Doors - Electrical Problems On Driver's Side
Bulletin No.93-051
Issue Date
DEC 17, 1993
Model
1992 - 93
CIVIC
Applicable To
See VEHICLES AFFECTED
File Under
ELECTRICAL
Electrical Problems in Driver's Door
SYMPTOM
The power door locks make a buzzing noise or do not work. The left front speaker may cut out.
PROBABLE CAUSE
The door harness connector is corroded.
VEHICLES AFFECTED
1992 - 93 Civic 4-door LX and EX
1993 Civic Coupe EX
CORRECTIVE ACTION
Repair the door harness connector.
1. Disconnect the door harness connector and examine the pins for signs of corrosion.
^ If you find corrosion, continue with this CORRECTIVE ACTION.
^ If you do not find signs of corrosion, troubleshoot the problem in the normal manner.
2. Make sure you have the anti-theft code for the radio. Record the frequencies for the radio's preset buttons.
3. Remove the pin from the door detent assembly.
4. Remove the circlips from the door hinge pins.
5. Remove the door hinge pins and the door. Place the door on a soft surface so it does not get scratched.
6. Disconnect the negative cable from the battery.
7. Remove the cruise control unit and its mounting bracket.
8. Remove the wire tie from the kick panel; then remove it from the wiring harness.
9. Remove the harness boot from the A pillar. Push the grommet/harness/connector assembly through the hole in the A pillar into the interior.
10. Remove and discard the terminal lock. Examine the wires coming out of the connector; some cars have more than one wire of the same color. Mark these wires so you install them in the proper locations later.
11. Use Terminal Pin Tool A (see REQUIRED SPECIAL TOOLS) to remove all the terminals from the connector. Discard the plastic connector.
12. Remove and discard the rubber boot.
13. Use a felt-tip pen to mark the wire harness at the end of the corrugated plastic tube.
14. Remove the corrugated plastic tube from the harness. Remove any tape up to the "Y."
15. Examine the terminals for corrosion. For any terminals that are corroded, select pigtails of the same wire size and color from the Door Wire Harness Connector Kit (see PARTS INFORMATION).
16. Select a corroded terminal and its matching pigtail. Lay one on top of the other, and cut both wires 20 mm away from the "Y."
17. Strip the insulation from the harness wire and the pigtail.
^ If it is a medium-diameter wire, strip off 7 mm.
^ If it is a small-diameter wire, strip off 6 mm.
18. Select the proper splice connector from the Wire Harness Connector Kit. Use a red connector for a medium-diameter wire, and a yellow connector for a small-diameter wire.
19. Crimp the splice connector onto the harness wire and pigtail. Use the Crimping Tool (T/N 07NGZ-001010A) contained in Terminal Pin Kit B (see REQUIRED SPECIAL TOOLS).
20. Use the heat gun (T/N 07NGZ-001020A) from Pin Kit B to heat the shrink tubing until it is tight around the wire.
21. Repeat steps 16 through 20 for all corroded terminals. Space each splice 20 mm down the wire from the previous splice so they only partially overlap. If you are doing more than four splices, position the fifth splice even with the first splice and work down again.
22. Install the original corrugated plastic tube around the harness at the mark made in step 13. Use the insulating tape (see REQUIRED MATERIALS) to secure the tube.
23. Temporarily tape all the terminals together. Leave a long tail of tape to be used for pulling the harness through the rubber tubes.
24. Insert the harness through the new upper boot half from the kit. Do not use silicone to lubricate the tube; it can cause a poor electrical connection.
25. Place the short corrugated tube from the kit over the harness.
26. Insert the harness through the new lower boot half from the kit.
27. Slide the two boot halves over the corrugated tube. Wrap the joint with insulating tape.
28. Remove the tape from the terminals. Thoroughly clean the terminals with contact cleaner.
29. Install the terminals in the proper locations in the new plastic connector from the kit. Install the terminal lock.
30. Apply a generous amount of lithium dielectric grease (see REQUIRED MATERIALS) to the back of the connector with a putty knife.
31. Apply a small amount of the same grease to the front of the connector; use just enough grease to coat the terminals.
32. Install the boot around the connector. Feed the harness back through the hole in the A pillar.
33. Install the bracket and cruise control unit.
34. Install the door, hinge pins, and door detent pin.
35. Remove the door panel.
36. Remove the speaker mount and speaker. Disconnect the speaker connector.
37. Remove the harness connector from the door edge. Disconnect the wire tie from the door and pull the connector out through the speaker opening.
38. Remove the wire tie from the harness.
39. Remove and discard the terminal lock. Examine the wires coming out of the connector; as with the other connector, there may be more than one wire of the same color. Mark these wires so you install them in the proper locations later.
40. Remove the terminals from the connector. Discard the plastic connector.
41. Remove the boot from the harness.
42. Remove the plastic corrugated tube and tape to about 200 mm away from the terminals.
43. Examine the terminals for corrosion. Replace any corroded terminals with splices according to the procedure in steps 16 through 20. Remember to space the splices down the wires so they do not fully overlap.
44. Reinstall the plastic corrugated tube and tape it securely with the insulating tape.
45. Install the new boot over the harness.
46. Install the terminals in the new plastic connector. Install the new terminal lock.
47. Apply a generous amount of lithium dielectric grease to the back of the connector with a putty knife.
48. Apply a small amount of the same grease to the front of the connector; use just enough grease to coat the terminals.
49. Install the boot over the connector. Tape the boot to the plastic tube with the insulating tape.
50. Feed the harness back through the speaker opening. Install the connector in the door edge.
51. Reconnect the body side of the door harness connector to the door side. Make sure it is fully connected and locked in place.
52. Reconnect the connector to the speaker. Install the speaker mount.
53. Reinstall the door panel.
54. Connect the battery. Test the operation of the power windows, power door locks, power mirrors, and left door speakers.
55. Enter the audio system security code, if needed. Enter the customer's radio station presets.
REQUIRED MATERIALS
19 mm Insulating Tape:
P/N 4100-0002, H/C 4452165
Lithium Dielectric Grease:
P/N 08798-9001, H/C 3720976
REQUIRED SPECIAL TOOLS
Terminal Pin Kit B:
T/N 07QAZ-003020A
Terminal Pin Tool A:
T/N 07JAZ-002010A
(part of Terminal Kit 07JAZ-003000A)
PARTS INFORMATION
Door Wire Harness Connector Kit:
P/N 06320-SR4-305, H/C 4436135
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
Operation number: 737215
Flat rate time: 4.0 hours
Failed part: P/N 32751-SR4-A01
H/C 4096780
Defect code: 032
Contention code: B01