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Door panel gap issue

MoreIceTea

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Just took the MY25 delivery, immediately spot the door panel fitment issue.

First thing noticed, driver side door does not align with the rear quarter panel. BMW spec it as +1.3mm to -0.3 mm, where + means door bump out and - means quarter panel bump out. I don't have the Supra special version of ISTA so the spec was from BMW Z4. This is barely within the +1.3mm.

IMG_3185.jpeg


For reference, passenger side has a perfect alignment, almost flush. These panels should always follow the principle that the one in the front should bump out a tiny little bit or flush to reduce wind noise and drag.

IMG_3186.jpeg


Now here is the real issue: This is not caused by door striker alignment. I moved to the front end of the driver side door. It sticks out to the hood. BMW spec it to be +0.8mm ±1.1mm, meaning either the hood should stick out for a max 1.9mm, or the door can stick out for 0.3mm max. In my case, this is the exact opposite. Door sticks out way more than 2mm, more than 7 times over the spec. That explains why there was excessively amount of wind noise on my way back to home.

IMG_3187.jpeg


Again as the reference, the passenger side looks perfectly fine, within the spec:

IMG_3188.jpeg


Now look at them at the front, Driver side door panel is bumping out from the hood, while passenger side is not.

IMG_3193.jpeg
IMG_3190.jpeg


There are two door hinges hold each of the door. It's a simple fix, loose the upper one so it's just able to move, push the door in and secure these bolts again. These are T40 Trox so the bits should be easy to get. They do require low profile bits and I'll have to get a new set, current set doesn't fit into the tiny gap between the door and the body. Torque spec is 19NM.

IMG_3189.jpeg


Panel gap spec, and torque for the door striker if these need to be adjusted as well. 21 NM is standard for most BMWs. I took them from Z4 since unable to get the ISTA for supra. They should be identical.
IMG_3183.jpeg
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This is such a typical issue for BMW, I own another BMW and it was much much worse. 5 panels were not aligned from factory, and hood won't close unless you slam it. I blame the Spartanburg plant at the time. But nope, BMW just don't care about checking if all the panel gaps even for these low volume vehicles, and apparently Toyota QA is not playing a role here.
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MoreIceTea

MoreIceTea

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FYI for my BMW, one of the doors stick out quarter of an inch at the rear end, and according to the dealer "This is within the spec".
 

BMWAF

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But nope, BMW just don't care about checking if all the panel gaps even for these low volume vehicles, and apparently Toyota QA is not playing a role here.
While I understand your pain, this is literally the first time I have seen someone complain about the panel gaps on an MKV. Maybe it was just a Friday build.. it happens. Good that its an easy fix at any rate.
 
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MoreIceTea

MoreIceTea

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While I understand your pain, this is literally the first time I have seen someone complain about the panel gaps on an MKV. Maybe it was just a Friday build.. it happens. Good that its an easy fix at any rate.
I was able to find a couple threads on early model years, mainly complaining the hood alignment. Door alignment is kinda rare.
 

adrian56k

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These panels should always follow the principle that the one in the front should bump out a tiny little bit or flush to reduce wind noise and drag.

That explains why there was excessively amount of wind noise on my way back to home.

IMG_3193.webp
IMG_3190.webp
If you're worried about wind noise, I don't think these small mm gaps are the issue, but you might want to look into wind deflectors. This is a known issue with stock Supras.

Anti-Buffeting Wind Deflectors - Mk5 Toyota Supra | Verus Engineering

Just a heads up, majority of aftermarket parts, especially the hood, don't fit 100% so have fun with that. Especially if you're critical of gaps by the mm.
 
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MoreIceTea

MoreIceTea

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If you're worried about wind noise, I don't think that these small mm gaps are the issue, but you might want to look into wind deflectors. This is a known issue with stock Supras.

Anti-Buffeting Wind Deflectors - Mk5 Toyota Supra | Verus Engineering

Just a heads up, majority of aftermarket parts, especially the hood, don't fit 100% so have fun with that.
Already got the AWE deflectors and will be installing these once it gets warmer. I'm getting these painted, clear coated using airbrush then polished so they match the black trim pieces.

You are right that these small gaps don't matter for most panels, but the exception is when it's either close to the mirror, or close to B pillar, where you can really hear anything that leaks into the cabin.
 

adrian56k

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Already got the AWE deflectors and will be installing these once it gets warmer. I'm getting these painted, clear coated using airbrush then polished so they match the black trim pieces.

You are right that these small gaps don't matter for most panels, but the exception is when it's either close to the mirror, or close to B pillar, where you can really hear anything that leaks into the cabin.
I'm confident all your wind noise issues will be solved once you install the wind deflectors.
 
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MoreIceTea

MoreIceTea

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I'm confident all your wind noise issues will be solved once you install the wind deflectors.
I don't have these installed yet so can't comment on how they reduce the noise when windows down, but I wasn't aware they reduce noise even when the windows up and closed. You are the first mentioned it.
 

razorlab

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I don't have these installed yet so can't comment on how they reduce the noise when windows down, but I wasn't aware they reduce noise even when the windows up and closed. You are the first mentioned it.
They don’t. They actually create more wind noise with the windows up.
 

FuzzyRev

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Just wait until you put it on the alignment rack

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Last time I looked "barely within spec" is "actually" within spec.

Phil
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