A15-040

(g)HONDA
Service Bulletin
15-040
June 5, 2015
02025 Version 1
Safety Recall: Driver's Airbag lnflator Can Be Over-Pressurized
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
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 if the vehicle was 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.
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.
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 12
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.
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-SSA-305
04 770-SSA-305
1
04770-SSA-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-SSA-408
04770-SSA-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-SSA-305
04 770-SSA-305
04 770-SSA-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, ideally within 48 hours of the repair. 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.
•
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.
Page 2 of 12
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 supplied with the inflator kit. If you have any questions
about shipping, call Warranty Parts Inspection (WPI) at 937-642-2737.
Template IDs cannot be used because there are different inflator part numbers available and it would be too
complex to have a template ID for each part number.
The replacement inflator part number and serial number are printed on the label that should be attached to the
R.O.
To avoid non-payment of warranty claims, the new airbag inflator part number must be included in each claim and
the serial number must be entered into the Diagnostic Trouble Codes field. For more information, refer to step 2 of
REPAIR PROCEDURE.
The serial number is encoded into the bar code printed on the label. If your dealership uses a scanner, you can
scan the serial number into the claim.
Year/Model
Operation
Number
Description
Flat
Rate
Time
Defect
Code
Symptom
Code
Failed Part
Number
2001-02 Accord
7521 H8
0.5 hr
5VZ00
JQ900
06770-SDA-AS0ZA
2003-07 Accord
7521 H8
Replace the
driver's airbag
inflator.
0.5 hr
5VZ00
JQ900
06770-SDA-AS0ZA
2001-05 Civic
7521 H8
2001-05 Civic GX
7521 H8
0.5 hr
5VZ00
JR000
06770-S5A-A 1OZA
2003-05 Civic
Hybrid
7521 H8
2002-06 CR-V
7521 H8
0.5 hr
5VZ00
JR100
06770-S9A-A80ZA
2003-11 Element
7521 H8
0.5 hr
5VZ00
JR200
06770-SCV-AS0ZA
2002-04 Odyssey
7521 H9
0.5 hr
5VX00
JR300
06770-S0X-A 1OZA
2003-08 Pilot
7521 H9
0.5 hr
5VX00
JR400
06770-S9V-A01 ZA
2006 Ridgeline
7521 H9
0.5 hr
5VX00
JR500
06770-SJC-A 1OZA
2001-05 Civic
7521J0
0.3 hr
5VZ00
JR000
06770-S5A-A 1OZA
Skill Level:
Remove and
reinstall the
Autoliv airbag.
Repair Technician
Page 3 of 12
REPAIR PROCEDURE
NOTE:
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, 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.
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
Page 4 of 12
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 8.
TAKATA
7.
Peel the label located inside the inflator box from its backing and attach it to the R.O. 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 R.O. 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 R.O. The part number always starts with 04 7.
INFLA TOR PARTS BOX
SERIAL NUMBER
RETAINER
PLATE
SELF-ADHESIVE
LABEL
INFLATOR
INSTALLATION
PARTS
(if applicable)
Page 5 of 12
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 6 of 12
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 7 of 12
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
04 770-SCV-306
04 770-SJC-306
Refer to Driver's lnflator Type 1 in the video.
•
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 8 of 12
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
04770-S9A-405
Refer to Driver's lnflator Type 2 in the video.
04 770-SCV-405
04770-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 9 of 12
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 10 of 12
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 11 of 12
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 R.O. 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 12 of 12