A14-040 - 6-30-1

(g)HONDA
Service Bulletin
14-040
June 30, 2015
ATB 51811-01884 Version 10
Safety Recall: Front Passenger's Airbag lnflator Can Be
Over-Pressurized
Supersedes 14-040, dated June 16, 2015; see Revision Summary
Replaces 14-041, Safety Recall: Civic, CR-V, and Odyssey- Front Passenger's Airbag lnf/ator Can Be OverPressurized
AFFECTED VEHICLES
Year
Model
2002-03
CR-V
2003
Element
2002-03
Odyssey
2003
Pilot
Trim
ALL
ALL
ALL
ALL
VIN Range
Check the iN
Check the iN
Check the iN
Check the iN
VIN
VIN
VIN
VIN
status
status
status
status
for eligibility
for eligibility
for eligibility
for eligibility
REVISION SUMMARY
New and different inflators are available. You may receive a different part number than ordered, and the inflator may
physically look different from previous replacement parts. 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.
A new inflator has been added to the video included in this bulletin.
On June 18, 2015, there was a change in the return process for driver and front passenger inflators. Refer to the PIB
A 15-0002, lnflator Kit Return Process for more information.
BACKGROUND
As the result of Takata defect determinations and NHTSA directives, American Honda has moved the 2003 Accord,
2002-03 Civic, 2002-03 Civic GX, and 2003 Civic Hybrid from this airbag inflator campaign into SB 15-041, Safety
Recall: Front Passenger's Airbag lnflator Can Be Over-Pressurized. If an RO was opened on June 14, 2015 or earlier
for these vehicles, use the included warranty information to file a claim. Any applicable vehicles with an RO
date on June 15, 2015 or later, refer to SB 15-041.
In certain vehicles, the passenger'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 be propelled upward toward the windshield, or downward toward the front passenger's foot well,
possibly causing an injury to vehicle occupants.
Vehicles sold and/or registered in Alabama, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas,
Puerto Rico, Guam, Saipan, American Samoa, and the U.S. Virgin Islands were superseded to Service Bulletin 14-070,
Safety Recall: Front Passenger's Airbag lnflator May Produce Excessive Pressure After Long-Term Exposure To High
Absolute Humidity.
NOTE: If the VIN status inquiry indicates that the vehicle is subject to any open safety recalls, including a
driver'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 20
CUSTOMER NOTIFICATION
Owners of affected vehicles will be sent 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 a dealership sell an unrepaired vehicle that subsequently causes an 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 campaign, do a VIN status
inquiry before selling it.
CORRECTIVE ACTION
Install a passenger's airbag inflator kit, then return the original undeployed inflator as directed.
PARTS INFORMATION
Part Name
Part Number
Ordered
You may receive any of
the following
Quantity
2002-03 CR-V Passenger (Front) Airbag lnflator Kit
04 785-S9A-307
04 785-S9A-307
1
04 790-S9A-308
2003 Element Passenger (Front) Airbag lnflator Kit
04 785-SCV-307
04 785-SCV-307
1
04 790-SCV-308
2002 Odyssey Passenger (Front) Airbag lnflator Kit
04 785-S0X-307
04 785-S0X-307
04 790-S0X-308
1
2003 Odyssey Passenger (Front) Airbag lnflator Kit
04 785-S0X-306
04 785-S0X-306
04 790-S0X-305
1
2003 Pilot Passenger (Front) Airbag lnflator Kit
04 785-S9V-307
04 785-S9V-307
04 790-59V-308
1
NOTE:
• The inflator kit box must be used to return the old inflator to its supplier, ideally within 48 hours of the repair.
Be careful not to damage the inflator kit box.
•
If the recalled, undeployed inflator is not returned, the warranty claim for that vehicle will be charged back to your
dealership.
• To return the undeployed inflators, follow the shipping instructions outlined in PIB A15-0002.
•
If you are a dealer in Alaska, Hawaii, Puerto Rico, Guam, Saipan, American Samoa, or the U.S. Virgin Islands call
Menlo at 210-250-5078 or email [email protected] for special instructions.
Page 2 of 20
WARRANTY CLAIM INFORMATION
NOTE:
•
Process claims as quickly as possible so that resources can be properly allocated.
•
Enter the part number of the inflator that you received into the warranty claim, not the part number that you
ordered. For more information, refer to step 6 of REPAIR PROCEDURE.
To avoid non-payment of warranty claims, the serial number on the box of the new airbag inflator must be entered
in the Diagnostic Trouble Codes field on each warranty claim. For more information, refer to step 6 of REPAIR
PROCEDURE.
•
•
To avoid a warranty claim being charged back to your dealership, you must return the original undeployed inflator to
its supplier. Follow the shipping instructions outlined in PIB A 15-0002.
