vrata Hyundai

8/8/2019 vrata Hyundai

1/24

Page 1 of 24

Technical ServiceBulletin

Subject

Group

Number

Date

Model

BODY ELECTRICAL

06-90-008

FEBRUARY, 2006

2001-2003 ELANTRA

2001-03 ELANTRA CORROSION IN THEFRONT DOOR WIRING CONNECTOR

This bulletin supersedes TSB# 03-90-009 to update the sealant information.

DESCRIPTION:

A water leak between the front outer panel and cowl panels may result in corrosion ofthe front door wiring connector pins if the vehicle is operated in areas where road salt isused. The corrosion may affect the operation of the electrical circuits in the door, suchas the speakers, power windows, etc.

To correct this condition, reseal the seams and inspect the door wiring connectors forcorrosion. If necessary, replace the door wiring connector and the door wiring byfollowing the service procedures described in this TSB.


2/24

Page 2 of 24

PARTS REQUIRED:

Detailed List of Parts Included in the Kit:

MODEL KIT NAME KIT PART NUMBER PART NAME QTY

ELANTRA

produced before

October 20, 2000

Floor Harness -

Drivers side door

wiring connector kit assembly (C)

91500-2DC00

Wiring Assy (1) 1

Vinyl Sheet (2) 2

Heat Shrink Tube (3) 26

Floor Harness -

Passengers side door

wiring connector kit assembly (D)

91500-2DD00

Wiring Assy (1) 1

Vinyl Sheet (2) 2


ELANTRA

produced after

November 2, 2000

Floor Harness -

Drivers side door

wiring connector kit assembly (A)

91500-2DA00

Wiring Assy (1) 1

Vinyl Sheet (2) 2


Floor Harness -

Passengers side door

wiring connector kit assembly (B)

91500-2DB00

Wiring Assy (1) 1

Vinyl Sheet (2) 2


NOTE: For vehicles produced between October 20, 2000 and November 2, 2000, the wire harness wire colors were

mixed based on vehicle options. Check the wire colors on Pin #2 (Driver Side - MD01) and Pin #8 (Passenger Side -

MD03) on each side to determine which kits will be color matched to the vehicle being repaired. (See Connector Kit

Identification section below).

The difference between the two LH kits is the wire colors; so they can be interchanged if necessary, by splicing the

wires by pin location, not color. The same applies to the RH kits.

CONNECTOR KIT IDENTIFICATION:

ID TAPE COLOR BLACK (A) BLUE (B) YELLOW (C) RED (D)

3

2

1

ID TAPE COLOR

A: BLACKB: BLUEC: YELLOW

D: RED

KIT CONTENT:

1. Wiring Assy.

2. Vinyl Sheet

3. Heat Shrink Tube


3/24

Page 3 of 24


Group

Number

PARTS REQUIRED (CONTINUED):

Connector P/N (91500- )

Wire color 2DA00 2DB00 2DC00 2DD00

Pin #2 (MD01) Gray - Brown -

Pin #8 (MD03) - Gray - Brown

PART NAME PART NUMBER FIGURE

3M Flexiclear Body SeamSealer (PN-051135-08405) or

equivalent and cartridgeapplicator

Source Locally

Undercoating: 3M undersealrubberized under-coating(PN-08883) or equivalent

Source locally

Contact Cleaner Source Locally

Connector Grease 00305-F0000-39

CONNECTOR KIT IDENTIFICATION:

BODY ELECTRICAL

06-90-008


4/24

Page 4 of 24

SERVICE PROCEDURE:


5/24

Page 5 of 24


Group

Number

SEALING THE PANEL SEAMS:

NOTE: This sealing procedure applies to both left and right sides.1. Open the hood.

2. Locate the A pillar outer panel and cowl panel seaming area at the baseof the A pillar.

3. Lift up the lower end of windshield glassmolding to obtain space for sealantapplication.

4. Clean the sealant application area on boththe left and right sides of the vehicle(fender removed in photo for clarity).

