Body - Various Wind Noise Concerns
No: 76/10/03/NAS*Issue: 6
Date: 05 June 2006*
Wind Noise Corrective Actions
*CHANGES MADE FOR ISSUE "6" ARE HIGHLIGHTED WITH GREY BACKGROUND AND NOTED BY ASTERISKS*.
AFFECTED VEHICLE RANGE:
New Range Rover (LM)
See Individual Repairs
SITUATION
VARIOUS WIND NOISE LOCATIONS MAY REQUIRE CORRECTIVE ACTION
The customer may complain of wind noise appearing to come from a variety of locations:
* High pitched hiss or buzzing from the windshield
* Noise from the top of the windshield
* Whistle from front of vehicle when driven at highway speeds
* Hiss or leaking sound from A-pillar and side mirror area (above 40 mph (65 kph))
* Buzzing sound from central area of headliner or rear of vehicle
* High level noise from A-pillar area
RESOLUTION:
PERFORM INDIVIDUAL REPAIR PROCESSES FOR EACH SYMPTOM
Each of the specific problem areas has a unique repair to resolve the noise complaint. After investigation to determine the source of the sound, perform the repair specific to that area.
PARTS INFORMATION:
Repair 1..........A HIGH-PITCHED HISS FROM THE WINDSHIELD
No parts required
Repair 2..........BUZZING FROM THE WINDSHIELD AT HIGHWAY SPEEDS
Polyurethane Sealant - Locally sourced
Repair 3..........NOISE FROM THE TOP CORNERS OF THE WINDSHIELD
No parts required
Repair 4..........HIGH-PITCHED WHISTLE NOISE FROM THE FRONT OF THE VEHICLE
XCH500020..........Rubber strip Qty 2 per vehicle
Repair 5..........HISS OR LEAKAGE NOISE AROUND THE 'A' PILLAR AND DOOR MIRROR
CTT500020..........Foam Pad Qty 2 per vehicle
Polyurethane Sealant - Locally sourced
Repair 6..........BUZZING SOUND FROM CENTER OF HEADLINER OR REAR OF VEHICLE
Polyurethane Sealant - Locally sourced
Repair 7..........HIGH LEVEL OF WIND NOISE FROM 'A' PILLAR AREA
79086L..........Black expanding clip Qty 8
DYA000040..........Grommet Qty 8
DYC500020..........Yellow clip Qty 8
Repair 8..........HISSING/FLUTTERING NOISE FROM THE REAR DOOR FIXED SIDE GLASS
Polyurethane Sealant - Locally sourced
*Repair 9..........WHISTLE NOISE FROM CENTER OF WINDSHIELD AT HIGHWAY SPEEDS
* MWC9832PMA..........Fir-tree fastener Qty 1*
Repairs 10 - 13..........VARIOUS WIND NOISES No parts required.
WARRANTY CLAIMS:
Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
REPAIR 1: ALL VEHICLES
A gap between the windshield trim and the roof causes a high-pitched hiss from the windshield at approximately 38 - 50mph (60-80km/h).
CAUTION:
The top trim piece of the windshield must be protected to prevent damage. A gap must not be created between the bottom edge of the trim strip and the windshield.
1. Using a nylon block and rubber mallet, move the windshield top trim upwards to close the gap. (Figure 1, Inset A)
2. Align trim to the roof until a "touch" condition is achieved along the entire length of the trim. (Figure 1, Inset B)
REPAIR 2: ALL VEHICLES
A gap or bulge between the windshield lower trim piece and the windshield causes a buzzing from the windshield area at highway speeds.
1. Lift wipers away from the windshield for access.
2. Clean the windshield at the junction with the plenum seal along the entire length of the plenum seal.
3. Filling all gaps completely, apply polyurethane sealant between the seal and the windshield along the entire length of the seal. (Figure 2)
4. Remove any excess sealant.
5. Position wipers onto the windshield.
REPAIR 3: ALL VEHICLES
A gap between the windshield and the roof molding causes noise from the top corners of the windshield. (Figure 3, Inset A)
NOTE: The roof molding must be set in the correct fore/aft position to achieve a flush fit.
NOTE: GTR lookup sequence is as follows: GTR Home > NAS > Service Information/ LM - New Range Rover/2003 (or as applicable)> Workshop Manuals > Service Procedures > Bookmark "76-2 - Exterior Fittings (or as applicable)" Link "76.43.68 Roof Moulding (or as applicable)"
1. Refer to GTR Workshop Manual section 76-2 - Exterior Fittings procedure 76.43.68 and remove the roof molding.
2. Install the molding, aligning the rear end of the molding with the rear edge of the roof.
REPAIR 4: UP TO VIN 3A106721
A gap between the direction indicator lamp and the fender causes a high-pitched whistle noise from the front of the vehicle at high speeds.
