Interior - Rear Door Trim Panel/Seal Rattles

NVH
NV004-04

Title:
REAR DOOR TRIM PANEL LOWER SEAL RATTLE

Models:
'02 - '03 ES 300 & '04 ES 330

May 3, 2004

Introduction
In cold ambient temperatures, the rear door trim panels may rattle while driving. The door trim lower seal has been improved to correct this condition. Please use these instructions in conjunction with TSIB No. NV003-02 Rear Interior Door Trim Panel Rattle."

Applicable Vehicles

^ 2002 - 2003 model year ES 300 vehicles.

^ 2004 model year ES 330 vehicles produced BEFORE the Production Change
Effective VINs shown below.





Production Change Information





Parts Information





Warranty Information

Applicable Warranty*:

This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.





Required Tools & Material

NOTE:
The Max Gun Tacker(C) Staple Gun (or equivalent) and staples are available from any local hardware store.

Repair Procedure

1. Remove the rear door trim. Refer to the Technical Information System (TIS) 2002 to 2004 model year ES 300 or ES 330 Repair Manual: Engine Hood/Door: Rear Door: Overhaul.





2. Remove the 3 clips on the underside of the door trim inner surface (portions shown in red circles in Figure 1).

3. Cut the EPT sealer (shaded portion in Figure 1) which is applied to the door trim seal of the rear door trim inner side as shown.

4. Place the door trim on a stable workbench with the outer side facing up.





5. Remove the five staples of the door trim seal using a screwdriver and remove the door trim seal as shown below (Figure 2).

6. Install the new modified door trim seal using the following procedure.





A. Position the door trim seal (P/N: 67745-33021). There is a step 140 mm (5.5 in.) behind the courtesy lamp on the door trim. Place the rear end of the door trim seal flush against the step as shown (Figure 3).





B. Pull up the lip area away from the door panel as shown below (Figure 4).





C. Position the staple gun so that the staple can be located 2 mm (0.08 in.) away from the corner of the lip area as shown below (Figure 5).





D. Hold the staple gun securely, and staple the door trim seal in 11 places beginning from the rear side to the front side as shown (Figure 6).

NOTE:
Ensure the door trim is placed on a stable workbench and hold down the staple gun securely when stapling. If the door trim is not put on a stable workbench, adequate force cannot be applied when stapling and the staple may not penetrate the door trim, as shown in the illustration.





7. Fit EPT sealer to the door trim seal as shown (Figure 7).

EPT Sealer Dimensions:
Width: 10 mm (0.39 in.)
Length: 510 mm (20 in.)
Thickness: 10 mm (0.39 in.)

8. Reinstall the 3 clips to original positions.

9. Reinstall the rear door trim.