof panel No. 1 and roof panel No. 2 are flush (±1.5 mm). Click Here to Watch Supplemental Video Figure 19. Figure 20. 2 4 1 Front 2 Roof Panel No. 2 3 Roof Panel No. 1 4 Adjustment Screw 5 Measurement Point 6 Set Screw 5 1 6 3 22. Tighten the lock screw of the adjustment screw on both right and left sides. Figure 21. . © 2010 Lexus, a division of Toyota Motor Sales, USA November 16, 2010 L-SB-0149-10 Page 16 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 23. Measure the height difference between the roof No. 1 and No. 2 panels. Figure 22. Measurement Points. Tolerance: ±1.5 mm AREA MEASUREMENT A 0 mm (0 in.) B 0 mm (0 in.) C 0 mm (0 in.) A B C Figure 23. A Area A B Area B C Area C . b b Measurement Location © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 17 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 24. Confirm the U-shaped hook contacts the eccentric pin on the strength arms (both right and left sides). Click Here to Watch Supplemental Video Figure 24. If there is a gap, adjust the eccentric pin until it contacts the bottom of the U-shaped hook. Figure 25. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 18 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 25. On roof panel No. 3, loosen the 2 bolts holding the 2-3 lock striker (on both right and left sides). Click Here to Watch Supplemental Video Figure 26. NOTE With the roof closed, the 2/3 lock striker can only be accessed from the rear seat area. 26. Pull the striker bracket’s external side towards the front of the vehicle, and temporarily tighten one bolt on the external side (on right and left bracket sides). Figure 27. . © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 19 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 27. Pull the striker bracket’s internal side towards the front of the vehicle, and tighten both bolts (on right and left brackets). Figure 28. Figure 29. 28. Confirm that the rubber stopper where the 2/3 Lock contacts the striker is tight and will not rotate (tightly clasped) (on right and left sides). Figure 30. . 29. Open the roof halfway. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 30. Manually lock the 2/3 Lock (turn clockwise approx. 360◦). Figure 31. 31. Remove the 2/3 Lock cable (on right and left sides). Figure 32. © 2010 Lexus, a division of Toyota Motor Sales, USA Page 20 of 48 L-SB-0149-10 November 16, 2010 Page 21 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 32. Loosen the 3 bolts attaching the 2/3 Lock to the roof panel No. 2 and install a 1 mm shim (P/N 90201-11011) on the bottom 2 bolts in between the 2/3 Lock and the roof panel and tighten the bolts (on right and left sides). Torque: 12 N*m (122 kgf*cm, 9 ft*lbf) NOTE Do NOT remove the shim attached to the 2/3 Lock. The new shims are an addition to the existing shim(s). Figure 33. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 33. Install the 2/3 Lock cable (on right and left sides). Figure 34. . © 2010 Lexus, a division of Toyota Motor Sales, USA Page 22 of 48 L-SB-0149-10 November 16, 2010 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 34. Manually release the 2/3 Lock (turn counterclockwise approx. 360◦). Figure 35. 35. Install the rubber stoppers on both sides. Figure 36. 1 1 Rubber Stopper © 2010 Lexus, a division of Toyota Motor Sales, USA Page 23 of 48 L-SB-0149-10 November 16, 2010 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 36. Apply chalk to roof panel contact points below on both sides. NOTE Please use chalk as it is easy to remove and reapply. A. 2/3 Lock striker. Figure 37. B. Panel No. 1 to No. 2 adjustment screw. Figure 38. © 2010 Lexus, a division of Toyota Motor Sales, USA Page 24 of 48 L-SB-0149-10 November 16, 2010 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) C. Header lock pins. Figure 39. 