Body - Popping Noise Upon Opening/Closing Front Doors

NVH
NV003-07
REVISED

Title:
DOOR CHECK POPPING NOISE

Models:
'04 - '06 Sienna

March 23, 2007

TSB REVISION NOTICE:

^ November 28, 2007: The note below the Warranty Information table has been updated.

^ July 6, 2007: The Warranty Information table has been updated with separate "Combo A" Op Codes.

^ May 29, 2007: The Warranty Information has been updated. The note before step 1 of the Repair Procedure has been updated.

Previous versions of this TSB should be discarded.

Introduction

Some customers may experience a popping noise when opening and/or closing the front doors on their vehicle. Use the following procedure to diagnose and correct the condition.

Applicable Vehicles

^ 2004 - 2006 model year Sienna vehicles produced BEFORE the Production Change Effective VINs shown below.





Production Change Information





Warranty Information

Applicable 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.

Repair Procedure

NOTE:
Inspect the door frame around the door check mounting area.

^ If a spot weld or check mount area is cracked or split, the following repair method CANNOT be performed and the door assembly MUST be replaced.

^ If a door is to be replaced, all hemming flanges and body panel seams MUST be sealed with body seam sealer prior to painting the door assembly. Refer to the Technical Information System (TIS), CRIB (Collision Repair Information Bulletin), "Bulletin # 16:1987 All: Sealing of Hemming Flanges And Body And Panel Seams," and "Bulletin # 44:1991 All: Body Seam And Joint Sealer Application ". (Note that the CRIBs are located within the CR tab of the main TIS screen.)

^ If a spot weld has separated, have a body shop perform the following procedure.





1. Confirm that a spot weld has separated by pushing on the door check mounting panel. If the panel can be pushed in by hand, the weld is loose.

2. At the spot weld, drill an 8.0-mm (0.32-in.) hole through the door frame ONLY.





NOTE:
When drilling and welding the door, be sure to protect other components of the door, either by covering them or removing them.

3. Fill the drilled area using a MIG welder to connect all panels.

4. Use an appropriate color touch up paint on the welded material.

NOTE:
When touching up or fogging in paint, be sure to protect unaffected areas of the door and vehicle from overspray.