Interior - Buzz/Rattle From Front/Rear Door panels
NUMBER: 23-009-07GROUP: Body
DATE: March 20, 2007
SUBJECT:
Radio Speaker Misdiagnosis - Rattle/Buzz Sounds in Door Modules
OVERVIEW:
This bulletin involves removing the Bolster and Door Panel Modules and applying foam tape at critical points of wiring, actuator rods, panel connection points and the side Instrument Panel end caps.
PARTS REQUIRED:
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
SYMPTOM/CONDITION:
Rattle or Buzz like sounds in the door module area, (front or rear). This is most noticeable with the radio on during high volume/deep base settings and is most likely caused by door links or wiring vibrating in the door module. The door module rattle or buzz sounds will not be heard with the radio off. Several areas of concern are involved and if the vehicle operator complains of rattles or buzz noises, perform the following Repair Procedure on ALL doors and both ends of Instrument Panel before replacing speakers.
DIAGNOSIS:
If the symptom/condition is present, perform the Repair Procedure.
FRONT DOOR REPAIR PROCEDURE:
1. Lower the front windows:
a. MK: 89 mm (3.5 in.)
b. PM: 102 mm (4 in.)
2.5GLower the rear windows 152 mm (6 in.), (Preparing for rear door Repair Procedure).
3. Disconnect and isolate negative battery cable.
4. Pull weatherstrip off front of door at wire harness door bracket entering door. Remove 2 bolts, (5 mm hex), at retaining plate. Disconnect wire harness from body of vehicle. Pull wiring from behind weatherstrip.
5. Remove trim cap and screw, (T-20 Torx), at inside door handle.
6. Remove manual window crank handle, (if equipped).
7. Remove interior trim flag for outside mirror, disconnect wire harness to electric mirror, (if equipped).
8. Using trim stick, remove speaker cover.
9. Remove top front and lower rear speaker screws only, (T-20 Torx). (Speaker will stay with door module).
10. Remove bolt(s), (10 mm hex), retaining door module near speaker:
a. MK: 2 bolts.
b. PM: 1 bolt.
11. Remove (2) longer bolts, (10 mm hex), retaining door module at bottom of door module.
12. Remove trim cap and screw, (T-20 Torx), at inside door pull cup.
13. Using trim stick, release bolster, swing down and allow to hang by tethers.
14. Release both window latches on regulator, pull up and roll back of window up to remove from door from the outside of door. Set glass aside on protected surface.
15. Remove bolts, (10 mm hex), behind bolster, (2 in regulators and 1 at center of door module).
16. Disconnect linkages at door latch to:
a. Outside door handle, (both sides of vehicle).
b. Lock cylinder, (drivers side only).
17. Remove (3) screws, (T-30 Torx), retaining latch to door.
18. Maneuver door module up, then forward, then down to remove from door.
19. Place removed door module face down on a clean, protected surface.
20. Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA), in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 1) for MK and (Fig. 2) for PM. Reinstall wiring and convolute tubing in retainers.
21. Follow specific instructions based on vehicle below:
a. MK: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 25 mm (1 in.) lengths and stack, (if needed), to back up actuator rods as shown in (Fig. 1), above. Place a piece of Itch and Squeak Tape, (p/n 05019054AA) on the top layer of Closed Cell Low Density Foam Tape where it contacts actuator rod.
b. PM: Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 12 mm (.5 in.) length to back up actuator rod as shown in (Fig. 3) below.
NOTE:
Actuator rod is removed and pulled from stay for easy installation
22. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) below. Bottom of Bolster is shown, Top is similar.
23. Loosely install the lower bolt(s), (10 mm hex), for window regulator in bottom of door module. Thread bolt(s) into door module so that threads protrude through module about 12 mm, (.5 in.) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module. Be sure window regulator guide tab is in proper position in door module.
24. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weather-strip and guide window regulators and door latch mechanisms in place inside door shell.
25. Align top of door module in position and slide down in place. Lower window regulator bolts installed earlier in step Step # 23 should slide in "V" notch(s) in bottom of door with regulators inside door shell.
NOTE:
Be sure mirror wiring protrudes through opening in top of door module.
26. Start, (do not tighten), all remaining bolts for door module and window regulators. Once all bolts are loosely installed, tighten all bolts to 8 N.m (71 in. lbs.)
27. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.).
28. Connect linkage(s) to door latch mechanism.
29. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip.
30. Connect wire harness to body from door.
31. Connect mirror wire harness, (if equipped) and install trim flag.
32. Install screw, (T-20 Torx), at inner door handle and replace trim.
33. Install door glass making sure glass clips into regulator securely.
34. Install door bolster trim panel.
35. Install screw, (T-20 Torx), and trim cap at door pull cup.
36. Install manual window crank handle, (if equipped).
37. Install speaker screws, (T-20 Torx), and speaker grille.
38. Clean glass.
39. Repeat this process for other front door.
REAR DOOR REPAIR PROCEDURE:
1. Pull weatherstrip off front of door at wire harness bracket entering door. Remove 2 bolts, (5 mm hex) at wire harness door bracket. Disconnect wire harness from body of vehicle.
