Canada - Body - Door Sill Water Instrusion/Corrosion/Rusting
Bulletin
TSB2423R
Issue Date
2006-07-11
Market
Canada
Title
DOOR SILL PROTECTION TAPE APPLICATION
Component
BODY
Models
'03 - '06 Corolla & Matrix
TSB REVISION NOTICE:
- September 08, 2006: The Production Change Effective VINs have been updated in Production Change Information.
Previous versions of this TSB should be discarded.
INTRODUCTION:
Some 2003 - 2006 model year Corolla and Matrix vehicles may require the application of protective tape to the door sills due to water and contaminate infiltration under the door scuff plates causing paint and/or rust damage. The following repair procedure has been made available to correct this condition.
APPLICABLE VEHICLES:
- 2003 - 2006 model year Corolla and Matrix vehicles produced BEFORE the Production Change Effective VINs shown below.
PRODUCTION CHANGE INFORMATION:
PARTS INFORMATION:
WARRANTY INFORMATION:
REQUIRED TOOLS & MATERIAL:
REPAIR PROCEDURE:
A. REMOVE FRONT DOOR SCUFF PLATE
B. CLEAN AND INSPECT FRONT DOOR SILL SURFACE
a) Clean the entire application area to remove grease and wax. Wipe the application area clean with the water (70%) / isopropyl alcohol (30%) solution. Immediately dry the installation area using a clean, dry, lint free cloth.
b) Inspect and repair vehicle surfaces as may be required to remove rust and corrosion. (See Procedure "K")
NOTE:
If door sill surface has been repaired, ensure that the repaired (painted) surfaces are completely dry / cured prior to installing the door sill protective tape
C. APPLY PROTECTIVE TAPE TO THE FRONT DOOR SILL
a) Lift and remove the front door garnish and lift the secondary weather seal away from sheet metal flange.
b) Remove the liner paper covering the adhesive from the front door sill protection tape. Properly align the cut outs in the tape to the sheet metal holes in the door sill and ensure that the halo area around the sheet metal hoses are equal side to side and top to bottom. Use a rag and finger to apply the tape around the compound areas next to the holes in the sheet metal as required as a final step.
NOTE:
- Tape and vehicle application area temperature must be between 20°C and 33°C for optimum installation.
- Tape should not be installed in direct sunlight or under windy conditions.
c) Squeegee the protection tape to the vehicle using overlapping strokes.
d) Remove the premask by pulling it back 180° over the applied protection tape.
e) Using a clean lint free cloth and firm hand pressure, apply the protection tape over the outer edge of the door sill and at the flange radius and then resqueegee using overlapping squeegee strokes.
f) Inspect Final Installation
a. Check for loose edges, wrinkles, bubbles and proper alignment.
b. Check for surface scratches.
c. Wipe the application area clean.
g) Re-install front door garnish and the secondary weather seal.
D. RE-INSTALL FRONT SCUFF PLATE
E. REPEAT PROCEDURE ON OPPOSITE DOOR SILL
F. REMOVE REAR DOOR SCUFF PLATE
G. CLEAN AND INSPECT REAR DOOR SILL SURFACE
a) Clean the entire application area to remove grease and wax. Wipe the application area clean with the water (70%) / isopropyl alcohol (30%) solution. Immediately dry the installation area using a clean, dry, lint free cloth.
b) Inspect and repair vehicle surfaces as may be required to remove rust and corrosion. (See Procedure "K")
NOTE:
If door sill surface has been repaired, ensure that the repaired (painted) surfaces are completely dry / cured prior to installing the door sill protective tape.
H. APPLY PROTECTIVE TAPE TO THE REAR DOOR SILL
a) Lift and remove the rear door garnish and lift the secondary weather seal away from sheet metal flange.
b) Remove the liner paper covering the adhesive from the front door sill protection tape. Properly align the cut outs in the tape to the sheet metal holes in the door sill and ensure that the halo area around the sheet metal hoses are equal side to side and top to bottom. Use a rag and finger to apply the tape around the compound areas next to the holes in the sheet metal as required as a final step.
NOTE:
- Tape and vehicle application area temperature must be between 20°C and 33°C for optimum installation.
- Tape should not be installed in direct sunlight or under windy conditions.
c) Squeegee the protection tape to the vehicle using overlapping strokes.
d) Remove the premask by pulling it back 180° over the applied protection tape.
e) Using a clean lint free cloth and firm hand pressure, apply the protection tape over the outer edge of the rear door sill and at the flange radius and then resqueegee using overlapping squeegee strokes.
f) Inspect Final Installation
a. Check for loose edges, wrinkles, bubbles and proper alignment.
b. Check for surface scratches.
c. Wipe the application area clean.
g) Re-install rear door garnish and the secondary weather seal.
I. RE-INSTALL REAR SCUFF PLATE
J. REPEAT PROCEDURE ON OPPOSITE DOOR SILL
K. REMOVE RUST SPOTS, PRIME AND PAINT
1. INSPECT DOOR SILL PLATE FOR RUST AND PREPARE
a) Wipe off grease or oil on the surfaces to be repaired with a rag soaked in a grease, wax and silicone remover, such as PPG DX330 Wax and Grease Remover.
b) Dry fit the tape that is appropriate to the panel being worked on to ensure that rusted areas are inside the tape surface area. Note: If rust extends beyond the tape surface area, the vehicle must be repaired and painted in the Body Shop.
2. REMOVE RUSTED AREAS
a) Wire brush the rust affected areas until rust scale is removed. Try not to disturb non-rusted areas as much as possible.
b) Use the emery paper to sand down the affected areas to bare metal and to feather the outer painted edges.
c) Wipe down the surfaces again with wax and grease remover and wipe dry.
3. APPLY PRIMER
a) Prepare approximately 30ml (1 ounce) each of Etch Primer and Etch Primer Catalyst and mix thoroughly.
b) Dab the paint brush into the primer mixture and apply a thin coat to the repaired areas. Wipe away any runs with a clean cloth or paper towel. (You will still be able to see the repair area through the primer).
c) Allow the primer to dry or force dry with the Spectratek Infrared Heater or a blow dryer.
4. APPLY EPOXY PAINT
a) Measure out approximately 60ml (2 ounces) of Epolac paint.
b) Dab the paint brush into the paint and apply a thin coat to the repair areas. Wipe away any runs with a clean cloth or paper towel.
c) Allow the paint to dry or force dry with the Spectratek Infrared Heater or a blow dryer.
d) Proceed to Repair Procedures "C" and H, "Apply Protective Tape to the Door Panels".
NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.