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Canada - Body - Rear Door Frame Black Tape Wrinkled






Bulletin
TSB2079

Issue Date
September 20, 2004

Market
Canada



Title
REAR DOOR FRAME BLACK TAPE WRINKLED

Component
BODY COMPONENT

Models
'04 Prius

To improve the appearance of the blackout tape on the rear doors, the following procedure has been developed.

APPLICABLE VEHICLES:
- 2004 model year Prius vehicles.






PARTS INFORMATION:






REQUIRED TOOLS & MATERIAL:






WARRANTY INFORMATION:






PRECAUTIONS:

1. Check the ambient temperature. The ideal tape application area temperature is 25°C (77°F).
a. When the ambient temperature is 15°C (59°F) or less, use a heat light to increase the tape application area temperature to approximately 20 to 30°C (68 to 86°F).

HINT:
If the ambient temperature is too low, the tape may harden and lose adhesive strength.

b. When the ambient temperature is 35°C (95°F) or higher, allow the tape application area temperature to cool down to less than 35°C (95°F).

HINT:
If the ambient temperature is too high, the tape may become soft and unusable.

2. Remove dust and other foreign matter from the vehicle body application area and surrounding area. This will prevent air bubbles between the body and tape.

HINT:
Ensure that the work area surrounding the vehicle is clean.

3. Place tape between two hard, flat objects (for example, cardboard) in a dry, level surfaced area.

NOTE:
- Be careful with the tape as it curls, shrinks and damages easily.
- Do not leave the tape in a high--temperature area.
- Do not bend the tape.






DISASSEMBLY PROCEDURE:







1. Remove Rear Door Inside Handle Bezel.
a. Using a screwdriver, disengage the 3 claws and remove the bezel.

NOTE:
Tape the screwdriver tip before use.







2. Remove Door Pull Handle.
a. Remove the screw and pull handle







3. Remove Rear Door Armrest Base Panel Upper.
a. Using the taped screwdriver, disengage the 2 clips and 4 claws, and remove the armrest base panel upper.
b. Disconnect the switch connector.







4. Remove Rear Door Trim Board Sub--Assembly.
a. Remove the screw.
b. Using a screwdriver, disengage the 7 clips and remove the trim board.

NOTE:
- In order to prevent the door panel from being damaged, use protective tape to cover the areas indicated by the arrow marks in the illustration.
- If the clip cannot be reached with the clip remover, pull on the lower trim to remove it.







5. Remove Rear Door Inside Handle Sub--assembly.
a. Using a taped screwdriver, disengage the claw (A).
b. Move the inside handle in the direction indicated by the arrow mark in the illustration. The will release the claws (B) and allow removal of the inside handle.
c. Disconnect the 2 cables from the inside handle.







6. Remove Rear Door Belt Moulding.
a. Put protective tape under the moulding.
b. Using a moulding remover, pry out the moulding.







7. Remove Rear Door Window Frame Moulding.
a. Pull back weather strip inside top right corner.
b. Remove the screw.
c. Using a heat light, heat the moulding.
d. Remove the moulding.

NOTE:
When removing the moulding, heat the body and moulding using a heat light.






Heating temperature:

NOTE:
- Do not heat the body and moulding excessively.
- If planning to reuse the moulding, take care not to damage the moulding.







8. Remove Door Frame Garnish.
a. Using a clip remover, disengage the claw and remove the garnish.







9. Remove Rear Door Service Hole Cover.
a. Disconnect power window regulator motor assembly, door lock assembly and speaker.
b. Remove the 2 screws and bracket.
c. Remove the service hole cover.

NOTE:
Remove the remaining tape on the door side.







10. Remove Rear Door Window Guide Sub--assembly Rear.
a. Pull back weather strip.
b. Remove the 3 screws (A), bolt and window guide rear with the guide seal.
c. Connect the power window regulator switch.
d. Lower window and peel back window guide channel felt.
e. Remove the screw (B) and rear door guide seal.







11. Remove Rear Door Glass Sub--assembly.

NOTE:
Insert a cushion inside the door panel to prevent the glass from being scratched.

a. Position window so that the 2 window to regulator bolts (see arrows) are accessible through the door service holes.
b. Remove the 2 bolts and glass.

NOTE:
Be careful when removing the bolts as the glass may fall and become damaged.

C. Disconnect the power window regulator switch.

12. Remove Rear Door Weatherstrip.
a. Using a clip remover, disengage the clips and remove the weatherstrip.

NOTE:
If the clips are damaged, replace them with new clips.

