Campaign - Trunk Lock Cylinder Update: Overview
08-040August 19, 2008
Applies To:
2009 TSX - From VIN JH4CU2...9C000098 thru JH4CU2...9C013325
Product Update: Valet Key Opens the Trunk
BACKGROUND
Because of a manufacturing error, the valet key can open the trunk using the trunk lock behind the left rear head restraint. (The valet key should work only in the ignition switch and the driver's door lock.) A valet key that opens the trunk gives trunk access to anyone using that key, including a valet service.
CLIENT NOTIFICATION
All owners of affected vehicles will be sent a notification of this product update. An example of the client notification is at the end of this service bulletin.
Some of the vehicles affected by this product update may be in your new vehicle inventory. These vehicles should be updated before they are sold or leased.
To verify vehicle eligibility, check for at least one of these items:
^ The client has a notification letter.
^ The vehicle is shown as eligible on a VIN status inquiry.
In addition, check for a punch mark above the first character of the engine compartment VIN. A punch mark in that location means this product update has already been completed.
CORRECTIVE ACTION
Update the trunk lock by installing a trunk key cylinder kit.
PARTS INFORMATION
Trunk Key Cylinder Kit: P/N 06748-TL0-000 (Contains two sub-tumblers, tumbler spring, K-ring, lock rod holder, seat lock cable clip, and door lining clip)
REQUIRED SPECIAL TOOLS
KTC Trim Tool Set, T/N S0JATP2O14
Lock Tumbler Holder, T/N 070AF-TL20120
In late August 2008, each dealer was sent a pair of lock tumbler holders. To order additional holders, use normal parts ordering channels.
WARRANTY CLAIM INFORMATION
NOTE:
This product update ends on August 19, 2011. After that, any applicable warranty would apply.
Operation Number: 8231 P6
Flat Rate Time: 0.3 hour
Failed Part: P/N 74861-TL2-AO1
Defect Code: 5TX00
Symptom Code: Q8800
Template ID: 08-040A
Skill Level: Repair Technician
REPAIR PROCEDURE
NOTE:
^ Wear protective gloves while handling the trunk key cylinder bracket.
^ Do not use the service manual procedure to remove/reinstall the trunk key cylinder bracket.
1. Move the driver's and the front passenger's seats fully forward.
2. Fold both rear seat-backs forward.
3. To protect the rear bulkhead cover from scratches, apply low tack masking tape around the center seat belt lid and the left cover.
4. Using the appropriate trim tool from the KTC trim tool set, carefully pry off the center seat belt lid and the left cover from the rear bulkhead cover.
5. Carefully pull forward on the lower edge of the rear bulkhead cover to release its two lower clips.
6. While sitting on the folded rear seat, use your knee to carefully pull the middle of the rear bulkhead cover toward you. This gives you access to the trunk key cylinder bracket from under the bulkhead cover.
NOTE:
To avoid damaging the bulkhead cover, pull on it just enough to work on the trunk key cylinder bracket.
7. Remove the inboard bolt from the key cylinder bracket.
8. Using a small screwdriver, detach the seat lock cable clip from the key cylinder bracket.
9. Carefully remove the end of the lock rod cable from the key cylinder bracket using a hook tool. Be careful not to damage the neck of the cable.
10. Remove the outboard bolt from the key cylinder bracket.
11. Carefully flex the bulkhead cover up and toward you, enough to free the key cylinder bracket's captive nut from the bulkhead, then remove the key cylinder bracket through the bulkhead's left cover opening.
12. Detach the lock rod cable end from its holder.
13. Place the key cylinder bracket upside down on a clean work surface.
14. Using a small screwdriver, remove the metal K-ring from the key cylinder, then remove the plastic cam plate.
15. Note the installed position of the key cylinder body spring, then carefully remove the spring.
16. Fully insert the valet key into the key cylinder (to prevent the sub-tumblers from falling out), then remove the key cylinder from its bracket by tapping the back of it with a plastic hammer.
17. Position the key cylinder with the top of the sub-tumblers facing up, then slide the lock tumbler holder tool over the key cylinder, lining up the grooves in the holder with the center of the sub-tumblers. With the holder correctly installed, the sub-tumbler on the end of the key cylinder (the one you'll be replacing) is visible.
18. Pull the key out about 5 mm, until the sub-tumbler on the end of the key cylinder pops up, then carefully remove the sub-tumbler.
NOTE:
Do not remove the small spring that may pop up when the sub-tumbler is removed. If you lose the spring, replace it with the spring from the kit.
19. Look at the ID number stamped into the sub-tumbler:
^ If the ID number is X1, you'll be replacing it with the sub-tumbler stamped Y3 from the kit.
^ If the ID number is X2, you'll be replacing it with the sub-tumbler stamped Y4 from the kit.
20. Insert the correct new sub-tumbler (Y3 or Y4) into the open slot in the key cylinder. Press the sub-tumbler flush with the key cylinder while you fully reinsert the key.
21. Remove the lock tumbler holder from the key cylinder.
22. With the top side of the sub-tumblers facing up, reinsert the key cylinder into its bracket. Then align the key cylinder cover, and press it back in place. Remove the key.
23. Check the keys in the lock. The master key should turn the lock smoothly, and the valet key should not turn it at all. If the keys don't work this way, recheck your work.
24. Reinstall the key cylinder body spring.
25. Remove the lock rod holder from the cam plate, and install a new lock rod holder from the kit.
26. Install the cam plate on the key cylinder with a new K-ring from the kit.
27. Reinstall the key cylinder bracket in the reverse order of removal, noting these items:
^ Torque the inboard and outboard bracket bolts to 22 N.m (16 lb-if).
^ If the seat lock cable clip is damaged, replace it with the clip from the kit.
^ The door lining clip from the kit may or may not be needed.
28. Center-punch a completion mark above the first character of the engine compartment VIN.
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