Repair Procedure - Pilot

NOTE:

^ Some vehicles may have been repaired under Service Bulletin 07-027, Low Beam Headlights Intermittently Do Not Come On. If you find a vehicle that has a replacement wire and connector, you still must do this recall. Cut the wire out at the wire splice connector, and continue with the repair.

^ Over 90 percent of affected vehicles should be repairable with the Combination Light Switch Wire Kit.

^ SRS components are located in this area. Before you begin, review the SRS component locations, cautions, and procedures in the service manual.

^ Be careful not to damage the dashboard or other interior trim pieces.

^ For more information on wire terminal replacement and wire splicing, refer to Service Bulletin 00-099, Terminal Replacement Instructions.





1. Remove the steering column covers.





2. Disconnect the 16P connector from the combination light switch. Then carefully pull the wire harness to the right of the steering column.

3. Turn the ignition switch to ACC (I), then turn the steering wheel 90 degrees to the left to allow room for removal of the combination light switch.





4. Remove the two screws from the combination light switch.

5. Using a flat-tip screwdriver wrapped with tape, slightly lift the switch cover, then remove the switch.





6. If the procedures in S/B 07-027 were previously done, there will be a RED/WHT wire and a splice connector present on the terminal No. 6 wire. Cut the wire on the WHT/RED side of the splice connector, and continue with the repair.





7. Using the secondary lock opener from the Terminal Maintenance Set (T/N 070AZ-S5A0100), carefully pry open the secondary lock on the WHT/RED wire side of the combination light switch 16P connector.

NOTE:
Make sure you check the WHT/RED wire in terminal No. 6.

8. Twist off a terminal remover from the Terminal Maintenance Set (T/N 070AZ-S5A0100). Insert the terminal remover into the center row cavity of the 16P connector, above the WHT/RED wire cavity, then remove the WHT/RED wire from the 16P connector.





9. Using the photos, check for signs of heat damage on the 16P connector, the terminal end of the WHT/RED wire, and the 16P terminals of the combination light switch.

^ If you don't find any signs of heat damage, the combination light switch will be reused because you'll only be installing a Combination Light Switch Wire Kit. Go to step 11.

^ If you do find signs of heat damage, the combination light switch must not be reused because you'll be installing a Combination Light Switch Repair Kit. Go to step 9.

10. Using the secondary lock opener from the Terminal Maintenance Set (T/N 070AZ-S5A0100), carefully pry open the other secondary lock on the 16P connector.





11. Twist off a terminal remover from the Terminal Maintenance Set (T/N 070AZ-S5A0100). Insert the terminal remover into a center row cavity of the original 16P connector, remove the corresponding wire from its cavity, and transfer it to the same cavity in the new 16P connector from the repair kit. Repeat this for all the wires except the original WHT/RED wire; this wire will be installed later.





12. On the new RED/WHT wire provided in the kit, measure 50 mm from the terminal end, and wrap a 50 mm section of the wire with three turns of electrical tape. This taped section of the wire will be secured to the combination light switch in step 22.

13. Strip off 7 mm of insulation from the opposite end of the new RED/WHT wire.





14. Cut the vehicle side WHT/RED wire near the terminal, then strip off 7 mm of insulation from the end of the wire.

NOTE:
If there was any heat damage to the wire, make sure to cut off the damaged area before you strip off the insulation.





15. Insert the stripped end of the new RED/WHT wire and the original WHT/RED wire into each side of the splice connector from the kit, then, using the wire crimper from Terminal Pin Kit C, crimp the connector on both sides. Slightly pull on both sides of the wire to make sure its secured in the splice connector.

NOTE:
To get the correct amount of pressure on the splice connector, you need to use the wire crimper from Terminal Pin Kit C.





16. With a non-combustible material between the wire and the vehicle wire harness, use a heat gun to shrink the splice connector casing.

NOTE:

^ Be careful not to get burned.

^ Do not overheat the wire.





17. Place the wire splice on top of the combination switch wire harness, then attach the splice to the harness by wrapping them together with electrical tape.

18. Insert the new RED/WHT wire into its proper position in the 16P connector, then snap the connector secondary locks closed.





19. Release the cover locks on the combination light switch, then remove the switch cover. Release the switch cover locks.





20. As shown, route the wire tie from the kit through the hole in the lower corner of the switch cover. Then use the wire tie to secure the RED/WHT wire (in the section you taped in step 11) to the switch cover. Cut off the excess wire tie.





21. Reattach the switch cover to the combination light switch. Make sure the switch cover is properly locked in place.

22. Connect the 16P connector to the combination light switch. Make sure the connector is securely connected.

23. Install the combination light switch with the two original screws.

24. Check the operation of the headlights, the parking lights, and the turn signals.

25. Install the steering column covers.