BLACK OUT TAPE (for Front Door) INSTALLATION

Tech Tips


  • Use the same procedure for the RH side and LH side.

  • The following procedure is for the LH side.


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Click here.

  2. REPAIR INSTRUCTION


    1. Clean the vehicle body surface.


      1. Using a heat light, heat the vehicle body surface.

        Heating Temperature
        Item Temperature
        Vehicle Body 40 to 60°C (104 to 140°F)

        Note

        Do not heat the vehicle body excessively.

      2. Wipe off any tape adhesive residue with cleaner.

    2. Installation temperature


      1. When the ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is above 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 and 30°C (68 and 86°F) prior to installation.

        Tech Tips


        • The most appropriate temperature for installing the tape is 25°C (77°F).

        • When the temperature is low, the tape turns stiff and comes off easily. When the temperature is high, the tape elasticity increases.

    3. Before installation


      1. Remove any coating roughness or dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance.

        Tech Tips

        Spray water on the shop floor to settle any dust.

    4. Key points for handling the tape


      1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and flat.

        Note

        Do not bend the tape or leave it in high temperature places.

    5. Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces)

      Note


      • Position the tape accurately to achieve a neat finish and to avoid peeling.

      • The tape cannot be reused because it deforms and will not fit any more after being removed.


      1. To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not touch the vehicle body prematurely. Tilt the squeegee at 40 to 50° (pressing forward) or 30 to 45° (pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf, 4.5 to 6.7 lbf) at a constant slow speed of 30 to 70 mm (1.18 to 2.76 in.) per second.

        A01HYUHE06
        Text in Illustration
        *A Pressing Forward *B Pulling
        *1 Door Stripe - -
        *a Side View *b Non-padded Side
        *c Padded Side *d Squeegee
        *e Release Paper - -
        Standard Measurement
        Area Measurement Area Measurement
        A 10 to 20 mm (0.394 to 0.787 in.) B 30 to 70 mm/sec. (1.18 to 2.76 in./sec.)
        C 40 to 50° (for pressing forward) D 30 to 45° (for pulling)

        Note

        Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles or air bubbles.

        Tech Tips


        • Either angle of the squeegee (pressing forward or pulling) is acceptable.

        • Be sure to apply the tape while removing the release paper 10 to 20 mm (0.394 to 0.787 in.) from the edge of the squeegee.

    6. Key points for installation of the tape (How to use a squeegee and installation procedure for hemmed surfaces)


      1. A01I1J5E12
        Text in Illustration
        *a Squeegee
        *b Hem
        *c First
        *d Second
        *e Third

        If it is difficult to apply the tape, install it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem.

        Tech Tips

        When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee.

    7. Key points for installation of the tape (How to use a squeegee and installation procedure for corners)


      1. Remove the release paper and apply the tape carefully with your fingers.

      2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, avoiding wrinkles on the tape to achieve a neat finish.

    8. Check after installation


      1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape.

        Note

        Do not reuse the tape.

  3. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE


    1. Refer to the illustration to position a new front door lower outside stripe.

      A01I0CWE02
      Text in Illustration
      *A LH Side *B RH Side
      *a Edge of Curved Surface *b Square
      *c Round - -
      Standard Measurement
      Area Measurement Area Measurement
      A 1.5 mm (0.0591 in.) B 1.0 mm (0.0394 in.)

    2. Remove the release paper and install the front door lower outside stripe.

  4. INSTALL FRONT DOOR STRIPE


    1. Refer to the illustration to position a new front door stripe.

      A01I09GE02
      Text in Illustration
      *A LH Side *B RH Side
      *a Edge of Curved Surface *b Square
      *c Round - -
      Standard Measurement
      Area Measurement Area Measurement
      A 1.5 mm (0.0591 in.) B 1.0 mm (0.0394 in.)

    2. Remove the release paper and install the front door stripe.

  5. INSTALL DOOR FRAME GARNISH


    1. A01I243

      Engage the clip to install a new door frame garnish.

  6. INSTALL FRONT DOOR WEATHERSTRIP


    1. A01HYQ1

      Engage the 19 clips and install the front door weatherstrip.

  7. INSTALL FRONT DOOR CHECK ASSEMBLY


    1. Apply MP grease to the sliding parts of the front door check assembly.

    2. Clean the bolt hole on the vehicle body.

    3. Clean the bolt threads of the bolt.

    4. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. A01HXSRE02

      Install the front door check assembly with the 3 bolts.

      Torque:
      Bolt (A)
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      Bolt (B)
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  8. INSTALL FRONT DOOR GLASS RUN


    1. A01I0U5

      Install the front door glass run.

  9. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


    1. Connect the cable to the negative (-) battery terminal.

    2. for Driver Side:


      1. Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

      2. Disconnect the power window regulator master switch assembly.

    3. for Front Passenger Side:


      1. Connect the power window regulator switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

      2. Disconnect the power window regulator switch assembly.

    4. Disconnect the cable from the negative (-) battery terminal.

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

      Note

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

    5. A01I0K0E02

      Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated by the arrows, in the order shown in the illustration.

      Note

      Do not damage the front door glass sub-assembly.

    6. A01I0GP

      Install the front door glass sub-assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    7. A01I1K2

      Install the grommet.

  10. INSTALL NO. 2 FRONT DOOR SERVICE HOLE SEAL


    1. A01I216

      Install the No. 2 front door service hole seal.

  11. INSTALL NO. 1 FRONT DOOR SERVICE HOLE SEAL


    1. A01HYIH

      Install the No. 1 front door service hole seal.

  12. INSTALL FRONT DOOR SERVICE HOLE COVER


    1. Apply new butyl tape to the front door panel.

    2. A01I023E01
      Text in Illustration
      *a Reference Point

      Pass the front door lock remote control cable assembly, front door inside locking cable assembly and each connector through a new front door service hole cover.

    3. Install the new front door service hole cover according to the reference points on the front door panel.

      Note

      Securely install the front door service hole cover preventing wrinkles and air bubbles.

    4. Engage the 5 clamps.

    5. Install the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    6. Connect each connector.

  13. INSTALL DOOR SIDE AIRBAG SENSOR


    1. Check that the ignition switch is off.

    2. Check that the cable is disconnected from the negative (-) battery terminal.

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    3. Before connecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

      A01HY50E01
      Text in Illustration
      *a Incorrect *b Correct

    4. Insert the pin (stopper) into the door hole and install the door side airbag sensor to the front door panel with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

      Note


      • If the door side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one.

      • When installing the door side airbag sensor, be careful that the SRS wiring does not interfere with or is not pinched between other parts.

      • Make sure that the pin (stopper) is securely inserted into the body hole.

      • Tighten the bolt while holding the door side airbag sensor because the door side airbag sensor pin (stopper) is easily damaged.

    5. Connect the connector to the door side airbag sensor.

      Note

      When connecting any airbag connector, take care not to damage the airbag wire harness.


      1. Be sure to engage the connectors until they are locked (when locking, make sure that a click sound can be heard).

        A01HZL9E12
        Text in Illustration
        *1 White Housing Lock *2 Yellow CPA
        *a Connection is Completed - -

        Tech Tips

        When engaged, the white housing lock will slide. Be sure not to hold the white housing lock and part (A), as it may result in an insecure fit.

    6. Check that there is no looseness in the installation parts of the door side airbag sensor.

  14. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Click here

  15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  16. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side)

    Click here

  17. INSPECT POWER WINDOW OPERATION

    Click here

  18. INSPECT SRS WARNING LIGHT

    Click here