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02-031 - Tegger

1. HONDA Export Service Bulletin 02 031 Applies To See VEHICLES AFFECTED September 2002 Safety Recall Ignition Switch Supersedes 02 031 dated August 2002 BACKGROUND PARTS INFORMATION Electrical contacts in the ignition switch can wear Ignition Switch prematurely due to high electrical current passing 1997 Accord P N 35130 SY8 305 through the switch Worn out ignition contacts could cause the engine to stall without warning Although the 1998 99 Accord P N 35130 S84 305 engine will restart in most cases a vehicle that stalls 1998 99 Civic P N 35130 S04 305 while driving increases the risk of a crash left hand drive 1999 Civic _ P N 35130 S04 306 aiid ae P N 35130 S10 306 e 1997 Accord L4 left hand drive without immobilizer system see ae Apear and Ve 1999 CR V P N 35130 S10 405 e 1998 99 Civic left hand drive with immobilizer system e 1997 99 CR V 1998 99 CR V P N 35130 S10 305 1997 99 Odyssey right hand drive e 1997 99 Prelude 1997 Odyssey P N 35130 SX0 406 left h i Not every vehicle in the years and models listed Ue nenigetive above is affected by this campaign Before 1997 Odyssey P N 35130 SX0 405 beginning work verify that the vehicle is eligible by right hand drive checking your campaign responsibility report 1998 Odyssey P N 35130 SX0 305 left hand drive 1999 Odyssey P N 35130 SO0X 305 left hand drive 1998 99 Odyssey P N 35130 SX0 306 right han
2. remove and discard the switch and its harness ELECTRICAL SWITCH 10 Install the new electrical switch with the original screws 02 031 11 16 17 Remove the secondary lock from the 7P connector of the new main harness NEW MAIN HARNESS SECONDARY LOCK Reinstall BLU WHT BLU WHT M T A T 5 _WHT GRN J an Wire side of female terminals Install the terminals you removed from the original 7P connector into the new 7P connector Wrap both parts of the 7P main harness together with electrical tape Attach the new wire tie clips to the main harness in the same position as the original ties Route and attach the ignition switch harness and main harness the same way the original harnesses were installed Connect the 5P and 7P connectors Install the steering column covers the knee bolster and the driver s dashboard lower cover 02 031 18 Center punch a completion mark above the eighth character of the engine compartment VIN Center punch here 2HGEJ6XXXXHXXXXXX Procedure D 1997 99 CR Vs 1 Remove the drivers dashboard lower cover and the knee bolster see the 1997 01 CR V Shop Manual 2 Disconnect the ignition switch harness 5P connector from the under dash fuse relay box and the 3P connector from the main wire harness 3P CONNECTOR 5P CONNECTOR 3 Remove the steering column covers see the shop manual 4 Note how the ignition electrical
3. switch harness routes to the fuse box and main wire harness you ll need to route the new switch harness the same way Make sure the ignition switch is turned to LOCK 0 Remove the screws from the electrical switch then remove and discard the switch and its harness ELECTRICAL SWITCH 7 Install the new electrical switch with the original screws Route its harness to the fuse box and main wire harness the same way the discarded harness was routed 8 Connect the 5P and 3P connectors 5 of 7 9 Install the steering column covers the knee bolster and the driver s dashboard lower cover 10 Center punch a completion mark above the eighth character of the engine compartment VIN Center punch here JHLRD1XXXXHXXXXXX Procedure E 1997 98 Odysseys 1 Remove the dashboard lower cover the knee bolster and the steering column covers see the 1998 Odyssey Shop Manual Disconnect the ignition switch harness 7P connector from the under dash fuse relay box 7P CONNECTOR Note how the ignition electrical switch harness routes to the fuse box you ll need to route the new switch harness the same way Make sure the ignition switch is turned to LOCK 0 Remove the screws from the electrical switch then remove and discard the switch and its harness U7 Ss ELECTRICAL SWITCH Install the new electrical switch with the original screws Route its harness to the fuse box the same way the
