Recall - Engine Stalling/No Start Condition
11-001September 30, 2011
Applies To:
See VEHICLES AFFECTED
Safety Recall: Loose Wire Terminal May Cause Engine Stalling or No Start (Supersedes 11-001, dated January 15, 2011, to revise the information marked by the black bars and asterisks)
*REVISION SUMMARY
Under REPAIR PROCEDURE, connector views were added to step 9.*
BACKGROUND
A loose wire terminal in the engine wire harness C101 connector may cause the engine to stall or prevent it from starting. An engine that stalls while driving increases the risk of a crash.
VEHICLES AFFECTED
Not all vehicles within the affected VIN ranges have a potential problem with the engine wire harness connector. To verify vehicle eligibility, check for at least one of these items:
^ The customer has a notification letter.
^ The vehicle is shown as eligible on an iN VIN status inquiry.
In addition, check for a punch mark above the first character of the engine compartment VIN. A punch mark in that location means the vehicle has already been repaired.
Some of the vehicles affected by this campaign may be in your used vehicle inventory. These vehicles must be updated before they are sold or leased. To see if a vehicle is affected by this campaign, do an iN VIN status inquiry before selling it, leasing it, or returning it to a service customer.
Should an unrepaired vehicle that was in inventory, or that came in for service after this service bulletin was issued, cause an injury or property damage because of the campaigned 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.
CUSTOMER NOTIFICATION
All owners of affected vehicles will be sent a notification of this campaign. An example of the customer notification is at the end of this service bulletin.
CORRECTIVE ACTION
Install a Wire Harness Connector Repair Kit.
PARTS INFORMATION
Wire Harness Connector Repair Kit:
P/N 06323-R40-305
(Includes an 80 mm wire with attached terminal, a pink wire splice connector, and a junction connector.)
TOOL INFORMATION
NOTE:
The tools below were previously sent to your dealership. If you need additional tools, order them through the parts ordering system.
Pin Tool Set: T/N O7JAZ-002000A
Terminal Pin Kit C: T/N O7QAZ-003020C (Contains the wire crimper and the heat gun used for wire splicing.)
WARRANTY CLAIM INFORMATION
Operation Number: 7370D1
Flat Rate Time: 0.3 hour
Failed Part: P/N 06323-R40-305
Defect Code: 5WE00
Symptom Code: R6100
Skill Level: Repair Technician
REPAIR PROCEDURE
NOTE:
^ If you need more details on the items listed below, bookmark them in the appropriate service manual, or view them online:
- Battery Terminal Disconnection and Reconnection
- CR-V only: Air Cleaner Removal/Installation
^ For more information on wire terminal replacement and wire splicing, refer to Service Bulletin 00-099, Terminal Replacement Instructions.
^ For a complete list of the wire terminals and circuits in the C101 junction connector, refer to Connector Terminal View 264 in the 2010 Accord ETM, or Connector Terminal View 279 in the 2010 CR-V ETM.
1. Do the battery terminal disconnection procedure.
2. CR-V only: Remove the air cleaner.
3. Locate the C101 junction connector; it's under the hood, near the left damper tower.
4. Detach the junction connector from its bracket on the body.
5. Disconnect the dash harness connector from the junction connector, then disconnect the engine harness connector from the junction connector by releasing the engine harness connector cam lock. The junction connector will not be reused.
6. With the engine harness connector disconnected from the junction connector, press the two spring-loaded lock tabs on the engine harness connector cam lock, and close the cam lock.
7. Unwrap and discard the tape from the corrugated tubing closest to the engine harness connector, then remove the corrugated tubing. Retain the tubing for reinstallation. Unwrap and discard the tape under the tubing to expose the wires going into the engine harness connector.
8. Using the Pin Tool (T/N 07JAZ-002050A) from the Pin Tool Set P/N 07JAZ-002000A), remove the terminal lock retainer from the engine harness connector.
9. Using the Pin Tool P/N 07JAZ-002010A) from the Pin Tool Set (T/N 07JAZ-002000A), gently release the BLK/WHT wire's terminal lock tab while carefully pulling the wire from the connector. Be careful not to damage the lock tab.
10. Cut off the end of the BLK/WHT wire, about 50 mm from the engine harness connector, then strip off 7 mm of insulation from the end of the cut wire.
11. Insert the stripped end of the BLK/WHT wire from the kit and the BLK/WHT wire on the vehicle into each side of the pink splice connector from the kit. Then crimp the splice connector using the middle splicing slot on the wire crimper (T/N 07NGZ-001010A) from Terminal Pin Kit C. 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 (T/N 07NGZ-001010A) from Terminal Pin Kit C.
12. With a non-combustible material between the BLK/WHT wire and the engine wire harness, use the heat gun from Terminal Pin Kit C to shrink the splice connector casing.
NOTE:
^ Be careful not to get burned.
^ Do not overheat the wire.
13. With the locking tab on the terminal of the new BLK/WHT wire end pointing up, carefully push the terminal into its hole in the engine harness connector. Be careful not to damage the connector's orange weather seal while pushing the terminal into place.
14. Using new electrical tape, rewrap the wires going into the engine harness connector, then reinstall the corrugated tubing, and rewrap it.
15. Reinstall the terminal lock retainer.
16. Return the engine harness connector cam lock to its open position, then connect the engine harness connector to the new junction connector.
17. Connect the engine compartment harness connector to the new junction connector, then attach the junction connector to its bracket on the body.
18. CR-V only: Reinstall the air cleaner. Torque the air cleaner bolt to 12 Nm (8.7 lb-ft).
19. Do the battery terminal reconnection procedure.
20. Center-punch a completion mark above the first character of the engine compartment VIN.
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