Recall - Headlamp Low Beams Inoperative: Overview
10-082March 11, 2011
Applies To:
2007-08 Fit - ALL
Safety Recall: 2007-08 Fit Low Beam Headlights May Not Work
(Supersedes 10-082, dated January 28, 2011, to revise the information marked by the black bars and asterisks)
*REVISION SUMMARY
Under REPAIR PROCEDURE, the illustrations in steps 22 and 23 were changed.*
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
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.
To verify vehicle eligibility, you must check 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 to the listed items, check for a punch mark above the seventh 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 repaired 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.
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:
Base models: P/N 06323-SAA-307
Sport models: P/N 06323-SAA-309
(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, fiat-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: 5L500
Symptom Code: R5800
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.
1. Make sure you have the anti-theft code for the radio, then disconnect the negative cable from the battery.
2. Remove the driver's dashboard undercover.
3. Remove the steering column covers.
4. Remove the steering column front nuts and rear bolts.
5. Disconnect the 16P connector from the combination light switch and the 5P or 1 3P connector from the cable reel. Then carefully pull the wire harness to the right of the steering column.
6. Turn the ignition switch to ACC (I), then turn the steering wheel 90 degrees to the left to allow room for removal of the combination light switch.
7. Remove the two screws from the combination light switch.
8. Using a flat-tip screwdriver wrapped with tape, slightly lift the switch cover, then remove the switch.
NOTE:
To allow removal clearance for the combination light switch, slightly shift the steering column to the right.
9. 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 combination light switch 16P connector.
10. Twist off a terminal remover from the Terminal Maintenance Set (T/N 070AZ-S5A0100). Insert the terminal remover into the center row cavity of the 16P connector, above the RED/WHT wire cavity, then remove the RED/WHT wire from the 16P connector.
11. Using the photos below, check for signs of heat damage on the 16P connector, the terminal end of the RED/WHT wire, and the 16P terminals of the combination light switch.
^ If you don't find any signs of heat damage, retain the combination light switch because you'll only be installing a Combination Light Switch wire Kit. Go to step 14.
^ If you do find signs of heat damage, discard the combination light switch because you'll be installing a Combination Light Switch Repair Kit. Go to step 12.
12. 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.
13. Twist off a terminal remover from the Terminal Maintenance Set (T/N 070AZ-S5A01 00). 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 the original RED/WHT wire; this wire will be installed later.
14. On the new RED/WHT wire provided in either 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.
15. Strip off 7 mm of insulation from the opposite end of the new RED/WHT wire.
16. Cut the vehicle side RED/WHT 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 RED/WHT wire, make sure to cut off the damaged area before you strip off the insulation.
17. Insert the stripped end of the new and the original RED/WHT wire into each side of the splice connector from the kit, then, using the wire crimper from Terminal Pin Kit C, crimp the connector. 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.
18. 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.
^ Do not overheat the wire.
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 RED/WHT wire into its proper 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.
22. As shown, route the wire tie from the kit through the hole in the lower corner of the switch cover. Then use the wire tie to secure the RED/WHT wire (in the section you taped in step 14) to the switch cover. Cut off the excess wire tie.
23. Reattach the switch cover to the combination light switch. Make sure the switch cover is properly locked in place.
24. Connect the 16P connector to the combination light switch, then route the RED/WHT wire under the 5P or 13P cable reel connector, and reconnect the connector. Make sure the connectors are securely connected.
25. Install the combination light switch with the two original screws.
26. Connect the negative cable to the battery.
27. Check the operation of the headlights, the parking lights, and the turn signals.
28. Install the steering column front nuts and rear bolts.
29. Install the steering column covers.
30. Reinstall the driver's dashboard lower cover.
31. Enter the radio anti-theft code.
32. Center-punch a completion mark above the seventh character of the engine compartment VIN.
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