4. L4 and V6 e Use Procedure C on 1998 99 Civics e Use Procedure D on 1997 99 CR Vs e Use Procedure E on 1997 98 Odysseys e Use Procedure F on 1999 Odysseys e Use Procedure G on 1997 99 Preludes E Procedure A 1997 Accords L4 1 Remove the dashboard lower cover the knee bolster and the steering column covers see the 1997 Accord Shop Manual 2 Disconnect the 7P and 8P connectors from the ignition switch body 7P CONNECTOR 2of7 8P CONNECTOR 3 Remove the steering column holder mounting bolts and nuts Lower the steering column es Oa COLUMN HOLDER MOUNTING NUTS 16 N m 12 lb ft MOUNTING BOLTS 38 N m 28 Ib ft 4 Center punch both shear bolts on the ignition switch body and drill off each bolt head with a 5 mm 3 16 in drill bit Be careful not to damage the switch body Y 5 Remove the shear bolts from the ignition switch body and discard them Then separate the switch body from the steering column 02 031 6 Remove the screws from the electrical switch then Procedure B 1998 99 Accords L4 and V6 remove the electrical switch from the ignition switch 1 Remove the dashboard lower cover see the body Discard the electrical switch 1998 02 Accord Shop Manual ELECTRICAL amp 2 Disconnect the ignition switch harness 6P SWITCH D connector from the drivers under dash fuse relay box IGNITION SWITCH BODY 7 Install the new electrical switch
5. with the original screws 6P CONNECTOR 8 Hold the ignition switch body up to the steering 3 Remove the steering column covers see the shop column and loosely install the new shear bolts manual 9 Insert the key in the ignition switch Make sure the 4 Note how the ignition electrical switch harness key turns freely and the steering column lock routes to the fuse box you ll need to route the new works correctly switch harness the same way 10 Tighten the shear bolts until the hex heads twist off a Make sure the ignition switch is turned to LOCK 0 SHEAR BOLT 6 Remove the screw from the side of the electrical j switch cover om Ee TWIST OFF PORTION 11 Raise the steering column and install it with its mounting bolts and nuts Torque the bolts to 38 Nm 28 Ib ft and the nuts to 16 Nm 12 lb ft 12 Connect the 7P and 8P connectors 13 Install the steering column covers the knee bolster and the dashboard lower cover 14 Center punch a completion mark above the eighth 7 Remove the screws from the electrical switch then character of the engine compartment VIN remove and discard the switch and its harness Center punch here 8 Install the new electrical switch with the original screws and cover Route its harness to the fuse box the same way the discarded harness was 1HGCD5XXXXHXXXXXX rauited 9 Connect the 6P connector 10 Install the steering column covers and the dashboard lower
6. cover 11 Center punch a completion mark above the eighth character of the engine compartment VIN Center punch here 1HGCG5XXXXHXXXXXX 02 031 3 of 7 Procedure C 1998 99 Civics 1 Remove the driver s dashboard lower cover and the knee bolster see the 1996 00 Civic Shop Manual 2 Disconnect the ignition switch harness 5P connector from the under dash fuse relay box and the 7P connector from the main wire harness 7P CONNECTOR 5P CONNECTOR 3 Remove the steering column covers see page 17 37 of the service manual 4 Note how the ignition electrical switch harness routes to the fuse box and main harness you ll need to route the new switch harness the same way 5 Remove and discard the wire tie clips from the 7P connector main wire harness Part of the harness will be reused 6 Remove the secondary lock from the 7P connector SECONDARY LOCK Remove TERMINAL PIN TOOL P N 07JAZ 002020A BLU WHT M T A T BLU WHT M T A T WHT YEL WHT BLU A T _ A T Wire side of female terminals 4of7 Remove terminals 2 and 4 M T vehicles or l terminals 2 4 5 6 and 7 A T vehicles from the 7P connector using the Terminal Pin Tool P N O7JAZ 002020A NOTE Terminals 2 and 4 have BLU WHT wires To avoid mixing them up label terminal 4 with a small piece of tape Make sure the ignition switch is turned to LOCK 0 Remove the screws from the electrical switch then
