Service Bulletin

Service Bulletin
Applies To:
10-039
2001–02 Accord – Check the iN VIN status for eligibility
2001–03 Civic – Check the iN VIN status for eligibility
2003 Civic Hybrid – Check the iN VIN status for eligibility
2002–04 CR-V – Check the iN VIN status for eligibility
2002 Odyssey – Check the iN VIN status for eligibility
February 6, 2015
Safety Recall: Replacement Driver’s Airbag Inflator Can Be
Over-Pressurized
(Supersedes 10-039, dated October 31, 2014, to revise the information marked by the black bars)
REVISION SUMMARY
The inspection procedure for Takata driver’s airbags
was removed because all Takata driver’s airbag
inflators installed in the recall vehicle population are
being replaced.
CUSTOMER NOTIFICATION
All 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.
BACKGROUND
The inspection procedure for Takata driver’s airbags
was removed because all Takata driver’s airbag
inflators installed in the recall vehicle population are
being replaced. For Civic models only, Autoliv airbags
are OK and can be reinstalled in the vehicle.
A manufacturing error can produce over-pressurization
of some replacement driver’s (front) airbag inflators
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.
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 driver’s airbag inflator kit, then return the
defective, undeployed inflator as directed.
NOTE: For Civic models only, inspect the airbag and,
if it is a Takata inflator, replace the driver’s airbag
inflator, and return the original, undeployed inflator as
directed.
 2015 American Honda Motor Co., Inc. – All Rights Reserved
ATB 46168-01469 (1502)
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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.
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.
Torx Airbag Bolts: P/N 90134-S04-A81
(Two bolts are required to reinstall Autoliv airbag
modules in certain Civic vehicles)
Driver’s Airbag Inflator Kit (Accord, Civic, Civic Hybrid,
Odyssey):
P/N 04770-S5A-305*
Includes inflator with wire harness, locknuts (4), felt
tape, felt washers (4), Torx bolts (2), and shipping
instructions.
NOTE: The felt tape and the felt washers are used
only on Accords.
Driver’s Airbag Inflator Kit (CR-V):
P/N P/N 04770-S9A-306*
Includes inflator with wire harness, locknuts (4),
Torx bolts (2), and shipping instructions.
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.
*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 in Civic vehicles
only. Do not use it to claim any labor on Takata
airbags.
• 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.
OP#
Description
FRT
7525A6
Replace the driver’s airbag inflator.
0.5
7525A9
Remove and reinstall the Autoliv airbag.
0.3
Failed Part:
Defect Code:
Symptom Code:
Skill Level:
P/N 06770-S84-A11ZA
5US00
R5400
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 not be the correct 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 by referring to the
applicable electronic service manual.
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2. Write down the serial number located on the right
side of the new inflator’s box. For the warranty
claim to be paid, your warranty clerk must enter this
serial number in the Diagnostic Trouble Codes
field on the warranty claim.
INFLATOR BOX
SERIAL NUMBER
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 is 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.
3. Place the airbag, face down, on a clean shop towel.
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5. Remove the four horn plate mounting bolts, the
mounting bolt felt washers, and the horn plate. The
felt washers will not be reused.
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.
HORN PLATE
MOUNTING BOLTS
MOUNTING BOLT
FELT WASHERS
LOCKNUTS
(Discard.)
(Discard.)
INFLATOR
(Return to
manufacturer.)
AIRBAG
HORN PLATE
FELT TAPE
(Discard.)
8. Use shop air to clean any debris that may be on the
inflator, then remove the inflator from the airbag.
6. Remove and discard the felt tape covering the
lower two inflator locknuts.
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.
9. Turn over the airbag (inflator side down), and shake
it to remove any debris from the inflator opening.
10. Install the new inflator in the airbag with new
locknuts. Torque the locknuts to 3.9 N.m (2.8 lb-ft,
34 lb-in).
NOTE: The new inflator is slightly different than the
original inflator, but they are still interchangeable.
11. Cover the lower two inflator locknuts with new felt
tape.
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12. 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.
REPAIR PROCEDURE B – CIVIC, CIVIC HYBRID,
CR-V, AND ODYSSEY
13. Reinstall the driver’s airbag using new Torx bolts:
• 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 not be the correct 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 Civic you are inspecting 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 by referring to the
applicable electronic service manual.
• Refer to page 23-279 of the service manual, or
• Online, enter keywords DRIVER AIR, and select
Driver’s Airbag Replacement from the list.
14. Center-punch a completion mark below the fifth
character of the engine compartment VIN:
1HGCXXXXXXXXXXXXX
Center-punch here.
15. Give your warranty clerk the inflator serial number
you wrote down in step 2. For the warranty claim to
be paid, your warranty clerk must enter the
appropriate serial number in the Diagnostic
Trouble Codes field on the warranty claim.
NOTE:
2. Write down the serial number located on the right
side of the new inflator’s box. For the warranty
claim to be paid, your warranty clerk must enter this
serial number in the Diagnostic Trouble Codes
field on the warranty claim.
INFLATOR BOX
SERIAL NUMBER
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 is 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.
AUTOLIV (not affected)
TAKATA
SRS
*HQL41V897*
M/D-1000
77800-S5A-A813-M1
7917
Q4
Locate serial
number here.
• If the airbag is made by Autoliv, the airbag is OK.
Reinstall the Autoliv airbag. 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.
LOCKNUTS
(Discard.)
INFLATOR
(Return to
manufacturer.)
AIRBAG
10. Reinstall the driver’s airbag using new Torx bolts:
• Refer to the appropriate service manual, or
• Online, enter keywords DRIVER AIR, and select
Driver’s Airbag Replacement from the list.
11. Center-punch a completion mark below the fifth
character of the engine compartment VIN:
1HGCXXXXXXXXXXXXX
Center-punch here.
12. Give your warranty clerk the inflator serial number
you wrote down in step 2. For the warranty claim to
be paid, your warranty clerk must enter the
appropriate serial number in the Diagnostic
Trouble Codes field on the warranty claim.
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 foreign objects 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.
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 with new
locknuts. Torque the locknuts to 3.9 N.m (2.8 lb-ft,
34 lb-in).
NOTE:
• The new inflator is slightly different than the
original inflator, but they are still interchangeable.
• There may be some minor surface rust or
corrosion on the new inflator; this is OK.
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