Foreign service

Motor, Dec 2002 by Marinucci, Dan

The root cause of several annoying Honda behavior problems may be hiding in plain sight and close at hand. Dan explains where to look.

i briefly mentioned Honda ignition switch failure in my July 2000 column. Since then, I've found topic awareness is a mixed bag. On the one hand, some readers are well-acquainted with the variety of symptoms a failing ignition switch can cause. But many others I've talked to just aren't informed. So when Honda recently issued an ignition switch recall for some models, I knew it was time to revisit this topic, only in much greater detail.

First of all, Honda has recalled the following models in order to replace the ignition switch: 1997-99 Accords, CR-Vs and Preludes, 1998-- 2000 Civics and 1997-2000 Odysseys. A punch mark above the eighth character of the underhood VIN is supposed to verify that the recall repair has been done. Center-punching this confirmation mark is a required final step in that job.

Second, all the Honda specialists I spoke with agreed that ignition switch failures-including intermittent ones-are not uncommon on previous models dating back to the 1980s. Considering the number of Hondas on the road, you're likely to see one of these conditions sooner or later, if you haven't already. Here, I'll give you some switch test tips and describe the kooky symptoms you may encounter.

Third, the accompanying photos show exampies of worn contacts inside failing Honda ignition switches, so don't miss the simple step of measuring voltage drop across these contacts. For instance, crank the engine and check the drop across the switch's START contacts, which power the starter solenoid. I've found that a .20-- to .30-volt drop across the START contacts is typical on a known-good ignition switch, less than .20 volt on a brand-new switch. Meanwhile, the drop across the RUN contacts is usually .10 to .20 volt on a known-good switch with all the accessories turned on.

Usually there's no guesswork with a failing switch because its voltage drop is substantially greater than the numbers I just cited. Also, don't quit if the first test doesn't reveal a problem. You may have to repeat the test 10 to 15 times before you see excessive voltage drop across an intermittently failing switch.

For instance, I was diagnosing an intermittent no-start/no-crank condition on a Civic last summer. Nine consecutive times I saw a normal voltage drop across the START contacts. But when I tried to crank the engine the tenth time, the starter didn't run and the voltage drop was a whopping 12.00 volts! A new ignition switch fixed the car.

Fourth, savvy Honda specialists say that besides the symptoms listed on the next page, two things often point them right toward a suspect ignition switch. One is the motorist who has added current-hungry electrical accessories to circuits powered by the RUN contacts. Another is the driver with the proverbial jailer's key ring laden with every key he or she has ever owned. The additional current and/or the extra weight of the keys eventually take their toll on an ignition switch.

List of Symptoms

Watch for these ten signs of Honda ignition switch failure:

1. The engine stalls without warning.

2. The engine starts readily but stalls out as soon as the driver releases the ignition switch to the RUN position. If the driver fiddles with the key, he or she can keep the engine running by holding the key in just the right position. Sometimes, the engine will continue running if the driver releases the key very, very gently.

3. When the engine stalls as described above, the driver may notice that the dashboard warning lights are off even though the ignition switch is in the RUN position.

4. Intermittently, the dash warning lights won't come on during a routine, key-on/engine-off bulb-check.

5. The engine stalls when the car goes over a railroad crossing or big bump. When the engine dies, the driver may notice that the ignition switch is still on but the dash lights are off.

6. The brake warning light should illuminate when you apply the parking brake and then turn the ignition switch on. When the ignition switch is failing, the brake warning light may not come on under these conditions, or else it lights up and then goes out.

7. The car has an intermittent no-- start/no-crank condition but no other symptoms of a starting or charging system problem.

8. The idle speed control system is working normally but the engine stalls intermittently when the driver turns on a lot of electrical accessories powered by the RUN contacts.

9. If you know the feel of a normal Honda ignition switch, the suspect switch feels noticeably sloppier. You can feel excessive movement in the switch.

10. The car has one or more of the symptoms listed above and blobs of solder fall out of the lower steering column cover when you remove it.

I'll wrap up this column with two very practical tips from Honda ace Denis Kerechuk at Kerechuk Motors in Alhambra, California. They're off the topic of worn electrical contacts, but are worth passing on to you: