Canada - Body - Front Window Wind Noise At Highway Speeds
BulletinTSB2798
Issue Date
July 7, 2010
Title
WIND NOISE FROM FRONT SIDE WINDOW AREA AT HIGHWAY SPEEDS
Component
BODY
Models
'07 - '09 LS460; '08-'09 LS600h
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. 2460.
- Step A: Install EPT Foam to Various Locations has been updated with new figures and application of additional foam.
- Step B: Replace and Seal Lower Door Frame Cover was added to the Repair Procedure.
TSB No. 2460 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding.
INTRODUCTION:
Some 2007 - 2009 model year LS460L (Long Wheelbase) and LS600hL vehicles may exhibit 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 LS460, 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.
APPLICABILITY:
PRODUCTION CHANGE INFORMATION:
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
WARRANTY INFORMATION:
REQUIRED TOOLS & MATERIALS:
PARTS INFORMATION:
REPAIR PROCEDURE: 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.
A. If noise is gone or significantly reduced, do NOT perform the rest of this TSB.
B. If the wind noise is still the same, perform this TSB.
REPAIR PROCEDURE OVERVIEW:
The repair procedure consists of Installing EPT foam to various locations (except for step B, where a rubber stabilizer strip is glued on).
A. Add EPT foam behind chrome belt moulding.
B. Replace and seal lower door frame cover.
C. Add rubber stabilizer to outer door glass seal lip.
D. Add EPT foam to glass run rubber.
E. Add EPT foam behind body colour windshield moulding at base of A-pillar.
F. Add EPT foam under fender at base of A-pillar.
G. 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 moulding sub-assembly.
HINT
Use the same procedures for the RH side and LH side. (The procedures listed below are for the LH side).
A. Lower the front door glass so that approximately 2 inches of glass is remaining above the belt moulding.
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 negative (-) battery 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.
1. Using the plastic pry tool, detach the 3 claws and remove the bezel plug.
2. Remove the screw located behind the bezel plug.
E. Remove front power window regulator master switch assembly.
1. Using the plastic pry tool, disengage the 2 clips.
2. Disconnect the connector and remove the power window regulator master switch.
3. 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.
1. Disengage the 13 clips and remove the trim cover.
2. Disconnect the 2 cables from the inside handle.
3. 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.
1. Remove the screw.
2. Using a clip remover, detach the 5 clips.
I. Remove the front door belt moulding end cover rear. Using the plastic pry tool, disengage the lower clip and remove the moulding end cover.
J. Remove the door frame garnish. Using the plastic pry tool, remove the 2 clips and garnish.
K. Remove the front No. 1 speaker assembly by removing the 4 screws, and disconnecting 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 front door service hole cover LH. Remove the lower half of the service hole cover.
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.
1. Remove the hole plug.
2. Remove the 2 bolts.
NOTE
Be careful when removing the bolts as the glass may fall and become damaged.
3. Remove the door glass by rotating the glass forward then pulling up as indicated by the arrows in the illustration.
NOTE
Be careful NOT to damage the glass.
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 Figure 19).
- Drill out the 3 rivets that do NOT have a pink paint mark next to the rivet.
1. Wrap tape around a 4 mm (0.157 in.) drill bit.
2. Lightly press the drill against the rivet and drill off the rivet's flange.
NOTICE
- 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.
3. Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled area.
Remove the two screws at the rear edge of the door frame.
4. Loosen the 5 belt line screws indicated by the arrows.
NOTE
These 5 screws do not have to be fully removed.
5. Remove the 4 screws and belt moulding (See Figure 22).
NOTICE
Remove any fragments of the 3 rivets remaining on the moulding assembly.
REPAIR PROCEDURE:
Perform the required repairs as described below.
Step A: Add EPT foam behind the chrome belt moulding.
1. Add EPT foam behind the chrome belt moulding.
Dimensions: 5 x 5 x 925 mm (0.20 x 0.20 x 36.40 in.)
2. Attach the NEW EPT foam on the front door belt moulding. (refer to 2 in figure 23).
3. Replace existing foam. (refer to 4 and 5 in Figure 23).
A. Remove the original EPT foam (refer to 4 and 5 in Figure 23) and replace with NEW EPT foam (from the repair kit) as shown above.
NEW EPT Foam Dimensions: 5 x 10 x 142 mm (0.20 x 0.40 x 5.6 in.).
NOTE
Make sure there is NO gap between the NEW foam and existing foam (refer to 4, 5, and 6 in Figure 23).
B. Attach and replace sponge sealer on front door belt moulding (Figure 24 shows proper placement of the new sponge sealers).
1. Attach the sponge sealer (7 x 7 x 70 mm with brown backing paper) from the Circle "B" area in Figure 24 and the edge indicated by "D" in cross sectional view from Figure 26.
2. Attach sponge sealer (5 x 5 x 925 mm) starting at the front surface of sponge sealer (7 x 7 x 70 mm with brown backing paper).
NOTICE
Ensure both sponge sealer sections, 2 (7 x 7 x 70 mm) with brown backing paper and 3 (5 x 5 x 925 mm), contact each other.
3. Attach the sponge sealer (12 x 12 x 60 mm) upward.
NOTICE
- Make sure the glass channel edge is sealed (refer to 1 in Figure 28).
- Both sponge sealer sections should contact each other at Circle 2.
C. Attach the NEW foam (refer to 5 in Figure 23), overlapping the existing foam (refer to 4 in Figure 23).
HINT
When installing foam (refer to 2 in Figure 23), cut the foam 10 mm (0.3 in.) from the rear edge of the front door belt moulding.
