Power Accessories, Speakers/Courtesy Lamp - Inoperative
BULLETIN NO.: 00-T-36ISSUE DATE: July, 2000
CATEGORY TYPE: Electrical-06
CATEGORY: Wiring
CORPORATION NO.: 00-0845-003
SUBJECT:
Left and/or Right Rear Door Power Lock, Power Window, Speaker, or Courtesy Lamp Inoperative (Repair or Replace Bent or Damaged Terminals in Black 15-Way Rear Door Connector)
MODELS AFFECTED:
2000 Saturn L-Series Vehicles
CONDITION:
Some customers may comment that the power lock, power window, speaker, or courtesy lamp is inoperative on the left and/or right rear door.
CAUSE:
Terminals in the black 15-way rear door connector at the base of the B-pillar may have been damaged during assembly of the left and/or right rear door.
CORRECTION:
Inspect black 15-way rear door connector and repair or replace any bent or damaged terminals.
PROCEDURE:
Connector Inspection
1. Disconnect negative battery cable.
2. Open the front door on the affected side of vehicle to the full open position.
3. Open the rear door on the affected side of vehicle to the first detent position.
4. Remove rubber grommet at base of B-pillar that contains the body-to-rear door harness. (Refer to illustration above.)
5. Pull harness and black 15-way rear door connector out of B-pillar.
6. Disconnect black 15-way rear door connector and inspect terminals.
^ If terminals are not badly bent or damaged, straighten terminals.
^ If terminals are damaged beyond repair, replace terminals as necessary. (Refer to "Terminal Replacement" procedure in this bulletin.)
^ If no problem is found at black 15-way rear door connector, refer to additional diagnostic information in the appropriate L-Series service manual.
7. Connect black 15-way rear door connector.
8. Carefully tuck body-to-rear door harness back into B-pillar.
9. Install rubber grommet that contains the body-to-rear door harness back into B-pillar.
10. Connect negative battery cable.
Torque:
Battery Terminal Bolts: 17 Nm (13 ft-lbs) Terminal Replacement
1. Remove terminal position assurance (TPA) retainer.
2. Insert the proper terminal lock release tool into connector body.
3. Depress the terminal locking tang to unseat terminal.
4. Pull wire and terminal out of connector body.
5. Reference illustration and terminal P/N tables below and obtain proper replacement terminal.
6. Cut old terminal off wire to be repaired.
7. Strip insulation from wire. Recommended wire strip length is 4.8 mm (3/16 in.) for 12-20 gauge wires and 9.5 mm (3/8 in) for 22 gauge wire so it can be folded in half. Caution must be used when stripping wire to prevent cutting wire strands.
8. Using a crimp and seal splice sleeve (supplied with replacement terminal), position stripped end of wire in sleeve until wire hits stop.
9. Hand crimp splice sleeve using correct jaws in Packard crimper (P/N 12085115) or appropriate crimping tool. Gently tug on wires to ensure they are secure before applying heat to seal sleeve.
CAUTION:
DO NOT USE A MATCH OR OPEN FLAME TO APPLY HEAT TO SPLICE SLEEVE.
10. Apply heat using Ultratorch(R) or heat gun. Heat to 175°C (347°F) until glue flows around edges of sleeve.
11. Slide repaired wire and terminal into connector body until terminal locking tang engages.
12. Install TPA retainer.
PARTS REQUIREMENTS:
CLAIM INFORMATION:
To receive credit for the repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows shown.
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