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REPORT NUMBER - HONAC03420 MAKE HONDA | MODEL ACCORD YEAR 11/2003 | ENGINE 4 cylinder
Customer Complaint
Drivers side headlight not operating.
Problem Summary
All other lights on vehicle working correctly. Drivers side park light working. No headlight or high beam on driver’s side.
Diagnostic Sequence
NOTE, care should be taken when working on this vehicle as the headlights are a high voltage system (pic1)
Started by testing all fuses and battery power and earth connections. Both front headlights separately fused. Driver’s headlight fuse blown.
Connected short tester/light to drivers headlight fuse. Disconnect drivers side headlight globe. Short still present.
Disconnect main headlight assembly plug, short goes away. Removal of complete headlight assembly, removal of front bumper bar required.
After removal of headlight assembly, High voltage control unit mounted directly under headlight assembly. (pic2)
After removal of Control unit it was noticed that there was water damage. After opening control unit water was still present inside control unit.
Fault Description
The high voltage control unit is mounted directly under the headlight. Water was entering the headlight unit and then leaking into the control unit via the wiring harness hole. (pic3) The water had caused corrosion within the control unit and the moisture was also causing the electrical short.
Fault Solution In our particular case, drying out the control unit and resealing the headlight enable us to repair the situation. (pic4) Otherwise replacement of the control unit may be required.
Recommended Time
Labour time was 2.5 hours, taking into account research time, location of parts and actual time spent fixing the problem.
Useful Tips
Because of the high voltage used in late model vehicles, extra care must be taken when diagnosing problem within these systems. Good quality rubber globes should be worn when working with high voltage systems
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