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Safety Recall: Ignition Switch Key Interlock (03-034)

Publication date: 2004-01-28
Reference number: 03-034

SAFETY RECALL: IGNITION SWITCH KEY INTERLOCK

SAFETY RECALL: IGNITION SWITCH KEY INTERLOCK

SERVICE CAMPAIGN BULLETIN

Reference Number(s): 03-034, Date of Issue:  January 28, 2004
ACURA: 1998-99 2.3CL, 1998-99 3.0CL, 1999 3.2TL
CATEGORY: Body Electrical
APPLIES TO: See VEHICLES AFFECTED
Superceded Bulletin(s): 03-034, Date of Issue:  January 15, 2004
NOTE: Supersedes 03-034, dated January 15, 2004.

BACKGROUND

Limited batches of an ignition switch component do not have sufficient surface hardness. An ignition switch with this defective component may wear excessively, making it possible to remove the key when the shift lever is not in Park. If the driver does not set the parking brake when parking, the vehicle could roll, and a crash could occur.

VEHICLES AFFECTED

1998 2.3CL: ALL

1998 3.0CL: ALL

1999 2.3CL: From VIN 19UYA3...XL000001 thru 19UYA3...XL005705

1999 3.0CL: From VIN 19UYA2...XL000001 thru 19UYA2...XL006544

1999 3.2TL: From VIN 19UA56...XA000001 thru 19UA56...XA023963

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:

In addition to the bulleted verification items, check for a punch mark above the sixth character of the engine compartment VIN. A punch mark in that location means the key interlock 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 campaign, do a VIN status inquiry before selling it.

Some of the vehicles involved in this campaign are affected by other campaigns and may not have been repaired. As a convenience to your client, do a VIN status inquiry, and complete all outstanding campaigns on the same visit. 

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

Inspect the interlock function of the ignition switch, and depending on whether or not the key can be removed, install Key Interlock Repair Kit A or Key Interlock Repair Kit B.

PARTS INFORMATION

Key Interlock Repair Kit A: P/N 06351-S84-000

Fig 1: Key Interlock Repair Kit A: P/N 06351-S84-000
G03350986

Key Interlock Repair Kit B: P/N 06352-S84-000

Fig 2: Key Interlock Repair Kit B: P/N 06352-S84-000
G03350987

REQUIRED SPECIAL TOOLS

Interlock Tool Kit: T/N 07AAC-S84A130 (Includes slide hammer, gauge block, two roll pin punches, and eight extractor wires)

Fig 3: Interlock Tool Kit Components
G03350988

REQUIRED MATERIALS

Permalube Grease (3-ounce tube): P/N 08734-0030

WARRANTY CLAIM INFORMATION

WARRANTY CLAIM INFORMATION

OP# Description FRT Template ID
725502 Inspect ignition switch key interlock, and install Key Interlock Repair Kit A 0.5 03-034A
725503 Inspect ignition switch key interlock, and install Key Interlock Repair Kit B 0.9 03-034B
FAILED PART AND DEFECT CODE

Failed Part: P/N 35100-SY8-A11
Defect Code: 5EA
Symptom Code: P16
Skill Level: Diagnostic Technician

INSPECTION PROCEDURE

NOTE: Before attempting any repairs, you must thoroughly understand this service bulletin.
  1. Remove the steering column covers. Refer to section 17 of the appropriate service manual.
  2. Remove and discard the plastic cover from the ignition switch key interlock solenoid.
    Fig 4: Removing Plastic Cover From The Ignition Switch Key Interlock Solenoid
    G03350989
  3. Note the position of the interlock solenoid plunger; you'll need to install it the same way.
  4. Remove and discard the screw from the interlock solenoid. Keep the solenoid attached to its electrical connector.
    NOTE:
    • Be careful not to lose the solenoid plunger; it slides out easily.
    • Keep the plunger free of dirt or grease while it's removed from the solenoid.
  5. Note the position of the interlock lever spring; you'll need to install the new spring the same way. Also, measure the installed height of the interlock lever pin with vernier calipers. This measurement will be used in both repair procedures.
    Fig 5: Measuring Height Of Interlock Lever Pin From Top Of Ignition Switch Housing
    G03350990
  6. Attach the slide hammer to the interlock lever pin, and use it to remove the pin. Discard the pin, the lever, and the spring.
    Fig 6: Removing Pin, Lever And Spring
    G03350991
  7. Insert the key into the ignition switch, turn the switch to the ACCESSORY (I) position, and install the gauge block.
    Fig 7: Installing Gauge Block
    G03350992
  8. With the gauge block fully seated, try to turn the ignition switch to the LOCK (0) position.
    • If you cannot turn the switch to the LOCK (0) position, install Key Interlock Repair Kit A (see REPAIR PROCEDURE A  ).
    • If you can turn the switch to the LOCK (0) position, install Key Interlock Repair Kit B (see REPAIR PROCEDURE B  ).

