Technical Service BULLETIN

Transcription

1 Technical Service BULLETIN ugust 12, 2004 Title: Models: 04 Prius BO BODY Introduction To improve the appearance of the blackout tape on the rear doors, the following procedure has been developed. pplicable Vehicles 2004 model year Prius vehicles. Parts Information PREVIOUS PRT NUMBER CURRENT PRT NUMBER PRT NME QTY Seal, RR Door RR Guide, RH Seal, RR Door RR Guide, LH Same Tape, Blackout, No. 2, RH Same Tape, Blackout, No. 2, LH 1 Required Tools & Material TOOLS & MTERIL PRT NUMBER QUNTITY Kent crysol Squeegee 3M P 1 (or equivalent) 1 Kent crysol may be ordered by calling Kent Industries at Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 BD4012 R & R Rear Door Glass & pply Blackout Tape 3.2 Combo Opposite Side # pplicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle s in-service date. * Warranty application is limited to correction of a problem based upon a customer s specific complaint. Toyota Supports SE Certification Page 1 of 12

2 Precautions 1. Check the ambient temperature. The ideal tape application area temperature is 77 F (25 C).. When the ambient temperature is 15 C (59 F) or less, use a heat light to increase the tape application area temperature to approximately 68 to 86 F (20 to 30 C). If the ambient temperature is too low, the tape may harden and lose adhesive strength. B. When the ambient temperature is 95 F (35 C) or higher, allow the tape application area temperature to cool down to less than 95 F (35 C). 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. 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. 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. Page 2 of 12

3 Disassembly Components Rear Door Glass Run Rear Door Window Molding Front Rear Door Glass Sub assembly LH RH 8.0 (82, 71 in. lbf) Blackout Tape No. 2 Rear Door Rear Guide Seal Door Frame Garnish Rear Door Window Guide Sub assembly Rear Rear Door Belt Molding ssembly Door Pull Handle Rear Door Weatherstrip Rear Door Trim Board Sub assembly Rear Door Inside Handle Sub assembly Rear Door Inside Handle Bezel Rear Door Trim Bracket No. 2 Butyl Tape Rear Door rmrest Base Panel Upper Rear Door Service Hole Cover N m (kgf cm, ft lbf) : Specified Torque Non reusable Part 1. Remove Rear Door Inside Handle Bezel.. Using a screwdriver, disengage the 3 claws and remove the bezel. Tape the screwdriver tip before use. : Claw Page 3 of 12

4 Disassembly (Continued) 2. Remove Door Pull Handle.. Remove the screw and pull handle. 3. Remove Rear Door rmrest Base Panel Upper.. Using the taped screwdriver, disengage the 2 clips and 4 claws, and remove the armrest base panel upper. B. Disconnect the switch connector. : Clip : Claw 4. Remove Rear Door Trim Board Sub ssembly.. Remove the screw. B. Using a screwdriver, disengage the 7 clips and remove the trim board. 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. : Protective Tape : Clip 5. Remove Rear Door Inside Handle Sub assembly.. Using a taped screwdriver, disengage the claw (). B. Move the inside handle in the direction indicated by the arrow mark in the illustration. This will release the claws (B) and allow removal of the inside handle. C. Disconnect the 2 cables from the inside handle. : Claw B Page 4 of 12

5 Disassembly (Continued) 6. Remove Rear Door Belt Molding.. Put protective tape under the molding. B. Using a molding remover, pry out the molding. Tape Molding Remover 7. Remove Rear Door Window Frame Molding.. Pull back weatherstrip inside top right corner. B. Remove the screw. C. Using a heat light, heat the molding. D. Remove the molding. When removing the molding, heat the body and molding using a heat light. Heating temperature: ITEM Body Molding TEMPERTURE 104 to 140 F (40 to 60 C) 68 to 86 F (20 to 30 C) Do not heat the body and molding excessively. If planning to reuse the molding, take care not to damage the molding. Page 5 of 12

6 Disassembly (Continued) 8. Remove Door Frame Garnish.. Using a clip remover, disengage the claw and remove the garnish. 9. Remove Rear Door Service Hole Cover.. Disconnect power window regulator motor assembly, door lock assembly and speaker. B. Remove the 2 screws and bracket. C. Remove the service hole cover. Remove the remaining tape on the door side. 10. Remove Rear Door Window Guide Sub assembly Rear.. Pull back weatherstrip. B. Remove the 3 screws (), 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. Bolt B Page 6 of 12

