A15-040

(g)HONDA
Service Bulletin
15-040
December 19, 2015
02025 Version 4
Safety Recall: Driver's Airbag lnflator Can Be Over-Pressurized
Supersedes 15-040, dated September 16, 2015, to revise the information highlighted in yello
Replaces 14-045, Recall: Driver's Airbag lnflator May Produce Excessive Pressure After Long-Term Exposure to
High Absolute Humidity
Replaces 15-022, Recall: Driver's Airbag lnflator May Produce Excessive Pressure After Long-Term Exposure to
High Absolute Humidity
Replaces 10-039, Safety Recall: Replacement Driver's Airbag lnflator Can Be Over-Pressurized
Replaces 08-093, Safety Recall: Driver's Airbag lnflator Can Be Over-Pressurized
AFFECTED VEHICLES
Year
Model
2001-07 Accord
2001-05 Civic
2001-05 Civic GX
2003-05 Civic Hybrid
2002-06 CR-V
2003-11
Element
2002-04 Odyssey
2003-08 Pilot
2006
Ridgeline
Trim
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
VIN Range
Check the iN
Check the iN
Check the iN
Check the iN
Check the iN
Check the iN
Check the iN
Check the iN
Check the iN
VIN
VIN
VIN
VIN
VIN
VIN
VIN
VIN
VIN
status
status
status
status
status
status
status
status
status
for eligibility
for eligibility
for eligibility
for eligibility
for eligibility
for eligibility
for eligibility
for eligibility
for eligibility
REVISION SUMMARY
A new video about counterfeit airbags was added to the REPAIR PROCEDURE.
BACKGROUND
American Honda consolidated the previous airbag inflator campaigns into this current bulletin based on decisions made
by NHTSA. Do an iN VIN status inquiry and, if indicated, repair the vehicle even though the vehicle may have been
repaired under a previous campaign.
In certain vehicles, the driver's (front) airbag inflator could produce excessive internal pressure during airbag
deployment. If an affected airbag deploys, the increased internal pressure may cause the inflator casing to rupture.
Metal fragments could pass through the airbag cushion material, possibly causing injury or fatality to vehicle occupants.
NOTE: If the VIN status inquiry indicates that the vehicle is subject to any open safety recalls, including a front
passenger's airbag inflator campaign/recall, make sure to also complete those recall repairs before returning
the vehicle to the customer. If you are unable to complete any open recall, advise the customer of the recall
status and when the recall could be completed.
CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools,
equipment, and training to correctly and safely maintain your vehicle. These procedures should not be attempted by "do-it-yourselfers," and you
should not assume this bulletin applies to your vehicle, or that your vehicle has the condition described. To determine whether this information
applies, contact an authorized Honda automobile dealer.
© 2015 American Honda Motor Co., Inc. - All Rights Reserved
Page 1 of 14
New and different inflators are available. You may receive a different part number than ordered, and the inflator may
appear different. As a result, there may be different installation instructions. Make sure you review this service bulletin
for installation instructions and details about model applicability. PARTS INFORMATION and REPAIR PROCEDURE
were updated to reflect these new parts.
On June 18, 2015, there was a change in the return process for driver and front passenger inflators. Refer to
PIB A15-0002, lnflator Kit Return Process for more information.
CUSTOMER NOTIFICATION
Owners of affected vehicles will receive a notification of this campaign.
Do an iN VIN status inquiry to make sure the vehicle is shown as eligible.
Some vehicles affected by this campaign may be in your used vehicle inventory. These vehicles must be repaired
before they are sold.
Should your dealership sell an unrepaired vehicle that subsequently causes injury or damage because of the recalled
item, the dealership will be solely responsible to the damaged party, and will be required to defend and indemnify
American Honda for any resulting claims. To see if a vehicle in inventory is affected by this recall, do a VIN status
inquiry before selling it.
CORRECTIVE ACTION
Replace the driver's airbag inflator, then return the original, undeployed inflator as directed.
NOTE: For Civic models only, inspect the airbag and, if necessary, replace the driver's airbag inflator, then return the
original, undeployed inflator as directed.
Page 2 of 14
PARTS INFORMATION
NOTE: Always use new Torx bolts to reinstall the airbags. The new Torx bolts are coated with threadlock to make sure
they do not come loose.
