Recall - Potential Roof Opening Panel Separation
No.: P009Issue: 1
Date: 17 MAR 2008
SECTION: 501
RECALL: LR2 Roof Opening Panel Function
AFFECTED VEHICLE RANGE:
LR2 (LF) VIN: 8H000212 - 8H087347
Model Year: 2008
CONDITION SUMMARY:
ROOF OPENING PANEL FUNCTION
Situation:
A concern with the operation of the roof opening panel on LR2 vehicles has been identified where failure of either the left- or right-side roof opening panel guide rail could cause the roof opening panel to become detached from its operating mechanism and bind. The operator may hear a cracking noise if this condition occurs. If this condition occurs, the roof opening panel glass panel will remain attached to its frame, but further attempts to operate will result in continued noise and abnormal operation due to the binding condition. If a vertical force is applied (for example: a customer manually aiding the roof opening panel to close or wind lift) the glass panel can become fully detached from the vehicle. This unexpected separation of the roof openings glass panel could possibly distract the driver, increasing the risk of a vehicle crash or loss of vehicle control. In addition, should the glass panel fully detach from the vehicle it may impact nearby persons or objects resulting in personal injury and/or vehicle and property damage.
Action:
Install two retention inserts as per the Repair Procedure outlined below.
PARTS
WARRANTY:
NOTE:
Always check DDW to verify that the vehicle is affected by this Recall prior to undertaking any repair. Some vehicle within the VIN-range will have been repaired in port. DDW reflects only those vehicles affected and un-repaired.
NOTE:
Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.
Warranty claims should be submitted quoting program code P009. This will result in payment of the stated time. As option codes are used, there is no requirement for you to enter parts or labor; these are repeated here for information only.
REPAIR PROCEDURE
RAISING THE ROOF OPENING PANEL FOR ACCESS
1. Verify all roof opening panel functions; one-touch open / close, tilt, etc. If the roof opening panel does not operate correctly, diagnose and repair before proceeding as a separate Warranty Claim.
2. Apply a strip of masking tape to the front edge of the left- and right-hand sides of the fixed-section of the rear glass to prevent damage to the glass. (Figure 1)
NOTE:
The following step may require the aid of another technician.
3. Open the roof opening panel blind fully.
4. Switch ignition "ON".
5. Disable one-touch operation (Figure 2):
^ Remove the passenger compartment fuse box cover.
^ Locate fuse F10.
^ Open the roof opening panel and remove fuse F10 while the roof opening panel is moving rearward.
^ Install fuse F10.
^ Verify one-touch operation is disabled.
6. Open the roof opening panel glass fully.
7. Remove the roof opening panel glass guide locators (left-hand shown, right-hand similar). (Figure 3)
^ Remove the T15 Torx screw.
^ Apply downward pressure (1) and slide forward (2) to remove the guide locator (3).
^ Repeat for the opposite side.
CAUTION:
Do not operate the roof opening panel after supporting it in the raised position.
CAUTION:
Care must be taken when lifting and supporting the roof opening panel glass to prevent damage to the glass panel from contact with the accessory roof rails.
8. If fitted with accessory roof rails:
^ Apply strips of masking tape to the front corners of the roof opening panel glass to prevent damage to the glass when lifting the panel.
^ Close the roof opening panel glass to 85 mm (3.3 in) to release the front of the glass. (Figure 5)
^ Switch ignition off.
^ Lift up on front of roof opening panel.
^ Slide the roof opening panel glass 230 mm (9.0 in) rearwards from the front body edge to the line of the roof rail joint. (Figure 6)
^ Raise the roof opening panel glass by 75 mm (3.0 in)
^ Support the panel in the raised position with a soft block. (Figure 7)
^ Using a non-permanent marker, mark the seal to show the driving slider position to ease in installation. (Figure 8)
9. If not fitted with accessory roof rails.
^ Close the roof opening panel glass to 85 mm (3.3 in) to release the front of the glass. (Figure 5)
^ Switch ignition off.
^ Raise the roof opening panel glass by 100 mm (4.0 in).
NOTE:
The block must be positioned between the roof opening panel and the track, not the body.
^ Support the panel in the raised position with a soft block between the glass panel and the roof opening panel track. (Figure 9)
^ Using a non-permanent marker, mark the seal to show the driving slider position to ease in installation. (Figure 8)
INSTALLING THE BLOCKS
NOTE:
This step may require the aid of another technician.
