Driver's Side Door Wiring Connector & Door Wiring Repl.

NOTE:
This procedure applies to an excessively corroded driver's side door wiring connector. Steps 1- 8 involve replacing the connectors on the floor wire harness, and steps 9 - 19 involve replacing the door wire harness.





1. Cut and remove the first 2.5 - 3 inches (about 70 mm) of the vinyl sheathing from the door wiring. Be careful not to nick the wires.





2. Take the most corroded wire in the connector first. Cut it about 1 inch (25 mm) from the connector. If it is corroded at the cut, cut an additional 1 inch. If the wire is black, it is OK. Strip the wire end about 0.25 inch (7mm).

NOTES:

^ Only cut and solder one wire at a time to avoid confusing the same color wires in each connector. If you have the wrong driver's side door wiring connector kit, you will be able to match the wires by pin location, even though the colors will not exactly match.

^ Pin 17 of MD02 connector will have a smaller gauge yellow wire if the vehicle has the factory keyless entry option. Connect it to the larger red wire supplied on the connector.

^ If the wires are corroded more than 2 inches from the connector, you may need to access them from inside the vehicle. The procedure for removing the cowl trim and connector cover is similar to the passenger side inspection procedure noted in this TSB.





3. Strip the corresponding wire from the replacement connector (0.25 inch, 7 mm). Be sure to verify the wire position in the new connector matches the position the wire was cut from in the original connector.

4. Slide a piece of the heat shrink tube onto the wire. Interlace the two stripped wires.

5. Solder the wires.

WARNING:
Do not allow the solder to drip on the vehicle paint or trim. Protect the area as necessary.





6. Slide the heat shrink tube over the soldered joint and exposed wire; apply heat to the tube until it shrinks, covering the wire completely. Heat shrink tubing should extend 0.5 inch (13 mm) past the exposed wire on both ends of the joint.

NOTE:
Apply steps 2) through 6) to the other wires in both connectors.





7. Some wires on the new door connector kit may not be used (different options). In this case, cut the unused wires 1 inch (25 mm) from the connector and tape the cut ends.





8. Wrap the spliced wire harnesses with the supplied vinyl sheet.





9. Remove the front door quadrant inner cover from inside the mirror mounting area.





10. Remove the door trim mounting screws and door inside handle housing from the front door assembly. Pop the trim clips loose along the bottom edge of the door. Remove the power window switch connector and related connectors and remove the door trim panel assembly.





11. Remove the door trim seal.

NOTE:
The door trim seal must be replaced if it is torn or damaged. Any leaks may cause door trim panel damage, or water leakage into the vehicle interior.





12. Disconnect the door speaker connector and then remove the door speaker.





13. Remove the front door wiring.





14. Replace the door wiring with a new part.

IMPORTANT:
Verify you have the correct new door wiring assembly part number. Refer to Door Wiring Assembly Part Number Information table in this bulletin.





DOOR WIRING ASSEMBLY PART NUMBER INFORMATION:

15. Install the front door speaker.

16. Install the front door trim seal.

17. Install the front door trim panel.

18. Install the front door quadrant inner cover.





19. Apply a small amount of the clear sealant around the edges of the grommet as shown in the photo.

20. Place the removed front door assembly back on the jack, lined up with the hinges. Have a helper support the door.





21. Connect the door connectors to the vehicle connectors. Carefully install the door wire connector back into the mounting hole. Be careful to keep the grommet in position.

NOTE:
If the grommet separates from the connector, remove the connector, refit the grommet in position, reapply a small amount of sealant to the grommet, and reinstall the connector. The grommet must make a water tight seal to the body.

22. Install the front door assembly and install the front door checker.

NOTE:
Check the door opening and closing efforts and the door alignment to the body. Adjust the door if necessary.

23. Close the door.