2002 Honda CR-V electrical problems

What is wrong

Honda (American Honda Motor Co.) is recalling certain 2002-2006 CR-V vehicles. Moisture may enter the driver side power window master switch, causing the switch to fail or melt.

Risk

If the switch fails, it could overheat and smoke, increasing the risk of a fire.

Remedy

Honda will notify owners, and dealers will replace the power window master switch and inspect the wiring harness for damage, replacing it if necessary, free of charge. The recall began January 29, 2021. Owners may contact Honda customer service at 1‑888‑234‑2138. Honda's number for this recall is P9D.

Recall number 20V768000 · Recall details

What is wrong

Honda is recalling certain model year 2002-2006 CR-V passenger vehicles, manufactured from February 19, 2002, through July 28, 2006. The driver-side power window switch may fail or melt.

Risk

If the switch fails, it could overheat, smoke, and cause a fire. A switch failure, and a fire, could occur even if the vehicle is not in use. As a precaution, owners are advised to park outside until the recall repair has been performed.

Remedy

Honda will notify owners, and dealers will inspect and repair the switches, as necessary, free of charge. The safety recall began on November 2, 2012. Owners may contact Honda at 1‑800‑999‑1009.

Recall number 12V486000 · Recall details

What is wrong

On certain sport utility vehicles, metal particles in the key cylinder body could interfere with the interlock lever operation, making it possible to remove the ignition key without shifting the transmission to "park."

Risk

If the vehicle operator does not shift to "park" before removing the key and fails to engage the parking brake, the vehicle could roll and a crash could occur.

Remedy

Dealers will inspect and test ignition switches for contamination interference. Any switches that fail the test will be repaired. Owner notification began on novenber 3, 2003. Owners should contact honda at 1‑800‑999‑1009.

Recall number 03V422000 · Recall details

This investigation was prompted by Preliminary Evaluation (PE) 11-017, and was based on reports from consumers alleging that both low beam headlights stopped illuminating simultaneously.Some complainants also reported that the combination switch (switch) that controls the headlights and turn signals, and/or its electrical wiring harness connector were damaged by overheating.ODI's PE information request letter asked Honda for certain data on model years (MY) 2002-2006 CR-V, 2003-2008 Pilot, 2003-2008 Element, 2001-2005 Civic, and 2000-2001 S 2000 vehicles.Analysis of complaint and Honda data show that a complete low beam headlight circuit failure occurs in models with 2-bulb headlight systems (i.e., a single bulb on each side for high and low beam).Models with 2-bulb systems include MY 2002-2004 CR-V, 2003-2005 Pilot, 2001-2003 Civic, and 2003-2008 Element.Models with 4-bulb headlight systems (i.e., two bulbs on each side, one for high and one for low beam) have different electrical circuits for the headlights and do not experience the same failure mechanism as the 2-bulb system.MY 2000-2001 S 2000 models with 2-bulb high intensity discharge headlights also have different electrical circuits for the headlights and do not experience the same failure mechanism.Honda introduced the 4-bulb headlight system in CR-V in MY 2005, in Pilot in MY 2006, and in Civic in MY 2004.On March 29, 2012 Honda submitted a defect information report (DIR) to recall 554,428 vehicles, including MY 2002-2004 CR-V and MY 2003 Pilot.In the DIR, Honda stated that tension from the combination switch wiring harness to the electrical terminal for the low beam headlight circuit could cause a small amount of motion as the combination switch was operated.This motion, over time, can wear the surface of the terminal creating copper oxide, increasing electrical resistance, which may cause the terminal to melt within the harness connector.ODI continued its investigation, and on August 31, 2012 Honda submitted another DIR to recall an additional 820,789 vehicles.This report included the MY 2002 Civic vehicles which were not subject to a prior safety recall (04V‑086) for headlights, all of MY 2003 Civic, and MY 2004-2005 Pilot.Honda's DIR advised that operation of the turn signal switch lever at high speed and/or with heavy force can cause movement between the combination switch body and the sub-harness wiring connector.This can cause wear and continued movement can create copper oxide, increasing electrical resistance, and potentially causing the terminal to melt within the harness connector. Please see both DIRs at http://www-odi.the federal safety agency.dot.gov/recalls/ under safety recall 12V‑136 for complete details.Honda also provided additional information on the Element model, stating that it was not recalled due to it's very low failure rate.Honda sold 301,497 Element vehicles in the United States and received 17 reports, while ODI received one report (see VOQ 10395219).Honda's technical explanation for the low rate, which was submitted under request for confidentiality, is that the headlight switch, as installed in the Element, reacts differently to the forces applied to it as compared to the recalled models.See attachment for additional information.

EA11012

The Office of Defects Investigation (ODI) opened this investigation based on 12 reports from consumers alleging the low beam headlights stopped working simultaneously.Several of the complainants reported that the headlight switch and/or its wiring harness connector required replacement to repair the low beam headlight circuit, and also reported that the switch and/or the wire harness connector were damaged from overheating.Based on information provided by Honda in response to ODI's Preliminary Evaluation information request, ODI is upgrading the investigation to EA11-012.

