Weird/extremely annoying electrical problem.. need help!



Just a wild guess here, it might be a loose ground connection causing headlight current to flow through the passenger door module interfering with it's ability to "listen" to the CANbus. Ground points are a screw post coming out of the chassis with one or more usually brown wires connected via ring lugs. The ring lugs should be clean, shiney, and clamped tightly by the nut. A loose or corroded connection can cause headlight current not to be connected to ground, and the current then flows backward through the door module.
It could also be a defect in the processor/firmware of the front SAM that causes the undesired operation you observe. Replacement or a reman front SAM would be needed.
A little poking around with a voltmeter on the pins of the passenger door module might lead to the culprit. If any of the brown wires has more than a few millivolts to ground with the headlights on, but goes away with the lights off, you need to make sure all ground posts have a low impedence path to the chassis. Also check the battery negative connection and cable to chassis.
Good luck.