1. Refer to GTR Workshop Manual section 86-2 - Lighting procedure 86.40.29 and remove the Left Hand and Right Hand front directional lamp assemblies.
2. Clean the fender area where the adhesive strip will be applied. (Figure 4)
3. Remove protective backing from the adhesive rubber strip and secure to the fender. (Figure 4)
4. Install directional assemblies.
REPAIR 5:* UP TO VIN 4A152789*
A noise path between the mirror and the 'A' pillar causes a hiss or leakage noise from around the 'A' pillar and door mirror area at speeds greater than 40mph (64km/h).
NOTE: Noise may be present even if NO gap exists.
1. Lower both front windows.
2. Ease out approximately 200mm (8 inches) of the window channel seal to expose the door seal channel. (Arrowed in Figure 5)
CAUTION:
The foam must extend equidistant to either side of the angle and must not overhang on either side of the seal.
3. Center the foam (CTT500020) on the angle in the seal and stick it onto the back of the seal directly over the angle. (Shaded in Figure 6)
4. Carefully fit the window channel seal to the door.
5. Repeat for the opposite side.
6. Refer to Technical Information Bulletin 76/18/03/NAS and verify that the window 'one touch' mode is operating correctly.
7. If the window 'one touch' mode is NOT operating correctly, complete the following steps:
* Remove the 200mm (8 inches) of the window seal again to expose the seal channel. (Arrowed in Figure 5)
* Remove the foam pad inserted above.
* Wipe the surface surrounding the joint with alcohol. (Figure 7)
NOTE: The outer most corner of the joint must be completely sealed with sealant.
* Apply a small amount of sealant into the base of the angle and push the sealant firmly into the back of the channel. (Inset in Figure 7)
* Apply sealant until it starts to protrude from the hole at the top of the cheater panel.
* Wipe off excess sealant.
* Install the glass seal to the door.
8. Refer to Technical Information Bulletin 76/18/03/NAS and verify that the window 'one touch' mode is operating correctly.
REPAIR 6: *UP TO VIN 3A131067*
A gap between the 'E' pillar seal and the quarter glass can result in a buzzing sound from the rear of vehicle or center of the headlining.
1. Refer to GTR Workshop Manual section 76-2 - Exterior Fittings procedure 76.43.36 and remove the 'E' pillar trim.
2. Clean quarter glass and 'E' pillar trim.
3. Apply a 2mm (3/32 in.) bead of sealant along the entire forward edge of the 'E' pillar trim seal. (Arrowed in Figure 8)
4. Carefully install the 'E' pillar trim.
5. Remove excess sealant from 'E' pillar trim seal and the quarter glass. (Figure 9)
6. Repeat procedure for the alternate side.
REPAIR 7: UP TO VIN 3A114820
A gap between the side trim and windshield or a rocking / loose side trim may result in a high level of wind noise from 'A' pillar area at highway speeds.
NOTE: The noise is most likely due to the side trim having been previously removed for windshield replacement.
1. Refer to GTR Workshop Manual section 76-2-Exterior Fittings procedure 76.43.39 and remove the 'A' pillar windshield side trim.
2. Remove and discard the black clips from the trim and retaining inserts from the 'A' pillar. (Arrowed in Figure 10)
3. Install new yellow clips (DYC500020) to secure the trim to the front of the 'A' pillar.
4. Install new retaining inserts (DYA000040) into the 'A' pillar.
5. Install new expanding clips (79086L) into the trim piece.
6. Position the trim to the front of the 'A' pillar and secure using expanding clips.
REPAIR 8: *ALL VEHICLES*
The rear door fixed side glass is not sufficiently bonded to the door *or gaps* are present in the *bonding* causing a *hissing or fluttering* noise from the top rear corner of the fixed door glass.
* 1. Apply tape around the interior perimeter of the fixed side door glass, ensuring a sufficient seal between the glass and surround molding, to confirm the cause of the noise during a road test.
2. Remove the tape from the side door glass.
3. Refer to GTR Workshop Manual section 76-1 - Doors procedure 76.34.04 and remove the rear door trim casing for access.
4. Remove the fixed side glass surround trim.
5. Remove interior waist seal. (Figure 11)
NOTE: For the fixed side glass to be correctly bonded, all Body-In-White (BIW) clips around the periphery of the glass must be completely covered by the bonding material. The bonding is not correct if there are any gaps in the bonding or if any BIW clips are visible. (Figure 12)
6. Visually inspect for correct bonding around the perimeter of the fixed side door glass. (Figure 13)
7. If the bonding material around the perimeter of the glass has any gaps or does not completely cover all Body-In-White (BIW) clips, apply sufficient Polyurethane Sealant to fill any gaps and completely cover all BIW clips, ensuring that the sealant is hidden by the black band around the glass edges.*
8. If the rear door fixed glass is not properly bonded, refer to GTR Workshop Manual section 76-1 - Doors procedure 76.31.31 and remove the rear door fixed side glass.
