Body - Front Door Wind Noise
NO: 83-37DATE: 08-01-2005
MODEL: All new S40/V50.
MY: MY04 - MY06.
SUBJECT:
Wind noise from front door, check and adjust.
REFERENCE: VADIS/VIDA
DESCRIPTION:
Customers may complain about wind noise from the front doors. A variety of possible causes for this wind noise has been detected. To handle this in an efficient way, repair instructions for all known wind noise causes are collected in this Tech Net Note.
VEHICLES AFFECTED:
Cars after the break points shown have all actions below already performed from the factory!
MATERIAL AND TOOLING
SERVICE METHOD:
1. Information
The instruction applies to both front doors.
2. Preparations
An S-shaped sealing strip as shown here must not be used, see illustration.
Note!
If the sealing strip has this appearance, it must be replaced. The rubber lip placed below the side windows rear mounting in the window regulator must also be replaced.
3. Preparations, continued
If the sealing strip has no visible damage continue with step 11.
4. Remove the sealing strip
Remove the inner door panel, see VADIS/VIDA:
Removal replacement and installation
Body and interior
Interior
Trim for door panel.
Front side door panel replace.
Remove:
- the door mirror by unplugging the connector(s)
- 1 nut
- the trim panel by removing the strip at the rear edge of the door arch.
- the S screws in the trim panel.
- the sealing strip.
5. Install the sealing strip
Note!
Wait to install the sealing strip at the rear edge of the door arch until the trim panel has been adjusted, see steps 6 and 7.
6. Adjusting the trim panel
Press the S clips upward.
7. Adjusting the trim panel, continued
Press the trim panel upward. Then press the panel inward and hold see illustration.
Make sure that the sealing strip lies straight in the top edge of the trim panel (1) see illustration.
Insert the S trim panel screws.
Note!
Start with the centre screw and tighten.
Install the sealing strip.
8. Remove the rubber lip (window regulator)
Remove the front side window see VADIS/VIDA:
Removal replacement and installation
Body and interior
Exterior trim components glass weather strips
Glass of side doors and windows
Window front side door replace.
9. Remove the rubber lip (window regulator), continued
Remove the rubber lip placed in the glass clamp using bent needle-nosed pliers and pull out through rear hole of door module see illustration.
10. Install the rubber lip (window regulator)
Install the new rubber lip through the hole in the door module and keep it in position by means of the pliers. Insert a long flat tool (e.g. cover for manifold PN9995723) down between the inner and outer door plate see illustration.
Then press the rubber lip into position in the glass clamp.
Note!
Following information only applies to the side window. It does not apply to the inner door panel and door mirror.
Reinstall the front side window see VADIS/VIDA:
Removal replacement and installation
Body and interior
Exterior trim components glass weather strips
Glass of side doors and windows
Window front side door replace.
Note!
Make sure that the glass is centered in the clamp, see illustration.
Note!
Before checking the side window, install the inner weather strip.
11. Checking the position of the side window pane in the sealing strip
Lower the window 4 - 6 inch (100-150 mm). Position and number the masking tape pieces see illustration.
12. Checking the position of the side window pane in the sealing strip, continued
First lower the side window completely.
Then use the "Auto up" function to raise the side window completely.
Use a pen to mark all the tape pieces see illustration.
13. Checking the position of the side window pane in the sealing strip, continued
Measure the distance between the markings and the top of the side window pane. The distance should be as follows:
Position 1: within 0.16-0.24 inch (4-6 mm)
Position 2: no less than 0.06 inch (1.5 mm)
Position 3: within 0.16-0.24 inch (4-6 mm)
14. Checking the position of the side window pane in the sealing strip, continued
If the measurements are within the aforementioned intervals remove the tape pieces and continue with step 18. If the measurement is less than 0.06 inch (1.5 mm) at position 2 continue with step 15.
15. Adjusting the position of the side window pane in the sealing strip
Place a piece of masking tape on the rear part of the door arch level with the side window pane.
Use a pen to mark the tape piece see illustration.
Note!
No less than 0.08 inch (2 mm) and no more than 0.12 (3 mm) between the markings. This facilitates adjustment of the side window pane.
16. Adjusting the position of the side window pane in the sealing strip, continued
Undo the rear retaining screw (at the B-pillar) of the pane mounting two turns.
Lift the rear edge of the side window pane up to the upper marking on the tap (max. 0.12 inch/max 3 mm). Hold the side window pane in place and tighten the rear screw to 6 lb ft (8 Nm).
Check the position of the pane in the sealing strip as described in steps 11, 12, 13 and 14.
The measurement at position 2 must be at least 0.06 inch (1.5 mm).
17. Checking side window functionality
Close the side window.
Open the side window using the "Auto down" function. Close the side window using the "Auto up" function.
18. Sealing below door mirror
Start by cutting one of the foam blocks in half see illustration.
Note!
Save the other half of the foam block for the other door.
19. Sealing below door mirror, continued
Use the foam block to plug the hole below the door mirror. Begin sealing with one of the cut foam blocks starting at the front of the opening (1).
Then fill with the two other foam blocks (2, 3).
The foam should be level with the outer plate (4) of the front door.
20. Adjusting play between the outer and inner door plate.
Note!
Only applies to vehicles with chassis no:
S40 (04-) - 099432
V50 - 098414
21. Adjusting play between the outer and inner door plate, continued.
Measure the distance between the outer and inner door plate in three places see illustration.
The measurement must not exceed 0.97 inch (24.7 mm). If the measurement exceeds the specified value adjust the play between the outer and inner door plate to no less than 0.91 inches (23 mm) but no more than 0.95 inches (24 mm).
22. Adjusting play between the outer and inner door plate, continued.
Caution!
Measure between the outer plate and the inner plate's ridges, see illustration.
23. Adjusting play between the outer and inner door plate, continued.
Protect the area with suitable tape see illustration.
24. Adjusting play between the outer and inner door plate, continued.
Adjust the inner door plate using a wood block and hammer.
Adjust so that the measurement is no less than 0.91 inches (23 mm) but no more than 0.95 inches (24 mm).
Tip! Begin adjustment in the corners.
Check the measurements during adjustment see steps 21 and 22.
25. Sealing below door mirror, continued
Install:
- the door mirror by loosely fitting it against the door arch
- the connector(s)
- 1 nut loosely in the door mirror.
Caution!
To ensure that the door mirror has proper contact with the sealing strip, turn the door mirror slightly before tightening the nut.
Check that the door mirror has proper contact with the sealing strip see illustration.
26. Sealing on inside of front door
Detach and remove the inner and outer weather strip.
27. Sealing on inside of front door, continued
Remove the rear tape on the inside of the door.
28. Sealing on inside of front door, continued
Remove the front tape on the inside of the door.
29. Sealing on inside of front door, continued
Use a 2-inch piece of butyl tape and position it on the door where the rear tape was previously placed see illustration. A = 0.79 inches (20 mm).
Flatten the tape somewhat.
Note!
Make sure that all gaps and seams are closed.
30. Sealing on inside of front door, continued
Use a 2-inch piece of butyl tape and position it on the door where the front tape was previously placed see illustration. A = 0.79 inches (20 mm).
Flatten the tape somewhat.
Note!
Make sure that all gaps and seams are closed.
31. Sealing on inside of front door, continued
Use butyl tape to seal around the opening for the cable harness.
Flatten the tape somewhat and make sure all gaps are closed.
32. Install the inner door panel
Note!
Applies to vehicles with chassis no:
S40 (04-) 083490 - 110891
V50 081518 - 110882
If one of the six point socket screws is missing at the door panel mounting at the inner door handle, install a new one.
Install the inner door panel see VADIS/VIDA:
Removal replacement and installation
Body and interior
Interior
Trim for door panel
Front side door panel replace.
Warranty Claim Information