HOOD PANEL HOOD PANEL

RIGHT FENDER PANEL LEFT FENDER PANEL

WINDSHIELD GLASSMOLDING

LEFTFENDERPANEL

CLEANTHE SEALANTAPPLICATIONAREA COWL

DOORHINGE

FENDER

MOUNTINGBRACKET

A PILLAR

BODY ELECTRICAL

06-90-008


6/24

Page 6 of 24

5. Apply clear sealant along the seam linebetween A pillar panel and cowl panelfrom the engine compartment as shownin the photo.

6. Use appropriate tool or finger (with rubber

nitrate gloves) to smooth material to sealthe sealant.

NOTE: Apply enough sealant tocompletely fill the seam.Be careful not to drip excesssealant in the engine compartmentor on the hood.

- Photo shows panel seams wheresealant is applied on left side.

- Repeat for the right side.

7. Open the front door.

8. Apply the clear sealant to the seambetween A pillar panel and the fendermounting bracket from inside the dooropening.

9. Apply the clear sealant to the bottom ofthe fender mounting bracket and the topof the hinge.

10. Use appropriate tool or finger (withrubber nitrate gloves) to smooth materialto seal the sealant.

NOTE: Apply enough sealant tocompletely fill the seam. Becareful not to drip excess sealanton the door trim or in the interior.

- Sealant is applied along the topedge of the fender bracket.

SEALANTTUBE

COWL

DOORHINGE

FFENDERMOUNTINGBRACKET

A PILLAR

SEALANTAPPLICATION

AREA

FENDERMOUNTINGBOLT

SEALANTTUBE

A PILLAR

SEALANTAPPLICATION

AREA

A PILLAR

FENDERMOUNTINGBRACKET


7/24

Page 7 of 24


Group

Number

- Sealant is applied along the bottomof the fender mounting bracket and

the top of the hinge.

DRIVERS SIDE DOOR WIRING CONNECTOR INSPECTION:

1. Turn on the ignition key and lower the doorglass. Record the customers radiostations. Turn the ignition off and thenremove the negative battery cable.

NOTE: The following procedure requirestwo people to perform part of theoperations.

2. Open the drivers side front door. Positiona floor jack under the middle of the door.

Cover the top of the jack with padding.Raise the jack just enough to partiallysupport the door.

3. Remove the front door checker mountingbolt (1EA) from the front door and removethe upper and lower door hinge mounting

bolts (4EA). Balance the door on the jack.

NOTE: Be careful not to scratch ordamage the door. Be sure tosupport the door so it does not fallduring removal.

APPLYSEALANTTO TOP OFHINGE

APPLYSEALANTTO THEBOTTOMOF THEFENDER-MOUNTINGBRACKET

JACK

FRONT DOOR

BODY ELECTRICAL

06-90-008


8/24

Page 8 of 24

- The top hinge bolts.

- The bottom hinge bolts are similar.

4. Have a helper support the door. Use apair of needle nose pliers to gently pullthe rubber grommet off of the connector.

5. Release the 4 connector locking clips bypressing them one at a time, workingaround the connector.

6. Disconnect the connectors.

GROMMET

NEEDLENOSEPLIERS

2

3

1

4

GROMMET

MD01

MD02


9/24

Page 9 of 24


Group

Number

7. Remove the front door assembly. Set it ona clean soft cloth where it will not be

scratched or damaged.

NOTES:

Be careful not to scratch or damagethe door panel, fender panel orrocker panel when removing thefront door assembly.

Carefully store the removed doorpanel where it will not be scratchedor damaged.

8. Check the removed connectors forcorrosion and dirt.

9. If the connectors are not corroded or arejust slightly corroded, use an electricalcontact cleaner to flush the connectorsuntil they are clean. Flush the door sideof the connector clean as well.

Inject connector grease into eachopening of the female connector terminalon the floor wire harness side.

________________________________

Recommended Grease:GREASE - NYOGEL 760G

P/N 00305-F0000-39________________________________

MD02

MD01

CONNECTORGREASE

BODY ELECTRICAL

06-90-008


10/24

Page 10 of 24

NOTE: If the connector terminals havemore than light corrosion, theycannot be cleaned, they must bereplaced.

