Canada - Body - Popping Noise Upon Opening/Closing Front Doors

Bulletin
TSB2723R

Issue Date
May 30, 2007

Market
Canada

Title
DOOR CHECK POPPING NOISE

Component
BODY COMPONENT

Models
'04 - '06 Sienna

TSB REVISION NOTICE:
- August 30, 2007: OPN code has been change under Warranty Information.
The previous 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:

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 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.







NOTE:
- It may be necessary to remove the door from the vehicle to gain sufficient access for drilling and welding. If so, lay door flat on a padded workstation.
- Doors on early production vehicles have two (2) panels, the door frame and the door check mount panel. Doors on later vehicles have a third reinforcement panel. Refer to the illustration for reference.







2. If there are two (2) panels in the door, the door frame and the door check mount, drill a 7.5-mm (0.295-in.) hole through one panel (refer to "A" in the illustration). If there are three panels in the door, the door frame, the door check mount and a reinforcement panel, drill a 7.5-mm (0.295-in.) hole through two (2) panels (refer to "B" in the illustration).

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.

Road test the vehicle to confirm the condition is NO longer present.

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.