Recall - DC Converter Output Cable Pinching: Overview
07-009February 6, 2007
Applies To:
2006 Civic Hybrid - ALL
Safety Recall: DC-DC Converter Output Cable Is Pinched by IPU Lid
BACKGROUND
The Civic Hybrid's IPU (intelligent power unit) is behind the rear seat-back. On some vehicles, the DC-DC converter output cable terminal may contact the IPU lid. This can cause the IPU lid to pinch the rubber boot on the terminal when a passenger sits in the rear seat. If the rubber boot gets damaged, the terminal could short to body ground and blow the 100 A (BAT) power distribution fuse. A blown fuse will cause the engine to stall, increasing the risk of 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.
Before working on a vehicle, you must verify its eligibility by checking at least one of these items:
^ The customer has a notification letter.
^ The vehicle is shown on your campaign responsibility report.
^ The vehicle is shown as eligible on a VIN status inquiry.
In addition to these verification items, check for a punch mark below the third character of the engine compartment VIN. A punch mark in that location means this campaign has already been completed.
Some vehicles affected by this campaign may be in your new or used car inventory. These vehicles must be repaired before they are sold or leased. To see if a vehicle is affected by this campaign, do a VIN status inquiry.
CORRECTIVE ACTION
Install a terminal cover kit on the end of the DC-DC converter output cable.
PARTS INFORMATION
Terminal Cover Kit:
P/N 06060-RMX-000, H/C 8621013
WARRANTY CLAIM INFORMATION
Operation Number: 1180A1
Flat Rate Time: 0.6 hour
Failed Part: P/N 1B830-RMX-A00
H/C 8202889
Defect Code: 5DZ00
Symptom Code: Q3500
Template ID: 07-009A
Skill Level: Repair Technician
REPAIR PROCEDURE
NOTE:
The area you will be working in contains high- voltage parts. To work in this area, you must be familiar with the IMA (integrated motor assist) system. Before continuing, make sure you have read the IMA service precautions in the service manual:
^ Refer to page 12-3 of the 2006-2007 Civic Hybrid Service Manual, or
^ Online, enter keyword PRECAUTION and select IMA System Service Precautions from the list.
1. Make sure you have the anti-theft code for the audio unit or the navigation system (if equipped).
2. Turn the ignition switch to LOCK (0), then disconnect the negative cable from the 12 V battery.
3. Remove the rear seat cushion and the rear seat- back:
^ Refer to page 20-117 of the 2006-2007 Civic Hybdd Service Manual, or
^ Online, enter keyword REAR SEAT and select
Rear Seat Removal/Installation from the list.
4. Remove the battery module switch lid from the battery module.
5. Turn the battery module switch to OFF. Make sure the bolt above the switch is showing.
6. Wait at least 5 minutes for the IMA system capacitors to discharge.
7. Remove the IPU lid bolts and the IPU lid.
8. Check the position of the DC-DC converter output cable terminal. If the terminal sticks up from the DC-DC converter, bend it down slightly with your hand.
9. Disconnect the output cable terminal (one bolt). Remove the rubber boot covering the terminal.
10. Disconnect the DC-DC converter ground cable terminal (one bolt). Also, remove the bolt to the left of the output cable terminal. Discard the bolts. These two bolt holes will be used to attach the terminal cover mounting bracket.
11. Hold the mounting bracket over the two bolt holes, then attach it and the ground terminal using the two bolts from the terminal cover kit.
12. Insert the base of the terminal cover under the cable and into the mounting bracket. Reconnect the output cable terminal with its original bolt.
13. Snap the terminal cover in place over the output cable terminal.
14. Reinstall the IPU lid. Torque the IPU lid bolts to 9.8 N.m (7.2 lb-ft).
15. Turn the battery module switch to ON.
16. Reinstall the battery module switch lid. Torque the switch lid bolts to 9.8 N.m (7.2 lb-ft).
17. Reinstall the rear seat-back and the rear seat cushion.
18. Reconnect the negative cable to the battery.
19. Enter the anti-theft code for the audio unit or the navigation system (if equipped). Set the clock (vehicles without navigation system).
20. With the transmission in P, start the engine. Hold the engine speed at 3,500 rpm until the IMA battery level indicator shows 50 percent or more charge.
21. Center-punch a completion mark below the third character of the engine compartment VIN:
^ Slide open the FRAME NUMBER door on the center cowl cover.
^ Use a long punch to reach the VIN.
Disclaimer