Step B: Exchange front door lower frame cover.
1. Remove the original door lower frame cover and clean up the adhesive mark of front door belt moulding to attach new cover.
2. Attach sponge sealer (3 x 3 x 19 mm) to the new door lower frame cover, aligning it to the edge of the cover.
NOTICE
There must be no gap at circle 1 (see Figure 30).
3. Attach sponge sealer (3 x 4 x 65 mm) just beside the tape.
NOTICE
There must be no gap at circle 2 (see Figure 30).
4. Install the modified lower cover to the front door belt moulding.
5. Cover the clip area clearance by FIPG (Non-Silicon Type) as in Figure 31.
Step C: Add rubber sealer to outer door glass seal lip.
Add rubber sealer to outer door glass seal lip.
Rubber Sealer Dimensions: 1.5 x 4 x 740 mm (0.06 x 0.16 x 29.13 in.)
Attach the rubber sealer (refer to 1 in Figure 32) in the front door glass outer weatherstrip.
Rubber Sealer Dimensions: 1.5 x 4 x 740 mm (0.06 x 0.16 x 29.13 in.)
1. Clean the area of the moulding that the rubber stabilizer will be installed. Make sure that the area is dry before installing the rubber stabilizer.
2. Attach the rubber stabilizer (refer to 1 in Figure 32) using instant "super" glue.
3. Start from the rear (near the B-Pillar end of the belt moulding).
4. Align the end of the rubber stabilizer to the last screw hole in the front door glass outer weatherstrip.
Step D: Add EPT foam to glass run rubber.
1. Add EPT foam to glass run rubber.
Foam Dimensions: 7 x 7 x 70 mm (0.07 x 0.07 x 2.76 in.)
2. Add EPT foam with white backing paper (refer to 6 in Figure 33) in front door glass run at the rear lower corner of the window opening.
A. Remove the original sponge sealers (7 x 7 x 40 mm) and attach the new sponge sealer (7 x 7 x 70 mm) from where the bottom of sponge sealer was attached originally inside the front door glass run.
B. Attach sponge sealer (7 x 7 x 70 mm with white backing paper) from dimple (Arrow 1) upward as shown in Figure 33.
3. Remove the existing piece of foam behind the glass run at the location shown in Figure 33. Attach the new longer piece of foam (refer to 6 in Figure 33).
NOTE
Position the NEW piece of foam (refer to 6 in Figure 33) starting at the lower end of the previous piece of foam.
Step E: Add EPT foam behind body colour windshield moulding at base of A-pillar.
1. Add EPT foam behind body colour windshield moulding (Roof Drip Side Finish moulding) at base of A-Pillar. (20 x 15 x 55 mm foam)
Foam Dimensions: 20 x 15 x 55 mm (0.79 x 0.60 x 2.17 in.)
2. Remove the front fender to cowl side seal.
3. Partially remove the roof drip side finish moulding.
NOTICE
- Be careful when removing the moulding.
- Protect the Painted surfaces by applying masking tape during repair procedure.
- Move the bottom of the moulding out from behind the fender and hood.
- Wrap the tip of the moulding temporarily with a piece of cloth to protect the vehicle paint from damage.
4. Push on the retaining clips on the moulding to release the white clips (one-time use). Install 4 NEW clips to the A-pillar (NOT to the moulding).
5. Attach EPT foam at the front of the roof drip side finish moulding
NOTE
- The front surface of the EPT foam MUST be aligned 30 mm (1.18 in.) from the cut out section in the moulding.
- Align the foam so that the foam top surface is touching the bottom surface of the painted section of the moulding.
Step F: Add EPT foam under fender at base of A-pillar.
1. Add I-Shaped foam under the fender at the base of the A-Pillar.
Start by installing the I-shaped spacer piece from the top of the fender as shown.
NOTE
- When fully installed, the top of the I-shaped spacer should be parallel with the edge of the windshield.
- Adhesive should be attached to fender.
2. Pull the adhesive backing paper off after the I-shaped spacer is correctly positioned.
Figure 41 shows the position of the I-shaped spacer after installation behind the fender.
Step G: Add EPT foam to outside door panel near base of A-pillar.
Add EPT foam to outside door panel near base of A-Pillar.
Foam Dimensions: 5 x 10 x 50 mm (0.20 x 0.40 x 1.97 in.)
1. Attach EPT foam to the door panel sheet metal. The location is at the front triangle area (behind where the chrome moulding is normally located).
2. Align the center of the EPT foam with the location as shown in the illustration by the red arrow. (See Figure 42)
3. Attach sponge sealer (4 x 7 x 70 mm) to door panel at back corner of belt line.
A. Attach the sponge sealer (4 x 7 x 70 mm) starting at Arrow 2, aligning it with the door panel flange.
NOTICE
The sponge sealer (4 x 7 x 70 mm) should contact the flange of door panel.
NOTE
These hints only apply to vehicles that received the foam repairs (2007 model year vehicles produced BEFORE the Production Change VIN shown in the Production Change Information table).
During assembly, be aware of the following areas where care MUST be taken.
1. When installing the chrome belt moulding 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 moulding sub-assembly and door panel, firmly press down on the front door belt moulding 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.
Foam Dimensions: 5 x 5 x 25 mm (0.20 x 0.20 x 0.98 in.)
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 (near A-pillar).
Make sure that the inner glass seal is sitting on the outside of the glass run.
NOTE
Figure 48 shows the glass seal installed incorrectly.
4. No gaps should exist in the window glass run as indicated in the illustration below. If gaps exist, reposition the door glass run until the gaps are removed.
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.