Recall - Rear Wire Harness Modification
04-026September 17, 2004
Applies To:
2004 TSX - From VIN JH4CL9...4C000070 thru JH4CL9...4C040281
Safety Recall: TSX Rear Wire Harness
(Supersedes Preliminary Service Bulletin 04-026, dated September 3, 2004)
Updated information is shown by asterisks and black bars.
BACKGROUND
The rear wire harness near the left side trunk hinge is not adequately protected and could be damaged when the trunk is repeatedly opened and closed. A damaged wire harness can cause a blown fuse or an open *circuit, with either resulting in a loss of the backup lights, the license plate light, the left or right taillight, and/or the trunk release button function.* Driving without back-up lights or driving at night without taillights can make it difficult for other drivers to see the vehicle, and a crash could occur.
NOTE:
This problem does not affect the brake lights.
CUSTOMER NOTIFICATION
All owners of affected vehicles will be sent a *notification of this recall. An example of the customer notification is at the end of this service bulletin.
Not all vehicles within the VIN ranges are affected by this recall. Before beginning work on a vehicle, verify its eligibility by checking at least one of these items:
^ The customer has a notification letter.
^ The vehicle is shown on your campaign responsibility report.
^ The vehicle is shown as eligible on an iN VIN status inquiry.
In addition to these verification items, check for a punch mark above the third character of the engine compartment VIN. A punch mark in that location means the rear wire harness has already been inspected and repaired.
Some vehicles affected by this recall may be in your new vehicle inventory. According to federal law, these vehicles cannot be sold or leased until they are repaired. To see if a vehicle is affected by this recall, do a VIN status inquiry before selling it.
CORRECTIVE ACTION
Inspect the rear wire harness for twisting or damage.
^ If the rear wire harness is not twisted or damaged, cover it with protective tubing and tape near the left side of the trunk lid.
^ If the rear wire harness is twisted or damaged, replace it.*
PARTS INFORMATION
Corrugated Plastic Tube Kit: P/N 06321-SEA-000
(Contains one tube, two wire harness clips, and
one roll of electrical tape)
*Rear Wire Harness: P/N 32108-SEA-A01*
WARRANTY CLAIM INFORMATION
Failed Part: P/N 32108-SEA-A00
Defect Code: 5KA00
Symptom Code: P4500
Skill Level: Repair Technician
INSPECTION PROCEDURE
1. Remove the trunk floor, the trunk rear trim panel, the left side trunk trim panel, and the left side trunk lid hinge cover:
^ Refer to pages 20-61 and 20-62 of the 2004 TSX service manual.
^ In ISIS, enter keyword TRUNK, and select
Interior Trim Removal/Installation - Trunk
Area and - Trunk Lid from the list.
*2. Inspect the rear wire harness where it attaches to the left hinge of the trunk. The harness should have only a slight bend in it. It should not be twisted or damaged.
^ If the rear wire harness is not twisted or damaged, go to REPAIR PROCEDURE A.*
*^ If the rear wire harness is twisted and/or damaged, go to REPAIR PROCEDURE B.*
REPAIR PROCEDURE A
1. Detach the two wire harness clips from the hinge and the body, then remove and discard these clips.
2. Install the corrugated plastic tube on the wire harness in the area between the removed clips. Then wrap the tube with the electrical tape, and install new clips over the tube as shown.
NOTE:
Make sure the wire harness bends smoothly without any kinks.
3. Attach the wire harness clips to the body and to the hinge.
4. Check the rear lights and the trunk opener. If there are any problems, check your work.
5. Reinstall the trunk trim pieces, and replace any trim clips that may have broken.
6. Center-punch a completion mark above the third character of the engine compartment VIN.
*REPAIR PROCEDURE B
1. Disconnect the clips attaching the rear wire harness to the vehicle.
2. Lay out the new rear harness inside the trunk.
3. Using the rear wire harness chart/illustration, locate connector number 1 (3P, GRY, right rear turn signal) on the original harness.
4. Disconnect connector number 1 from the original harness, and connect the appropriate connector from the new harness in its place.
5. Using the chart/illustration on page 3, continue disconnecting the connectors (and the body ground terminal) from the original wire harness, and connect the appropriate connectors from the new wire harness. Discard the original wire harness.
NOTE:
^ Do not bend or twist the new wire harness excessively.
^ Make sure all connectors on the new wire harness are secure.
6. Insert the clips on the new wire harness into the appropriate holes on the vehicle.
NOTE:
Make sure the new wire harness is not pinched or excessively loose in any areas.
7. Check the rear lights and the trunk opener. If there are any problems, recheck the fit of the connectors.
8. Reinstall the trunk trim pieces, and replace any trim clips that may have broken.
9. Center-punch a completion mark above the third character of the engine compartment VIN.*
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