Service Bulletin

Service Bulletin
Applies To:
08-093
November 15, 2014
See VEHICLES AFFECTED
Safety Recall: Driver’s Airbag Inflator Can Be Over-Pressurized
(Supersedes 08-093, dated September 12, 2014, to revise the information marked by the black bars)
REVISION SUMMARY
• Under PARTS INFORMATION and WARRANTY
CLAIM INFORMATION, information was added for
Autoliv airbags.
• Under REPAIR PROCEDURE, a step was changed.
CUSTOMER NOTIFICATION
Owners of affected vehicles have or will receive a
notification of this campaign. An example of the
customer notification is at the end of this service
bulletin.
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.
CORRECTIVE ACTION
Install a driver’s airbag inflator kit, then return the
original, undeployed inflator as directed.
VEHICLES AFFECTED
Not all vehicles within the following model years are
affected by this campaign:
2001–02 Accord
2001–03 Civic
2003 Civic Hybrid
2002 CR-V
2003 Pilot
2002–03 Odyssey
Do an iN VIN status inquiry to make sure the vehicle
is shown as eligible.
In addition, check for a punch mark below the third
character of the engine compartment VIN. A punch
mark in that location means this campaign has already
been completed.
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.
 2014 American Honda Motor Co., Inc. – All Rights Reserved
PARTS INFORMATION
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 and Pilot):
P/N 04770-S9A-306*
Includes inflator with wire harness, locknuts (4),
Torx bolts (2), and shipping instructions.
Torx Bolts (two required for reinstalling Autoliv airbags
only):
P/N 90134-S04-A81
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.
ATB 40918-00480 (1411)
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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.
WARRANTY CLAIM INFORMATION
NOTE:
• Use the Autoliv claim for removing and installing
Autoliv airbags 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 1 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
7521F4
Replace the driver's airbag inflator
(Takata).
0.5 hr
7525B0
Remove and reinstall the Autoliv
airbag with new Torx bolts.
0.3 hr
Failed Part:
Defect Code:
Symptom Code:
Skill Level:
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.
1. 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
13-DIGIT SERIAL NUMBER
P/N 06770-S84-A11ZA
5SZ00
Q9600
Repair Technician
2. Remove the driver’s airbag:
• Refer to page 23-278 of the 1998–2002 Accord
Service Manual, or
• Online, enter keywords DRIVER AIR, and select
Driver’s Airbag Replacement from the list.
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. Remove the four horn plate mounting bolts, the
mounting bolt felt washers, and the horn plate. The
felt washers will not be reused.
HORN PLATE
MOUNTING BOLTS
MOUNTING BOLT
FELT WASHERS
(Discard.)
HORN PLATE
FELT TAPE
(Discard.)
6. Remove and discard the felt tape covering the
lower two inflator locknuts.
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7. Using needle-nose Vise Grips, 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.
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.
LOCKNUTS
13. Reinstall the driver’s airbag using new Torx bolts:
• Refer to page 23-279 of the service manual, or
• Online, enter keywords DRIVER AIR, and select
Driver’s Airbag Replacement from the list.
INFLATOR
14. Center-punch a completion mark below the third
character of the engine compartment VIN:
(Discard.)
(Return to
manufacturer.)
1HGCXXXXXXXXXXXXX
Center-punch here.
AIRBAG
15. Give your warranty clerk the serial number you
wrote down in step 1. 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.
REPAIR PROCEDURE – CIVIC, CIVIC HYBRID,
CR-V, ODYSSEY, AND PILOT
NOTE: .
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 in the box the new inflator came in (see
INFLATOR PACKING AND GROUND
SHIPPING INSTRUCTIONS: DEALERS IN THE
48 CONTIGUOUS STATES or INFLATOR
PACKING AND AIR SHIPPING
INSTRUCTIONS: DEALERS IN ALASKA AND
HAWAII).
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 S5A inflator is slightly taller than the
S84 inflator, but they are still interchangeable.
• 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.
1. 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
13-DIGIT SERIAL NUMBER
11. Cover the lower two inflator locknuts with new felt
tape.
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2. Remove the driver’s airbag:
• Refer to page 23-137 of the 2001–2005 Civic
Service Manual, or
• Refer to page 23-112 of the 2003–2004 Civic
Hybrid Service Manual, or
• Refer to page 23-131 of the 2002–2004 CR-V
Service Manual, or
• Refer to page 23-368 of the 1999–2004 Odyssey
Service Manual, or
• Refer to page 23-105 of the 2003–2004 Pilot
Service Manual, or
• Online, enter keywords DRIVER AIR, and select
Driver’s Airbag Replacement from the list.
3. Place the airbag, face down, on a clean shop towel.
08-093
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.
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5. Determine if the airbag is made by Autoliv or
Takata by comparing inflators to those in the
images below.
NOTE: The Autoliv serial number label is different
from the Takata label.
6. Using needle-nose Vise Grips, 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 5.
LOCKNUTS
AUTOLIV (not affected)
(Discard.)
INFLATOR
(Return to
manufacturer.)
AIRBAG
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 airbag using new Torx bolts.
• If the airbag is made by Takata, go to step 6.
