Rear Doors - Water Leaks To Interior
NUMBER: 23-06-00GROUP: Body
DATE: Feb.18, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-53-99, DATED DEC.17, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699- 00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND NOW INCLUDES THE LEFT FRONT DOOR.
SUBJECT:
**Water Leak From Top Edge Of Right Or Left Front Door**
OVERVIEW:
This bulletin involves covering the step in the sheet metal with tape or a seam sealer.
MODELS:
2000 (PL) Neon
SYMPTOM/CONDITION:
Fig. 1:
**Water leaks from the top edge of the right and/or left front door into the passenger compartment. ** This leak is due to a step in the sheet metal laser welded joint seam (Figure 1).
DIAGNOSIS:
Fig. 1:
Inspect the right and left front door frame at the top laser welded joint seam. If one side of the joint is raised above the other, perform the Repair Procedure (Figure 1).
PARTS REQUIRED:
AR NPN 3M ScotchCal Paint Protection Film #84701 Or Equivalent
AR NPN Sure Check Clear Sealer (LSC) 5 oz Tube Or Equivalent
NOTE:
THE 3M SCOTCHCAL PAINT PROTECTION FILM AND SURE CHECK CLEAR SEALER CAN BE FOUND AT MOST LOCAL AUTOBODY SUPPLIERS. IF THE SURE CHECK CLEAR SEALER IS NOT AVAILABLE IT CAN BE OBTAINED BY CALLING 1-800-265-0790.
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OF OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
1. **Open the front door(s). Measure the top laser welded joint seam on each door, if the step is less than 1 mm (0.039 in), perform Repair Procedure 1. If the step is more than 1mm (0.039 in) perform the Repair Procedure 2. **
Repair Procedure 1 (Film) (Less Than lmm (0.039 In.)
1. Carefully pull the top of the window flag portion of the door trim panel outward to gain full access to the frame at the top laser welded joint seam. It is not necessary to remove the door trim panel.
2. Clean the step area with isopropyl alcohol.
3. Cut two 101 mm (4 in.) x 25 mm (1 in) pieces of the 3M ScotchCal Paint Protection Film or equivalent. The two pieces of film will be put one on top of the other before attaching to the vehicle.
4. Remove the protective paper from one piece of the film cut in step 3.
5. Place the piece of film directly over the other piece and use an applicator to completely smooth out any air bubbles. It is important for the appearance that the two pieces be lined up exactly and any air bubbles be removed.
6. Remove the protective paper from the joined pieces of film and beginning at the top edge, install over the step. Use a plastic spreader such as one used for applying body fillers to smooth out any air bubbles. Ensure the tape is firmly seated.
7. Using a razor blade trim the excess tape at the top of the door frame.
8. Push the window flag portion of the door trim panel in until the clip is fully seated.
9. Water test the vehicle to insure complete sealing.
Repair Procedure 2 (Sealer) (More Than 1mm (0.039 In.)
1. Remove the door trim panel.
Fig. 1:
2. Clean the step area with isopropyl alcohol (Figure 1).
Fig. 2:
3. Tape off the area around the step leaving a 1/4 inch space around the seam step (Figure 2).
4. Squeeze out a quarter size portion of the Sure Check Clear Sealer or equivalent onto a plastic pallet. Use a plastic spreader such as one used for applying body fillers, to spread the sealer across the taped off area. Ensure that the sealer is applied even and smooth.
5. Remove the tape, by pulling it away from the sealed area at right angles. This will prevent damage to the sealer edges.
6. Allow the sealer to cure for 45 minutes before closing the door.
7. Shut the door and water test the area. If the leak is still present, repeat steps 2 through 6 to add an additional layer of sealer onto the seam.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
**23-85-53-9O Door Frame, Right Or Left Front 0.2 Hrs.
Repair Procedure 1**
**23-85-53-91 Door Frame, Right Or Left Front 0.3 Hrs.
Repair Procedure 2**
FAILURE CODE: AM - Authorized Modification