Service Bulletin

Service Bulletin
08-093
April 14, 2015
40918-01681
Safety Recall: Driver’s Airbag Inflator Can Be Over-Pressurized
Supersedes 08-093, dated November 15, 2014, to revise the information highlighted in yellow
AFFECTED VEHICLES
Year
Model
2001–02
Accord
2001–03
Civic
2003
Civic Hybrid
2002
CR-V
2002–03
Odyssey
2003
Pilot
Trim
ALL
ALL
ALL
ALL
ALL
ALL
VIN Range
Check the iN VIN status for eligibility
Check the iN VIN status for eligibility
Check the iN VIN status for eligibility
Check the iN VIN status for eligibility
Check the iN VIN status for eligibility
Check the iN VIN status for eligibility
REVISION SUMMARY
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.
NOTE: Step 10 under REPAIR PROCEDURE was changed to include installation procedures for all applicable inflator
part numbers.
BACKGROUND
A manufacturing error can produce over-pressurization of the driver’s (front) airbag inflator 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 an injury or fatality to vehicle occupants.
CUSTOMER NOTIFICATION
Owners of affected vehicles were 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 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.
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
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CORRECTIVE ACTION
Install a driver’s airbag inflator kit, 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 Inflator Kit
Order Part Number
You may receive any
of the following
Quantity
04770-S5A-305
04770-S5A-305
1
04770-S5A-405
2001–03 Civic (includes Hybrid) Driver’s Airbag
Inflator Kit
04770-S5A-305
2002 CR-V Driver’s Airbag Inflator Kit
04770-S9A-306
04770-S5A-305
1
04770-S5A-405
04770-S9A-306
1
04770-S9A-405
2002–03 Odyssey Driver’s Airbag Inflator Kit
04770-S5A-305
04770-S5A-305
1
04770-S5A-405
2003 Pilot Driver’s Airbag Inflator Kit
04770-S9A-306
04770-S9A-306
1
04770-S9A-405
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.
* The kit contains FedEx Ground shipping documents and instructions for the airbag inflator. If you are a dealer in
Alaska or Hawaii, call the WPI administrative office at 937-642-2737 for FedEx Air shipping documents and instructions;
do not use the documentation included in the airbag inflator kit.
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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.
• 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 2 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 2 of REPAIR
PROCEDURE.
• 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.
Operation
Number
Description
Flat Rate
Time
Defect Code
Symptom
Code
Failed Part Number
7521F4
Replace the driver’s
airbag inflator.
0.5 hr
5SZ00
Q9600
06770-S84-A11ZA
7525B0
Remove and reinstall the
Autoliv airbag.
0.3 hr
5SZ00
Q9600
06770-S84-A11ZA
Skill Level:
Repair Technician
REPAIR PROCEDURE – ACCORD ONLY
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.
1. Remove the driver’s airbag.
2. Write down the serial number and part number located on the right side of the new inflator’s box. 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: Make sure you give the part number on the side inflator box that you received to the warranty clerk.
Do not give the warranty clerk the part number that you ordered.
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3. Place the airbag, face down, on a clean shop towel.
4. Visually inspect the airbag and the inflator for any unusual writing or markings.
•
•
5.
If there is nothing unusual about the airbag or the inflator, go to step 5.
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.
Remove the four horn plate mounting bolts, the mounting bolt felt washers, and the horn plate. The felt washers will
not be reused.
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6. Remove and discard the felt tape covering the lower two inflator locknuts.
7. 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 8.
8. 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.
9. Turn over the airbag (inflator side down), and shake it to remove any debris from the inflator opening.
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10. 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 replacing 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.
Check your part number against the ones listed for each installation procedure. Use the correct installation
procedure for the part you received.
Part Number
04770-S5A-305
Refer to Driver’s Inflator Type 1 in the video.
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• Insert the inflator into the opening.
NOTE: Make sure the inflator wires toward the bottom of the airbag. If you install the inflator incorrectly, you may
not be able to reconnect the SRS airbag harness.
Check your part number against the ones listed for each installation procedure. Use the correct installation
procedure for the part you received
Part Number
04770-S5A-405
Refer to Driver’s Inflator Type 2 in the video.
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• Insert the airbag inflator into the opening. Do not force it into the airbag module.
NOTE: Make sure the inflator wires 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.
11. Install and torque the new locknuts to 3.9 N·m (2.8 lb-ft, 34 lb-in).
12. Cover the lower two inflator locknuts with new felt tape.
13. Reinstall the horn plate with new felt washers on its mounting bolts. Torque the mounting bolts to
3.9 N·m (2.5 lb-ft, 30 lb-in), then make sure the horn plate moves freely.
14. Reinstall the driver’s airbag using new Torx bolts. Torque the bolts to 9.8 N·m (7.2 lb-ft).
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15. Give your warranty clerk the inflator serial number and part number that you wrote down in step 2. 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.
REPAIR PROCEDURE – CIVIC, CIVIC HYBRID, CR-V, ODYSSEY, AND PILOT
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.
1. Remove the driver’s airbag.
2. Write down the serial number and part number located on the right side of the new inflator’s box. 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: Make sure you give the part number on the side inflator box that you received to the warranty clerk. Do not
give the warranty clerk the part number that you ordered.
3. Place the airbag, face down, on a clean shop towel.
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4. 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 5.
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.
5. 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 6.
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6. 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 7.
7. 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.
8. Turn over the airbag (inflator side down), and shake it to remove any debris from the inflator opening.
9. 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 replacing 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 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
04770-S5A-305
Refer to Driver’s Inflator Type 1 in the video.
04770-S9A-306
• Insert the inflator into the opening.
NOTE: Make sure the inflator wires toward the bottom of the airbag. If you install the inflator incorrectly, you may
not be able to reconnect the SRS airbag harness.
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
04770-S5A-405
Refer to Driver’s Inflator Type 2 in the video.
04770-S9A-405
• Insert the airbag inflator into the opening. Do not force it into the airbag module.
NOTE: Make sure the inflator wires toward the bottom of the airbag. If you install the inflator incorrectly, you may
not be able to reconnect the SRS airbag harness.
Page 13 of 14
•
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.
10. Install and torque the new locknuts to 3.9 N·m (2.8 lb-ft, 34 lb-in).
11. Reinstall the driver’s airbag using new Torx bolts. Torque the bolts to 9.8 N·m (7.2 lb-ft).
12. Give your warranty clerk the inflator serial number and part number that you wrote down in step 2. 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.
END
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