9. Install the rear side door fixed glass following adhesive guidelines in the GTR Workshop Manual. (Figure 14)
REPAIR 9: ALL VEHICLES
A whistle noise is heard from the centre of the windshield at speeds in excess of 60mph (97km/h). The noise may be caused by airflow over the passenger side plenum drain tube opening. The plenum drain tube opening is divided into four quadrants.
1. Tape over plenum drain tube opening to verify cause of the noise.
* 2. Remove tape after road test.
3. Insert Fir-tree fastener (MWC9832PMA) into the in-board, front quadrant of the drain tube opening. (Figure 15)*
REPAIR 10: ALL VEHICLES WITH SUNROOF
A general wind noise is heard from the front leading edge of the sunroof when traveling in excess of 50mph (80km/h). The likely cause is poor sunroof alignment profile.
1. Tape the leading edge of the sunroof to verify cause of the noise.
2. Remove tape after road test.
NOTE: GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM - New Range Rover/2003 > Workshop Manuals > Range Rover - Workshop Manual - Service Procedures > Bookmark "76-6 - Sunroof" > Link "76.84.82 Sunroof - align to roof panel & adjust"
3. Refer to GTR section 76.84.82 and perform sunroof adjustment and alignment to roof panel.
REPAIR 11: ALL VEHICLES
A whistle is heard from the lower windshield area at speeds in excess of 50mph (80km/h) only when the recirculation damper is shut. The noise is likely to be caused by a trapped foot well lamp wire in the recirculation "snail shell" housing.
NOTE: In the event of a concern of a noise from behind the instrument panel when the Heating Ventilation Air Conditioning (HVAC) is in recirculation or automatic mode, evident at road speeds of above 60mph (100km/h), refer to Technical Bulletin 82/01/05/NAS - Range Rover (LM) - Noise From HVAC System.
1. Reproduce the complaint during a test drive and cycle in and out of recirculation mode to confirm the suspected cause of the complaint.
2. Remove the pollen filter to access snail shell housing and free the trapped wire. (Figure 16)
REPAIR 12: ALL VEHICLES
A general wind noise is heard from the top of the B-pillar area at speeds in excess of 30mph (48km/h). The noise may be caused by the front door glass being set too far forward.
1. Close the affected window completely.
2. Determine if the top corner radius of the window glass, adjacent to the B-Pillar, is visible indicating that the window is set too far forward. (Figure 17)
3. If the corner is not visible, use a blunt plastic implement to gently probe the top rear edge of the seal to assess the overlap of the seal over the glass. (Figure 18)
4. If the glass can be felt, it is unlikely that improper window glass alignment is the cause of the complaint.
5. If the glass cannot be felt, lower the window by approximately 260mm (10 inches), to position window glass for access to the securing torx bolts. (Figure 19)
NOTE: GTR lookup sequence is as follows: GTR Home > NAS > Service Information/ LM - New Range Rover/2003 > Workshop Manuals > Range Rover - Workshop Manual - Service Procedures > Bookmark "76-1 Doors" > Link "76.34.01 Trim casing - front door"
6. Refer to GTR Workshop Manual section 76.34.01 and remove the front door casing for access only.
7. Partially release the plastic sheet and temporarily secure up and out of the way to gain access to torx bolts securing glass. (Figure 20)
NOTE: If attempts are made to move the glass rearwards without lifting the glass out of the clamps, the glass may return to original position due to elasticity of the rubber clamps.
8. Loosen torx bolts securing glass.
9. Lift glass out of clamps and move glass rearward by the amount of the observed gap at initial inspection. (Figure 21)
10. Lower glass back into the clamps.
11. Secure front glass torx bolts to 10 Nm (7 lbf-ft).
12. Temporarily connect the harness to confirm operation of window glass and ensure window glass has been set correctly and can raise fully. (Figure 22)
13. Install partially removed plastic sheet and verify that a good seal to the door panel has been achieved.
14. Refer to GTR Workshop Manual section 76.34.01 and install the front door casing.
15. Verify correct operation of door mounted switchpack and speakers after the door casing is installed.
REPAIR 13: ALL VEHICLES
A general wind noise and whistle from top of windshield at speeds in excess of 50mph (80km/h) may be heard. The noise could be caused by the leading edge of the roof rail finisher lifting.
1. Unclip roof rail finisher, position the finisher correctly, and reinstall the clip. (Figure 23)
Disclaimer