BLACK OUT TAPE (for Rear Door) INSTALLATION

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.

      

      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. 

      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.

INSTALL REAR DOOR FRAME GARNISH

INSTALL REAR DOOR GLASS SUB-ASSEMBLY

INSTALL REAR DOOR QUARTER WINDOW GLASS

INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY

INSTALL REAR DOOR GLASS RUN

INSTALL REAR DOOR WEATHERSTRIP

INSTALL REAR DOOR CHECK ASSEMBLY

INSTALL REAR DOOR SERVICE HOLE COVER

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

2. 

   Text in Illustration

   *a	Reference Point

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

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

   Note

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

4. Connect the connector.

INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

INSTALL REAR ARMREST ASSEMBLY

INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL

INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG