Land Rover Discovery: General Information / Diagnosis and Testing

Inspection and verification

CAUTION:

Diagnosis by substitution from a donor vehicle is NOT acceptable.

Substitution of control modules does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor vehicle.

NOTES:

• If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and Procedures manual, or determine if any prior approval programme is in operation, prior to the installation of a new module/component.
• Check DDW for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the specific customer complaint and carry out the recommendations as required.
• Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection

MECHANICAL

• Incorrectly aligned door(s)
• Obstruction within door aperture or door latch
• Door latches and strikers
• Door frame seal(s)
• Door aperture seal(s)
• Door hinges

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.

SYMPTOM CHART

PINPOINT TESTS

PINPOINT TEST A : SQUEAK/CREAK FROM THE FRONT OR REAR DOOR(S)

TEST CONDITIONS/ DETAILS/RESULTS/ACTIONS

A1: LOCATING DOOR FRAME NOISE

1. Obtain a complete description of the customer concerns or suspected condition

• Front Door
• Seal A - Margin Seal (outer door frame seal)
• Seal B - Door Frame Weatherstrip - Primary Seal (this seal is bonded to the door)
• Seal C - Secondary Seal (this seal is mounted to the door aperture)

2. Verify the customer concern by carrying out a road test, as closely as possible reproducing the drive/road conditions under which the noise occurs

• Rear Door
• Seal A - Margin Seal (outer door frame seal)
• Seal B - Door Frame Weatherstrip - Primary Seal (this seal is bonded to the door)
• C - Secondary Seal (this seal is mounted to the door aperture)

3. Try to establish if the noise is coming from the front or rear door(s), above or below the waist line?

Is the noise coming from the front door(s) Yes Front door noise GO to A2.

No Rear door noise GO to A7.

A2: FRONT DOOR FRAME ALIGNMENT - MARGIN SEAL

1. Check the front and rear above waistline door frame B pillar finisher alignment, the front B pillar finisher to rear B finisher should be flush +-1.5mm. The opening gap between both finishers is 5mm +-1.5mm

If the noise coming from the front door frame margin seal.

Is the door striker/alignment correct? Yes

No If the B pillar alignment is not correct, adjust the door striker. Road test the vehicle to confirm if the noise has stopped

A3: FRONT DOOR FRAME - MARGIN SEAL

1. Apply suitable tape to the inner face of the front door frame finisher, on the area which contacts the rear door frame margin seal
2. Carry out a road test, as closely as possible reproducing the drive/road conditions under which the noise occurs

Has the tape stopped the noise coming from the front door frame margin seal? Yes If the tape has stopped the noise, apply four coats of AC602/2 to the rear door frame margin seal, allowing drying time between coats Remove the tape from the front door finisher and clean.

Road test the vehicle to confirm if the noise has stopped At this point it is advisable to apply the coating, to the opposite front door frame margin seal

No

A4: FRONT DOOR FRAME - MARGIN TOP SEAL

1. Apply suitable tape to the front body aperture, on the area which contacts the front door frame top margin seal
2. Carry out a road test, as closely as possible reproducing the drive/road conditions under which the noise occurs

Has the tape stopped the noise coming from the front door frame top margin seal? Yes Apply coating AC612/21 (liquid) 50ml pump spray to the flock coating on the front door frame top margin seal Remove the tape from the front body aperture and clean.

Road test the vehicle to confirm if the noise has stopped At this point it is advisable to apply the coating, to the opposite front door frame top margin seal No

A5: FRONT DOOR APERTURE - SECONDARY SEAL

1. Apply suitable tape to the front door frame inner trim, on the area which contacts the front door aperture secondary seal
2. Carry out a road test, as closely as possible reproducing the drive/road conditions under which the noise occurs

Has the tape stopped the noise coming from the front door aperture secondary seal?

Yes

Apply four coats of AC602/2 to the front door aperture secondary seal allowing drying time between coats Remove the tape from the front door frame inner trim and clean. Road test the vehicle to confirm if the noise has stopped At this point it is advisable to apply the coating, to the opposite front door aperture secondary seal

No

A6: FRONT DOOR WEATHERSTRIP - PRIMARY SEAL (THIS SEAL IS BONDED TO THE DOOR)

1. Apply suitable tape to the front door aperture, on the area which contacts the front door frame weatherstrip
2. Carry out a road test, as closely as possible reproducing the drive/road conditions under which the noise occurs

Has the tape stopped the noise coming from the front door weatherstrip?