REPAIR PROCEDURE A

  1. Remove the gauge block, then wipe off any debris from the lever's sliding surface on the ignition switch with a clean cloth or a cotton swab.
    NOTE: To keep debris out of the ignition switch, do not clean it with compressed air.
    Fig 8: Lever's Sliding Surface On Ignition Switch
    G03350993
  2. Attach the slide hammer to the new lever pin, insert the new lever into the ignition switch, and seat the pin with the slide hammer.
    Fig 9: Installing Lever And Pin Into Ignition Switch
    G03350994
  3. Use vernier calipers to measure the installed height of the lever pin. The height should be close to the measurement you made in step 5 of the inspection procedure. If the height is more than 5.3 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin.
    NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated.
    Fig 10: Measuring Installed Height Of Lever Pin
    G03350995
  4. Install a new spring on the lever. Make sure you attach the ends of the spring correctly:
    • The right end goes into the slot on the ignition switch.
    • The left end goes behind the notch on the interlock lever.
    • Once the spring is correctly installed, make sure the lever moves freely and returns properly.
      Fig 11: Installing Spring On Lever
      G03350996
  5. Insert the plunger into the interlock solenoid, then install the solenoid using a new screw. Make sure the groove of the solenoid plunger is in the fork on the lever.
    Fig 12: Installing Plastic Cover On Interlock Solenoid
    G03350997
  6. Install a new plastic cover on the interlock solenoid.
  7. Set the parking brake, and turn the ignition switch to the ON (II) position.
  8. With the brake pedal pressed, shift the transmission to Neutral.
  9. Try to turn the ignition switch from the ON (II) position to the LOCK (0) position five times.
    • If you cannot turn the ignition switch to the LOCK (0) position, your repair was successful; go to step  12 .
    • If you can turn the ignition switch to the LOCK (0) position, go to step 10.
  10. Remove the solenoid cover, and make sure the groove of the solenoid plunger is installed in the fork on the lever.
    • If needed, correct the position of the solenoid plunger, then go to step 11.
    • If the solenoid plunger is correctly installed, there is an electrical problem with the interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the interlock is working normally, go to step 11.
  11. Install the solenoid cover.
  12. Install the steering column covers.
  13. Center-punch a completion mark above the sixth character of the engine compartment VIN.
    Fig 13: Completion Mark Above VIN - Repair Procedure A
    G03350998

