WINDNOISE AT FRT.OF REAR DOORS INSPECT/REPAIR SEALS AS NEC.. Saturn Saturn 1992

For 1990-2009 cars

# WINDNOISE AT FRT.OF REAR DOORS INSPECT/REPAIR SEALS AS NEC.

#### SUBJECT: Windnoise From Front and Rear Doors (Inspect and Repair Seals as Required)

Due to the addition of "MODELS AFFECTED," this bulletin supersedes bulletin 91-T-21, which should be discarded.

#### MODELS AFFECTED: 1991 - 1992 Saturns

CONDITION: Some customers may express a concern that they hear windnoise coming from the front doors around the mirror area, or from the front and/or rear doors around the upper door frame areas or from the upper corners of the door glass.

CAUSE: Depending on location of windnoise, the cause could be one of the following:

o Insufficient sealing under mirror patch gasket

o Missing sealer at certain locations such as door frame to door assembly at the beltline

o Insufficient contact of the secondary seals to door openings

o Door glass run channel not sealing to door glass at upper corners of doors

CORRECTION: Before attempting repairs, please review the following windnoise diagnosis procedures:

#### WINDNOISE DIAGNOSIS

#### Windnoise Condition

The first step of the repair process in correcting windnoise is to identify the cause(s) of the noise. A determination must be made as to whether the cause of the noise is air escaping from the vehicle or outside air turbulence.

To assist in diagnosing the cause of a windnoise concern, answers to the following questions should be obtained from the customer:

1. What specific noise is objectionable?

a. Whistle

b. Flutter

c. Rush of air

2. At what speed does the noise occur?

3. Does the noise appear to be:

a. Air leaving the body? (internal windnoise)

b. Air passing over the body's exterior surface? (external windnoise)

4. In what general area does the noise appear to originate?

a. Front of the vehicle

b. Side of the vehicle

5. Is the heater/AC blower motor ON or OFF?

#### ANALYZING WINDNOISE

When analyzing windnoise, it is important to understand the forces that act upon the vehicle that can create this condition. As air strikes and bends around the front of a vehicle in motion, it causes a low-pressure area to develop around the front pillars and side window locations of the body. At the same time, air flow that is filtered through the vehicle's vents and/or AC system will cause a high-pressure to build-up inside the passenger compartment. The faster the vehicle is traveling, the greater the pressure difference between the inside and outside of the vehicle becomes.

The high inside pressure and low outside pressure is separated only by the vehicle's exterior panels, glass, weatherstrips, and body seals. When an opening is created at a body seam or weak weatherstrip contact, the high inside pressure will move towards the low outside pressure and create an internal windnoise.

Wind rush or external windnoise is created by the air passing over and around misaligned body components such as mirrors, and door moldings.

#### THE ROAD TEST

A road test is required to determine if the windnoise condition is external, internal, or a combination of the two.

#### NOTE: Often there is one primary leak source and one or more secondary leaks that contribute to the noise condition. Repairing only one of these sources may not completely repair the total condition, but only reduce it.

The following items should be used by the technician during the test drive to aid in locating the leak area:

1. Mechanic's stethoscope or vacuum hose

2. Masking tape (2 inches in width)

3. Strip caulk

4. China marking pencil

The vehicle should be driven at the speed in which the noise was noticed by the customer or until it is heard.

#### CAUTION:

SAFE LEGAL SPEEDS SHOULD NEVER BE EXCEEDED.

If the noise can be heard with the door glass lowered and the vehicle driven, it is most likely external windnoise.

Locating an external windnoise is accomplished by taping off various moldings and gaps until the noise is eliminated pinpointing the exact cause of the noise.

If the noise is more distinct with the windows in a full-up position while the car is driven, it is most likely internal windnoise caused by an open body seam or poor glass/door weatherstrip sealing surface.

#### Visual Inspection

Visually check for misaligned components, loose fasteners, torn weatherstrips, broken weld joints and/or sealer and/or adhesive skips.

#### Tracing Powder or Chalk Test

Clean the weatherstrips and contact surfaces with cleaning solvent. Apply powder or chalk in an unbroken line around the perimeter of the trunk lid, door, door glass or hood. Surrounding areas must be free of chalk or powder. Close panel completely. Do not slam closed. The line applied on the weatherstrip will be marred where contact is good. A corresponding imprint will be on the mating surfaces. Gaps or irregularities in the powder or chalk line indicate a poor seal.

#### Air Pressure Test

Turn on the vehicle's ventilation fan. Close all openings, doors windows, etc. An abnormal amount of high-pressure will build up in the vehicle and will escape through voids or poor seals. With a stethoscope or length of heater (vacuum) hose, listen for escaping air along the door and window seals. A smoke tester or dusting powder can be used in the same manner. The exact location can be seen as the smoke or powder travels through the void or bad seal.

The actual repair procedure depends on the type of seal being repaired. Leaks may require panel or glass alignment, sealer application or weatherstrip alignment or replacement.

#### PROCEDURES:

---------- Windnoise at Upper Rear Corners of Front Door --------------------------------------------- 1. Lower door glass to the full - down position.

