Service Bulletin

Service Bulletin
April 17, 2015
14-040
ATB 51811-01830 Version 7
Safety Recall: Front Passenger’s Airbag Inflator Can Be
Over-Pressurized
Supersedes 14-040, dated December 11, 2014, to revise the information highlighted in yellow
Replaces 14-041, Safety Recall: Civic, CR-V, and Odyssey - Front Passenger’s Airbag Inflator Can Be OverPressurized
AFFECTED VEHICLES
Year
Model
2003
Accord
2002–03
Civic
2002–03
Civic GX
2003
Civic Hybrid
2002–03
CR-V
2003
Element
2002–03
Odyssey
2003
Pilot
Trim
ALL
ALL
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
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 11 under REPAIR PROCEDURE was changed to include installation procedures for all applicable inflator
part numbers.
BACKGROUND
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Puerto Rico, Guam, Saipan, American Samoa, and the U.S. Virgin Islands were superseded to Service Bulletin 14-070,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 Inflator 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
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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
Accord Passenger (Front) Airbag Inflator Kit
04785-SDA-307
04785-SDA-307
1
04790-SDA-308
Civic Passenger (Front) Airbag Inflator Kit (includes
GX and Hybrid)
04785-S5A-307
CR-V Passenger (Front) Airbag Inflator Kit
04785-S9A-307
04785-S5A-307
1
04790-S5A-308
04785-S9A-307
1
04790-S9A-308
Element Passenger (Front) Airbag Inflator Kit
04785-SCV-307
N/A
1
2002 Odyssey Passenger (Front) Airbag Inflator Kit
04785-S0X-307
N/A
1
2003 Odyssey Passenger (Front) Airbag Inflator Kit
04785-S0X-306
N/A
1
Pilot Passenger (Front) Airbag Inflator Kit
04785-S9V-307
N/A
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.
• 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.
• If you are a dealer in Alaska, Hawaii, Puerto Rico, Guam, Saipan, American Samoa, or the U.S. Virgin Islands call
the WPI administrative office at 937-642-2737 for special instructions; do not use the documentation included in the
airbag inflator kit.
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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 1 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 1 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 supplied with the inflator kit. If you have any questions about shipping,
call Warranty Parts Inspection (WPI) at 937-642-2737.
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
04785-SDA-307
0.7 hr
5JK00
JJ600
14-040Z
06780-SDA-A80ZA
7541A9
04790-SDA-308
0.7 hr
5JK00
JJ600
14-040Y
06780-SDA-A80ZA
7541A9
04785-S5A-307
0.7 hr
5JK00
JJ700
14-040X
06780-S5A-A80ZA
7541A9
04790-S5A-308
0.7 hr
5JK00
JJ700
14-040W
06780-S5A-A80ZA
7541A9
04785-S9A-307
0.7 hr
5JK00
JJ800
14-040V
06780-S9A-A80ZA
7541A9
04790-S9A-308
0.7 hr
5JK00
JJ800
14-040U
06780-S9A-A80ZA
2003 Element
7541A9
04785-SCV-307
0.8 hr
5JK00
JJ900
14-040T
06780-SCV-A80ZA
2002 Odyssey
7541A0
04785-S0X-307
0.7 hr
5UK00
JK000
14-040S
06780-S0X-A10ZA
2003 Odyssey
7541A0
04785-S0X-306
0.7 hr
5UK00
JK000
14-040R
06780-S0X-A10ZA
2003 Pilot
7541A0
04785-S9V-307
0.8 hr
5UK00
JK100
14-040Q
06780-S9V-A80ZA
2003 Accord
2002–03 Civic
2002–03
Civic GX
2003
Civic Hybrid
2002–03 CR-V
Skill Level:
Repair Technician
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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.
• Be careful not to damage any parts when replacing the inflator, and follow the procedure exactly.
• The procedure shows the Civic/CR-V airbag. The bracket on the other vehicles are slightly different but the repair
procedure is the same.
1. Write down the serial number located on the right side of the new inflator 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 warranty clerk the part number of the inflator you received, not the part number that
was ordered.
2. Remove the front passenger’s airbag by referring to the applicable electronic service manual.
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3. 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.
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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. Remove the harness from both ends of the inflator bracket.
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6. 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.
•
Tape the twisted ends with electrical tape.
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7. 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.
•
Strip away about an inch of the wire insulation, then twist the wires together.
•
Tape the twisted ends with electrical tape.
8. Remove the four inflator nuts.
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9. Remove the inflator bracket.
NOTE: You can only remove one of the brackets, as the other is welded to the airbag housing.
10. Remove the inflator by pushing it out.
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11. 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
04785-SDA-307
04785-SDA-306
04785-S5A-307
04785-S9A-307
04785-S9A-306
04785-SCV-307
04785-S0X-307
04785-S0X-306
04785-S9V-307
04785-S9V-306
04785-SJC-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.
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•
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.
•
Reinstall the inflator bracket. There should be no space or gap between the bracket and inflator.
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Check your part number against the ones listed for each installation procedure. Use the correct installation
procedure for the part you received.
Part Number
04790-SDA-308
04790-S5A-308
04790-S9A-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.
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•
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.
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•
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.
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12. Install the new 5 mm locknuts and torque them in sequence to 3.9 N•m (34 lb-in).
13. Remove the stickers covering the terminals on both sides of the new inflator.
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14. 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.
•
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.
•
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.
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15. 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.
16. Reinstall the passenger’s airbag into the vehicle and torque the new locknuts to 9.8 N•m (7.2 lb-ft).
17. 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.
18. Follow the shipping instructions supplied with the inflator kit to return the undeployed inflator. If you have any
questions about shipping, call Warranty Parts Inspection (WPI) at 937-642-2737.
19. Give the warranty clerk the inflator serial number and part number that you wrote down in step 1. For the warranty
claim to be paid, your warranty clerk must enter replacement inflator part number that you received into the
warranty claim and enter the serial number in the Diagnostic Trouble Codes field.
END
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