REPAIR PROCEDURE B

  1. Remove the gauge block.
  2. Make sure you have the anti-theft code for the radio and the navigation system (if equipped), then write down the radio station presets, and remove the key from the ignition switch.
  3. Disconnect the negative cable from the battery.
  4. Using a center-punch and a hammer, carefully "walk out" the two bolts from the steering column bracket. Discard the bolts. Before you discard the bracket, write down the alphanumeric stamped on the center of it. You'll need them for step  29 .
    Fig 14: Removing Steering Column Bracket Bolts With Center Punch
    G03350999
  5. Remove the ignition switch body from the ignition switch by disconnecting the ignition switch connector (CLs) or by removing the screws (TLs). Discard the screws (TLs). Leave the electrical portion of the ignition switch in the vehicle.
    Fig 15: Removing Ignition Switch Body From Ignition Switch
    G03351000
  6. Remove the immobilizer receiver unit from the ignition switch body, and disconnect the receiver unit connector. Discard the two screws.
    Fig 16: Removing Immobilizer Receiver Unit From Ignition Switch Body
    G03351001
  7. Remove the illumination ring from the ignition switch body, and disconnect the illumination ring connector:
    • Insert the key, and turn the ignition switch to the ACCESSORY (I) position.
    • Remove and discard the two screws from the illumination ring.
    • Pull the illumination ring partially away from the ignition switch to clear its micro-switch from the interlock switch pin.
    • Remove the key, the illumination ring, and the interlock switch pin. Discard the interlock switch pin.
    Fig 17: Removing Illumination Ring From Ignition Switch Body
    G03351002
  8. Insert the key, and keep the ignition switch in the LOCK (0) position.
  9. Insert an extractor wire into the lock cylinder roll pin hole. Then, while pushing the key into the ignition switch, tilt and rotate the extractor wire to "walk" the roll pin out of its hole. Discard the roll pin.
    NOTE: If you don't have an extractor wire, use a push pin.
    Fig 18: Inserting Extractor Wire Into Lock Cylinder Roll Pin Hole
    G03351003
  10. Pull the lock cylinder body out of the ignition switch body. If the lock cylinder spring also comes out, put it back into the ignition switch body.
    Fig 19: Pulling Lock Cylinder Body Out Of Ignition Switch Body
    G03351004
  11. Turn the key 90 degrees clockwise to expose the lock cylinder inner collar roll pin. Then, while supporting the lock cylinder shaft on a flat surface, carefully remove the inner collar roll pin with the roll pin punch and a small hammer. Discard the roll pin.
    Fig 20: Removing Lock Cylinder Inner Collar Roll Pin
    G03351005
  12. Wipe off the end of the lock cylinder shaft with a clean cloth, then turn the key to the LOCK (0) position.
    Fig 21: Lock Cylinder Shaft Area
    G03351006
  13. Slide the inner collar off the lock cylinder shaft, and remove the shaft from the lock cylinder body. Retain the lock cylinder shaft. Discard the inner collar and the lock cylinder body.
    NOTE: Do not remove the key from the lock cylinder shaft. If you do, the tumblers will fall out.
    Fig 22: Removing Lock Cylinder Shaft From Lock Cylinder Body
    G03351007
  14. Remove the slider key from the lock cylinder shaft, and install the new slider key from the kit.
    Fig 23: Removing Slider Key From Lock Cylinder Shaft
    G03351008
  15. Apply Permalube grease to a new lock cylinder body and a new inner collar in the areas shown below.
    Fig 24: Applying Permalube Grease To New Lock Cylinder Body And A New Inner Collar
    G03351009
  16. Insert the lock cylinder shaft into the new lock cylinder body, then turn the key 90 degrees clockwise.
    Fig 25: Inserting Lock Cylinder Shaft Into New Lock Cylinder Body
    G03351010
  17. With the roll pin notch on the inner collar facing up, slide the collar onto the lock cylinder shaft. Carefully install a new (long) roll pin using the roll pin punch and a small hammer. Make sure the roll pin is centered.
    Fig 26: Installing Roll Pin In Shaft
    G03351011
  18. Turn the key to the LOCK (0) position, then remove it. Slide the lock cylinder body into the ignition switch body.
    Fig 27: Installing Lock Cylinder Body Into Ignition Switch Body
    G03351012
  19. Install a new (short) roll pin in the hole on the lock cylinder body with a 6 mm (or larger diameter) flat punch and a small hammer. Do not use the rollpin punch to drive the new roll pin. When correctly installed, the top of the roll pin is flush with the lock cylinder body. 
    NOTE: To avoid damaging the lock cylinder shaft and its tumblers, do not drive the roll pin past its flush position on the lock cylinder body.
    NOTE: The new roll pin is about 1/2 mm longer than the original one. Do not install the original roll pin; it cannot be fully seated in the new lock cylinder body.
    Fig 28: Correct And Incorrect Installation Of Roll Pin
    G03351013
  20. Wipe off any debris from the interlock lever's sliding surface on the ignition switch with a clean cloth or a cotton swab.
    NOTE: To keep debris out of the ignition switch, do not clean it with compressed air.
    Fig 29: Interlock Lever's Sliding Surface On Ignition Switch
    G03351014
  21. Attach the slide hammer to a new lever pin, then insert the lever into the ignition switch body, and seat the pin with the slide hammer.
    Fig 30: Inserting Lever Into Ignition Switch Body
    G03351015
  22. Use vernier calipers to measure the installed height of the lever pin. The height should be close to the measurement you made in step 5 of the inspection procedure. If the height is more than 5.3 mm, the pin is not seated. If needed, reattach the slide hammer, and seat the pin.
    NOTE: It's normal for the interlock lever to be loose, even when the pin is fully seated.
    Fig 31: Measuring Height Of Pin From Top Of Ignition Switch Housing
    G03351016
  23. Install a new lever spring on the lever. Make sure you attach the ends of the spring correctly:
    • The left end goes into the slot on the ignition switch.
    • The right end goes behind the notch on the interlock lever.
    • Once the spring is correctly installed, make sure the lever moves freely and returns properly.
      Fig 32: Installing New Lever Spring On Lever
      G03351017
  24. Apply a small amount of Permalube grease to a new interlock switch pin, then carefully install the pin on the lock cylinder body.
    NOTE: Make sure the pin is installed, or the interlock function will not work.
    Fig 33: Installing New Interlock Switch Pin
    G03351018
  25. Install the illumination ring and the immobilizer receiver unit on the ignition switch body with four new screws.
  26. Install the interlock solenoid on the ignition switch body with a new screw. Make sure the groove of the solenoid plunger is in the fork on the interlock lever.
    Fig 34: Installing Illumination Ring And Immobilizer Receiver Unit On Ignition Switch Body
    G03351019
  27. Install a new plastic cover on the interlock solenoid.
  28. Attach the ignition switch body to the electrical portion of the ignition switch by connecting the ignition switch connector (CLs) or by installing new screws (TLs).
  29. Install the ignition switch on the steering column with two new shear bolts and a new steering column bracket. Tighten the bolts only finger-tight.
    NOTE: Make sure the alphanumeric stamped on the new bracket match those on the original bracket.
  30. Reconnect the illumination ring and the immobilizer receiver unit connectors.
  31. Reconnect the negative cable to the battery.
  32. Set the parking brake, and turn the ignition switch to the ON (II) position.
  33. With the brake pedal pressed, shift the transmission to Neutral.
  34. Try to turn the ignition switch from the ON (II) position to the LOCK position five times.
    • If you cannot turn the ignition switch to the LOCK (0) position, your repair was successful; go to step  37 .
    • If you can turn the ignition switch to the LOCK (0) position, go to step 35.
  35. Remove the solenoid cover. Make sure the groove of the solenoid plunger is installed in the fork on the interlock lever. Also make sure the interlock switch pin is installed on the ignition switch body (see step  24 ).
    • If needed, correct the position of the solenoid plunger and install the switch pin, then go to step 36.
    • If the solenoid plunger and the switch pin are correctly installed, there is an electrical problem with the interlock system; refer to the Automatic Transmission section of the appropriate service manual for troubleshooting information. Once the interlock is working normally, go to step 36.
  36. Install the solenoid cover.
  37. Make sure the ignition switch turns freely. Then remove the key, and make sure the steering column lock works correctly. If needed, reposition the ignition switch to make the lock work.
  38. Tighten the two steering column shear bolts until their heads twist off.
  39. Install the steering column covers.
  40. Enter the radio anti-theft code and the navigation system anti-theft code (if equipped), then enter the radio station presets, and set the clock.
  41. Center-punch a completion mark above the sixth character of the engine compartment VIN.
    Fig 35: Completion Mark Above VIN - Repair Procedure B
    G03351020