7. d drive CUSTOMER NOTIFICATION All owners of affected vehicles must be sent a notification letter of this campaign An example of the customer notification letter was sent with this service bulletin 1997 99 Prelude P N 35130 S30 305 TOOL INFORMATION CORRECTIVE ACTION Terminal Pin Tool P N O7JAZ 002020A Replace the electrical ignition switch part of Terminal Pin Tool Set NOTE Reinstalling aftermarket parts security Bei tlnz COC ONOR systems alarms audio systems etc connected to the ignition wiring is not covered under this campaign lf a customer wants a non Honda part reinstalled the customer or the shop that installed the part must do the work and assume liability In addition the customer is responsible for all costs associated with the non Honda part and its installation If you have any questions about this please contact the Export Service Department 2002 American Honda Motor Co Inc All Rights Reserved XTB 24102 24406 0209 1 of 7 WARRANTY CLAIM INFORMATION Description FRT Replace ignition switch 1997 Accord 0 5 1998 99 Accord 0 4 1998 99 Civic 0 6 1997 99 CR V 0 4 1997 98 Odyssey 0 4 1999 Odyssey 0 7 1997 99 Prelude 0 5 Operation Number 725108 Failed Part Defect Code Contention Code L55 REPAIR PROCEDURE P N 35130 S84 A01 5B0 the 0 is a zero p e Use Procedure A on 1997 Accords L4 e Use Procedure B on 1998 99 Accords
8. discarded harness was routed Connect the 7P connector 6 of 7 Install the steering column covers the knee bolster and the dashboard lower cover Center punch a completion mark above the eighth character of the engine compartment VIN Center punch here JHMRA1XXXXHXXXXXX Procedure F 1999 Odysseys 1 Remove the dashboard lower cover see the 1999 02 Odyssey Shop Manual Remove the driver s door sill molding and the left kick panel see the shop manual Remove the mounting nut and detach the clips from the driver s under dash fuse relay box Pull the fuse box away from the body DRIVER S UNDER DASH FUSE RELAY BOX 6P CONNECTOR Located on the back of the fuse box Disconnect the ignition switch harness 6P connector from the back of the fuse box Remove the steering column covers see the shop manual Note how the ignition electrical switch harness routes to the fuse box the main harness and the ignition switch body you ll need to route the new switch harness the same way 02 031 7 Disconnect the ignition switch harness 4P connector from the main harness Then disconnect its 5P connector from the ignition switch body 4P CONNECTOR IGNITION SWITCH BODY ELECTRICAL SWITCH 8 Make sure the ignition switch is turned to LOCK 0 9 Remove the screws from the electrical switch then remove and discard the switch and its harness 10 Install the new electrical switch wit
9. h the original screws Route its harness to the fuse box the same way the discarded harness was routed NOTE To avoid harness damage make sure you route the 5P connector portion of the harness the exact way the original harness was routed 11 Connect the 5P connector to the ignition switch body the 4P connector to the main harness and the 6P connector to the fuse box 12 Install the fuse box 13 Install the door sill molding the kick panel the steering column covers and the dashboard lower cover 14 Center punch a completion mark above the eighth character of the engine compartment VIN Center punch here 2HKRL1XXXXHXXXXXX 02 031 Procedure G 1997 99 Preludes 1 Remove the steering column covers see the 1997 99 Prelude Shop Manual Make sure the ignition switch is turned to LOCK 0 Disconnect the 7P connector from the ignition switch body ELECTRICAL SWITCH A i S NYY SS G 7P CONNECTOR COVER 4 Remove the cover from the electrical switch then remove the screws Remove and discard the electrical switch and its harness 5 Install the new electrical switch with the original screws and cover 6 Connect the 7P connector N Install the steering column covers Center punch a completion mark above the eighth character of the engine compartment VIN Center punch here JHMBB6XXXXHXXXXXX 7 of 7

02-031 - Tegger

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