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    Rav42 Устранение Скрипа Задней Двери

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    This document provides a field fix for a rattling noise from the back door area of various Toyota RAV4 models. The rattle is caused by poor spot welds from a narrow welding pitch. The fix involves re-welding the problem spots by drilling holes and plug welding, then refinishing and reassembling the back door area.

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    Rav42 Устранение Скрипа Задней Двери

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    ВИКТОР СЕВЕР
    28 views6 pages
    This document provides a field fix for a rattling noise from the back door area of various Toyota RAV4 models. The rattle is caused by poor spot welds from a narrow welding pitch. The fix involves re-welding the problem spots by drilling holes and plug welding, then refinishing and reassembling the back door area.

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    This document provides a field fix for a rattling noise from the back door area of various Toyota RAV4 models. The rattle is caused by poor spot welds from a narrow welding pitch. The fix involves re-welding the problem spots by drilling holes and plug welding, then refinishing and reassembling the back door area.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    28 views6 pages

    Rav42 Устранение Скрипа Задней Двери

    Uploaded by

    ВИКТОР СЕВЕР
    This document provides a field fix for a rattling noise from the back door area of various Toyota RAV4 models. The rattle is caused by poor spot welds from a narrow welding pitch. The fix involves re-welding the problem spots by drilling holes and plug welding, then refinishing and reassembling the back door area.

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    You are on page 1of 6

    Section : Wind noise/

    Squeak/ Rattle
    Ref. No. : WS-3002
    Date : Dec., 2003
    Page : 1 of 6

    Area Application : USA/CANADA, Europe, Australia, G.C.C Countries,


    General
    Model Name : RAV4
    Model Code : ACA20, ACA21, ACA26, CLA20, CLA21, ZCA25, ZCA26

    Subject : Back Door Rattle

    This is to inform you of a field fix which has been developed to prevent the rattle noise from the
    back door area while driving.

    Cause:
    This rattle generated from the poor welding points that resulted from a shunt current due to the
    narrow welding pitch.

    < Back Door > < Back Door inside >


    Reinforcement,
    Back door inside panel

    Poor weld

    Narrow
    welding
    pitch
    Reinforcement,
    Spare wheel mounting

    Cut outer panel

    TOYOTA MOTOR CORPORATION Overseas Customer Service Technical Division


    Ref. No. : WS-3002
    Page : 2 of 6

    Field Fix Method

    Re-welding of the affected welding points LH


    and/or RH.

    1. Disconnect the battery negative terminal.


    2. Remove the spare tire cover and the
    spare tire.
    3. Remove the back spare tire bracket.
    Remove the 4 bolts and the back spare tire bracket.
    4. Remove the wiper arm.
    Remove the wiper arm head cap, the nut and the
    rear wiper arm.
    5. Remove the back door trim board.
    Using a screwdriver, remove the back door trim
    board.
    HINT:
    Tape the screwdriver tip before use.

    6. Remove the service hole cover.

    7. Remove the rear wiper motor.


    (a) Remove the grommet.
    (b) Disconnect the connector, then unfasten the 3
    bolts.
    (c) Remove the rear wiper motor.
    (d) Remove the wire harness.

    TOYOTA MOTOR CORPORATION Overseas Customer Service Technical Division


    Ref. No. : WS-3002
    Page : 3 of 6

    8. Apply a protective cover to the back door


    glass inside to avoid any damage during
    the welding.
    9. Drill two holes of 8mm in diameter and
    1.7mm in depth using spot-cutter (SST P/N
    09060-10060) as shown in the illustration
    below.
    (a) Drill one hole at the top of the upper spot-
    welding point as shown in the illustration
    below.
    (b) Drill the other hole at the bottom of the lower
    spot-welding point as shown in the illustration
    below.

    HINT:
    Drill slowly and carefully to confirm the hole depth.
    Be sure not to penetrate the reinforcement.

    A (A-A cross view)


    0.7 1.0 1.0
    (a) The top of the upper
    10. Reinforcement,
    spot-welding point 1.7mm
    Spare wheel mounting
    New

    Previous

    A
    (b) The bottom of the
    Reinforcement,
    lower spot-welding point
    Back door inside panel
    Back door inside panel

    TOYOTA MOTOR CORPORATION Overseas Customer Service Technical Division


    Ref. No. : WS-3002
    Page : 4 of 6

    10. Remove paint around the upper and lower


    spot-welding points, and remove paint in
    one place for earth connection point.

    11. Plug-weld the two holes using a plug


    welding machine. (Use a electrode of
    0.6mm in diameter)

    12. Smooth the two welded points using a


    grinder.

    13. Touch-up (paint) the position where paint


    has been removed.
    14. Apply primer (rust preventive paint) on the
    reverse side of the welded points.
    15. Remove the protective cover from the back
    door glass inside.

    TOYOTA MOTOR CORPORATION Overseas Customer Service Technical Division


    Ref. No. : WS-3002
    Page : 5 of 6

    16. Reinstall the rear wiper motor.


    (a) Reinstall the wire harness.
    (b) Reinstall the rear wiper motor with the 3 bolts.
    Torque: 5.5 N-m (55 kgf-cm, 49 in.-lbf)
    (c) Reinstall the grommet.
    (d) Connect the connector.
    17. Reinstall the service hole cover.
    HINT:
    Pull out the links through the service hole cover.

    18. Reinstall the back door trim board.

    19. Reconnect the battery negative terminal.


    20. Reinstall the wiper arm.
    (a) Reinstall the wiper arm and torque the nut by
    hand.
    (b) Operate the wiper once and turn the wiper
    switch OFF.
    (c) Adjust the installation position of the wiper arm
    to the position as shown in the illustration.
    A: Approx. 6.2 mm (0.244 in.)
    (d) Torque the nut.
    Torque: 5.5 N-m (55 kgf-cm, 49 in.-lbf)
    (e) Reinstall the wiper arm head cap.
    21. Reinstall the back spare tire bracket with
    the 4 bolts.
    Torque: 28 N-m (285 kgf-cm, 21 ft-lbf)
    22. Reinstall the spare tire cover and the
    spare tire.

    TOYOTA MOTOR CORPORATION Overseas Customer Service Technical Division


    Ref. No. : WS-3002
    Page : 6 of 6

    Production Effective:

    Body Power
    Model VIN (Reference only) Production Date Plant
    Type Train

    ACA20 JTEYH20V600038363 3 Door

    10th July, 2002 TAHARA

    JTEHH20V420184277

    ACA21 5 Door
    TOYOTA
    JTEHH20V926068540 15th July, 2002 Industries
    Nagakusa
    4WD

    CLA20 JTEYG20V200009462 3 Door

    10th July, 2002 TAHARA

    JTEHG20V000025112

    CLA21 5 Door
    TOYOTA
    JTEHG20V506011672 15th July, 2002 Industries
    Nagakusa

    ZCA25 JTEXR20V300014580 3 Door

    ZCA26 JTEGR20VX00032381 10th July, 2002 TAHARA

    2WD

    JTEGH20V820080113 5 Door

    ACA26
    TOYOTA
    JTEGH20V626010512 15th July, 2002 Industries
    Nagakusa

    TOYOTA MOTOR CORPORATION Overseas Customer Service Technical Division

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