37. Completely close the roof. © 2010 Lexus, a division of Toyota Motor Sales, USA Page 25 of 48 L-SB-0149-10 November 16, 2010 Page 26 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 38. Open the roof halfway and inspect the chalk transfer marks on each contact point. A. Header lock. If header pins have poor contact with the latch, return to step 1. Figure 40. Chalk Marks to Header Latch NOTE Chalk needs to be transferred on upper portion of triangle shaped catch. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 27 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) B. Panel No. 1 to No. 2 adjustment screw. If adjustment screw has poor contact, return to step 21. Figure 41. C. 2/3 Lock. If striker does not contact both sides, remove shims from steps 31 - 33 and return to step 25. Figure 42. 39. Completely close the roof. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 28 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) 40. Confirm the gaps between the roof panels. Figure 43. Measurement Points. A B C A. Front windshield header to roof panel No. 1. Figure 44. a a b Gap Height Difference Gap (a) (Tolerance ±1.5 mm) AREA MEASUREMENT A 7.0 mm (0.276 in.) B 7.0 mm (0.276 in.) C 7.0 mm (0.276 in.) Height Difference (b) (Tolerance ±1.5 mm) AREA MEASUREMENT A 0.5 mm (0.02 in.) B 0.5 mm (0.02 in.) C 0.5 mm (0.02 in.) © 2010 Lexus, a division of Toyota Motor Sales, USA b L-SB-0149-10 November 16, 2010 Page 29 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) B. Roof panel No. 1 to roof panel No. 2. Figure 45. b a b Gap Height Difference Gap (a) (Tolerance ±1.5 mm) AREA MEASUREMENT A 7.0 mm (0.276 in.) B 7.0 mm (0.276 in.) C 7.0 mm (0.276 in.) Height Difference (b) (Tolerance ±1.5 mm) AREA MEASUREMENT A 0 mm (0 in.) B 0 mm (0 in.) C 0 mm (0 in.) © 2010 Lexus, a division of Toyota Motor Sales, USA a L-SB-0149-10 November 16, 2010 Page 30 of 48 Convertible Top Component Rattle Repair Procedure A: Metal Top Roof Panel Alignment (Continued) C. Roof panel No. 2 to back window frame assembly. Figure 46. a b a b Gap Height Difference Gap (a) (Tolerance ±1.5 mm) AREA MEASUREMENT A 8.5 mm (0.335 in.) B 8.5 mm (0.335 in.) C 8.5 mm (0.335 in.) Height Difference (b) (Tolerance ±2.0 mm) AREA MEASUREMENT A 2.8 mm (0.11 in.) B 2.8 mm (0.11 in.) C 2.8 mm (0.11 in.) D. If any of the measurements are outside of the specified range, follow the Repair Manual for convertible top panel adjustments. Refer to TIS, 2010 IS 250C/350C Repair Manual: • Vehicle Exterior – Sliding Roof/Convertible – “Sliding Roof/Convertible: Metaltop Roof: Installation” © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 31 of 48 Convertible Top Component Rattle Repair Procedure B: Package Tray Alignment & Insulation 1. If not already installed, temporarily install the tonneau cover board in the tonneau cover sensors so the roof will operate. NOTICE Make sure that nothing is in the vehicle that will damage the roof during operation. 2. Open the roof until the back window assembly enters the trunk. Figure 47. . © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 32 of 48 Convertible Top Component Rattle Repair Procedure B: Package Tray Alignment & Insulation (Continued) 3. Paint the area around the 4 (four) nuts used to secure the package tray assembly to the rear bulkhead. Click Here to Watch Supplemental Video Figure 48. 4. Remove the package tray assembly. 5. Remove the shim from the lower package tray mounting stud (if present). Figure 49. . © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 33 of 48 Convertible Top Component Rattle Repair Procedure B: Package Tray Alignment & Insulation (Continued) 6. Reinstall the package tray assembly in the original location using the paint marks from step 3 as a guide. Figure 50. 7. Completely close the roof and open the trunk. