Sunroof - Popping/Clicking Noise On Opening
No: 76/23/97/NASRef: WSM Section 76
* Issue: 2 *
Date: 01/16/98
Revisions are noted by asterisks.
Sunroof Popping Noise on Opening
AFFECTED VEHICLE RANGE:
DISCOVERY (LJ) From VA732112 to VA736490
SITUATION:
SUNROOF POPPING OR CLICKING
When opening, the sunroof makes a popping or clicking noise before going into tilt position. This is because the rear locking catch of the glass is not disengaging fully before the roof goes into tilt.
RESOLUTION:
MODIFY SUNROOF ASSEMBLY
To resolve a complaint of a "popping" noise it is necessary to shave off a 1 mm (0.040 inch) piece of plastic material within the sunroof assembly as outlined in the repair procedure.
PARTS INFORMATION:
No parts required to repair this problem (Discovery sunroofs within VIN range stated above).
WARRANTY CLAIMS:
76.84.89/27 Time 0.40 hrs.
Modify plastic buffer to eliminate sunroof "popping" noise.
COMP CODE: 9D1K
Normal warranty policy and procedures apply
REPAIR PROCEDURE:
MODIFY SUNROOF
1. Using Figures 1 and 2, identify black plastic buffer on side rail of open sunroof.
2. Mark black plastic buffer 1 mm (0.040 in.) away from the rear face of the buffer as shown in Figure 3.
3. Place a piece of tape along the 1 mm line and down the exposed vertical face of the buffer also at 1 mm from the buffer edge.
CAUTION:
Removing more material than the specified 1 mm (0.040 inch) may result in an imperfect seal or sunroof rattle.
4. Using a sharp blade or a file, shave off the specified 1 mm (0.040 in.) of material up to the tape (the extent of the shaded area shown in Figure 3).
5. Remove tape.
6. Go to step 2 and repeat the process on the buffer on the alternate side.
* SUNROOF GLASS ALIGNMENT
1. Loosen four sunroof, glass panel retaining screws.
2 Refer, to Figure 4 positions A and B place two 6.5 mm (1/4 inch) spacers between front edge of the glass and the upper frame assembly.
3. Position spacers approximately 230 mm (9 inches) from either side of the center line of glass.
4. With glass correctly positioned, tighten glass retaining screws to 3.0 to 3.5 Nm (27 to 31 lbf. in.).
5. Verify glass clearance with 6.5 mm (1/4 inch) spacers at positions A and B (Figure 4).
6. Verify roof operates without popping sound after modifications and alignments are complete. *