PE11017

This investigation was prompted by Preliminary Evaluation (PE) 10-047 and was based on reports from consumers alleging that smoke and/or fire, as defined in 49 CFR ? 579.4, had occurred inside of the driver's door.The subject vehicles, model year (MY) 2006 CR-V, were manufactured at two different assembly plants.The vehicles manufactured in Japan (Sayama plant) were produced with a power window master switch (PWMS) supplied by the Thai Toyo Denso Company, Ltd. (Denso).The vehicles manufactured in the United Kingdom (UK, Swindon, England plant) were produced with a PWMS supplied by the Omron Corporation (Omron).Honda provided 45 reports on the subject vehicles responsive to this investigation.Of this number, 24 reports concerned Japan-built vehicles, 19 reports on UK-built vehicles, and two reports without a vehicle identification number which could not be identified by assembly plant. Four of Honda's reports were duplicative of ODI reports.ODI received nine reports on the subject vehicles:five on Japan-built and four on UK-built vehicles, and one additional report on a MY 2005 UK built vehicle.The ODI reports can be reviewed at http://www-odi.the federal safety agency.dot.gov/owners/Searchreference under the following identification (ODI) numbers: 10343884, 10307287, 10321646, 10375324, 10386750, 10425406, 10437807, 10439880, 10469350, and 10406979.In most cases, it was reported that the PWMS and/or its electrical wiring harness had sustained heat related damage requiring replacement of the affected component(s).However, in three of the cases involving an Omron PWMS (UK built), a fire breached the driver's door panel and spread into the vehicle interior.Two of the three vehicles were determined to be a total loss by insurance companies, and one was repaired.All three fires occurred as the vehicles were parked with the ignition switch turned off.On September 6, 2011 Honda submitted a Defect Information Report (DIR) to recall 80,111 subject vehicles built in Japan.In it's DIR, Honda explained that the Denso PWMS assembly has switches made of a resin material that can allow residues to accumulate over time.Residue from silicone based cleaning products used near the PWMS can adhere to the electrical contacts of the switch and repeated operation of the switch may accelerate wear of the electrical contact.Silicone particles that have accumulated between the power source and the ground in the switch can become heated when electrical power is supplied to the circuit.If this occurs, the resin material of the switch can carbonize and form an electrically conductive path which causes the resin material to heat up.As a result, the switch may melt and produce smoke.In the worst case, the switch cover may burn.ODI notes that this recall was limited to MY 2006 because the PWMS subject to the recall (P/N 3750-S9A-C05ZA) was made of a new resin material introduced during MY 2006 production.ODI continued its investigation with respect to UK built vehicles with the Omron PMWS.On October 4, 2012 Honda submitted an additional DIR to recall 268,655 MY 2002-2006 CR-V vehicles.Honda's DIR stated that water or other fluids can enter the Omron PWMS assembly and over time cause electrical resistance in the switch.Increased resistance can result in overheating and melting of the switch, which could potentially cause a fire.Please see both DIRs at http://www-odi.the federal safety agency.dot.gov/recalls/ under safety recalls 11V456 and 12V486 for further details of the recalls.

EA11004

All but one odi complaint and all odi crashes are duplicative of honda reports.all 7 crashes were roll-away crashes that occurred when the interlock system malfunctioned and the vehicles were parked unsecured (not in park, brake not engaged).the 3 noted injuries were relatively minor.the warranty claims shown under other were confirmed by honda as interlock system failures.in the subject vehicle ignition-park interlock system, an electrically driven solenoid operates a blocking lever to prevent ignition key removal when the shift lever is not in the park position.according to honda, an ignition switch manufacturing operation could occasionally produce metal debris.in some cases the debris could fall into the area between the interlock lever and the body of the ignition switch where relative movement occurs.debris trapped in this area can increase friction between the lever and the switch body.if the debris is of sufficient size, it may slow the response of the level when the solenoid is energized.in this situation, if the transmission is not in park and the ignition key is rotated in a certain manner the interlock system may fail to prevent key removal, as required under fmvss 114.honda implemented manufacturing changes in march 2002 to prevent debris from entering the ignition switch assembly.honda also changed end-of-line inspection procedures to improve detection of debris.the presence of debris in the ignition switch is otherwise unapparent to the operator of the vehicle.under safety recall 03v‑422, honda will recall vehicles manufactured prior to march 2002 to test the interlock system for the presence of debris.vehicles that fail the test will receive new ignition switch assemblies.

EA03018

All odi complaints and crashes are duplicative of honda complaints.the warranty claim count shown for other represents incidents where honda's analysis of claim detail indicates the interlock system malfunctioned.the cr-v interlock system utilizes an ecu to control a solenoid driven blocking device that prevents key removal when the shifter is not in park.honda documents identified a condition where metallic debris interferes with the operation of the blocking solenoid and causes the interlock system to malfunction.honda determined that a manufacturing process was the source of the debris and implemented a countermeasure in march 2002.approximately 62,000 vehicles were produced prior to this date.odi recognizes 63 incidents of interlock failure, which include 7 rollaway crashes, two of which resulted in three injuries and a multi vehicle accident.all 63 failures occurred on vehicles produced prior to the march countermeasure.noting the population of potentially affected vehicles, both the failure and crash rates are of significant concern to odi.

PE03013