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 34 of 48 Convertible Top Component Rattle Repair Procedure B: Package Tray Alignment & Insulation (Continued) 8. From inside the trunk, check the gap between the package tray assembly and the back window assembly weatherstripping. There should be a tight fit with no gaps. Click Here to Watch Supplemental Video NOTE If there is not tension between the package tray assembly and the back window assembly, the package tray may rattle. Figure 51. Figure 52. 1 2 1 Back Window Assembly 2 Package Tray Assembly Figure 53. 1 Acceptable 2 Unacceptable If there is still a gap, follow steps A and B below. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 35 of 48 Convertible Top Component Rattle Repair Procedure B: Package Tray Alignment & Insulation (Continued) A. Lower the package tray assembly 1 mm from the original position. Figure 54. B. From inside the trunk, check the gap between the package tray assembly and the back window assembly weatherstripping. There should be a tight fit with no gaps. If there is still a gap, repeat steps A and B above. © 2010 Lexus, a division of Toyota Motor Sales, USA November 16, 2010 L-SB-0149-10 Page 36 of 48 Convertible Top Component Rattle Repair Procedure B: Package Tray Alignment & Insulation (Continued) 9. Attach felt (0.5 mm thick) and gray foam (5.0 mm thick) to the package tray trim cover. QUANTITY MATERIAL THICKNESS LENGTH WIDTH 1 Felt 0.5 mm (0.02 in.) 25 mm (0.98 in.) 10 mm (0.39 in.) 8 Foam 5.0 mm (0.20 in.) 40 mm (1.57 in.) 15 mm (0.59 in.) Figure 55. A B B B B B B A B A 0.5 mm Felt B 5.0 mm Gray Foam © 2010 Lexus, a division of Toyota Motor Sales, USA B B November 16, 2010 L-SB-0149-10 Page 37 of 48 Convertible Top Component Rattle Repair Procedure B: Package Tray Alignment & Insulation (Continued) 10. Attach felt (0.5 mm & 2.0 mm thick) to the package tray trim cover (P/N 64342-53010). NOTE Add the felt (2.0 mm thick) over the existing felt (1.0 mm thick). QUANTITY MATERIAL THICKNESS LENGTH 1 Felt (A) 0.5 mm (0.02 in.) 25 mm (0.98 in.) 9 Felt (B) 2.0 mm (0.08 in.) 30 mm (1.18 in.) Figure 56. B B A B B A A 0.5 mm Felt B 2.0 mm Felt © 2010 Lexus, a division of Toyota Motor Sales, USA WIDTH 10 mm (0.39 in.) L-SB-0149-10 November 16, 2010 Page 38 of 48 Convertible Top Component Rattle Repair Procedure C: Interior Component Insulation 1. Attach gray foam (5.0 mm thick) to the roof side rail garnish No. 3 RH and LH (P/N 62441-53010 & 62442-53010). QUANTITY MATERIAL THICKNESS LENGTH WIDTH 2 Foam 5.0 mm (0.20 in.) 20 mm (0.79 in.) 20 mm (0.79 in.) Figure 57. © 2010 Lexus, a division of Toyota Motor Sales, USA November 16, 2010 L-SB-0149-10 Page 39 of 48 Convertible Top Component Rattle Repair Procedure C: Interior Component Insulation (Continued) 2. Attach felt (0.5 mm thick) in 10 places on each of the side rail rear spacers. HINT Add felt over the contact tabs on the side rail rear spacers. QUANTITY MATERIAL THICKNESS LENGTH WIDTH 10 Felt 0.5 mm (0.02 in.) 10 mm (0.39 in.) 5.0 mm (0.20 in.) Figure 58. © 2010 Lexus, a division of Toyota Motor Sales, USA November 16, 2010 L-SB-0149-10 Page 40 of 48 Convertible Top Component Rattle Repair Procedure C: Interior Component Insulation (Continued) 3. Attach felt (0.5 mm thick) in 4 places on the package tray trim pocket lid (64307-53010). QUANTITY MATERIAL THICKNESS LENGTH WIDTH 4 Felt 0.5 mm (0.02 in.) 10 mm (0.39 in.) 5.0 mm (0.20 in.) Figure 59. