Body - Water Leak at Top of Passenger Front Door
XL7Section Title: Body, Cab & Accessories
TSB No. TS 23 03027R
Division: Automotive
Category: Technical
SUBJECT:
WATER LEAK FROM THE TOP OF THE LEFT PASSENGER DOOR
MODEL(S):
XL7 (JC636)
YEAR:
2007
AFFECTED VIN(S):
~2S3DB917676114938 MANUFACTURED UP TO JAN. 19, 2007
REVISION:
The manufactured date shown in the affected VINs has been changed.
CONDITION:
The left passenger door may drip water into the passenger compartment during rain or car wash.
CAUSE:
A door panel seam at the top of the door may have uneven clearance causing a small opening between the weather seal and the door.
CORRECTION:
Please follow the instructions below to adjust the sealing pressure of the weather seal in the door opening against the door.
PART(S) INFORMATION:
WARRANTY CLAIM INFORMATION
Repair Procedure
1. Carefully remove the weather strip from the top of the left passenger door opening.
2. Bend a 50 mm wide area of the flange outward approximately 3 mm at the indicated location. See step 3.
3. Use a crescent wrench or a locking plier with a 50 mm wide jaw to evenly bend the indicated weld seam toward the door 2 to 3 mm from the original position.
CAUTION:
Place a clean shop towel between the jaw of the plier or crescent wrench and the weld seam to protect the paint.
4. Check the amount of bend by closing the door and measuring between the door and the seam.
5. The maximum distance is 15 mm from the inside of the door opening flange to the door edge.(Measured with the seal removed)
6. Re-install the weather stripping to the door opening.
7. With the door closed, re-check for leaks with gentle stream of water. If the leak is still present, bend the flange 1 to 2 more mm. Do not exceed 10 mm minimum gap. Please contact the S.M.A.R.T Hotline (Techline) if the water leak continues.
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