2. Remove trim cap and screw, (T-20 Torx), at inside door handle.
3. Remove manual window crank handle, (if equipped).
4. Using trim stick, remove speaker cover.
5. Remove top front and lower rear speaker screws only. (Speaker will remain with door module).
6. Remove bolt(s), (10 mm hex), retaining door module near speaker.
a. MK: 2 bolts
b. PM: 1 bolt
7. Remove (1) longer bolt, (10 mm hex), retaining door module and window regulator at bottom of door module.
8. Remove trim cap and screw, (1-20 Torx), at inside door pull cup.
9. Using trim stick, release bolster, swing down and allow to hang by tethers.
10. Release window latch retainer at bottom of glass from regulator.
11. Slide glass up in frame and duct tape from outside of window, up over frame to inside of window in the full UP position.
12. Remove bolts, (10 mm hex) behind bolster:
a. MK: 2 in regulator and 1 at center of door module.
b. PM: 1 in regulator, 2 in window motor brace and 1 in door module.
13. Disconnect linkage(s) at latch to:
a. MK49 - Compass 1). Outside door handle and 2). Fulcrum.
b. MK74 - Patriot and PM - Caliber Outside door handle.
14. Remove (3) screws, (T-30 Torx), retaining latch to door.
15. Maneuver door module up, then forward, then down to remove from door.
16. Place removed door module face down on a clean, protected surface.
17. Follow specific instructions based on vehicle below:
a. MK: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 6) below. Reinstall wiring and convolute tubing back in retainers.
b. PM: Remove wiring and convolute tubing from retainers and wrap with Open Cell Foam Tape, (p/n 05019057AA) in the areas described in below. Any wiring or convoluted tubing that is not wrapped or can come in contact with the door module shell should be wrapped with foam tape as shown in (Fig. 7) below. Reinstall wiring and convolute tubing back in retainers.
18. Cut the Closed Cell Low Density Foam Tape, (p/n 05019058AA) into 1" lengths and stack (if needed) to back up actuator rods with Itch and Squeak Tape, (p/n 05019054AA) as top layer, as shown in (Fig. 8) below.
NOTE:
If # 2 below is not existing, install it.
19. Follow specific instructions based on vehicle below:
a. MK: cut 12 mm (.5 in) Open Cell Foam Tape, (p/n 05019057AA) and put at top rear corner of door module as shown in (Fig. 9) below. Do not allow Foam Tape to protrude past outside edge of door module.
b. PM: cut 1.5 in Closed Cell Low Density Foam Tape, (p/n 05019058AA) and put at top rear corner of door module, inside outer lip as shown in (Fig. 10) below. Do not allow Foam Tape to protrude past outside edge of door module.
20. Turn door module over, (face up) and cut 6 lengths of Open Cell Foam Tape, (p/n 05019057AA) into 6.5 mm (.25 in.) strips lengthwise. Install on door bolster TOP and BOTTOM horizontal surfaces on the smooth surface where it meets door module opening. Start at the forward most section of the bolster to the rear most area of the horizontal surface isolating the Bolster from the mating surface of the door Panel Module. See (Fig. 4) above for front door.
21. Loosely install the longer bolt, (10 mm hex), for window regulator in bottom of door module. Thread bolt into door module so that threads protrude through module about 9.5 mm, (.375 in) then start threads into bottom of regulator. Bolt should now be threaded into door module and regulator with a space in between regulator and door module, similar to (Fig. 5) above. Be sure window regulator guide tab is in proper position in door module.
22. Position door module in door shell making sure to slip wiring to body, (at front of door), behind weatherstrip and guide window regulator and door latch mechanisms in place inside door shell.
23. Align top of door module in position and slide down in place. Lower window regulator bolt installed earlier in step Step # 21 should slide in "V" notch in bottom of door with regulator inside door shell.
24. Start, (do not tighten), all remaining bolts, (10 mm hex), for door module and window regulator. Tighten all bolts to 8 N.m (71 in. lbs.)
25. Install door latch screws, (T-30 Torx), Tighten to 7 N.m (62 in. lbs.).
26. Connect linkage(s) to door latch mechanism.
27. Position wire harness door bracket at front of door and install screws, (5 mm hex). Install weatherstrip.
28. Connect wire harness to body from door.
29. Install screw, (T-20 Torx), at inner door handle and replace trim.
30. Remove previously installed tape from door glass and slide door glass down making sure glass clips into regulator securely.
31. Install door bolster trim panel.
32. Install screw, (T-20 Torx), and trim cap at door pull cup.
33. Install manual window crank handle, (if equipped).
34. Install speaker screws and speaker grille.
35. Clean glass.
36. Repeat this process for other rear door.
INSTRUMENT PANEL END CAP REPAIR PROCEDURE:
1. Loosen weatherstrip along front edge of instrument panel end cap.
2. Remove instrument panel end cap.
3. Cut 8 (.5 in.) pieces, (4 for each side) of Open Cell Foam Tape, (p/n 05019057AA).
4. Install 4 pieces of Open Cell Foam Tape at the mating surface for the cover as shown in # 1 (Fig. 11) below.
5. Cut 6 square pieces, (3 for each side) of Closed Cell Low Density Foam Tape, (p/n 05019058AA).
6. Stack 3 pieces of Closed Cell Low Density Foam Tape and cover top layer with Itch and Squeak Tape, (pin 05019054AA). Adhere stack towards the center area of cover on the end of the instrument panel as shown in #2 (Fig. 11) below.
7. Replace instrument panel end cover and reposition weatherstrip.
8. Repeat steps (1) through (7) for other side of instrument panel.
9. Reconnect battery negative cable.
10. Check operation of all door related systems, and audio functions.
11. Reset clock for customer satisfaction.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.