Part Name
2001-02 Accord Driver's Airbag lnflator Kit
Order Part Number
You may receive any
of the following
Quantity
04 770-S5A-305
04 770-S5A-305
1
04770-S5A-405
2003-07 Accord Driver's Airbag lnflator Kit
04 770-SDA-305
04 770-SDA-305
1
04 770-SDA-406
2001-05 Civic (includes GX and Hybrid) Driver's
Airbag lnflator Kit
04 770-S5A-408
04770-S5A-408
1
2002-06 CR-V Driver's Airbag lnflator Kit
04 770-S9A-306
04 770-S9A-306
1
04 770-S9A-405
04 770-S9A-409
2003-11 Element Driver's Airbag lnflator Kit
04770-SCV-306
04 770-SCV-306
1
04 770-SCV-405
04 770-SCV-409
2002-04 Odyssey Driver's Airbag lnflator Kit
04 770-S5A-305
04 770-S5A-305
04 770-S5A-405
1
2003-08 Pilot Driver's Airbag lnflator Kit
04 770-S9A-306
04 770-S9A-306
1
04 770-S9A-405
04 770-S9A-409
2006 Ridgeline Driver's Airbag lnflator Kit
04 770-SJC-306
04 770-SJC-306
1
04 770-SJC-406
Torx Bolts (For reinstalling Autoliv airbags only)
90134-S04-A81
N/A
2
NOTE:
• The inflator kit box must be used to return the old inflator to its supplier. Be careful not to damage the inflator kit
box.
•
If the defective, undeployed inflator is not returned, the warranty claim for that vehicle will be charged back to your
dealership.
• To return the inflator, follow the instructions in PIB A 15-0002, lnflator Kit Return Process.
•
Parts staff can scan the part number and serial number from the outside of the box into the warranty claim by using
the Controlled Part Serial No. screen and scanning the applicable information. Refer to the Job Aid Ordering and
Managing Replacement lnflators for more information.
Page 3 of 14
WARRANTY CLAIM INFORMATION
NOTE:
Use the Autoliv claim for removing and reinstalling Autoliv airbags only. Do not use it to claim any labor on
Takata airbags.
•
To avoid a warranty claim being charged back to your dealership, the defective, undeployed inflator must be
returned to its supplier. Follow the shipping instructions in PIB A15-0002, lnflator Kit Return Process.
•
The replacement inflator part number and serial number are printed on the label that should be attached to the
RO.
•
To avoid non-payment of warranty claims, the new airbag inflator part number and serial number must be included
in each claim. For more information, refer to step 7 of REPAIR PROCEDURE.
•
The serial number is encoded into the bar code printed on the label inside of the box and on a label attached to the
outside of the box. If your dealership uses a scanner, you can scan the serial number from either place into the
claim.
•
The part number is encoded into a barcode attached to the outside of the box. If your dealership uses a scanner,
you can scan the part number into the claim.
•
If you confuse the serial number and part number when entering the claim information, your claim will
automatically be rejected.
•
For more information about scanning and filing airbag inflator recall claims, refer to Ordering and Managing
Replacement lnflators. From the iN, select Service, Warranty, then Claims Reference Guide. Under HOT
TIPS/TOPICS, select Ordering and Managing Replacement lnflators.
•
Year/Model
Operation
Number
2001-02 Accord
7521 H8
Replacement
Part Number
Flat
Rate
Time
Defect
Code
Symptom
Code
0.5 hr
5VZ00
JQ900
04 770-S5A-305
15-040C
0.5 hr
5VZ00
7521 H8
2001-05 Civic GX
7521 H8
2003-05 Civic
Hybrid
7521 H8
04770-S5A-408
15-040D
0.5 hr
5VZ00
JR000
04 770-S9A-306
2002-06 CR-V
2003-11 Element
7521 H8
7521 H8
04 770-S9A-405
0.5 hr
5VZ00
JR100
15-040H
04770-SCV-306
15-0401
04 770-SCV-405
0.5 hr
5VZ00
JR200
06770-SCV-AS0ZA
06770-S0X-A 1OZA
JR300
15-040M
04 770-S9A-306
15-04N0
0.5 hr
5VX00
JR400
15-0400
06770-S9V-A01 ZA
15-040P
04770-SJC-306
15-040Q
0.5 hr
7521 H9
06770-S9A-A80ZA
15-040L
5VX00
04 770-S9A-409
2006 Ridgeline
15-040J
04 770-S5A-405
04 770-S9A-405
06770-S5A-A 1OZA
15-040K
0.5 hr
7521 H9
7521 H9
15-040G
04 770-S9A-409
04770-S5A-305
2003-08 Pilot
15-040E
15-040F
04 770-SCV-409
2002-04 Odyssey
06770-SDA-AS0ZA
JQ900
04 770-SDA-406
2001-05 Civic
06770-SDA-AS0ZA
15-040B
04770-SDA-305
7521 H8
Failed Part
Number
15-040A
04 770-S5A-405
2003-07 Accord
Template
ID
5VX00
06770-SJC-A 1OZA
JR500
04 770-SJC-406
15-040R
Remove and Reinstall Autoliv Airbags Only
i 2001-05 Civic
I 7521J0
I NIA
I 0.3 hr I 5VZ00 I JR000
I 15-040S I 06770-S5A-A 1OZA
Page 4 of 14
REPAIR PROCEDURE
NOTE:
•
If the VIN status inquiry indicates that the vehicle is subject to any open safety recalls, including
fl passenger's airbag inflator campaign/recall, make sure to also complete those recall repairs before
returning the vehicle to the customer. If you are unable to complete any open recall, advise the customer of
the recall status and when the recall could be completed.