13. Remove Black Out Tape No. 2.
a. Using a heat light, heat the tape.

NOTE:
When removing the tape, heat the body and tape using a heat light.






Heating temperature:

NOTE:
Do not heat the body and moulding excessively.

b. Remove the tape.

APPLICATION PROCESS:

NOTE:
New tape must be used.

1. Remove the tape's peeling paper slightly. Apply the tape to the specified start position. The start position of the tape must not be more than 1.0 mm (0.04 in.) from the specified position.

HINT:
An incorrect tape start position will affect the vehicle's appearance and tape adhesive's strength.

2. Slowly remove the tape's peeling paper while pressing the tape to the surface with a squeegee. Pay attention to the following:
- Remove the tape's peeling paper from the tape 10 to 20 mm (0.4 to 0.79 in.) ahead from the squeegee while the tape is being applied. To prevent air bubbles, lift up the 10 to 20mm (0.4 to 0.77 in.) of exposed adhesive from the surface while pressing the squeegee to the tape, as shown in the illustration.
- Push or pull the squeegee depending on the application area on the vehicle body. Hold the squeegee at a 40 to 50 degree angle when pushing it, and hold it at a 30 to 45 degree when pulling it.
- Using the squeegee, apply approximately 20 to 30 N (2 to 3 kgf) of force to the tape.
- Gently move the squeegee at approximately 3 to 7 cm per second (1.2 to 2.8 in. per second).
- Make sure there are no air bubbles between the tape and surface.







HINT:
Keep the speed, angle and force constant. It you stop moving the squeegee or change the force halfway, a shock line may occur on the tape surface. If you move the squeegee very quickly, air bubbles may occur between the tape and vehicle body.







3. For hemmed area, press the squeegee over the hem 2 to 3 times as shown in the illustration. Pay extra attention to small hems. Use your fingertips or the thick end of a squeegee to apply the tape.

HINT:
After removing the last part of the peeling paper, press the tape to the hem with your fingertips or the thick end of a squeegee.

a. For corners and edges, use the following procedure: For each section of tape that needs to be folded over a corner/edge, first use a hair dryer to heat the section of tape. Then fold the tape over the corner/edge using your fingertips.

NOTE:
Heating each section of tape may help improve the appearance of the applied tape. After Application

APPLICATION PROCEDURE:

If the appearance of the applied tape is unsatisfactory, remove it and apply new tape.

NOTE:
- Always use new tape.
- For glossy tape used on exterior panels, do not use a needle to correct air bubbles.

NOTE:
If only a small amount of tape has come loose on a hem or corner/edge, use industrial-strength glue to reapply the tape.







1. Apply Black Out Tape No. 2.
a. Cut off the tape and the peeling paper at the perforations, and fit it to the attaching position.
b. Position it so that each fold matches the specified width, and hold in place with a clip or magnetic plate.
c. Remove the remaining peeling paper, and apply pressure to the whole area twice.
d. Apply pressure to the first part of the fold with the squeegee, then attach the hemming folded part. Attach the sash corner part only after the surrounding folded parts have been attached.
e. Check the whole area.







2. Install Rear Door Glass Sub--assembly.
a. Install the glass run.
b. Install the door glass to the window regulator with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)

NOTE:
Be careful not to damage the glass.







3. Install Rear Door Window Guide Sub-assembly Rear.
a. Replace the rear door guide seal.
b. Install the guide seal with the 3 screws (A).
c. Install the window guide rear with the screw (B) and bolt.







4. Install Rear Door Service Hole Cover.
a. Apply butyl tape to the door.
b. Install a new service hole cover.

HINT:
- When installing the service hole cover, pull out the links and connectors through the service hole cover.
- There should be no wrinkles or folds after attaching the service hole cover.
- After attaching the service hole cover, check the sealing quality.

C. Install the trim bracket with the 2 screws.







5. Install Rear Door Window Frame Moulding.
a. Remove the tape from the moulding.
b. Clean the contact surface of the body and outer edges of the moulding with a wax, grease and silicone remover, such as, Dupont Prepsol or Kent Acrysol.
c. Apply new double--sided tape to the moulding.






Specification:

d. Using a heat light, heat the body and moulding.
e. Remove the peeling paper from the moulding face.
f. Install the moulding with the screw.

HINT:
When installing the moulding, heat the body and moulding using a heat light.






Heating temperature:

NOTE:
Do not heat the body and moulding excessively.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.
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