Honda Service Bulletin 04-015
Contents
1. minutes 32 On 2001 Civic LX and EX 2 door models thru VIN 1HGEM2 1L016502 do the cruise control learn procedure e Drive the vehicle and set the cruise control above 40 miles per hour e Drive the vehicle for 5 to 10 minutes at the set speed If you cancel the set speed before driving 5 to 10 minutes repeat the procedure NOTE This procedure can also be done ona chassis dynamometer but it cannot be done with the vehicle on a lift 33 Center punch a completion mark above the 12th character of the engine compartment VIN Center punch here 1HGXXXXXXXXXXXXXX Example of Customer Letter Spring 2004 Safety Recall Campaign Headlight Switch Dear Honda Owner This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act What is the reason for this notice Honda Motor Co Ltd has decided that a defect relating to motor vehicle safety exists in certain 2001 02 Civics and 2000 01 Insights A terminal in the headlight wire harness can overheat and may cause the low beams to fail without warning Although the high beam position remains operational an unexpected loss of low beams could result in a crash 04 015 What should you do Call any authorized Honda dealer and make an appointment to have your vehicle repaired The dealer will inspect the headlight switch and replace all needed parts This work will be done free of charge Please plan to lea2. repair kits NOTE If you need additional tools order them through the parts ordering system 2004 American Honda Motor Co Inc All Rights Reserved ATB 26898 26996 0404 1of5 Skill Lever CUSTOMER INFORMATION The information in this bulletin is intended for use only by skilled technicians who have the proper tools equipment R and training to correctly and safely maintain your vehicle These procedures should not be attempted by do it yourselfers and you should not assume this bulletin applies to your vehicle or that your vehicle has the condition described To determine whether this information applies contact an REPAIR authorized Honda automobile dealer WARRANTY CLAIM INFORMATION OP Description FRT 728103 Replace the combination light switch and 0 7 the RED WHT wire in the headlight wire harness A Do the cruise control learn 0 3 2001 Civic 2 door thru VIN 1HGEM2 1L016502 728104 Replace the combination light switch the 0 8 RED WHT wire in the headlight wire harness and the 16P wire harness connector A Do the cruise control learn 0 3 2001 Civic 2 door thru VIN 1HGEM2 1L016502 Failed Part P N 35255 S5A A01 H C 6453336 Defect Code 5CN Symptom Code P23 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 servi
3. 3 0f 5 14 15 16 17 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 RED WHT WIRE ON VEHICLE SPLICE CONNECTOR 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 Insert the stripped end of the new RED WHT wire into the other side of the splice connector then crimp the connector 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 e Do not overheat the wire NON COMBUSTIBLE MATERIAL Protects the other wires in the harness 4of5 18 19 20 21 22 23 24 25 26 27 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 22 If the 16P connector is damaged go to step 19 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 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 sa
4. HONDA Service Bulletin Applies To See VEHICLES AFFECTED 04 015 April 1 2004 Safety Recall Combination Light Switch Supersedes 04 015 dated March 26 2004 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 VEHICLES AFFECTED 2001 Civic ALL 2002 Civic 2 door From VIN 1HGEM2 2L000001 thru 1HGEM2 2L024169 4 door From VIN 1HGES1 2L000001 thru 1HGES1 2L024203 From VIN 1HGES2 2L000001 thru 1HGES2 2L028089 From VIN 2HGES 2H500001 thru 2HGES 2H530552 From VIN JHMES1 2S000001 thru JHMES1 2S004507 From VIN JHMES2 2S000001 thru JHMES2 2S002838 Hatchback From VIN SHHEPS 2U300001 thru SHHEPS 2U300222 GX From VIN 1HGEN2 2L000001 thru 1HGEN2 2L000181 2000 01 Insight ALL CUSTOMER NOTIFICATION All owners of affected vehicles will be sent a notification of this recall An example of the customer notification is at the end of 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 e The customer has a notification letter e The vehicle is shown on your campaign responsibility report The vehicle is shown as eligible on an iN VIN status inquiry In additio