7 Disassembly (Continued) 11. Remove Rear Door Glass Sub assembly. Insert a cushion inside the door panel to prevent the glass from being scratched.. Position window so that the 2 window to regulator bolts (see arrows in illustration) are accessible through the door service holes. B. Remove the 2 bolts and glass. 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.. Using a clip remover, disengage the clips and remove the weatherstrip. If the clips are damaged, replace them with new clips. 13. Remove Blackout Tape No. 2.. Using a heat light, heat the tape. When removing the tape, heat the body and tape using a heat light. Heating temperature: ITEM Body Tape TEMPERTURE 104 to 140 F (40 to 60 C) 68 to 86 F (20 to 30 C) Do not heat the body and molding excessively. B. Remove the tape. Page 7 of 12

8 Blackout Tape pplication This is the procedure to be used when applying blackout tape. New tape must be used. 1. Remove the tape s peeling paper slightly. pply 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. n 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 20 mm (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. 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 to 7 cm ( in) Per Second PUSH METHOD 40 to 50 degree angle 3 to 7 cm ( in) Per Second PULL METHOD 10 to 20 mm ( in.) Squeegee Blackout Tape 10 to 20 mm ( in.) Squeegee Blackout Tape 30 to 45 degree angle Peeling Paper Peeling Paper Page 8 of 12

9 Blackout Tape pplication (Continued) 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. Squeegee Second Time First Time fter removing the last part of the peeling paper, press the tape to the hem with your fingertips or the thick end of a squeegee. Third Time Hemming Part. 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. Heating each section of tape may help improve the appearance of the applied tape. fter pplication If the appearance of the applied tape is unsatisfactory, remove it and apply new tape. lways use new tape. For glossy tape used on exterior panels, do not use a needle to correct air bubbles. If only a small amount of tape has come loose on a hem or corner/edge, use industrial strength glue to reapply the tape. Page 9 of 12

10 Blackout Tape pplication rea This is the location to apply blackout tape. 1. pply Blackout Tape No. 2.. 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. pply pressure to the first part of the fold with the squeegee, then attach the hemming folded part. ttach the sash corner part only after the surrounding folded parts have been attached. E. Check the whole area. Positioning Point 3.0 ± 1.0 mm (0.12 ± 0.04 in.) 5.0 ± 1.0 mm (0.2 ± 0.04 in.) 3.0 ± 1.0 mm (0.12 ± 0.04 in.) 5.0 ± 1.0 mm (0.2 ± 0.04 in.) Positioning Point Page 10 of 12

11 Reassembly 1. Install Rear Door Glass Sub assembly.. 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) Be careful not to damage the glass. 2. Install Rear Door Window Guide Sub assembly Rear.. Replace the rear door guide seal. B B. Install the guide seal with the 3 screws (). C. Install the window guide rear with the screw (B) and bolt. Bolt 3. Install Rear Door Service Hole Cover.. pply butyl tape to the door. B. Install a new service hole cover. 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. fter attaching the service hole cover, check the sealing quality. C. Install the trim bracket with the 2 screws. Page 11 of 12

12 Reassembly (Continued) 4. Install Rear Door Window Frame Molding.. Remove the tape from the molding. 2 B. Clean the contact surface of the body and outer edges of the molding with a wax, grease and silicone remover, such as Kent crysol. 1 3 C. pply new double sided tape to the molding. Specification: RE MESUREMENT 1: 360 mm (14.2 in.) 2: 37 mm (1.5 in.) 3: 440 mm (17.3 in.) B C B 5.0 mm (0.2 in.) C 1: 1.2 mm (0.05 in.) 2: 0.8 mm (0.03 in.) 3: 0.8 mm (0.03 in.) D. Using a heat light, heat the body and molding. E. Remove the peeling paper from the molding face. F. Install the molding with the screw. When installing the molding, heat the body and molding using a heat light. Heating temperature: ITEM Body Molding TEMPERTURE 104 to 140 F (40 to 60 C) 68 to 86 F (20 to 30 C) Do not heat the body and molding excessively. Page 12 of 12