Yes

Apply four coats of AC602/2 to the front door frame weatherstrip allowing drying time between coats Remove the tape from the front door frame aperture and clean. Road test the vehicle to confirm if the noise has stopped At this point it is advisable to apply the coating, to the opposite front door frame weatherstrip

No

The front door squeak/creak checks are now complete, If the noise is still evident, suspect the rear door(s)

A7: REAR DOOR FRAME - MARGIN TOP SEAL

1. Apply suitable tape to the rear door top aperture, on the area which contacts the rear door frame top margin seal
2. Carry out a road test, as closely as possible reproducing the drive/road conditions under which the noise occurs

Has the tape stopped the noise coming from the rear door frame top margin seal?

Yes

Apply coating AC612/21 (liquid) 50ml pump spray to the flock coating on the rear door frame top margin seal Remove the tape from the rear door aperture and clean.

Road test the vehicle to confirm if the noise has stopped

At this point it is advisable to apply the coating, to the opposite rear door frame top margin seal

No

A8: REAR DOOR APERTURE - SECONDARY SEAL

1. Apply suitable tape to the rear door frame inner trim, on the area which contacts the rear door aperture secondary seal
2. Carry out a road test, as closely as possible reproducing the drive/road conditions under which the noise occurs

Has the tape stopped the noise coming from the rear door aperture secondary seal?

Yes

Apply four coats of AC602/2 to the rear door aperture secondary seal allowing drying time between coats Remove the tape from the rear door frame inner trim and clean. Road test the vehicle to confirm if the noise has stopped At this point it is advisable to apply the coating, to the opposite rear door aperture secondary seal

No

A9: REAR DOOR WEATHERSTRIP - PRIMARY SEAL (THIS SEAL IS BONDED TO THE DOOR)

1. Apply suitable tape to the rear door aperture, on the area which contacts the rear door frame weatherstrip
2. Carry out a road test, as closely as possible reproducing the drive/road conditions under which the noise occurs

Has the tape stopped the noise coming from the rear door?

Yes

Apply four coats of AC602/2 to the rear door frame weatherstrip allowing drying time between coats Remove tape from the rear door frame aperture and clean.

Road test the vehicle to confirm if the noise has stopped At this point it is advisable to apply the coating, to the opposite rear door frame weatherstrip

No

Check if the rear door pad is making contact with the bodyshell

A10: REAR DOOR PAD MAKING CONTACT WITH BODYSHELL

1. Check if the rear door pad is making contact with the bodyshell 

Is the rear door pad making contact with the bodyshell?

Yes

Apply felt tape from S&R kit as barrier between door pad edge and bodyshell. Apply as per illustration

No

The side door squeak/creak tests are now complete. If the noise is still evident, it may be necessary to repeat some tests under different road conditions

Further diagnostics for various Squeaks / rattles / vibrations

There are numerous possibilities for squeaks & rattles and every effort should be made to replicate the customer concern to inform the appropriate repair. This may include a test drive with the customer to identify exactly where in the vehicle a condition arises and under what driving conditions To help with the identification and isolation of suspect squeaks & rattles, first remove from the vehicle all items that are not supplied as built; e.g.

CDs, keys, customer's bags, coins, etc. Empty all compartments such as glove box, glasses case, door pockets, etc. Ensure all vehicle accessories are secure; i.e. lifting jack, wrench, etc.

Ask the customer for details of the concern taking note of the driving/vehicle conditions present (i.e. Does the concern occur on particular road surfaces? Is it noted on cold start or when the engine is warm? What vehicle speeds are implicated?) and then try to replicate it. Try to record any sound with the customer present and confirming the issue. Then, when the vehicle is at the service centre, test drive the vehicle with two people in the vehicle, one driving and the other seated as close as possible to the reported location of the concern (NOTE: take care to adhere to safe driving practices at all times. i.e. in a seat with seatbelt secured). The person diagnosing the issue should then try to pin point the localised area of concern more precisely

LOCATING AND ADDRESSING SQUEAK / RATTLE / VIBRATION ISSUES

Use the table below to facilitate investigations and repairs in the event of customer reports of squeaks/rattles/vibrations

Rear end Sheet Metal Repairs Back Panel Inner (G1770945) - InstallationFront end Sheet Metal Repairs

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