Lexus ES: Installation
INSTALLATION
CAUTION / NOTICE / HINT
HINT:
- Use the same procedure for the RH side and LH side.
- The following procedure is for the LH side.
PROCEDURE
1. PRECAUTION
NOTICE:
After turning the engine switch (for Gasoline Model) or power switch (for HV Model) off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.
2. REPAIR INSTRUCTION
(a) 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) |
CAUTION:
- Do not touch the heat light and heated parts, touching the heat light may result in burns.
- Touching heated parts for a long time may result in burns.
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| *a | Heated Part |
| *b | Heat Light |
NOTICE:
Do not heat the vehicle body excessively.
(2) Wipe off any tape adhesive residue with cleaner.
(b) 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.
HINT:
- The most appropriate temperature for installing the tape is 25°C (77°F).
- When the temperature is low, the tape becomes stiff and comes off easily. When the temperature is high, the tape elasticity increases.
(c) 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.
HINT:
Spray water on the shop floor to settle any dust.
(d) 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.
NOTICE:
Do not bend the tape or leave it in high temperature places.
(e) Key points for installation of the tape (How to use a squeegee and installation procedure for flat surfaces)
NOTICE:
- Position the tape accurately to achieve a neat finish and to avoid peeling.
- The tape cannot be reused because it deforms after removal.
(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.
| *A | Pressing Forward | *B | Pulling |
| *1 | Black Out Tape | - | - |
| *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) |
NOTICE:
Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles or air bubbles.
HINT:
- 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.
(f) 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. HINT: When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee. |
|
(g) 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.
(h) Check after installation
(1) After completing the installation, check if the tape is installed neatly. If the tape is not installed neatly, install a new tape.
NOTICE:
Do not reuse the tape.
3. INSTALL FRONT INNER BLACK OUT TAPE
(a) Refer to the illustration to position a new front inner black out tape.
| *A | LH Side | *B | RH Side |
| *1 | Front Door Trim Board Sub-assembly | - | - |
| *a | Rib of Door Frame Garnish | *b | Edge of Curved Surface |
| *c | Square | *d | Round |
Standard Measurement:
| Area | Measurement | Area | Measurement |
|---|---|---|---|
| A | 7.0 mm (0.276 in.) | B | 5.0 mm (0.197 in.) |
| C | 1.5 mm (0.0591 in.) | D | 1.0 mm (0.0394 in.) |
(b) Remove the release paper and install the front inner black out tape.
4. INSTALL FRONT DOOR REAR INNER BLACK OUT TAPE
(a) Refer to the illustration to position a new front door rear inner black out tape.
| *A | LH Side | *B | RH Side |
| *1 | Front Door Weatherstrip | - | - |
| *a | Rib of Door Frame Garnish | *b | Square |
| *c | Round | - | - |
Standard Measurement:
| Area | Measurement | Area | Measurement |
|---|---|---|---|
| A | 5.0 mm (0.197 in.) | B | 7.0 mm (0.276 in.) |
| C | 0 mm (0 in.) | D | 0 mm (0 in.) |
(b) Remove the release paper and install the front door rear inner black out tape.
5. INSTALL FRONT DOOR WEATHERSTRIP
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6. INSTALL DOOR UPPER FRAME GARNISH
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7. INSTALL FRONT DOOR CHECK ASSEMBLY
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8. INSTALL FRONT DOOR GLASS RUN
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9. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY
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10. INSTALL FRONT DOOR PANEL PROTECTOR
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11. INSTALL FRONT DOOR VENT SEAL
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12. INSTALL FRONT DOOR SERVICE HOLE COVER
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13. INSTALL FRONT DOOR TRIM BRACKET
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14. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH
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15. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY
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16. INSTALL COURTESY LIGHT ASSEMBLY
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17. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side)
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18. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Front Passenger Side)
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19. INSTALL NO. 2 DOOR TRIM PAD
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20. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL
for 2GR-FKS:
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for A25A-FXS:
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for A25A-FKS:
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21. INITIALIZE POWER WINDOW CONTROL SYSTEM
for HV Model:
Click here
for Gasoline Model:
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22. INSPECT POWER WINDOW OPERATION
for HV Model:
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for Gasoline Model:
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READ NEXT:
Components
COMPONENTS ILLUSTRATION *1 COURTESY LIGHT ASSEMBLY *2 REAR DOOR TRIM BOARD SUB-ASSEMBLY *3 REAR DOOR UPPER TRIM PAD *4 REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR UP
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