Campaign - Door Seal Stiffener Installation

No: H105
Ref:
Issue: 1
Date: 02/07/03

SERVICE ACTION

Front Door Wind Noise Correction

AFFECTED VEHICLE RANGE:

Discovery Series II (LT) 3A767790 to 3A795758

SITUATION:

IMPROPERLY POSITIONED DOOR SEAL

Body tolerances can result in a situation where the door seal sits incorrectly on the door aperture flange permitting wind noise.

RESOLUTION:

INSTALLATION OF DOOR SEAL STIFFENER

Prior to retail sale 2003 Discovery vehicles in retailer inventory should be checked to determine if the seal door stiffener has been installed at the Port of Entry. If no repair has been performed at the port, a reinforcement tube is to be installed into the door seal at the "A" post waistline.

PARTS INFORMATION:

CFG500010 Door Seal Stiffener Kit Contains 2 reinforcement tubes

TOOLS

Insertion Tool ONE tool distributed to each Retailer

WARRANTY CLAIMS:

H105 Time 0.20 hrs.
Install door seal stiffeners

Normal warranty policy and procedures apply.
Material allowance is included in labor operation.

REPAIR PROCEDURE

INSERT REINFORCEMENT TUBES IN DOOR SEAL





1. If no evidence of port action is present, release 3 clips securing the "A" post upper trim finisher to the "A" post.

2. Disconnect the multi-plug from the tweeter.

3. Remove the "A" post upper trim finisher.





4. Release the door aperture seal from the "A" post door aperture flange. (Figure 2)

5. Lubricate the reinforcement tube with a soap-based solution.

6. Position the tube on the insertion tool.

7. Insert the tube using the following procedure.

^ Locate the access/air release hole in the door aperture seal.

^ Insert the reinforcement tube through the access hole to a position 10 mm (3/8 in) below the access hole. (Figure 2)

^ Grip the door seal to hold the tube inside and extract the tool.

8. Install the door aperture seal to the door aperture flange.

9. Position the "A" post upper trim finisher to the "A" post and connect the multi-plug to the tweeter.

10. Install and secure the "A" post upper trim finisher to the "A" post.

11. Repeat above procedure for opposite door seal.

INSTALL CAMPAIGN LABEL

NOTE:
Campaign labels may have multiple Campaign numbers written on them if multiple campaigns are performed at the same time.





1. When all specified repairs have been accomplished, prepare the campaign label (LRN0002LABEL) as follows:

a) Place the label on a hard surface.

b) Use a ballpoint pen to neatly write/scribe in the bare aluminum areas of the label the following information:

^ Campaign code "H105"

^ Your retailer code

^ The date of repair

2. Clean all grease and dirt from the radiator support member.

3. Peel the completed campaign label from the backing paper and position it on the cleaned area.

4. Roll the label with the special roller tool to ensure proper adhesion.