Body - Interior Drafts With Sunroof Open
Date: May 17, 2007Order No.: P-B-77.20/53
Supercedes:
Group: 77
SUBJECT:
All Model 203 Vehicles as per VINs Included in Content
Drafts in the Interior with Sliding Roof Open
If you receive customer reports in the above model vehicles of drafts in the interior when driving with the sliding roof open, this is caused by a vacuum affect due to the roof being open. The vacuum pulls air from any opening in the interior that is not completely sealed. Follow the procedures below to seal these areas.
A. Draft in Footwell Area from Air Leaks in Sound Deadening Material, Up to VIN A731367 and F634898:
1. Remove kick panels. Refer to WIS document AR68.20-P-2050P (driver side) and AR68.20-P-2070P (passenger side).
2. Loosen pedal assembly of parking brake and fold to the side. Brake cables do not need to be removed. Refer to WIS document AR42.20-P-0510P.
3. On passenger side footwell, inspect sound deadening material for correct installation and cracking (Figure 1, 1).
4. If cracked, replace sound deadening material making sure it covers openings completely.
5. Route electrical lines (Figure 1 - 2, 3) above sound deadening material.
6. Tape electrical lines (Figure 2 - 2, 3) to sound deadening material.
7. On driver side footwell, inspect sound deadening material for correct installation and cracking (Figure 3, 4).
8. If cracked, replace sound deadening material making sure it covers openings completely.
9. Cover sound deadening material (Figure 4, 4) and holes (Figure 4, 5) with adhesive tape.
10. Assemble vehicle in reverse order
B. Air Leaks Between Climate System Housing and Vehicle Firewall, Up to VIN A788400 and F693171:
1. Remove battery.
2. Remove the air inlet. Refer to WIS document AR83.25-P-1401P.
3. Seal climate housing to firewall using adhesive tape (Figure 5, 4).
Note:
Insure the recirculation flap and humidity sensor (B 31/2) are not obstructed with adhesive tape.
4. Reassemble in reverse order
5. Perform basic programming. Refer to WIS document AR00.19-P-0200P.
C. Air Leaks from Area of C-Pillar, Up to VIN A803730 and F706981
1. Remove side bolster of rear seat backrest. Refer to WIS document AR91.12-P-1710P.
2. Apply adhesive tape to the openings in the left rear (Figure 6, arrows) and right rear (Figure 7, arrows).
D. Air Leaks from Rear Door Panel, All Vehicles
1. Remove rear door panel. Refer to WIS document AR72.12-P-1010P.
2. Disassemble power window switch strip, door lever and door handle. Refer to WIS document AF72.12-P-3100-01P.
3. Seal switch strip with tape (Figure 8, 1) and reinstall in door panel.
4. Apply self-adhesive insulation mat (A220 682 07 08) over large surface of door panel in are of switch strip (Figure 9).
5. Seal opening by door lever with self-adhesive insulation (A203 682 04 31) (Figure 10). Cut to make two pieces 30 mm in length.
6. Note: Insure that lever remains free to move (Figure 10, arrow).
7. Remove door handle and install foam rubber piece (Figure 11). Position carefully with notch (Figure 11, arrow). Refer to parts table for applicable part number for left and right side. When foam is installed, it should cover the openings as shown in Figure 12.
8. Reassemble door panel in reverse order.
Note:
When the handle is installed the foam rubber is pressed against the openings. The foam rubber pieces must be positioned and bonded carefully to ensure the sealing is complete.
Parts Information
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated on May 17, 2007. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty, use the table.