NOTE:
Figure shows the screw on the inside of the vehicle and the block on the outside of the vehicle.
10. Install block (labeled "L" [left-hand] or "R" [right-hand]) with flat face positioned against the roof opening panel guide, using the supplied screw. (Figure 10)
^ Using a suitable magnetic tool, install the T10 Torx screw to the block and tighten to 0.9 Nm +/- 0.1 Nm (0.7 lbf-ft +/- 0.1 lbf-ft).
^ Repeat for the opposite side.
CAUTION:
Protect roof opening panel mechanism to prevent contamination by small plastic debris.
11. Using a clean shop rag, cover the roof opening panel mechanism to prevent contamination by small plastic debris.
12. Using a suitable utility knife, cut upwards to the metal bar and remove the plastic segment (shaded in Figure 11).
^ Repeat for the opposite side.
NOTE:
Only cut the guide enough to provide a stress-relief. It is not necessary to remove any of the guide material.
13. Using a suitable utility knife, cut roof opening panel guide approximately 6 mm (0.2 in) until it reaches the metal insert. (Figure 12)
^ Repeat for the opposite side.
14. Remove the protective cover / shop rag from the roof opening panel mechanism.
SETTING THE ROOF OPENING PANEL INTO PLACE
NOTE:
Left-hand shown, right-hand similar.
1. Remove the support block.
2. If fitted with accessory roof rails, slide the roof opening panel glass forwards until it is 85 mm (3.3 in) from the body edge. (Figure 5)
CAUTION:
Damage will occur if the roof opening panel is not aligned correctly.
NOTE:
This step requires the aid of another technician.
NOTE:
Left-hand shown, right-hand similar.
3. Align the connection bar with the roof opening panel guide. (Figure 13)
NOTE:
The mark arrowed in Figure 14 is the same mark as arrowed in Figure 6.
NOTE:
Once aligned, the front glass panel will "drop in".
4. Align the connection bar on the glass panel with the driving slider. (Figures 14 & 15)
^ Carefully align and position the roof opening panel glass to the driving slider.
^ The front of the glass panel will drop in when correctly aligned.
If resistance if felt, realign the connection bar and roof opening panel glass to the driving slider.
CAUTION:
Do not apply downward pressure while operating the roof opening panel.
NOTE:
A slight noise may be heard when the roof opening panel is operated for the first time.
5. Switch ignition "ON".
6. Using the roof opening panel switch, open the glass panel rearwards 50 mm (2.0 in) to ensure the panel is positioned correctly in the guide rail. (Figure 16)
^ If correctly positioned, fully open the roof opening panel.
^ If not correctly positioned, repeat steps 2-4.
7. Switch ignition off.
INSTALL THE ROOF OPENING PANEL GLASS GUIDE LOCATOR
NOTE:
The following refer to the numbers within Figure 17.
1. Position the front of the guide locator (1)
2. Raise upwards (2)
3. Position onto rail and slide rearwards (3).
4. Install T15 Torx screw and tighten to 2.5 Nm +/- 0.25 Nm (1.8 lbf-ft +/- 0.18 lbf-ft).
^ Repeat for the opposite side.
CAUTION:
Ensure the net deflector folds protrude rearwards when closing the roof opening panel glass. The net deflector is set to fold-up in one direction. If it is reversed, the folds can protrude forwards and can get trapped between the seal and the glass, and could provide a water leak path.
5. Switch ignition "ON".
6. Close roof opening panel.
INITIALIZE ROOF OPENING PANEL MOTOR
1. Manually initialize the roof opening panel motor:
^ Raise the roof opening panel glass to the full-tilt position.
^ Release the switch.
NOTE:
Do not release the switch until the roof opening panel has completed the open / close cycle.
^ Press and hold the front leading edge of the switch.
^ After 20 seconds, the roof opening panel glass will:
^ Stall in the tilt mode (causing a noise).
^ Perform a full open / close cycle.
^ Release the switch.
2. Remove all protective tape.
VERIFY ROOF OPENING PANEL OPERATION
NOTE:
One-touch close is inoperable from the tilt position.
1. Verify correct operation of the roof opening panel:
^ One-touch open (tilt and full-open).
^ One-touch close (from the full-open position). Tilt (from the full-closed position).
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