NUMBER: 23-002-03 GROUP: Body DATE: Jan. 17, 2003 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation. SUBJECT: Wind Noise OVERVIEW: This bulletin involves adjusting, replacing and/or sealing the A-pillar cavity, front door body mounted weatherstrip(s), door flag speakers, sunroof and windshield wipers. MODELS: 2001-2003 (LH) /Intrepid SYMPTOM/CONDITION: Wind noise heard from the sunroof or B-pillar forward in the vehicle while driving at highway speeds above 55 mph or at lower speeds into a headwind. DIAGNOSIS: Perform the wind noise diagnostic procedure outlined in Section 23 of appropriate Concorde/Intrepid/LHS/300M Service Manual or the MDS2. If this procedure and related repairs do not resolve the condition, perform the Repair Procedure. PARTS REQUIRED: Qty. Part No. Description AR (1) 0TE72TL2AG Weatherstrip, Front Right Body Mounted, Beige AR (1) 0TE72WL5AG Weatherstrip, Front Right Body Mounted, Taupe AR (1) 0TE72XT5AG Weatherstrip, Front Right Body Mounted, Sandstone AR (1) 0TE73TL2AG Weatherstrip, Front Left Body Mounted, Beige AR (1) 0TE73WL5AG Weatherstrip, Front Left Body Mounted, Taupe AR (1) 0TE73XT5AG Weatherstrip, Front Left Body Mounted, Sandstone AR (1) 0UP92XXXAC Weatherstrip, Front Right Body Mounted, Black AR (1) 0UP93XXXAC Weatherstrip, Front Left Body Mounted, Black AR (1) 0TE68WL5AI Weatherstrip, Rear Right Body Mounted, Taupe, Intrepid AR (1) 0TE68XT5AI Weatherstrip, Rear Right Body Mounted, Sandstone, Intrepid AR (1) 0TE69WL5AI Weatherstrip, Rear Left Body Mounted, Taupe, Intrepid AR (1) 0TE69XT5AI Weatherstrip, Rear Left Body Mounted, Sandstone, Intrepid AR (1) 0UP90XXXAC Weatherstrip, Rear Right Body Mounted, Black, Intrepid
23-002-03-2- Qty. Part No. Description AR (1) 0UP91XXXAC Weatherstrip, Rear Left Body Mounted, Black, Intrepid AR (1) 0WR32TL2AA Weatherstrip, Rear Right Body Mounted, Beige, AR (1) 0WR32WL5AA Weatherstrip, Rear Right Body Mounted, Taupe, AR (1) 0WR32XT5AA Weatherstrip, Rear Right Body Mounted, Sandstone, AR (1) 0WR33TL2AA Weatherstrip, Rear Left Body Mounted, Beige, AR (1) 0WR33WL5AA Weatherstrip, Rear Left Body Mounted, Taupe, AR (1) 0WR33XT5AA Weatherstrip, Rear Left Body Mounted, Sandstone, AR (1) 0WR34XXXAA Weatherstrip, Rear Right Body Mounted, Black, AR (1) 0WR35XXXAA Weatherstrip, Rear Left Body Mounted, Black, AR (4) 05019585AA Clip REPAIR PROCEDURE: Procedure A 1. Remove the instrument panel end cap. 2. Remove the A-pillar trim. 3. Apply a thumb grade sealer, Mopar Butyl Tape, p/n 04076274, or equivalent to completely close the hole at the base of the A-pillar (Fig. 1).
-3-23-002-03 Fig. 1 SEALER APPLICATION 1 - APPLY SEALER 4. Install A-pillar trim and end cap. 5. Repeat procedure on other side of vehicle as necessary. Procedure B 1. If wind noise improvements were noted during diagnosis when the gap between the front door and body were taped off, vehicles built after May 15, 2001 the weatherstrip(s) should be replaced. 2. For vehicles built on or before May 15, 2001, install clip, p/n 05019585AA, on the pinch flange in area where weatherstrip is loose. One clip in the center of the pulled away area should be enough (Fig. 2).
23-002-03-4- 1 - CLIP 2 - PINCH FLANGE Fig. 2 CLIP INSTALLATION 3. 2. Install the weatherstrip over the clips and pinch flange. NOTE: WEATHERSTRIPS CAN BE INSTALLED WITHOUT REMOVING TRIM PANELS. 4. Repeat procedure on all loose primary weatherstrips as necessary. Procedure C 1. There should be a visible gap (not touching) between the front edge of the front window flag speakers and the front door body mounted weatherstrips (Fig. 3). If a gap exists proceed to Procedure D. If no gap exists proceed to step 2.
-5-23-002-03 Fig. 3 FLAG SPEAKER GAP 1 - MUST HAVE VISIBLE GAP 2. Make sure the weatherstrip is fully seated on to its mounting flange. If the interference still exists, remove the two speaker enclosure attachment screws and remove the enclosure. 3. Remove the two speaker attaching screws and remove the speaker. 4. Loosen the two screws that attach the speaker mounting plate to the door. Reposition the plate rearward and reinstall the speaker and enclosure 5. If the interference still exists, remove the speaker mounting plate and slot the mounting holes 1-2 mm (1/16 in.) in the fore-aft direction to provide additional adjustment. Reassemble plate, speaker, and enclosure. 6. Repeat procedure on other side of vehicle as necessary. Procedure D 1. Check the position of the windshield wiper assemblies in the park (off) position. If the wipers are above the positioning ("tic") marks on the windshield adjust as necessary (Fig. 4).
23-002-03-6- 1 - WIPER POSITION "TIC" MARKS Fig. 4 WIPER POSITION Procedure E 1. Check the gap around the perimeter of the sunroof between the seal and the roof aperture. The seal should make contact all around and there should be no gap. Dragging a business card (~0.3mm thick) around the perimeter should be provide uniform resistance. 2. If there is a gap or low drag resistance at the front, or rear, edge of the glass, loosen the four attaching screws so that glass can be adjusted (Fig. 5). Reposition the glass panel so that it is evenly spaced front to back and again recheck the drag on the business card. Readjust until the front to back gap is uniform.
-7-23-002-03 Fig. 5 SUNROOF SCREWS 1 - ATTACHING SCREW 3. Retighten the four attaching screws. 4. Cycle the sun roof and check the glass flushness. If the flushness is good and the sunroof cycles normally the repair is complete. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Description Amount 23-50-09-99 Repair Procedure A, Both Sides 0.2 Hrs. 23-51-10-93 Repair Procedure B, Both Sides 0.2 Hrs. 23-10-00-91 Repair Procedure C, Right or Left Side 0.2 Hrs. 23-10-00-92 Repair Procedure C, Both Sides 0.3 Hrs. 23-43-35-95 Repair Procedure D, Both Sides 0.2 Hrs. 23-30-65-91 Repair Procedure E 0.2 Hrs. FAILURE CODE: XX Service Adjustment