Proceed with drivers side door

wiring connector and door wiringreplacement procedure asexplained in the Drivers SideDoor Wiring Connector and DoorWiring Replacement section onpage 14 of this TSB.

10. Fit the grommet over the flange on thedoor wire harness connector. Apply asmall amount of the clear sealant aroundthe edges of the grommet as shown in

the photo.

11. Place the removed front door assemblyback on the jack, lined up with thehinges. Have a helper support the door.

12. Connect the door connector to thevehicle connectors. Carefully install thedoor wire connector back into themounting hole. Be careful to keep thegrommet in position.

NOTE: If the grommet separates from theconnector, remove the connector,refit the grommet in position,reapply a small amount of sealantto the grommet and reinstall theconnector. The grommet mustmake a water tight seal to thebody.

13. Install the front door assembly and install

the front door checker.NOTE: Check the door opening and

closing effort and the dooralignment to the body. Adjust thedoor if necessary.

14. Close the door.

SEALANTINJECTOR

GROMMET


11/24

Page 11 of 24


Group

Number

PASSENGERS SIDE DOOR WIRING CONNECTOR INSPECTION:

1. Open the passengers side door.2. Remove the door sill trim.

3. Remove the right cowl side trim.

4. Unclip the main wire harness from theconnector cover. Cut the wire tie holdingthe MD03/MD04 connector wires to theconnector cover. Remove the wiringconnector cover mounting bolts (2EA) andthen remove the cover.

5. Follow the MD03/MD04 connector wiresup to the connectors, disconnect theconnectors. The release for the topconnector is on top, the release for thebottom connector is on bottom.

6. Release the 4 door wiring harnessconnector locking clips by pressing themone at a time, working around theconnector. Push the connector out of thebody hole.

COWL SIDETRIM

BOLT

CONNECTORCOVER

WWWWIRE TIE

(MD03/MD04CONNECTOR WIRES)

CLIP COVERINGBOLT

DOORCONNECTOR

BODY ELECTRICAL

06-90-008


12/24

Page 12 of 24

7. Inspect the removed connectors forcorrosion and dirt.

8. If connectors are not corroded or are justslightly corroded, use an electrical contactcleaner to flush the connectors until theyare clean. Flush the door side of theconnector clean as well.

WARNING: Protect the inside of thevehicle so the contactcleaner will not splash ontothe trim.

9. Inject connector grease into each openingof the female connector terminal on thefloor wire harness side.

________________________________

Recommended Grease:GREASE - NYOGEL 760G

P/N 00305-F0000-39________________________________

NOTE: If the connector terminals havemore than light corrosion, theycannot be cleaned, they must bereplaced.

Proceed with passengers side door wiring connector and door wiring replacement procedure as explained in the Passengers

Side Door Wiring Connector and Door Wiring Replacement

section on page 21 of this TSB.

REMOVED MD03/MD04CONNECTORS

CONDUCTIVEGREASE

MD03


13/24

Page 13 of 24


Group

Number

10. Fit the grommet over the flange on thedoor wire harness connector. Apply a

small amount of the clear sealant aroundthe edges of the grommet as shown in thephoto.

11. Carefully install the door wire connectorback into the mounting hole. Be careful tokeep the grommet in position.

NOTE: If the grommet separates from theconnector, remove the connector,refit the grommet in position,reapply a small amount of sealantto the grommet, and reinstall theconnector.

12. Reconnect the door wiring connector.

13. Install the wiring connector cover.

14. Re-clip the main wire harness in theconnector cover slip.

15. Use a wire tie to secure the doorconnector wires to the connector cover.

16. Install the right cowl side trim.

17. Install the door sill trim.

18. Connect the negative battery cable andreset the customers radio stations.

19. Close the hood.

SEALANTINJECTOR

GROMMET

PASSENGERS SIDE

GROMMET

CONNECTORCOVER

BOLT

WIRE TIE(DOOR CONNECTOR)

CLIP COVERINGBOLT

COWL SIDETRIM

BODY ELECTRICAL

06-90-008


14/24

Page 14 of 24

DRIVERS SIDE DOOR WIRING CONNECTOR AND DOOR WIRINGREPLACEMENT:

NOTE: This procedure applies to an excessively corroded drivers side doorwiring connector. Steps 1 - 8 involve replacing the connectors on thefloor 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 fromthe door wiring. Be careful not to nick thewires.