• Be careful not to damage any parts when replacing the inflator, and follow the procedure exactly.
•
If, before removing the airbag, you suspect that it may be the incorrect airbag for the vehicle or a counterfeit, do not
remove the airbag. Contact your DPSM for assistance.
Do not open the inflator kit until you have confirmed a Takata inflator is installed in the vehicle because if you have
•
to return the inflator kit, the kit must be unopened.
•
If the vehicle you are working on has an Autoliv airbag and inflator, do not disassemble the airbag because the
inflator cannot be reinstalled, and you will have to replace the airbag module.
•
Make sure you have reviewed the SRS Precautions and Procedures in the applicable electronic service manual
before doing the REPAIR PROCEDURE.
1.
Turn the ignition switch to the ON (II) position and check if the SRS indicator comes on for about 6 seconds, then
turns off.
•
•
If the indicator comes on, then turns off after about 6 seconds, go to step 2.
If the indicator does not come on, or if it stays on, contact your DPSM for assistance.
2.
Disconnect the battery negative cable and wait at least 3 minutes before continuing.
3.
Remove the driver's airbag. Refer to the applicable electronic service manual.
4.
Place the airbag, face down, on a clean shop towel.
Page 5 of 14
5.
Visually inspect the airbag and the inflator for any unusual writing or markings.
"IDENTIFYING
COUNTERFIT AIRBAGS"
VIDEO
•
•
If there is nothing unusual about the airbag or the inflator, go to step 6.
If there are any unusual markings, like an incorrect label or a model year written in marker, the airbag and
inflator may not be the correct airbag and/or inflator for the vehicle or it may be a counterfeit part. For more
information about counterfeit airbags, you can refer to safercar.gov, enter keywords MANAGING
COUNTERFEIT, and select Recommended Dealer Guidance for Managing Counterfeit Air Bags from the
list. If you suspect that the airbag or inflator is counterfeit, do not continue this procedure. Contact your
DPSM for assistance.
NON-STANDARD
SAFETY LABEL
NON-STANDARD
WIRES
Page 6 of 14
6.
Civic only- Determine if the airbag is made by Autoliv or Takata by comparing the inflators to those in the images
below.
NOTE: The Autoliv serial number label is different from the Takata label; the Autoliv has 11 characters, the Takata
has 9.
•
If the airbag is made by Autoliv, the airbag is OK. Reinstall the airbag using new Torx bolts. Torque the bolts to
9.8 N·m (7.2 lb-ft). If you already received a replacement inflator, return the unopened kit to American Honda.
•
If the airbag is made by Takata, go to step 7.
TAKATA
~
1~!111111!111111111 1 1111 1
mrsSA-ASi:1-~~
7.
Locate serial
number here.
Peel the label located inside the inflator box from its backing and attach it to the RO. For the warranty claim to be
paid, the replacement inflator part number that you received must be included in the warranty claim.
NOTE:
• The replacement part number is printed on the top part of the label and the serial number is printed on the
bottom. Make sure you attach the label to the RO and give it to the warranty clerk.
• There may also be a colored sticker located in the kit, ignore it because it is not used.
•
Not all inflator kits have a label included. In those cases, write the serial number and part number from the side
of the inflator box on the RO. The part number always starts with 04 7.
INFLATOR PARTS BOX
SERIAL NUMBER
RETAINER
PLATE
SELF-ADHESIVE
LABEL
INFLATOR
INSTALLATION
PARTS
(if applicable)
Page 7 of 14
8.
If there is no horn plate installed, go to step 9. If there is a horn plate installed, remove the four horn plate mounting
bolts, the mounting bolt felt washers, the horn plate, and remove the felt tape covering the lower two inflator
locknuts. The felt washers and felt tape will not be reused.
,,,.-----------------------[
IF APPLICABLE
HORN PLATE
W
\ii
'i
®
C:'~~~~
,---
)
HORN PLATE
MOUNTING BOLTS (4)
'l~@)II~
''
""/ftd '~)-:
~ ~-~ l;@:1
\J
=l =
I
<
!~
MOUNTING BOLT
FELT WASHERS (4)
Do not reuse.
FELT TAPE
Do not reuse.
'-------
9.
Using needle-nose vise grips or a 3/8 in. 6-point socket, remove the four locknuts from the inflator. The locknuts will
not be reused.
