Campaign - Moisture in Headlamp Assembly: Overview
07-016May 5, 2007
Applies To:
2004-05 TSX - ALL
Product Update: Moisture in Headlight
(Supersedes 07-016, dated March 10, 2007 to update the information marked by the black bars and asterisks)
BACKGROUND
*The hood contacts the headlight lens and, over time, may create a small gap for water to enter between the lens and the headlight body.*
CLIENT NOTIFICATION
All owners of affected vehicles will be sent a notification of this product update. An example of the client notification is at the end of this service bulletin.
To verify vehicle eligibility, check for at least one of these items:
^ The client has a notification letter.
^ The vehicle is shown on your campaign responsibility report.
^ The vehicle is shown as eligible on a VIN status inquiry.
In addition, check for a punch mark above the fifth character of the engine compartment VIN. A punch mark in that location means this product update has already been completed.
Some vehicles affected by this product update may be in used dealer inventory. These vehicles must be updated before they are sold or leased.
CORRECTIVE ACTION
Add two clips to the headlight units, and adjust the hood. In rare cases, if water is present, you may need to replace the headlight unit and one or more of these parts:
*NOTE:
The labor time to replace any needed parts is included when replacing the headlight.*
^ HID (high intensity discharge) unit
^ Headlight bulb
^ HID igniter (bulb socket) and wire harness
^ Low beam headlight fuse
PARTS INFORMATION
Headlight Lens Clips (enough to repair one vehicle):
P/N 06336-SEA-305
WARRANTY CLAIM INFORMATION
Failed Part: P/N 33101-SEC-A11
Defect Code: 5HLOO
Symptom Code: Q3600
Skill Level: Repair Technician
DIAGNOSIS
1. Turn on the headlights and see if they work.
^ If the headlights work, go to step 2.
^ If the headlights do not work, go to REPAIR PROCEDURE B: UPDATE HEADLIGHTS. Then troubleshoot the headlights using normal troubleshooting procedures. If needed, file a separate warranty claim.
* NOTE:
This product update covers water damage to the headlights and its components only.*
2. Remove the front grille cover (12 clips).
3. Inspect the headlight assemblies for obvious signs of water in the headlight unit.
^ If you see water, go to REPAIR PROCEDURE A: REPLACE HEADLIGHT UNIT.
^ If you don't see any water, go to step 4.
4. Inspect the headlight assembly for hidden water:
^ Disconnect the 3P connector from the high beam headlight.
^ Remove the rubber cover.
^ Fold a paper towel several times so that it is about eight inches long and one inch wide.
^ Slide the folded paper towel under the high beam reflector to the bottom of the headlight assembly.
^ Inspect the paper towel to see if it is wet:
- If the paper towel is wet, go to REPAIR PROCEDURE A: REPLACE HEADLIGHT UNIT.
- If the paper towel is not wet, go to REPAIR PROCEDURE B: UPDATE HEADLIGHTS.
REPAIR PROCEDURE A: REPLACE HEADLIGHT UNIT
1. Using a marker, mark the location of the headlight at the index on the radiator support.
2. Remove the fender trim.
3. Remove the front bumper:
^ Refer to page 20-127 of the 2004-07 TSX Service Manual, or
^ Online, enter keyword BUMPER and select Front Bumper Removal/Installation from the list.
4. Replace the headlight unit:
^ Refer to page 22-175 of the service manual, or
^ Online, enter keyword HEADLIGHT and select Headlight Replacement from the list.
NOTE:
There is a package of desiccant included with each headlight unit. Make sure the desiccant is attached inside the low beam headlight. If it isn't attached, peel the label and attach the desiccant inside the low beam headlight.
5. Replace any of the following components if they are damaged or corroded:
HID unit:
^ Refer to page 22-172 of the service manual, or
^ Online, enter keyword HEADLIGHT and select HID (High Intensity Discharge) Unit Replacement from the list.
Igniter and harness:
^ Remove the HID unit.
^ Replace the igniter (bulb socket) and the harness.
Headlight bulb:
^ Refer to page 22-173 of the service manual, or
^ Online, enter keyword HEADLIGHT and select HID (High Intensity Discharge) Bulb Replacement from the list.
Low beam fuses:
^ Replace fuse No.1(15 A) in the under-hood fuse/relay box.
^ Replace fuse No.6 (15 A) in the under-hood fuse/relay box.
6. Make sure the headlights work, and that they are properly aligned:
^ Refer to page 22-174 of the service manual, or
^ Online, enter keyword HEADLIGHT and select Headlight Adjustment from the list.
7. Reinstall the remaining parts in the reverse order of removal except the fender trim, then go to step 2 of REPAIR PROCEDURE B: UPDATE HEADLIGHTS.
REPAIR PROCEDURE B: UPDATE HEADLIGHTS
1. Remove the fender trim (see step 2 of REPAIR PROCEDURE A: REPLACE HEADLIGHT UNIT).
2. Attach two metal clips (four total) to each headlight unit as shown:
NOTE:
Make sure the clips are properly attached in the proper direction.
3. Make sure the hood is flush with the front fender and has at least 6.2 mm of clearance from the top of the hood to the top of the headlight. If needed, adjust the hood:
^ Refer to page 20-134 of the service manual, or
^ Online, enter keyword HOOD and select Hood Adjustment from the list.
4. Make sure the headlights work, and are aimed properly.
5. Center-punch a completion mark above the fifth character of the engine compartment VIN.
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