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

NOTES:

Only cut and solder one wire at a

time to avoid confusing the samecolor wires in each connector. Ifyou have the wrong drivers sidedoor wiring connector kit, you willbe able to match the wires by pinlocation, even though the colors willnot exactly match.

Pin 17 of MD02 connector will have asmaller gauge yellow wire if thevehicle has the factory keyless

entry option. Connect it to thelarger red wire supplied on theconnector.

70 mm

A PILLAR

A PILLAR


15/24

Page 15 of 24


Group

Number

If the wires are corroded more than 2inches from the connector, you may

need to access them from inside thevehicle. The procedure forremoving the cowl trim andconnector cover is similar to thepassenger side inspectionprocedure noted on page 11 of thisTSB.

3. Strip the corresponding wire from thereplacement connector (0.25inch, 7mm).Be sure to verify the wire position in the

new connector matches the position thewire was cut from in the originalconnector.

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

5. Solder the wires.

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

HEAT SHRINKTUBE

BODY ELECTRICAL

06-90-008


16/24

Page 16 of 24

6. Slide the heat shrink tube over thesoldered joint and exposed wire; applyheat to the tube until it shrinks, coveringthe wire completely. Heat shrink tubingshould extend 0.5 inch (13 mm) past theexposed wire on both ends of the joint.

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

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

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

HEAT SHRINKTUBE

TAPING

VINYL SHEET


17/24

Page 17 of 24


Group

Number

9. Remove the front door quadrant innercover from inside the mirror mounting

area.

10. Remove the door trim mounting screwsand door inside handle housing from thefront door assembly. Pop the trim clipsloose along the bottom edge of the door.Remove the power window switchconnector and related connectors andremove the door trim panel assembly.

11. Remove the door trim seal.

NOTE: The door trim seal must bereplaced if it is torn or damaged.Any leaks may cause door trimpanel damage, or water leakageinto the vehicle interior.

12. Disconnect the door speaker connectorand then remove the door speaker.

QUADRANTINNERCOVER

DOOR TRIM SEAL

DOORSPEAKER

CONNECTOR

BODY ELECTRICAL

06-90-008


18/24

Page 18 of 24

13. Remove the front door wiring.

14. Replace the door wiring with a newpart.

IMPORTANT: Verify you have thecorrect new door wiringassembly part number.Refer to page 19 of this

TSB.

DOORWIRING


19/24

Page 19 of 24


Group

Number

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.

PRODUCTION DATE RANGE PART DESCRIPTION PART NUMBER

Elantra produced7/01/00 - 4/23/01

(4DR & 5DR GLS)

Drivers Side Door Harness

WITHkeyless entry91600-2D010


(4DR & 5DR GLS)

Drivers Side Door HarnessWITHOUTkeyless entry

91600-2D030


(4 DR GL)


WITHOUTkeyless entry91600-2D040


(4DR & 5DR GLS)

Drivers Side Door HarnessWITHkeyless entry

91600-2D011


(4DR GL)



Elantra produced3/13/02 -

(4DR GL)



Elantra produced

3/13/02 -(4DR & 5DR GLS)

Drivers Side Door HarnessWITHkeyless entry

91600-2D012


(4DR & 5DR GLS)




(4DR & 5DR GL)

Drivers Side Door HarnessWITHOUTkeyless entry and

heated mirror91600-2D052


(5DR GL)


WITHOUTkeyless entry and

door courtesy lamp

91600-2D280

BODY ELECTRICAL

06-90-008


20/24

Page 20 of 24

19. Apply a small amount of the clear sealantaround the edges of the grommet asshown in the photo.

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

21. Connect the door connectors to thevehicle connectors. Carefully install the

door wire connector back into themounting hole. Be careful to keep thegrommet in position.

NOTE: If the grommet separates from theconnector, remove the connector,refit the grommet in position,reapply a small amount of sealantto the grommet, and reinstall theconnector. The grommet mustmake a water tight seal to thebody.

