Body - Rust Beneath Trunk Lid Trim Panel
NUMBERXT501-039
DATE
23 Oct 2006
MODEL
X-TYPE
SECTION:
501-08 - EXTERIOR TRIM AND ORNAMENTATION
Rust Bleeding from Underside of Bright Finish Trim Panel
AFFECTED VEHICLE RANGE:
X-TYPE
VIN:
C00001 to E90690
Model Year:
2002 to 2006
CONDITION SUMMARY:
RUST BLEEDING FROM UNDERSIDE OF TRUNK LID BRIGHT FINISH TRIM PANEL
Situation:
Rust can be seen beneath the trunk lid finish trim panel. The rust is typically seen at the top corner of the license plate mounting area where the bright finish trim panel meets the body.
A sharp corner of the bright finish trim panel can cut into the outer surface of the body paint at assembly. Over time, water can penetrate the surface paint and lead to the corrosion. Action: Should a customer express this concern, refer to the Repair Procedure detailed in this bulletin to complete the service fix.
PARTS:
C25 45279.....Foam pad (set of 2 as required) Qty 1
C25 45280.....Plastic washer (set of 2 as required) Qty 1
WARRANTY:
NOTE:
This operation does not require a repainting of the whole of the trunk lid. Repair times and materials are to be claimed for repairing, cleaning and painting the affected area, as outlined in the Body and Paint Repair Manual.
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.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
1. Open the trunk lid.
2. Remove the pull-down handle retaining screws. (Figure 1)
3. Remove the pull-down handle.
4. Remove the latch cover retaining scrivets. (Figure 1)
5. Remove the latch cover.
6. If a warning triangle is fitted, perform the following:
^ Remove the warning triangle.
^ Remove the warning triangle holding scrivets.
^ Remove the warning triangle holder.
7. Remove the trunk lid interior trim panel retaining clips. (Figure 2)
8. Remove the trunk lid interior trim panel.
9. Disconnect the electrical connector to the license plate lamp. (Figure 3)
10. Disconnect the electrical connector to the trunk lock release button. (Figure 4)
11. Displace and reposition the rubber grommet from the trunk lock harness. (Figure 5)
12. Displace and reposition the electrical harness.
13. Remove the four finish trim panel fastener nuts. (Arrowed in Figure 6)
14. Undo the two finish trim panel retaining clips and remove the trim panel. (Figure 7)
NOTE:
This operation does not require a repainting of the whole of the trunk lid. Repair times and materials are to be claimed for repairing, cleaning and painting the affected area, as outlined in Body and Paint Repair Manual located on GTR.
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > Service Information/ X400 - X-TYPE > Body and Paint Repair Manual
15. Refer to GTR Body and Paint Repair Manual and clean, repair and paint the corroded area of the body panel to match the vehicle.
16. Measure and cut two 6 mm (0.25 in) thick foam pads to 25 mm x 25 mm (1.0 in x 1.0 in) square dimension.
17. Install one foam pad at each end of the finish trim panel. (Inset in Figure 8)
NOTE:
The Teflon washers are installed under the foam pad surrounding the fastener bolts.
18. Perform the following to the two fastener bolts illustrated by the arrows in Figure 8:
^ Lift the foam pad surrounding the fastener bolt. (Arrowed in Figure 8)
^ Install one 1.2 mm (0.5) thick Teflon washer over the retaining bolt to lie under the foam pad. (Arrowed in Figure 8)
Replace the foam pad over the fastener bolt.
19. Align and install the upper finish trim panel to the trunk lid.
20. Install and fully seat the two trim panel retaining clips. (Figure 7)
21. Install and fully tighten the four trim finisher fasteners. (Figure 6)
22. Position the trunk lock electrical harness to align the rubber grommet for installation. (Figure 5)
23. Install and fully seat the rubber grommet.
24. Connect the electrical connector to the trunk lock release button.
25. Connect the electrical connector to the license plate lamp.
26. Align and install the trunk lid trim panel.
27. Install and fully seat the trunk lid trim panel retaining clips.
28. Align and install the latch cover to the trunk lid.
29. Install and fully seat the latch cover securing scrivets.
30. If a warning triangle was fitted, perform the following:
^ Align the warning triangle holder.
^ Install and fully seat the scrivets for the warning triangle holder.
^ Install the warning triangle.
31. Align and install the pull-down handle to the trunk lid.
32. Install and fully tighten the pull-down handle retaining screws to the trunk lid.
33. Close the trunk lid.
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