Canada - Doors - Front Door Wind Noise

Bulletin
TSB2592

Issue Date
September 30, 2008

Title
Front Door Wind Noise

Component
Body

Models
'07-'08 ES 350

TSB REVISION NOTICE:
- November 26, 2008: The Parts section has been updated.
Previous versions of this TSB should be discarded.

INTRODUCTION:
Some 2007-2008 model year ES 350 customers may complain of a wind noise from the front side window area when driving at speeds greater than 64 km/h. Perform the inspection procedure to verify the wind noise is heard from the front lower corner of the door window and use the following repair procedure 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.






APPLICABLE VEHICLES:






PRODUCTION CHANGE INFORMATION:






WARRANTY INFORMATION:






PARTS INFORMATION:






REQUIRED SSTs:

INSPECTION PROCEDURE:






Verify the wind noise is coming from the black triangle window moulding in front of the door glass by taping the joints and confirming the source of noise.

REPAIR PROCEDURE:

NOTE
Perform this repair procedure to both sides of the vehicle.

DISASSEMBLY PROCEDURE
1. Fully open the front door glass.






2. Using a screwdriver with the tip wrapped with protective tape, disengage the 3 claws, and remove the front door inside handle bezel plug.
3. Remove front door armrest base panel assembly.






A. Using a screwdriver with the tip wrapped with protective tape, disengage the 5 claws and 3 clips, and remove the front door armrest base panel assembly.
B. Disconnect the connector.

4. Remove courtesy light assembly.






A. Using a screwdriver with the tip wrapped with protective tape, disengage the claw and remove the courtesy light assembly.
B. Disconnect the connector.






5. Remove the door armrest cover.
6. Remove front door trim board sub-assembly.






A. Remove the 5 screws.
B. Using a clip remover, disengage the 9 clips.






C. Pull up the front door trim board in the direction indicated by the arrow.
D. Disengage the reference bosses from the front door panel.
E. Raise the front door trim board to disengage the 4 claws and remove the front door trim board together with the front door inner glass weatherstrip.






F. Disconnect the cables and each connector from the back side of the inside handle and remove the front door trim board subassembly.






7. Remove door frame garnish.
Using a clip remover, remove the clip. Disengage the clip and remove the front door frame garnish.






8. Partially remove the upper portion of the weatherstrip on the door.
A. Peel the back upper corner of the weatherstrip and disengage the clip.
B. Remove the weatherstrip down the top edge of the door revealing the 8 rivets. Be sure to peel off the double sided tape at the front lower corner of the weatherstrip.

NOTE
After removing the upper portion of the weatherstrip, it can be left hanging.






9. Partially remove the upper front door glass run. The upper glass run can be partially removed by pulling it down from the door frame.

NOTE
This is done to prevent damage during disassembly of the outer moulding.






10. Remove the front door rear window frame moulding.
When removing the front door rear window frame moulding, heat the vehicle body and front door rear window frame moulding using a heat light.

NOTE
Do not heat the vehicle body and front door front lower frame upper cover excessively. This may cause damage to the paint and door.






A. Disengage the clip on the upper back corner of the door.






B. Using a moulding remover, peel off the double-sided tape and remove the front door rear window frame moulding.






11. Put protective tape around the front door belt moulding assembly.
A. Using a moulding remover, disengage the 5 clips and remove the front door belt moulding assembly.






12. Remove the front door outside moulding subassembly.
A. Prepare a drill with a 4 mm (5/32 in.) bit drill.
B. Tape and cover the drill bit 5 mm from the tip. Use the tape as a drill depth guide.
C. Free the flange of head of each rivet by drilling to the 5 mm point on the bit.
D. Remove each of the 8 rivets.






E. Disengage the clip and guide, and remove the front door outside moulding sub-assembly from the door frame.

INSTALLATION PROCEDURE:
1. Install front door outside moulding sub-assembly.






A. Engage the moulding guide into the door frame.
B. Engage the clip and install the front door outside moulding sub-assembly to the door frame.






C. Using an air riveter or hand riveter install the 8 new rivets in the order shown in the Figure.

NOTE
- Do not leave any space between the moulding and door frame.
- Firmly hold together the 2 items while installing the rivet.
- Do not tilt the riveter when installing the rivet to the moulding.
- Do not leave any space between the rivet head and moulding.










D. Confirm that the rivets are seated properly against the moulding.

NOTE
Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.






2. Install front door front lower frame upper cover

When installing the front door front lower frame upper cover, heat the vehicle body and front door front lower frame upper cover using a heat light.

NOTE
Do not heat the vehicle body and front door front lower frame upper cover excessively.






A. Remove the release paper from the front door front lower frame upper cover. After removing the release paper, keep the exposed adhesive free from foreign matter.
B. Engage the clip and install the front door front lower frame upper cover.

3. Install front door rear window frame moulding.






A. Clean the vehicle body surface.

NOTE
Using a heat light, heat the vehicle body.

B. Remove the double-sided tape from the vehicle body

NOTE
Wipe off any tape adhesive residue with cleaner.

C. Remove the release paper from the new front door rear window frame moulding.

NOTE
After removing the release paper, keep the exposed adhesive free from foreign matter.






D. Engage the clip and install the front door rear window frame moulding.
E. Firmly press on the moulding making sure it properly adheres to the door.






4. Install front door glass run.
Ensure that the glass run fits tightly into the door frame.






5. Install the front door upper portion of the weatherstrip.
A. Ensure that the double sided tape adheres to the lower portion of the outer moulding assembly, and the weatherstrip fits tightly back into position
B. Clip in the upper back corner of the weatherstrip.

6. Install door frame garnish.






A. Engage the clip and install the door frame garnish.
B. Install the rear clip.

7. Re-Install the front door handle cables, trim board sub-assembly, door armrest, courtesy light, armrest base panel and connector, and handle bezel plug in reverse order of disassembly.






8. Install front door belt moulding assembly.
A. Slide the front portion of the belt moulding into the lower outside moulding.
B. Firmly press down on the moulding and ensure all clips snap into position.

9. Test drive the vehicle to confirm that the wind noise is reduced.

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.