2. Remove door window weatherstrip by carefully pulling it out of the upper door frame.

3. Cut two pieces of 1/4 inch foam tape such as Kent Industries #40105 (or equivalent). One piece should be 15 mm (0.60 inch) long and the other piece should be 10 mm (0.40 inch).

4. Install the 15 mm (0.60 inch) piece of tape horizontally at the top inside corner of the weatherstrip.

5. Install the 10 mm (0.40 inch) piece of tape vertically at the top inside corner of the weatherstrip.

6. Before inserting the seal back into the door frame, check to make sure that the gray tape, applied to the outside corner of the seal, is still attached. If the tape has pulled off the corner, attach the tape back onto the seal with a small amount of fast - drying adhesive. Install the corner into the door frame, making sure that the corner is fully seated.

7. Cycle window several times to check for proper operation.

#### Windnoise from Door Upper Frame Area Front and Rear Doors

1. Inspect for gaps between door secondary seals on door frame and door opening. Positive contact of all seals is required. The most critical areas would be at the wind- shield encapsulation molding, at the leading edge of the front upper door frame secondary seal.

2. Minor adjustment to remove gaps can be achieved by lowering the door glass to the full-down position and adjusting upper door frame to close out the gaps.

3. Additional adjustments can be made at the door hinges. Refer to the "Door Adjustment" procedures in the "Doors" section of the "Body Service Manual."

#### Windnoise from the Front Door Mirror Patch Area

1. Remove outside rearview mirror. Refer to "Outside Mirror" removal procedures in the "Doors" section of the "Body Service Manual."

2. Fill void between upper door frame and door assembly at front beltline using strip caulk such as 3M Strip Caulk #08578 (or equivalent).

3. Fill gaps at base of mirror patch area with strip caulk.

4. Seal mirror patch to door by applying strips of strip caulk such as 3M Strip Caulk #08578 (or equivalent) to the mirror patch gasket. Apply one strip to the rear of the gasket and two strips to the bottom of the gasket, as shown in the Figure.

#### IMPORTANT: Thickness of strip caulk should not be greater than 2 mm (0.080 inch).

5. Install a piece of 1/4 x 5/32 inch foam tape such as Kent Industries #40105 (or equivalent) to rear edge of mirror.

6. Install outside rearview mirror. Refer to "Outside Mirror" installation procedures in the "Doors" section of the "Body Service Manual."

Torque: Torque attaching nuts to 6 N-m (53 lbs. in.)

Windnoise at Front Beltline of Rear Door

1. Fill void between rear door upper frame and door assembly at front beltline of the rear door using a strip caulk sealer such as 3M Strip Caulk #08578 (or equivalent).

Windnoise at Upper Corners of Rear Door Glass

1. Lower the rear door glass to the full - down position.

2. Remove door window weatherstrip by carefully pulling out of upper door frame.

3. Cut four pieces of 1/4 inch foam tape such as Kent Industries #40105 (or equivalent). Two pieces should be 15 mm (0.60 inch) long and the other two pieces should be 10 mm (0.40 inch).

4. Install the two 15 mm (0.60 inch) pieces of tape horizontally at the top, front and rear inside corners of the weatherstrip.

5. Install the two 10 mm (0.40 inch) pieces of tape vertically at the top, front and rear inside corners of the weatherstrip.

6. Before inserting the seal back into the door frame, check to make sure that the gray tape, applied to the outside, two corners of the seal, are still attached. If the tape has pulled off either of the corners, attach the tape back onto the seal with a small amount of fast-drying adhesive. Install the corners into the door frame, making sure that the corners are fully seated.

7. Before installing the weatherstrip back into the door frame, seal the area at upper rear corner of glass run channel to stationary vent window with strip caulk.

8. Cycle window several times to check for proper operation.

CLAIM INFORMATION: To receive credit for this repair, submit a claim through the Saturn Dealer System using the appropriate the labor operation(s) listed below:

Labor Case Operation Type Description Code Time ---- ----------- --------- ---- VW Repair Windnoise at Mirrors Right Front Door T9525 0.4 hrs Left Front Door T9526 0.4 hrs

VW Repair Windnoise at Door Weatherstrips Right Front Door T9527 0.2 hrs Left Front Door T9528 0.2 hrs

VW Repair Windnoise at Door Weatherstrips Right Rear Door T9529 0.3 hrs Left Rear Door T9530 0.3 hrs

VW Seal Front Beltline of Rear Doors Right Rear Door T9531 0.1 hrs Left Rear Door T9532 0.1 hrs

VW Adjust Door Frame - Sedan - R/Front B4000 1.0 hrs VW Adjust Door Frame - Coupe - R/Front B4000 1.1 hrs VW Adjust Door Frame - Sedan - L/Front B4001 1.0 hrs VW Adjust Door Frame - Coupe - L/Front B4001 1.1 hrs VW Adjust Door Frame - R/Rear B4400 0.3 hrs VW Adjust Door Frame - L/Rear B4401 0.3 hrs

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.