Procedure

Inspection and Switch Replacement Flow-Chart

Inspection

CHECKING THE DOOR LATCH/SWITCH ASSEMBLY LOT DATE NUMBER

1. Referring to Section 42, Body in the service manual, remove both the driver's side and passenger's side front door latch/switch assemblies.








2. Using the illustration inspect the lot date number on the door latch. Refer to the table. Read the lot date number as: year/month/day. If the lot date number is 1301 through 2Y09, proceed with the switch replacement procedures.

If the lot date number is not in the affected range, reinstall the door latch and confirm operation of the automatic shoulder belt by closing and opening the door. If the shoulder belt operates properly, submit a warranty claim for. Inspection according to the Warranty Information section of this bulletin. If the belt does not operate check the door latch connector and/or the automatic shoulder belt system according to the procedures in the service manual.

Repair





REQUIRED TOOLS

DOOR LATCH SWITCH REPLACEMENT PROCEDURES
Proceed with the following switch replacement steps only after you have checked the door latch and found it to be within the affected lot code date range.

1. Place the latch assembly on a work stand. Using an electric drill with a 5 mm diameter drill bit, carefully drill out each of the two rivets which attach the door latch switch to the latch body.





a. Center the drill bit on the crimped end of the rivet (on the bracket side of the latch), not the rivet head, before starting to drill.

b. Remove any drilled out rivet material while drilling.





Caution
DO NOT drill into the latch body.





2. Using a hammer and the punch tool from the kit, with the latch body on the work stand, tap on the drilled end of the rivet until the head protrudes slightly from the other side of the latch body. use the side cutters to grip the head of the rivet then pull the rivet the remainder of the way out of the latch.





3. Cut the tie wraps which secure the switch wiring harness to the latch body.





4. Remove the harness from under the white plastic clamp on the latch then remove the original switch.

Note the direction of the switch lever as you remove the switch to ensure correct switch placement when installing the new switch.





5. Making sure the switch lever is facing in the correct direction, insert the new switch into the latch.

Note:
Keep the latch in the OPEN position while installing the new switch.





6. Insert each new rivet from the latch body bracket side (the head of the new rivet is inserted from the opposite direction from the original rivet).





7. Turn the latch assembly over and crimp the end of each rivet with the needle nose pliers as shown.





8. Route the harness wire around the latch body in the same manner as the original. Make sure to leave 7 to 15 mm clearance between the latch bracket and the harness wiring at the point where the wires exit the switch. Make sure the harness is placed under the bracket clamp as was the original.





9. Route the harness behind the tab on the latch bracket then secure the harness with the tie wraps as shown. Cut off excess tie wrap material as shown.

Note:
Use 1 tie wrap for each latch with manual door locks. Use 2 tie wraps for each latch with power door locks.





10. Using the ohmmeter, check the continuity of the new switch.

a. There should be continuity between Black (B) and Red (R) wires when the latch is in the half-lock position.

b. There should be continuity between Black (B) and Green (G) wires when the latch is in the full-lock position.

11. After confirming the continuity of the switch, refer to the service manual and reinstall the latch into the door.

12. Confirm proper operation of the automatic shoulder belt by closing and opening the door.

13. After completing the repairs and confirming the operation of the automatic shoulder belt on each door, submit the proper warranty claim according to the instructions in the Warranty Information section of this bulletin.

^ If one switch was replaced, submit a claim for Door Latch Inspection and Replacement (1 switch).

^ If you replaced both switches, submit a claim for Door Latch Inspection and Replacement (2 switches).