EXAMPLE OF CUSTOMER LETTER

January 2004

Safety Recall: Ignition Switch Key Interlock 

Dear Acura 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 determined that a defect relating to motor vehicle safety exists in certain 1998 2.3CLs, 1998-99 3.0CLs, and 1999 3.2TLs with automatic transmissions.

Limited batches of an ignition switch component do not have sufficient surface hardness. If the ignition switch in your vehicle contains this defective component, the switch may wear excessively and prevent proper interlock operation. The interlock ensures the transmission is in Park before the ignition key can be removed. Interlock failure may allow the ignition key to be removed when the gear selector lever is not in Park. If you do not set the parking brake when you park, the vehicle could roll and a crash could occur.

What should you do? 

Call any authorized Acura dealer, and make an appointment to have your vehicle repaired. The dealer will inspect the ignition switch interlock and replace all needed parts. This work will be done free of charge.  Please plan to leave your vehicle for half a day to allow the dealer flexibility in scheduling.

Until your vehicle is repaired, be sure to shift the transmission to Park and set the parking brake whenever you park. 

Who to contact if you experience problems. 

If you are not satisfied with the service you receive from your Acura dealer, you may write to:

American Honda Motor Co., Inc.

Acura Client Services

Mail Stop 500-2N-7E

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 1998 2.3CL, 1998-99 3.0CL, or 1999 3.2TL involved in this recall. 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.

Lessor Information. 

Federal law requires that any vehicle lessor receiving this recall notice must forward a copy 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 an Acura dealer, please call Acura Client Services at (800) 382-2238, and select menu option #2.

We apologize for any inconvenience this campaign may cause you.

Sincerely,

American Honda Motor Co., Inc. 

Acura Automobile Division 

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