Recall - Combination Light Switch/Headlamp Wiring Repair: Overview
04-015October 2, 2012
Applies To:
2001-02 Civic - Check the iN VIN status for eligibility
2000-01 Insight - Check the iN VIN status for eligibility
Safety Recall: Combination Light Switch
(Supersedes 04-015, dated March 26, 2004 to revise the information marked by the black bars and asterisks)
*REVISION SUMMARY
Under WARRANTY CLAIM INFORMATION, the flat
rate was changed because the battery disconnection/
reconnection procedures were deleted.*
BACKGROUND
A terminal in the headlight wire harness connector can overheat and may cause the low-beam headlights to fail without warning. Although the high-beam position remains operational, an unexpected loss of low beams could result in a crash.
CUSTOMER NOTIFICATION
All owners of affected vehicles will be sent a notification of this recall. An example of the customer notification is shown in 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 the bulleted verification items, check for a punch mark above the 12th character of the engine compartment VIN. A punch mark in that location means the combination light switch has already been repaired.
Some vehicles affected by this recall may be in your used car 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
Replace the combination light switch, the RED/WHT wire in the headlight wire harness, and if needed, the 16P headlight wire harness connector.
PARTS INFORMATION
Combination Light Switch Repair Kit:
(Includes switch, wire harness connector, 250 mm
wire with an attached terminal, and wire splice connector)
Civic: P/N 35012-S5A-307
Insight: P/N 35012-S3Y-306
TOOL INFORMATION
Terminal Pin Kit C: T/N 07QAZ-003020C, or equivalent (Terminal Pin Kit C contains the wire crimper and the heat gun used for wire splicing.)
Terminal Maintenance Set: T/N 070AZ-S5A0100*
[Contains Terminal Remover Set (six small, plastic tools used to remove terminals from the 16P headlight wire harness connector), and Secondary Lock Opener (a miniature, flat-tip screwdriver used to open the secondary locks on the 16P headlight wire harness connector)]
* This tool is being sent to your dealership along with your initial allocation of combination light switch repair kits.
NOTE
If you need additional tools, order them through the parts ordering system.
WARRANTY CLAIM INFORMATION
Failed Part: P/N 35255-S5A-A01
Defect Code: 5CN00
Symptom Code: P2300
Skill Level: Repair Technician
REPAIR PROCEDURE
NOTE:
^ 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 information about wire terminal replacement and wire splicing, refer to service bulletin 00-099 Terminal Replacement Instructions.
1. Remove the driver's dashboard lower cover:
^ For Civic 2/4 Door see page 20-97 of the
2001-04 Civic Service Manual, or
^ Online enter keyword DASHBOARD and select Driver's Dashboard Lower Cover Removal and Installation from the list.
^ For Civic Hatchback see page 20-61 of the
2002-04 Civic Hatchback Service Manual, or
^ Online enter keyword DASHBOARD and select Driver's Dashboard Lower Cover Removal and Installation from the list.
2. Remove the steering column covers:
^ For Civic 2/4 Door, see page 17-27, step 4 in the 2001-04 Civic Service Manual, or
^ Online enter keyword STEERING and select Steering Column Removal and Installation from the list.
^ For Civic Hatchback, see page 17-9, step 4 in the 2002-04 Civic Hatchback Service Manual, or
^ Online enter keyword STEERING and select Steering Column Removal and Installation from the list.
^ For Insight see page 17-9, step 5 in the 2000-04 Insight Service Manual, or
^ Online enter keyword STEERING and select Steering Column Removal and Installation from the list.
3. On Civics, disconnect the 16P connector from the combination light switch and the 5P connector from the cable reel.
On Civic Hatchbacks, also disconnect the 14P connector from the wiper switch. Then carefully pull the wire harness to the right of the steering column.
On Insights, disconnect the 16P connector from the combination light switch.
4. Turn the ignition switch to the ACCESSORY (I) position, then turn the steering wheel to the right.
5. Remove the two screws from the combination light switch.
6. Using a flat-tip screwdriver wrapped with electrical tape, slightly lift the switch cover, then remove the switch, and discard it.
7. Remove the tape or corrugated tubing/foam from the 16P connector wire harness to expose about 200 mm of wire. Discard the tape, but retain the tubing/foam.
8. Locate the RED/WHT wire in the 16P connector. Then measure 150 mm from the end of the connector, and cut the RED/WHT wire there.
9. Inspect the 16P connector for heat damage or discoloration.
^ If the connector is OK, go to step 10.
^ If the connector is damaged or discolored, go to step 12.
10. Using the Secondary Lock Opener from the Terminal Maintenance Set (T/N 070AZ-S5A0100), carefully pry open the secondary lock on the RED/WHT wire side of the 16P connector.
11. Twist off a terminal remover from the Terminal Remover Set (T/N 070AZ-S5A-011). Insert the terminal remover into the center row cavity of the 16P connector, above the RED/WHT wire cavity, then remove and discard the RED/WHT wire.
12. Strip off 7 mm of insulation from the vehicle wire harness side of the RED/WHT wire. Insert the stripped end into one side of the splice connector, and crimp the connector.
13. Cut the new RED/WHT wire 170 mm from the end of its terminal. Then strip off 7 mm of insulation from the cut end.
14. Insert the stripped end of the new RED/WHT wire into the other side of the splice connector, then crimp the connector.
15. With a non-combustible material between the RED/WHT 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.
16. If the original 16P connector is not heat damaged or discolored, insert the new RED/WHT wire into its proper terminal cavity on the connector, then go to step 20. If the 16P connector is damaged, go to step 17.
17. Using the secondary lock opener from the Terminal Maintenance Set (T/N 070AZ-S5A-010), carefully pry open the other secondary lock on the 16P connector.
18. Twist off a terminal remover from the Terminal Remover Set (T/N 070AZ-S5A-011). 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. Repeat this for all the wires except the original RED/WHT wire.
19. Insert the new RED/WHT wire into its proper terminal cavity in the new 16P connector.
20. Snap the secondary lock(s) closed on the 16P connector.
21. Using electrical tape, retape the wire harness or insert the wires into the corrugated tubing/foam and retape the tubing/foam.
22. Install the new combination light switch with the two original screws.
23. On Civics, reroute the wire harness over the steering column, then connect the 16P connector to the combination light switch, the 5P connector to the cable reel connector.
On Civic Hatchbacks, the 14P connector to the wiper switch.
On Insights, connect the 16P connector to the combination light switch.
24. Check the operation of the headlights, the parking lights, and the turn signals.
25. On Civics, install the driver's dashboard lower cover.
26. Install the steering column covers.
Disclaimer