Security/Electrical System - Intermittent Problems
98-028October 1 2001
* Applies To:
* 1996-01 3.5RL ALL
* 2002 3.5RL - From VIN JH4KA9...2C000001 thru JH4KA9. ..2C006092
Intermittent Electrical Problems
(Supersedes 98-028, Security System Sounds Intermittently, dated September 28, 1998). Changes are noted by Astricks and Bold black lines.
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
* 3M ultrapro Auto Body Sealent (Clear): 135-08302
* 3M 3 Auto Body Sealant (clear):
Lithium Dielectric Grease: P/N 08798-9001
WARRANTY CLAIM INFORMATION
In warranty: The normal warranty applies.
Failed Part: P/N 38800-5Z3-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 Parts and Service 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, foot rest, 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.
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.
5. Through the access holes, inspect for water in the front pillars and on connectors C445 (passenger's side) and C412 (driver's side).
^ 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.
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.
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
* NOTE:
If either side leaks, seal both sides of the car.
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.
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.
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 Nm (7.2 lb-ft).
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.
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