Recall - Headlamp Low Beams Are Inoperative
12-056September 14, 2012
Applies To:
2002-03 Civic - Check the iN VIN status for eligibility
2004-05 Pilot - Check the iN VIN status for eligibility
Safety Recall: Low Beam Headlights May Not Work
(Supersedes 12-056, dated August 31, 2012, to revise the information marked by the black bars and asterisks)
*REVISION SUMMARY
^ Under WARRANTY CLAIM INFORMATION, the Civic flat rate were changed because the battery disconnection/reconnection procedures are not required.
Example of the customer letter was added.*
BACKGROUND
A terminal in the combination light switch 16P 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 beam functionality could result in a crash.
CUSTOMER NOTIFICATION
Owners of affected vehicles have or will receive a notification for this campaign in September 2012. An example of the customer notification is included at the end of this service bulletin.
Do an iN VIN status inquiry to make sure the vehicle is shown as eligible.
Some vehicles affected by this campaign may be in your used vehicle inventory.
Should a dealership sell an unrepaired vehicle that subsequently causes an injury or damage because of the recalled item, the dealership will be solely responsible to the damaged party, and will be required to defend and indemnify American Honda for any resulting claims. To see if a vehicle in inventory is affected by this campaign, do an iN VIN status inquiry before selling it.
CORRECTIVE ACTION
Inspect the combination light switch wire harness 16P connector and, depending on what you find, install a combination light switch wire kit, or a combination light switch repair kit.
PARTS INFORMATION
NOTE:
Most vehicles require only the Combination Light Switch Wire Kit.
Combination Light Switch Wire Kit:
P/N 06322-SAA-305
(Includes 250 mm wire with attached terminal, wire splice connector, and wire tie.)
Combination Light Switch Repair Kit:
P/N 06323-SAA-307
P/N 06323-SAA-309 (2005 Pilots with Honda Genuine Accessory Fog Lights)
(Includes switch, 16P wire harness connector, 250 mm wire with attached terminal, wire splice connector, and wire tie.)
TOOL INFORMATION
NOTE:
The tools listed below were previously sent to your dealership for the completion of Service Bulletin 04-015, Safety Recall: Combination Light Switch. If you need additional tools, order them through the parts ordering system.
Terminal Pin Kit C: T/N 07QAZ-003020C (Contains the wire crimper and the heat gun used for wire splicing.)
Terminal Maintenance Set: T/N 070AZ-55A0100 (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].)
WARRANTY CLAIM INFORMATION
Failed Part: P/N 35255-55A-A02
Defect Code: 5LX00
Symptom Code: S5100
Skill Level: Repair Technician
REPAIR PROCEDURE
NOTE:
^ 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.
^ Pilot is shown, Civic is similar.
1. Remove the upper and lower column covers.
2. Disconnect the 1 6P connector from the combination light switch and the 5P connector from the cable reel (if equipped). On Civic Hatch backs also disconnect the 14P connector from the wiper switch. Then carefully pull the wire harness to the right of the steering column.
3. Turn the ignition switch to the ACC (I) position, then turn the steering wheel 90 degrees to the left to allow room for removal of the combination 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. For Civic - 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.
7. If you see a splice connector on the terminal No.6 wire, cut the wire above the splice connector as shown, and continue with the repair.
8. Using the secondary lock opener from the Terminal Maintenance Set (T/N 070AZ-S5A01 00), carefully pry open the secondary lock of the combination light switch 16P connector.
9. Twist off a terminal remover from the Terminal Maintenance Set (T/N O7OAZ-S5AO1OO). Insert the terminal remover into the center row cavity of the 16P connector, above terminal No.6, then remove the wire from the 16P connector.
NOTE:
Make sure the wire you are removing is Terminal No.6, as different models have different wire colors:
^ All Civics - RED/WHT
^ 2004 Pilot - WHT/RED
^ 2005 Pilot - YEL
10. Using the photos below, check for signs of heat damage on the 16P connector, the terminal end of the terminal No.6 wire, and the 16P terminals of the combination light switch.
^ If you don't find any signs of heat damage, the combination light switch connector will be reused because you'll only be installing a Combination Light Switch Wire Kit. Go to step 13.
^ If you do find signs of heat damage, the combination light switch connector must not be reused because you'll be installing a Combination Light Switch Repair Kit, which includes a new connector and a new switch. Go to step 11.
11. Using the secondary lock opener from the Terminal Maintenance Set (T/N 070AZ-55A0100), carefully pry open the other secondary lock on the 16P connector.
12. Twist off a terminal remover from the Terminal Maintenance Set (T/N O70AZ-55A0100). 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 terminal No.6 this wire will be installed later.
13. 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.
14. Strip off 7 mm of insulation from the vehicle wire harness side of the new RED/WHT wire.
15. Cut the vehicle side terminal No.6 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.
16. Insert the stripped end ofthe new and the original 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 it's 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.
17. 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.
18. Using electrical tape, retape the wire harness or insert the wires into the corrugated tubing/foam and retape the tubing/foam.
19. 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.
20. Insert the new REDIWHT wire into terminal No.6 position in the 16P connector, then snap the connector secondary locks closed.
21. Release the cover locks on the combination light switch, then remove the switch cover.
NOTE:
Make sure you are using the new headlight switch if you are installing the combination light switch repair kit.
22. As shown below, route the wire tie from the kit through the hole in the lower corner ofthe switch cover. Then use the wire tie to secure the REDIWHT wire (in the section you taped in step 13) to the switch cover. Reinstall the cover, and cut off the excess wire tie.
23. Reroute the wire harness over the steering column, the connect the 16P connector to the combination light switch, the 5P connector to the cable reel connector and, on Civic Hatchbacks, the 14P connector to the wiper switch.
24. Install the combination light switch with the two original screws.
25. Check the operation ofthe headlights, the parking lights, and the turn signals.
26. Install the steering column covers.