Intermittent Electrical Problems (98-028)

INTERMITTENT ELECTRICAL PROBLEMS

TECHNICAL SERVICE BULLETIN

SYMPTOMS

• The security system sounds intermittently while the vehicle is parked.
• The door locks cycle while driving.
• The instrument panel lights remain on.

PROBABLE CAUSE

Water is leaking into the front pillars. The water is getting into the connectors for the under-dash fuse/ relay box, the driver's multiplex control unit, or the door lock actuator, causing intermittent electrical problems.

CORRECTIVE ACTION

Test for water leaks. Clean the connectors and, if there is a leak, seal both sides of the cowl.

REQUIRED MATERIALS

1. 3M Ultrapro Auto Body Sealant (clear): 3M P/N 051135-08302
2. Lithium Dielectric Grease: P/N 08798-9001

WARRANTY CLAIM INFORMATION

In Warranty:  The normal warranty applies.

Op. #	Description	FRT	Template ID
813001	Test for water leaks. Clean and grease connectors. (Diagnosis and Repair Procedure A.)	1.2	98-028A
813003	Test for water leaks. Clean and grease connectors. Repair leaks on both sides. (Diagnosis, Repair Procedure A, and Repair Procedure B.)	3.6	98-028C

Failed Part: P/N 38800-SZ3-A01

Defect code: 059

Contention code: B06

Skill Level: Repair Technician

Out of warranty:  Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Technical Manager or your Zone Office. You must request consideration, and get a decision, before starting work.

DIAGNOSIS

Test for a water leak:

1. Remove the driver's front side trim, footrest, and kick panel.
2. Remove the under-dash fuse/relay box mounting bolt and the wire harness clip. Move the fuse/relay box toward the parking brake pedal to expose the front pillar access hole. See Fig 1 .
   Fig 1: Under Dash Fuse/Relay Box

   
3. Remove the passenger's front side trim and the kick panel.
4. Fill a bucket with 3 to 5 gallons of water. Pour the water on the windshield; empty the bucket in about 10 seconds. Refer to Fig 2 .
   Fig 2: Pouring Water Onto Windshield

   
5. Through the access holes, inspect for water in the front pillars and on connectors C445 (passenger's side) and C412 (driver's side). Refer to Fig 3 .
   • If you find a water leak, do REPAIR PROCEDURE A  and REPAIR PROCEDURE B  .
   • If you do not find a water leak, do REPAIR PROCEDURE A  only.
   Fig 3: Inspecting For Water Leak

   

REPAIR PROCEDURE A

1. Remove all four door panels.
2. Peel back the plastic cover to expose the door lock actuator connectors.
3. Unplug connectors C744 and C745 in the driver's door, C764 and C765 in the front passenger's door, C793 in the right rear door, and C783 in the left rear door. Refer to Fig 4 .
   Fig 4: Door Electric Connectors

   
4. Clean the connectors with contact cleaner. Blow dry both sides of the connectors with compressed air.
5. Pack the connectors with lithium dielectric grease.
6. Reinstall all removed parts in the reverse order of removal.
7. Reinstall the under-dash fuse/relay box.

REPAIR PROCEDURE B

1. Remove the front wheel on the side that leaked.
2. Remove the inner fender and the side sill panel.
3. Apply 2-inch-wide masking tape along the leading edge of the front door to prevent paint damage. See Fig 5 .
   Fig 5: Applying Tape

   
4. Remove the front fender.
5. Left side only: Drain and remove the washer fluid reservoir.
6. Blow dry the outer pillar seam.
7. Apply a 6-mm-wide bead of 3M Ultrapro Auto Body Sealant at the base of the A-pillar and to the outer pillar. Inspect the existing seam sealer for gaps or voids, and apply sealant as needed. See Fig 6 .
   Fig 6: Applying 3M Ultrapro Auto Body Sealant

   
8. Disconnect the door harness connector on the side you are repairing (C445 on driver's side, C412 on passenger's side) and clean the connector with contact cleaner.
9. Dry the connector with compressed air, then reconnect it.
10. Allow the seam sealer to dry for 10 to 15 minutes, then repeat the leak test.
11. Left side only: Reinstall the washer fluid reservoir.
12. Install the fender. Torque the fender mounting bolts to 9.8 N.m (7.2 lb-ft).
    Fig 7: Fender Mounting Bolts

    
13. Reinstall the side sill panel and the inner fender.
14. Reinstall the front wheel.
15. Remove the masking tape.
16. Left side only: Refill the washer fluid reservoir.
17. Inspect the fit of the fender at the hood, bumper and doors. Adjust as necessary.
18. Repeat this repair procedure on the other side.