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

Some customers may comment that the power lock, power window, speaker, or courtesy lamp is inoperative on the left and/or right rear door.

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.

Inspect the black 15-way rear door connector and repair or replace any bent or damaged terminals.

1. Disconnect the negative battery cable.
2. Open the front door on the affected side of the vehicle to the full open position.
3. Open the rear door on the affected side of the vehicle to the first detent position
4. Remove the rubber grommet at the base of the B-pillar that contains the body-to-rear door harness. Refer to the illustration above.
5. Pull the harness and black 15-way rear door connector out of the B-pillar.
6. Disconnect the black 15-way rear door connector and inspect the terminals.

•	If the terminals are not badly bent or damaged, straighten the terminals.

•	If the terminals are damaged beyond repair, replace the terminals as necessary. Refer to Terminal Replacement procedures in this bulletin.

•	If no problem is found at the black 15-way rear door connector, refer to additional diagnostic information in the appropriate L-Series service manual.

7. Connect the black 15-way rear door connector.
8. Carefully tuck the body-to-rear door harness back into the B-pillar.
9. Install the rubber grommet that contains the rear door harness back into the B-pillar.
10. Connect the negative battery cable.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb  ft).

1. Remove the terminal position assurance (TPA) retainer.
2. Insert the proper terminal lock release tool into the connector body.
3. Depress the terminal locking tang to unseat the terminal.
4. Pull the wire and terminal out of the connector body.
5. Reference the illustration and terminal P/N tables below and obtain the proper replacement terminal.

1. Cut old terminal off the wire to be repaired.
2. Strip the insulation from the wire. Recommended wire strip length is 4.8 mm (1/16 in) for 12-20 gage wires and 9.5 mm (3/8 in) for 22 gage wire so it can be folded in half. Caution must be used when stripping wire to prevent cutting wire strands.



3. Using a crimp and seal splice sleeve, supplied with replacement terminals, position the stripped end of the wire in the sleeve until the wire hits stop.
4. Hand crimp the splice sleeve using the correct jaws in the Packard crimper P/N 12085115 or the appropriate crimping tool. Gently tug on the wires to ensure they are secure before applying heat to the seal sleeve.

Caution: Do not use a match or open flame to apply heat to the splice sleeve.

5. Apply heat using Ultratorch® or heat gun. Heat to 175°C (347°F) until the glue flows around the edges of the sleeve.
6. Slide the repaired wire and terminal into the connector body until the terminal locking tang engages.
7. Install the TPA retainer.