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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 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 S5A inflator is slightly taller than the
S84 inflator, but they are still interchangeable.
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 third
character of the engine compartment VIN:
1HGEXXXXXXXXXXXXX
Center-punch here.
12. Give your warranty clerk the serial number you
wrote down in step 1. 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.
Example of Customer Letter No. 1
December 2011
Safety Recall: Driver’s Airbag Inflator NHTSA Recall 11V-260
Dear Honda Owner:
This notice is sent to you in accordance with the
requirements of the National Traffic and Motor Vehicle
Safety Act.
What is the reason for this notice?
Honda has decided that a defect related to motor
vehicle safety exists in certain 2001–2002 model year
Accord vehicles, 2001–2003 model year Civic, 2002–
2003 model year Odyssey vehicles, 2002 model year
CR-V vehicles and 2003 model year Civic Hybrid and
Pilot vehicles. In some vehicles, the driver's airbag
inflator could produce excessive internal pressure. If an
affected airbag deploys, the increased internal
pressure may cause the inflator to rupture. Metal
fragments could pass through the airbag cushion
material possibly causing injury or fatality to vehicle
occupants.
What should you do?
You must have your vehicle's driver's airbag inflator
replaced; this work will be done free of charge. You
must have the inflator replaced even if, earlier this
year, you 1) had your vehicle inspected and were told
that the driver's airbag inflator did not need to be
replaced, as we have now determined that the inflator
must be replaced, or 2) received a separate driver's
airbag recall notification letter and did not take any
action in response to it. In all cases, call any authorized
Honda dealer and make an appointment to have the
driver's airbag inflator replaced. The replacement
process may be completed in approximately 30
minutes; however, your vehicle will need to be at the
dealer for a longer period of time. We recommend that
you plan to leave your vehicle for half a day to allow the
dealer flexibility in scheduling.
Who to contact if you experience problems
If you are not satisfied with the service you receive
from your Honda dealer, you may write to:
American Honda Motor Co., Inc.
Honda Automobile Customer Service
Mail Stop 500-2N-7A
1919 Torrance Blvd.
Torrance, CA 90501-2746
If you believe that American Honda or the dealer has
failed or is unable to remedy the defect in your vehicle,
without charge, within a reasonable period of time
(60 days from the date you first contact the dealer for a
repair appointment), you may submit a complaint to:
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Ave., SE
Washington, DC 20590
You can also call the toll-free Safety Hotline at
1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
08-093
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Lessor information
Federal law requires that any vehicle lessor receiving
this recall notice must forward a copy of this notice to
the lessee within 10 days.
If you have questions
If you have any questions about this notice, or need
assistance with locating a Honda dealer, please call
Honda Automobile Customer Service at
1-800-999-1009, and select option 4. You can also
locate a dealer online at Hondacars.com.
We apologize for any inconvenience this campaign
may cause you.
Sincerely,
American Honda Motor Co., Inc.
Honda Automobile Division
Example of Customer Letter No. 2
December 2011
Safety Recall: Driver’s Airbag Inflator NHTSA Recall 11V-260
Dear Honda Owner:
This notice is sent to you in accordance with the
requirements of the National Traffic and Motor Vehicle
Safety Act.
What is the reason for this notice?
Honda has decided that a defect related to motor
vehicle safety exists in certain 2001–2002 model year
Accord vehicles, 2001–2003 model year Civic, 2002–
2003 model year Odyssey vehicles, 2002 model year
CR-V vehicles and 2003 model year Civic Hybrid and
Pilot vehicles. In some vehicles, the driver's airbag
inflator could produce excessive internal pressure. If an
affected airbag deploys, the increased internal
pressure may cause the inflator to rupture. Metal
fragments could pass through the airbag cushion
material possibly causing injury or fatality to vehicle
occupants.
If you believe that American Honda or the dealer has
failed or is unable to remedy the defect in your vehicle,
without charge, within a reasonable period of time
(60 days from the date you first contact the dealer for a
repair appointment), you may submit a complaint to:
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Ave., SE
Washington, DC 20590
You can also call the toll-free Safety Hotline at
1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Lessor information
Federal law requires that any vehicle lessor receiving
this recall notice must forward a copy of this notice to
the lessee within 10 days.
If you have questions
If you have any questions about this notice, or need
assistance with locating a Honda dealer, please call
Honda Automobile Customer Service at
1-800-999-1009, and select option 4. You can also
locate a dealer online at Hondacars.com.
We apologize for any inconvenience this campaign
may cause you.
Sincerely,
American Honda Motor Co., Inc.
Honda Automobile Division
What should you do?
Call any authorized Honda dealer and make an
appointment to have your vehicle repaired. The dealer
will replace the driver's airbag inflator. The replacement
process may be completed in approximately 30
minutes; however, your vehicle will need to be at the
dealer for a longer period of time. We recommend that
you plan to leave your vehicle for half a day to allow the
dealer flexibility in scheduling. This work will be done
free of charge.
Who to contact if you experience problems
If you are not satisfied with the service you receive
from your Honda dealer, you may write to:
American Honda Motor Co., Inc.
Honda Automobile Customer Service
Mail Stop 500-2N-7A
1919 Torrance Blvd.
Torrance, CA 90501-2746
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