NOTE: Do not remove the inflator from the airbag until you complete step 10.
LOCKNUTS (4)
Do not reuse. -~---.,...~~
~
INFLATOR
I
~
~:~~.~"'"'· ~~~
V
AIRBAG
Page 8 of 14
10. Use shop air to clean any debris that may be on the inflator, then remove the inflator from the airbag.
NOTE:
Do not allow any debris to enter the inflator opening in the airbag.
•
Do not deploy the inflator. The inflator must be returned to its supplier in the box the new inflator came in.
•
Follow the shipping instructions supplied with the inflator kit. If you have any questions about shipping, call
Warranty Parts Inspection (WPI) at 937-642-2737.
11. Turn over the airbag (inflator side down), and shake it to remove any debris from the inflator opening.
12. Install the new inflator in the airbag.
NOTE: There may be some minor surface rust or corrosion on the new inflator; this is OK.
Click on the image below for a short video about the different variations of the driver's and front passenger's
replacement inflators involved with the recalls related to Takata inflators. While both the driver's and front
passengers inflators are shown in the video, this is informational only. Replace inflators only as directed by the iN
VIN status inquiry.
Page 9 of 14
Check your part number against the ones listed for each installation procedure. Use the correct installation
procedure for the part you received.
Part Number
04 770-SSA-305
04 770-SDA-305
04 770-S9A-306
Refer to Driver's lnflator Type 1 in the video.
04770-SCV-306
04 770-SJC-306
•
Insert the inflator into the opening.
NOTE: Make sure the inflator wires are positioned toward the bottom of the airbag. If you install the inflator
incorrectly, you may not be able to reconnect the SRS airbag harness.
Page 10 of 14
Check your part number against the ones listed for each installation procedure. Use the correct installation
procedure for the part you received.
Part Number
04 770-SSA-405
04 770-SDA-406
04 770-S9A-405
Refer to Driver's lnflator Type 2 in the video.
04 770-SCV-405
04 770-SJC-406
•
Insert the airbag inflator into the opening. Do not force it into the airbag module.
NOTE: Make sure the inflator wires are positioned toward the bottom of the airbag. If you install the inflator
incorrectly, you may not be able to reconnect the SRS airbag harness.
----------------
•
Using a pair of pliers, gently pull up on each stud up while pushing the inflator module down until the airbag is
properly seated within the airbag module.
PROPERLY
SEATED
Page 11 of 14
Check your part number against the ones listed for each installation procedure. Use the correct installation
procedure for the part you received.
Part Number
04 770-SSA-408
Refer to Driver's lnflator Type 3 in the video.
The inflator is held down
by a directional retainer
that is keyed to the inflator.
~~
•
Place the inflator into the opening with the inflator harness toward the bottom of the airbag.
The inflator fits
easily into the
airbag assembly.
•
Install the bracket onto the studs. Make sure the locator tab fits into the locator hole as shown.
NOTE: Make sure the harness comes out through the center opening. Do not install the bracket over the
harness wires.
Page 12 of 14
Check your part number against the ones listed for each installation procedure. Use the correct installation
procedure for the part you received.
Part Number
04 770-S9A-409
Refer to Driver's lnflator Type 4 in the video.
04 770-SCV-409
The inflator is held down
by a directional retainer
that is keyed to the inflator.
•
Place the inflator into the opening with the inflator harness toward the bottom of the airbag.
Line up these three tabs
with the notches in the inflator.
•
•
Install the bracket onto the studs with the stamp LOWER at the bottom of the airbag.
Make sure the three tabs and notches are properly aligned.
NOTE:
•
•
The tabs and notches are designed to align in one direction only. If the tabs and notches are not aligned,
the inflator and bracket are not installed correctly.
Make sure the harness comes out through the center opening. Do not install the bracket over the harness
wires.
Page 13 of 14
13. Install and torque the new locknuts to 3.9 N·m (2.8 lb-ft, 34 lb-in).
14. If applicable, cover the lower two inflator locknuts with new felt tape.
15. If applicable, reinstall the horn plate with new felt washers on its mounting bolts. Torque the mounting bolts to
3.4 N·m (2.5 lb-ft, 30 lb-in), then make sure the horn plate moves freely.
16. Reinstall the driver's airbag using new Torx bolts and torque the bolts to 9.8 N·m (7 .2 lb-ft). Refer to the applicable
electronic service manual.
17. Reconnect the battery negative cable.
18. Start the vehicle and check that the SRS indicator comes on for about 6 seconds, then turns off.
19. Give your warranty clerk the RO that includes the replacement inflator serial number and replacement part number.
For the warranty claim to be paid, the replacement inflator part number must be included in the warranty claim.
END
Page 14 of 14