5. ce 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 Make sure you have the anti theft code for the radio if applicable then write down your customer s radio station presets Disconnect the negative cable from the battery On Civics remove the driver s dashboard lower cover For Civic 2 4 door see the 2001 04 Civic Service Manual page 20 97 For Civic Hatchback see the 2002 04 Civic Hatchback Service Manual page 20 61 2of5 Remove the steering column covers see the 2001 04 Civic Service Manual page 17 27 step 4 the 2002 04 Civic Hatchback Service Manual page 17 9 step 4 or the 2000 04 Insight Service Manual page 17 9 step 5 On the Insight steering column also remove the two front nuts and loosen the two rear nuts Insight is shown STEERING COLUMN COVERS REAR NUTS Loosen 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 CABLE REEL 5P CONNECTOR Civic is shown COMBINATION LIGHT SWITCH 16P CONNECTOR 04 015 6 Turn
6. me cavity in the new 16P connector Repeat this for all the wires except the original RED WHT wire ORIGINAL 16P CONNECTOR SECONDARY LOCKS NEW 16P CONNECTOR Insert the new RED WHT wire into its proper terminal cavity in the new 16P connector Snap the secondary lock s closed on the 16P connector Using electrical tape retape the wire harness or insert the wires into the corrugated tubing foam and retape the tubing foam Install the new combination light switch with the two original screws 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 and on Civic Hatchbacks the 14P connector to the wiper switch On Insights connect the 16P connector to the combination light switch Connect the negative cable to the battery Check the operation of the headlights the parking lights and the turn signals 04 015 28 On Civics install the driver s dashboard lower cover 29 Install the steering column covers 30 Enter the radio anti theft code if applicable then enter your customer s radio station presets Set the clock 31 Do the idle learn procedure e Make sure all electrical items A C audio unit lights etc are off then start the engine e Let the engine reach normal operating temperature the cooling fans cycle twice e Let the engine idle throttle fully closed for 10
7. n 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 H C 7743875 Insight P N 3501 2 S3Y 306 H C 7743883 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
8. opy of this notice to the lessee within 10 days If you have questions If you have any questions about this notice or need assistance with contacting a Honda dealer please call Honda Automobile Customer Service at 800 999 1009 and select menu option 2 We apologize for any inconvenience this campaign may cause you Sincerely American Honda Motor Co Inc Honda Automobile Division 5of5
9. the ignition switch to the ACCESSORY I position then turn the steering wheel to the right 7 Remove the two screws from the combination light switch SWITCH j COVER COMBINATION LIGHT SWITCH _ SCREWS COMBINATION LIGHT SWITCH 8 Using a flat tip screwdriver wrapped with electrical tape slightly lift the switch cover then remove the switch and discard it 9 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 CORRUGATED TUBING FOAM Retain Remove 10 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 WIRE 04 015 11 Inspect the 16P connector for heat damage or discoloration e f the connector is OK go to step 12 e f the connector is damaged or discolored go to step 14 12 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 SECONDARY LOCK OPENER RED WHT WIRE WIRE SECONDARY LOCK Pry carefully to open TERMINAL REMOVER 13 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
10. ve your vehicle for half a day to allow the dealer flexibility in scheduling Who to contact if you experience problems If you are not satisfied with the service you receive from your Honda dealer you may write to American Honda Motor Co Inc Honda Automobile Customer Service Mail Stop 500 2N 7A 1919 Torrance Blvd Torrance CA 90501 2746 If you believe that American Honda or the dealer has failed or is unable to remedy the defect in your vehicle without charge within a reasonable period of time 60 days from the date you first contact the dealer for a repair appointment you may submit a complaint to Administrator National Highway Traffic Safety Administration 400 Seventh Street SW Washington DC 20590 Or call the toll free Safety Hotline at 888 327 4236 What to do if you feel this notice is in error Our records show that you are the current owner or lessee of a 2001 02 Civic or 2000 01 Insight involved in this campaign If this is not the case or the name address information is not correct please fill out and return the enclosed postage paid Information Change Card We will then update our records If you already paid to have a defective headlight switch replaced you may be eligible for reimbursement Refer to the attached instructions for eligibility requirements and the reimbursement procedure Lessor Information Federal law requires that any vehicle lessor receiving this recall notice must forward a c
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