•
The Accord and Civic warranty information is included in case you opened an RO on or before June 14,
2015. Refer to S/B 15-041 for any repairs made after that date.
Replacing the front passenger's airbag inflator
Year/Model
Operation
Number
Replacement
Part Number
Flat
Rate
Time
Defect
Code
Symptom
Code
Template
ID
Failed Part
Number
7541A9
04 785-SDA-307
0.7 hr
5JK00
JJ600
14-040Z
06780-SDA-A80ZA
7541A9
04 790-SDA-308
0.7 hr
5JK00
JJ600
14-040Y
06780-SDA-A80ZA
7541A9
04 785-S5A-307
0.7 hr
5JK00
JJ700
14-040X
06780-S5A-A80ZA
7541A9
04 790-S5A-308
0.7 hr
5JK00
JJ700
14-040W
06780-S5A-A80ZA
7541A9
04 785-S9A-307
0.7 hr
5JK00
JJ800
14-040V
06780-S9A-A80ZA
7541A9
04 790-S9A-308
0.7 hr
5JK00
JJ800
14-040U
06780-S9A-A80ZA
7541A9
04 785-SCV-307
0.8 hr
5JK00
JJ900
14-040T
06780-SCV-A80ZA
7541A9
04 790-SCV-308
0.8 hr
5JK00
JJ900
14-04T0
06780-SCV-A80ZA
7541A0
04 785-S0X-307
0.7 hr
5UK00
JK000
14-040S
06780-S0X-A 1OZA
7541A0
04 790-S0X-308
0.7 hr
5UK00
JK000
14-04S0
06780-S0X-A 1OZA
7541A0
04 785-S0X-306
0.7 hr
5UK00
JK000
14-040R
06780-S0X-A 1OZA
7541A0
04 790-S0X-305
0.7 hr
5UK00
JK000
14-04R0
06780-S0X-A 1OZA
7541A0
04 785-S9V-307
0.8 hr
5UK00
JK100
14-040Q
06780-S9V-A80ZA
7541A0
04 790-59V-308
0.8 hr
5UK00
JK100
14-04Q0
06780-S9V-A80ZA
2003 Accord
2002-03 Civic
2002-03
CivicGX
2003
Civic Hybrid
2002-03 CR-V
2003 Element
2002 Odyssey
2003 Odyssey
2003 Pilot
Skill Level:
Repair Technician
Page 3 of 20
REPAIR PROCEDURE
NOTE:
•
If the VIN status inquiry indicates that the vehicle is subject to any open safety recalls, including a driver'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.
• Make sure you have the anti-theft code for the audio and navigation system (if applicable), then write down the
frequencies for the radio's preset buttons.
Be careful not to damage any parts when replacing the inflator, and follow the procedure exactly.
•
• The procedure shows the CR-V airbag. The bracket on the other vehicles are slightly different but the repair
procedure is the same.
•
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 front passenger's airbag by referring to the applicable electronic service manual.
4.
Place the airbag face-down on a clean shop towel as shown.
NOTE:
• The orientation of the airbag is critical because if the inflator is installed incorrectly, the harness will be too short
when you reinstall the airbag.
• The brackets between the various models are similar but may differ from the example shown in the procedure.
ELEMENT
CR-V
PILOT
Odyssey
Page 4 of 20
5.
Visually inspect the airbag and the inflator for any unusual writing or markings.
•
•
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
HAND ENGRAVING
NO LABELS ON INFLATOR
Page 5 of 20
6.
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 on the warranty claim and your warranty
clerk must enter the serial number in the Diagnostic Trouble Codes field.
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.
PASSENGER INFLATOR PARTS BOX
SELF-ADHESIVE
LABEL
7.
INSTALLATION
PARTS
INFLATOR
Remove the harness from both ends of the inflator bracket.
Page 6 of 20
8.
Short the red wires.
NOTE: You must cut and short the wires as indicated to prevent any accidental deployment.
•
Cut the red wires as shown.
•
Cut about 2 inches of the corrugated tube, then pull out the two red wires.
•
Strip away about 1 inch of the wire insulation, then twist the wires together.
I
•
Tape the twisted ends with electrical tape.
Page 7 of 20
9.
Cut off the connector and short the yellow wires.
You must cut and short the wires as indicated to prevent any accidental deployment.
•
Cut all four wires to remove the connector.
•
Cut about 2 inches of the corrugated tube, then pull out the yellow wires.
•
Tape the twisted ends with electrical tape.
10. Remove the four inflator nuts.
INFLATOR NUTS
Page 8 of 20
11 . Remove the inflator bracket.
NOTE: You can only remove one of the brackets, as the other is welded to the airbag housing.
INFLATOR BRACKET
12. Remove the inflator by pushing it out.
Page 9 of 20
13. Install the new inflator.
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 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.
Check your part number against the ones listed for each installation procedure. Use the correct installation
procedure for the part you received.
Part Number
04 785-S9A-307
04 785-SCV-307
04 785-S0X-307
04 785-S0X-306
04 785-S9V-307
•
One connector looks like a "D" whereas the other connector is a circle. Make sure you insert the "D" connector
into the airbag first.