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

NOTE: Check the door opening andclosing efforts and the dooralignment to the body. Adjust thedoor if necessary.

23. Close the door.

SEALANTINJECTOR

GROMMET

DRIVERS SIDE

GROMMET


21/24

Page 21 of 24


Group

Number

PASSENGERS SIDE DOOR WIRING CONNECTOR AND DOOR WIRINGREPLACEMENT:

NOTE: This procedure applies to an excessively corroded passengers side doorwiring connector. This section will refer to the individual steps that havebeen covered in earlier sections.

1. Lay down a protective covering over the passenger side carpeting. Perform thesame steps to solder the wiring connector kit to the vehicle wire as performed insteps 1 through 8 in the Drivers Side Door Wiring Connector and Door WiringReplacement section.

2. Replace the passenger front door wire harness. Follow the procedure in steps 9through 18 in the Drivers Side Door Wiring Connector and Door Wiring

Replacement section. Use the following part numbers to select the correctpassenger front door wire harness.


Elantra produced

7/01/00 - 4/23/01(4DR & 5DR GLS)

Passengers Side Door HarnessWITHkeyless entry

91620-2D010


(4DR GLS)

Passengers Side Door Harness


Elantra produced

7/01/00 - 4/23/01(4DR & 5DR GLS)

Passengers Side Door HarnessWITHOUTkeyless entry

91620-2D040


(4DR & 5DR GLS)



Elantra produced

4/23/01 - 3/13/02(4DR GL)

Passengers Side Door HarnessWITHOUTkeyless entry

91620-2D031


(4DR & 5DR GLS)



Elantra produced

3/13/02 -(4DR GL)


WITHOUTkeyless entry -no manual central door locking

91620-2D032


(4DR & 5DR GLS)



06-90-008

BODY ELECTRICAL


22/24

Page 22 of 24

3. Insert the door wire harness connector back into the body hole. Follow the

procedure in steps 19 and 21 in the Drivers Side Door Wiring Connector and DoorWiring Replacement section (Page 20).

4. Connect the connectors.

5. Finish the repair by following steps 12 through 19 in the Passengers Side DoorWiring Connector Inspection section on page 13 to reassemble the vehicle.



(4DR & 5DR GL & GLS)



Elantra produced

7/18/02 -(4DR & 5DR GL)

Passengers Side Door HarnessWITHOUTkeyless entry 91620-2D042


(4DR GL)

Passengers Side Door HarnessWITHOUTkeyless entry and

heated mirror

91620-2D062

Elantra produced

7/18/02 - 10/10/02(5DR GL)


WITHOUTkeyless entry anddoor courtesy lamp

91620-2D250


23/24

Page 23 of 24


Group

Number

INNER FENDER PANEL SEAM SEALING:

NOTE: This procedure applies to both left and right sides.1. Lift up the vehicle.

2. Remove the front wheel and tire.

3. Remove the plastic front wheel guard(splash trim).

4. Spray all panel seams through the accesshole inside the fender panel with 3MUNDERSEAL (3M PN-08883)undercoating or equivalent as shown inthe photo.

SPRAY

continued

BODY ELECTRICAL

06-90-008


24/24

4) continued:

Spray all panel seams with undercoating.

5. Reinstall the front wheel guard and tire.

6. Repeat for the opposite side.

7. Lower the vehicle and close the hood.

*N56: Rust, Corrosion

**C88: Water Entering

WARRANTY INFORMATION:

OP CODE OPERATIONOP

TIME

OP

QTY

CAUSAL

PART NUMBER

NATURE

CODE

CAUSE

CODE

91500R0FBody sealing and corrosion protection,

door wiring inspection (both sides)1.2

1 71110-2DA10 *N56 **C8891501R0F

Body sealing and corrosion protection,

door wiring inspection (both sides) and

replacement (one side only)

3.5

91502R0F

Body sealing and corrosion protection,

door wiring inspection (both sides) and

replacement (both sides)

4.6

BEFORE SPRAYING

ACCESSHOLE

UNDERCOATING

AFTER SPRAYING

Documents

vrata Hyundai