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 while applying the tape. 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	Non-padded Side	*2	Padded Side
      *3	Squeegee	*4	Black Out Tape
      *5	Release Paper	-	-
      *a	Side View	-	-

      Reference Measurement

      Area	Measurement
      A	10 to 20 mm (0.393 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. 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.

      

      Text in Illustration

      *1	Squeegee
      *2	Hem
      *a	First
      *b	Second
      *c	Third

      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

1. Engage the clip to install a new rear door frame garnish.

   

INSTALL REAR DOOR GLASS SUB-ASSEMBLY

1. Slide the rear door glass sub-assembly to install it as shown in the illustration.

   

INSTALL REAR DOOR QUARTER WINDOW GLASS

1. Install the rear door quarter window glass to the rear door quarter window weatherstrip.

2. Install the rear door quarter window glass together with the rear door quarter window weatherstrip in the direction indicated by the arrow in the illustration.

   

INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY

1. Install the rear door lower window frame sub-assembly with the screw and 2 bolts.

   

INSTALL REAR DOOR GLASS RUN

1. Install the rear door glass run.

   

INSTALL REAR DOOR WEATHERSTRIP

1. Engage the 20 clips to install the rear door weatherstrip.

   

INSTALL REAR DOOR CHECK ASSEMBLY

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

2. Apply adhesive to the threads of the bolt.

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

3. Install the rear door check assembly with the 2 nuts and bolt.

   

   Torque:

   Bolt

   29 N*m  { 296 kgf*cm, 21 ft.*lbf }

   Nut

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

INSTALL REAR DOOR SERVICE HOLE COVER

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

2. 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.

   

   Text in Illustration

   *1	Reference Point

3. Attach the 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

1. Install the rear door inner glass weatherstrip.

   

INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

1. Install the No. 1 door scuff plate clamp as shown in the illustration.

   

2. Connect the rear door lock remote control cable assembly and rear door inside locking cable assembly.

   

   Text in Illustration

   *1	Rear Door Inside Locking Cable Assembly
   *2	Rear Door Lock Remote Control Cable Assembly

3. Engage the rear door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.

   

   Text in Illustration

   *1	Reference Boss

4. Engage the 8 clips and install the rear door trim board sub-assembly.

   

5. Install the 3 screws.

6. If protective tape has been applied, remove it.

INSTALL REAR ARMREST ASSEMBLY

1. Engage the 2 guides, 3 clips and 7 claws to install the rear armrest assembly.

   

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

1. Connect the connector.

2. Engage the 4 guides, 2 clips and 5 claws to install the rear power window regulator switch assembly with rear door armrest base panel.

   

INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG

1. Engage the 3 claws to install the rear door inside handle bezel plug.

   

INSTALL LUGGAGE TRIM SERVICE HOLE COVER

1. Engage the claw to connect the luggage trim service hole cover.