Canada - Windows - Front Window Area Wind Noise
BulletinTSB2460
Issue Date
August 21, 2007
Title
WIND NOISE FROM FRONT SIDE WINDOW AREA AT HIGHWAY SPEEDS
Component
BODY COMPONENT
Models
'07 LS 460L (LONG WHEELBASE)
INTRODUCTION:
Some 2007 model year LS 460L (Long Wheelbase) customers may complain of a wind noise from the front side window area when driving at highway speeds. Use the repair procedure below to improve this condition.
NOTE:
It is important to note that this TSB addresses unusual interior noises caused by slight variations in certain parts, and by carefully following the instructions in this TSB, these noises can be improved. Your customers must be aware that some level of wind turbulence noise, especially in cross wind conditions, is present in all vehicles. A vehicle such as the LS 460L, which is one of the quietest vehicles on the market today, may tend to draw attention to normal wind turbulence or rushing sounds because of the relative absence of other ambient noises.
APPLICABLE VEHICLES:
- 2007 model year LS 460L (Long Wheelbase) vehicles produced BEFORE the Production Change Effective VIN shown below.
PRODUCTION CHANGE INFORMATION:
WARRANTY INFORMATION:
REQUIRED TOOLS & MATERIAL:
PARTS INFORMATION:
REPAIR PROCEDURE SECTIONS:
CHECKING FOR BODY PLUGS:
1. Check to make sure that the body plugs under the vehicle are present.
2. If the plugs are missing, order and install the body plugs.
3. Test drive the vehicle to see if the noise is gone or significantly reduced.
4. If noise is gone or significantly reduced, do not perform the rest of this TSB.
5. If the wind noise is still the same, perform this TSB.
REPAIR PROCEDURE OVERVIEW:
The repair procedure consists of installing EPT foam to all referenced locations as described in steps through F:
A. Add EPT foam behind chrome belt molding.
B. Add rubber stabilizer to outer door glass seal.
C. Add EPT foam to glass run rubber.
D. Add EPT foam behind body color windshield molding at base of A-Pillar.
E. Add EPT foam under fender at base of A-Pillar.
F. Add EPT foam to outside door panel near base of A-Pillar.
REPAIR PROCEDURE DISASSEMBLY:
1. Record the radio station presets.
2. Remove the front door trim board sub-assembly, front door glass sub-assembly and front door belt molding sub-assembly.
HINT:
Use the same procedures for the RH side and LH side. (The procedures listed below are for the LH side).
NOTE:
Overview illustration of parts involved.
A. Lower the front door glass so that approximately 2 inches of glass is remaining above the belt molding.
NOTE:
This will line up the window glass mounting bolts correctly for removal of the glass later in the process.
B. Remove the 6 clips and cowl top ventilator louver RH.
C. Disconnect the battery negative terminal.
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
D. Remove the front door inside handle bezel plug.
a. Using a plastic trim removal tool, detach the 3 claws and remove the bezel plug.
b. Remove the screw located behind the bezel plug.
E. Remove front power window regulator master switch assembly.\
a. Using a plastic trim removal tool, disengage the 2 clips.
b. Disconnect the connector and remove the power window regulator master switch.
c. Remove the screw located behind the switch assembly.
F. Remove the screw located below the armrest.
G. Remove the front door trim board sub-assembly.
a. Disengage the 13 clips and remove the trim cover.
b. Disconnect the 2 cables from the inside handle.
c. Disconnect the wiring connector from the front door trim board sub-assembly to the front door ECU LH.
H. Remove the front door trim cover.
a. Remove the screw.
b. Using a clip remover, detach the 5 clips.
I. Remove the front door belt molding end cover rear.
a. Using a trim removal tool, disengage the lower clip and remove the front door belt molding end cover rear.
J. Remove the door frame garnish.
a. Using a plastic trim removal tool, remove the 2 clips and garnish.
K. Remove the front No. 1 speaker assembly by removing the 4 screws, and disconnecting the connector.
NOTE:
The speaker is removed for access to the front window glass run. During assembly, use this access hole to make sure that the glass run is installed correctly inside the door.
L. Remove the lower half of the front door service hole cover LH
HINT:
Peel back the lower half of the cover and tape open temporarily to gain access to the door glass mounting bolt and the rear glass run
M. Remove the front door glass sub-assembly.
a. Remove the hole plug.
b. Remove the 2 bolts.
NOTE:
Be careful when removing the bolts as the glass may fall and become damaged.
c. Remove the door glass in the direction indicated by the arrows in the illustration.
NOTE:
Be careful NOT to damage the glass.
CAUTION:
The graphic shows additional components that need to be disassembled.
N. Remove the front door glass run.
O. Remove the front door no. 2 weatherstrip.
HINT:
This is the weatherstrip located at the top of the door.
P. Remove the front door belt molding sub-assembly.
NOTE:
- Only 3 of the 7 rivets need to be drilled out. (numbers 2, 4 & 5 in the illustration below)
- Drill out the 3 rivets that do NOT have a pink paint mark next to the rivet.
a. Wrap tape around a 4 mm (0.157 in.) drill bit.
b. Lightly press the drill against the rivet and drill off the rivet's flange.
c. Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled area.
NOTE:
- Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through.