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 41 of 48 Convertible Top Component Rattle Repair Procedure C: Interior Component Insulation (Continued) 4. Attach felt (0.5 mm & 2.0 mm thick) to the roll over garnishes (P/N 62417-53040 & 62418-53040). QUANTITY MATERIAL THICKNESS LENGTH 4 Felt (A) 2.0 mm (0.08 in.) 30 mm (1.18 in.) 14 Felt (B) 0.5 mm (0.02 in.) 15 mm (0.59 in.) WIDTH 10 mm (0.39 in.) Figure 60. B B A A A A B 2.0 mm Felt B 0.5 mm Felt © 2010 Lexus, a division of Toyota Motor Sales, USA November 16, 2010 L-SB-0149-10 Page 42 of 48 Convertible Top Component Rattle Repair Procedure C: Interior Component Insulation (Continued) 5. Attach felt (0.5 mm thick) to the edge of the quarter pillar garnishes. QUANTITY MATERIAL THICKNESS LENGTH WIDTH 2 Felt 0.5 mm (0.02 in.) 285 mm (11.22 in.) 5.0 mm (0.20 in.) Figure 61. © 2010 Lexus, a division of Toyota Motor Sales, USA November 16, 2010 L-SB-0149-10 Page 43 of 48 Convertible Top Component Rattle Repair Procedure C: Interior Component Insulation (Continued) 6. Attach felt (2.0 mm thick) between the cover, luggage compartment trim inner (P/N 64721-53030 & 64722-53060) and the rear bulkhead. QUANTITY MATERIAL THICKNESS LENGTH WIDTH 2 Felt 2.0 mm (0.08 in.) 20 mm (0.79 in.) 20 mm (0.79 in.) Figure 62. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 44 of 48 Convertible Top Component Rattle Repair Procedure C: Interior Component Insulation (Continued) 7. Attach a piece of felt to the front quarter trim panel (62510-53010 & 62520-53020) on both right and left sides. QUANTITY MATERIAL THICKNESS LENGTH WIDTH 2 Felt 0.5 mm (0.02 in.) 50 mm (1.97 in.) 5.0 mm (0.20 in.) Figure 63. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 45 of 48 Convertible Top Component Rattle Repair Procedure C: Interior Component Insulation (Continued) 8. Attach a piece of felt to the roof side rail garnish No. 3 on both right and left sides. QUANTITY MATERIAL THICKNESS LENGTH WIDTH 2 Felt 0.5 mm (0.02 in.) 10 mm (0.39 in.) 5.0 mm (0.20 in.) Figure 64. © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Convertible Top Component Rattle Repair Procedure D: Final Assembly & Repair Confirmation 1. Following the Repair Manual, install all components. 2. Confirm the rear window lip seal is not rolled into the quarter pillar garnish. Figure 65. . 3. Completely open the roof. © 2010 Lexus, a division of Toyota Motor Sales, USA Page 46 of 48 November 16, 2010 L-SB-0149-10 Page 47 of 48 Convertible Top Component Rattle Repair Procedure D: Final Assembly & Repair Confirmation (Continued) 4. Measure the gaps between the package tray panels. Figure 66. A B H C G D I J E F LOCATION GAP GAP DEVIATION GAP DIFFERENCE BETWEEN RIGHT & LEFT SIDES A 8.0 ±3.0 mm 3.0 mm or less 3.0 mm or less 0 ±3.0 mm – – B 2.8 ±2.5 mm – – 0 ±1.5 mm – – C 8.0 ±2.5 mm 2.5 mm or less 2.5 mm or less 0 ±2.5 mm – – D 8.0 ±2.5 mm 2.5 mm or less 2.5 mm or less 0 ±2.5 mm – – E 8.0 ±3.0 mm 2.5 mm or less 2.5 mm or less 0 ±2.5 mm – – F 4.5 ±2.0 mm 2.0 mm or less – 0 ±1.5 mm 2.0 mm or less – G 3.5 ±2.5 mm 3.0 mm or less – – – – H 2.0 mm or less 1.5 mm or less – – – – I 3.3 ±2.0 mm – – 0 ±2.5 mm – 3.0 mm or less J 6.0 ±2.0 mm 2.0 mm or less 3.0 mm or less 0 ±2.0 mm 2.0 mm or less 2.5 mm or less HEIGHT DIFFERENCE HEIGHT DIFFERENCE DEVIATION HEIGHT DIFFERENCE BETWEEN RIGHT & LEFT SIDES © 2010 Lexus, a division of Toyota Motor Sales, USA L-SB-0149-10 November 16, 2010 Page 48 of 48 Convertible Top Component Rattle Repair Procedure D: Final Assembly & Repair Confirmation (Continued) If measurements are not within the specified ranges, follow the Repair Manual Metaltop Roof Installation Procedure for Package Tray Panel Adjustment. Refer to TIS, 2010 model year IS 250C/350C Repair Manual: • Vehicle Exterior – Sliding Roof/Convertible – “Sliding Roof/Convertible: Metaltop Roof: Installation” 5. Conduct a water leak test. 6. Conduct a road test using driving conditions similar to those described by the customer in the “Interior Noise Concerns Questionnaire”. Refer to TIS, Reference Information – Technician Group – “Interior Noise Concerns Questionnaire” • If noise is still present from the package tray assembly area, replace the package tray assembly and perform Repair Procedure B: Package Tray Alignment & Insulation. • If noise is still present from the 2/3 Lock, perform step 36 of Repair Procedure A: Metal Top Roof Panel Alignment. © 2010 Lexus, a division of Toyota Motor Sales, USA