NOTE: There is a yellow band marking on the circle side.
D-SHAPED TERMINAL
A white sticker covers the terminal.
Page 10 of 20
•
Slide the inflator in until the "D" aligns with the tab on the inflator bracket. There should be no space or gap between
the inflator and bracket.
Page 11 of 20
Check your part number against the ones listed for each installation procedure. Use the correct installation
procedure for the part you received.
Part Number
04 790-S9A-308
04 790-SCV-308
04 790-S0X-308
04 790-S9V-308
•
One side of the inflator has a longer collar, a longer tab, a plastic cutout, and a small flat spot on the connector.
The other side of the inflator has a shorter collar, a shorter tab, and a red dot. Make sure you insert the end with
the longer collar into the airbag first.
CUTOUT
NEW INFLATOR
RED DOT
Page 12 of 20
•
Slide the inflator in until the plastic cutout and the small flat spot align with the tab on the bracket. There should
be no space or gap between the inflator and bracket.
FIXED BRACKET END
No gap
CUTOUT
Page 13 of 20
•
Install the bracket included in the kit onto the airbag module. There should be a red dot visible on the end of the
plastic connector. There should be no space or gap between the inflator and bracket.
ADJUSTABLE BRACKET END
No gap
ADJUSTABLE BRACKET
Page 14 of 20
Check your part number against the ones listed for each installation procedure. Use the correct installation
procedure for the part you received.
Part Number
04 790-S0X-305
•
The collars on this inflator are orange, not white. One side of the inflator has a longer collar, a tab, a plastic
cutout, and a small flat spot on the connector. The other side of the inflator has a shorter collar, no tab, and a
red dot. Make sure you insert the end with the longer collar into the airbag first.
NEW INFLATOR
I
.
. .r
RED DOT
•
"
•
Page 15 of 20
•
Slide the inflator in until the plastic cutout and the small flat spot align with the tab on the bracket. There should
be no space or gap between the inflator and bracket.
FIXED BRACKET END
No gap
CUTOUT
TAB ON FIXED BRACKET
Page 16 of 20
•
Install the bracket included in the kit onto the airbag module. There should be a red dot visible on the end of the
plastic connector. There should be no space or gap between the inflator and bracket.
ADJUSTABLE
BRACKET END
No gap
Page 17 of 20
14. Install the new 5 mm locknuts and torque them in sequence to 3.9 N•m (34 lb-in).
Be sure there are no gaps between
the inflator ends and the inflator brackets.
15. Remove the stickers covering the terminals on both sides of the new inflator.
STICKER
COVERING
TERMINAL
STICKER
COVERING
TERMINAL
Page 18 of 20
16. Install the new inflator harness.
•
Make sure the airbag and harness are aligned as shown.
NOTE:
Make sure you have the orientation correct as shown below. If you connect the harness incorrectly, the
harness cannot be removed, and you will not be able to reinstall the airbag because the harness will be too
short.
On the replacement inflators with plastic collars, connect the red wire connector to the connector with the
red dot.
On the replacement inflators without plastic collars, connect the red wire connector to the connector nearest
the yellow band.
RED WIRE
CONNECTOR
•
Connect the two connectors. Align the "T" shape in the inflator harness connector with the T-shaped
inflator connector, then press the connector into place.
~ Match up the ''T" shape as shown.
~ The connectors are directional.
INFLATOR
HARNESS
CONNECTOR
,;;\ Press the connector
\!;) into place until it clicks.
(';;\ Wiggle the connector to
\::!.J make sure it's secure.
l
•
After you hear each connector click, wiggle it to make sure it is secure .
NOTE: If the connector is not properly aligned, it will come out.
Page 19 of 20
17. Connect the harness to the inflator brackets.
•
Insert the side without the shrink-wrap tubing first. Insert the harness at the third "valley" in the corrugated tube.
•
Insert the side of the harness with the shrink-wrap tubing into the inflator bracket. Make sure the harness is
securely inserted and that it does not sag.
18. Reinstall the passenger's airbag into the vehicle and torque the new locknuts to 9.8 N•m (7 .2 lb-ft).
19. Reconnect the battery negative cable and enter the anti-theft code for the audio and navigation system
(if applicable), then enter the audio unit presets.
20. Turn the ignition to the ON (II) position and make sure the SRS indicator comes on for about 6 seconds, then turns
off.
21. Put the original inflator into the box the new one came in. Make sure there is no other hardware in the box because
if the package rattles, it will not be accepted by the courier.
22. Follow the shipping instructions outlined in PIB A 15-0002 to return the undeployed inflator.
23. Give your warranty clerk the RO that includes the inflator serial number and replacement part number. For the
warranty claim to be paid, the replacement inflator part number must be on the warranty claim and your warranty
clerk must enter the serial number in the Diagnostic Trouble Codes field.
END
Page 20 of 20