- Do not pry the rivet with the drill, because this may cause damage to the installation holes of the rivet or the drill bit.
d. Using the two screws at the rear of the window opening.
e. Loosen the 5 belt line screws indicated by the arrows.
NOTE:
These 5 screws do not have to be fully removed
f. Remove the 4 screws and belt molding.
CAUTION:
Remove any fragments of the 3 rivets remaining on the molding assembly.
REPAIR PROCEDURE, STEP (A):
Perform the required repairs as described below.
Repair Step (A): Add EPT foam behind the chrome belt molding. (5 x 5 x 925 mm) Attach the new EPT foam (4) on the front door belt molding. Replace existing foam (2).
1. Remove the original EPT foam (2) and replace with new EPT foam (from the repair kit) as shown above (5 x 10 x 142 mm).
NOTE:
Make sure there is no gap between the new foam (2) and existing foam (3) & (1).
2. Attach the new foam (4), overlapping the existing foam (3).
NOTE:
The new foam (4) must be located 1 mm (0.03 in.) from the bottom edge of molding (see cross section diagram C-C'.)
HINT:
When installing foam (4), cut the foam 10 mm (0.3 in.) from the rear edge of the front door belt molding.
REPAIR PROCEDURE, STEP (B):
Step (B): Add rubber stabilizer to outer door glass seal lip (1.5 x 4 x 740 mm strip of rubber). Attach the rubber stabilizer (5) in the front door glass outer weatherstrip.
A. Clean the area of the molding where the rubber stabilizer will be installed. Make sure that the area is dry before installing the rubber stabilizer.
B. Attach the rubber stabilizer (5) using instant "super" glue.
C. Start from the rear (near the B-Pillar end of the belt molding).
D. Align the end of the rubber stabilizer to the last screw hole in the front door glass outer weatherstrip.
REPAIR PROCEDURE, STEP (C):
Step (C): Add EPT foam to glass run rubber. (7 x 7 x 70 mm foam)
Add EPT foam (6) in front door glass run at the rear lower corner of the window opening.
Remove the existing piece of foam behind the glass run at the location shown in the picture above. Attach the new longer piece of foam (6).
NOTE:
Position the new piece of foam (6) starting at the lower end of the previous piece of foam.
REPAIR PROCEDURE, STEP (D):
Step (D): Add EPT foam behind body color windshield molding (Roof Drip Side Finish molding) at base of A-Pillar. (20 x 15 x 55 mm foam)
1. Remove the front fender to cowl side seal.
2. Partially remove the roof drip side finish molding.
NOTE:
Detach and replace only the 4 WHITE clips from the bottom of the A-pillar and partially remove the molding up to the top of the windshield. The clip at the lowest position usually does not require replacement.
CAUTION:
- Be careful when removing the molding.
- Protect the Painted surfaces by applying masking tape during repair procedure.
- Move the bottom of the molding out from behind the fender and hood.
- Wrap the tip of the molding temporarily with a piece of cloth to protect the vehicle paint from damage.
3. Remove the 4 white clips from the molding by pushing on the retaining clips on the molding to release the white clips (one time use). Install 4 new clips to the A-pillar (not to the molding).
4. Attach EPT foam (7) at the front of the roof drip side finish molding.
NOTE:
- The front surface of the EPT foam must be aligned 30mm (1.18in.) from the cut out section in the molding.
- Align the foam so that the foam top surface is touching the bottom surface of the painted section of the molding.
REPAIR PROCEDURE, STEP (E):
Step (E): Add L-Shaped foam under the fender at the base of the A-Pillar.
Start by installing the foam piece from the top of the fender as shown.
NOTE:
When fully installed. The top of the foam should be parallel with the edge of the windshield.
Pull the adhesive backing paper off after the foam is correctly positioned.
This picture shows the position of the foam after installation behind the fender.
REPAIR PROCEDURE, STEP (F):
Step (F): Add EPT foam to outside door panel near base of A-Pillar. (5 x 10 x 50 mm)
Attach EPT foam to the door panel sheet metal. The location is at the front triangle area (behind where the chrome molding is normally located).
REASSEMBLY:
1. Assembly is reverse of disassembly.
2. Reset the radio presets and clock.
3. Test drive the vehicle to confirm that the noise is improved.
REPAIR PROCEDURE ASSEMBLY HINTS:
During assembly, be aware of the following areas where care must be taken.
1. When installing the chrome belt molding assembly, be sure to engage the tabs at the front and rear lower glass runs correctly.
HINT:
Start by engaging the rear tab, then the front.
2. To reduce the gap between the front door belt molding sub-assembly and door panel, firmly press down on the front door belt molding sub-assembly while the 5 screws are tightened.
3. The door inner belt seal assembly has four metal clips that engage the metal flange of the door inner panel. At the top of the rear 3 of the 4 clips, a piece of foam is inserted to prevent noise from the metal to metal contact. These foam pieces are not glued in place so the foam pieces can fall out when the door inner trim panel is removed.
When reassembling the door inner belt seal assembly to the door panel, check that the foam pieces are in place. If not, insert new pieces (5 x 5 x 25 mm).
4. The door belt inner glass seal can be installed incorrectly causing a gap at the front end of the door glass run at the belt. Make sure that the inner glass seal is sitting on the outside of the glass run.
NOTE:
The illustration on the right shows the glass installed incorrectly.
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.