Repair Procedure

Perform the required repairs as described below.

Step A: Add EPT foam behind the chrome belt molding.

1. Add EPT foam behind the chrome belt molding.

Dimensions: 5 x 5 x 925 mm (0.20 x 0.20 x 36.40 in.)





2. Attach the NEW EPT foam on the front door belt molding (refer to 2 in Figure 23).

3. Replace existing foam (refer to 4 and 5 in Figure 23).

A. Remove the original EPT foam (refer to 4 and 5 in Figure 23) and replace with NEW EPT foam (from the repair kit) as shown above.

NEW EPT Foam Dimensions: 5 x 10 x 142 mm (0.20 x 0.40 x 5.6 in.).

Make sure there is NO gap between the NEW foam and existing foam (refer to 4, 5, and 6 in Figure 23).





B. Attach and replace sponge sealer on front door belt molding (Figure 24 shows proper placement of the new sponge sealers).








(1) Attach the sponge sealer (7 x 7 x 70 mm with brown backing paper) from the Circle "B" area in Figure 24 and the edge indicated by "D" in cross sectional view from Figure 26.





(2) Attach sponge sealer (5 x 5 x 925 mm) starting at the front surface of sponge sealer (7 x 7 x 70 mm with brown backing paper).

NOTICE
Ensure both sponge sealer sections, 2 (7 x 7 x 70 mm) with brown backing paper and 3 (5 x 5 x 925 mm), contact each other.

(3) Attach the sponge sealer (12 x 12 x 60 mm) upward.





NOTICE
^ Make sure the glass channel edge is sealed (refer to 1 in Figure 28).

^ Both sponge sealer sections should contact each other at Circle 2.

C. Attach the NEW foam (refer to 5 in Figure 23) overlapping the existing foam (refer to 4 in Figure 23).





NOTE
The NEW foam (refer to 2 in Figure 23) MUST be located 1 mm (0.04 in.) from the bottom edge of the molding (see cross section C - C' in Figure 29).

HINT
When installing foam (refer to 2 in Figure 23), cut the foam 10 mm (0.3 in.) from the rear edge of the front door belt molding.

Step B: Exchange front door lower frame cover.

1. Remove the original door lower frame cover and clean up the adhesive mark of front door belt molding to attach new cover.

2. Attach sponge sealer (3 x 3 x 19 mm) to the new door lower frame cover aligning it to the edge of the cover.





NOTICE
There must be no gap at circle 1 (see Figure 30).

3. Attach sponge sealer (3 x 4 x 65 mm) just beside the tape.

NOTICE
There must be no gap at circle 2 (see Figure 30).

4. Install the modified lower cover to the front door belt molding.





5. Cover the clip area clearance by FIPG (Non-Silicon Type) as in Figure 31.

Step C: Add rubber sealer to outer door glass seal lip.

Add rubber sealer to outer door glass seal lip.

Rubber Sealer Dimensions: 1.5 x 4 x 740 mm (0.06 x 0.16 x 29.13 in.)

Attach the rubber sealer (refer to 1 in Figure 32) in the front door glass outer weatherstrip.

Rubber Sealer Dimensions: 1.5 x 4 x 740 mm (0.06 x 0.16 x 29.13 in.)

1. Clean the area of the molding where the rubber stabilizer will be installed. Make sure that the area is dry before installing the rubber stabilizer.





2. Attach the rubber stabilizer (refer to 1 in Figure 32) using instant "super" glue.

3. Start from the rear (near the B-pillar end of the belt molding).

4. Align the end of the rubber stabilizer to the last screw hole in the front door glass outer weatherstrip.

Step D: Add EPT foam to glass run rubber.

1. Add EPT foam to glass run rubber.

Foam Dimensions: 7 x 7 x 70 mm (0.07 x 0.07 x 2.76 in.)





2. Add EPT foam with white backing paper (refer to 6 in Figure 33) in front door glass run at the rear lower corner of the window opening.

A. Remove the original sponge sealers (7 x 7 x 40 mm) and attach the new sponge sealer (7 x 7 x 70 mm) from where the bottom of sponge sealer was attached originally inside the front door glass run.

B. Attach sponge sealer (7 x 7 x 70 mm with white backing paper) from dimple (Arrow 1) upward as shown in Figure 33.

3. Remove the existing piece of foam behind the glass run at the location shown in Figure 33. Attach the new longer piece of foam (refer to 6 in Figure 33).

NOTE
Position the NEW piece of foam (refer to 6 in Figure 33) starting at the lower end of the previous piece of foam.

Step E: Add EPT foam behind body color windshield molding at base of A-pillar.





1. Add EPT foam behind the body color windshield molding (Roof Drip Side Finish molding) at base of A-pillar. (20 x 15 x 55 mm foam)

Foam Dimensions: 20 x 15 x 55 mm (0.79 x 0.60 x 2.17 in.)





2. Remove the front fender to cowl side seal.





3. Partially remove the roof drip side finish molding.

NOTICE

^ Be careful when removing the molding.

^ Protect the painted surfaces by applying masking tape during repair procedure.

^ Move the bottom of the molding out from behind the fender and hood.

^ Wrap the tip of the molding temporarily with a piece of cloth to protect the vehicle paint from damage.

4. Push on the retaining clips on the molding to release the white clips (one-time use). Install 4 NEW clips to the A-pillar (NOT to the molding).





5. Attach EPT foam at the front of the roof drip side finish molding.

NOTE
^ The front surface of the EPT foam MUST be aligned 30 mm (1.18 in.) from the cutout section in the molding.

^ Align the foam so that the foam top surface is touching the bottom surface of the painted section of the molding.

Step F: Add EPT foam under fender at base of A-pillar.

1. Add I-shaped spacer under the fender at the base of the A-pillar.





Start by installing the I-shaped spacer piece from the top of the fender as shown.

NOTE

^ When fully installed, the top of the I-shaped spacer should be parallel with the edge of the windshield.

^ Adhesive should be attached to fender.

2. Pull the adhesive backing paper off after the I-shaped spacer is correctly positioned.





Figure 41 shows the position of the I-shaped spacer after installation behind the fender.

Step G: Add EPT foam to outside door panel near base of A-pillar.

Add EPT foam to outside door panel near base of A-pillar.

Foam Dimensions: 5 x 10 x 50 mm (0.20 x 0.40 x 1.97 in.)

1. Attach EPT foam to the door panel sheet metal. The location is at the front triangle area (behind where the chrome molding is normally located).





2. Align the center of the EPT foam with the location as shown in the illustration by the red arrow (See Figure 42).





3. Attach sponge sealer (4 x 7 x 70 mm) to door panel at back corner of belt line.

A. Attach the sponge sealer (4 x 7 x 70 mm) starting at Arrow 2 aligning it with the door panel flange.

NOTICE
The sponge sealer (4 x 7 x 70 mm) should contact the flange of door panel.