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
September 26, 2014
Safety Recall: Replacement Driver’s Airbag Inflator Can Be
Over-Pressurized
(Supersedes 10-039, dated September 12, 2014, to revise the information marked by the black bars)
REVISION SUMMARY
• Not all serial numbers have 13 digits, so this
numerical reference was deleted from WARRANTY
CLAIM INFORMATION and REPAIR PROCEDURE.
• Under REPAIR PROCEDURE, a step was changed.
BACKGROUND
A small number of airbag modules with defective
inflators were sold as replacement parts to replace
deployed or damaged airbags.
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.
CUSTOMER NOTIFICATION
All owners of affected vehicles will be sent a
notification of this campaign. An example of the
customer notification is included at the end of this
service bulletin.
Do an iN VIN status inquiry to make sure the vehicle
is shown as eligible.
In addition, check for a punch mark below the 5th
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.
CORRECTIVE ACTION
Most vehicles will require an inspection only. Do the
INSPECTION PROCEDURE and, if needed, install a
driver’s airbag inflator kit, then return the defective,
undeployed inflator as directed.
 2014 American Honda Motor Co., Inc. – All Rights Reserved
ATB 46168-52690 (1409)
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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:
• All the vehicles involved in this campaign require
inspection. However, only a very small number of
these vehicles require replacement of the airbag
inflator compared to the large number of vehicles
that will require an inspection. Order an airbag
inflator kit only if the inspection shows that the
inflator must be replaced.
• Always use new Torx bolts to reinstall the
airbags, even on vehicles that do not need a new
inflator. 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 install an airbag)
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:
• If the airbag inflator is replaced, 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 B.
• 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
7525A5
Remove the driver’s airbag, check the
inflator serial number, and reinstall the
original airbag.
0.3
7525A6
Remove the driver’s airbag, check the
inflator serial number, and REPLACE the
airbag inflator.
0.5
Failed Part:
Defect Code:
Symptom Code:
Skill Level:
P/N 06770-S84-A11ZA
5US00
R5400
Repair Technician
INSPECTION PROCEDURE
NOTE:
• 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 vehicle 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:
• Refer to page 23-278 of the 1998–2002 Accord
Service Manual, or
• 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
• Online, enter keywords DRIVER AIR, and select
Driver’s Airbag Replacement from the list.
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2. 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 3.
• 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. 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; 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.
Go to REPAIR PROCEDURE A. If you already
received a replacement inflator, return the
unopened kit to American Honda.
• If the airbag is made by Takata, go to step 3.
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4. Locate the serial number on the bottom of the
airbag. Make sure you also have the VIN, then go
to the iN:
• Click on Service.
• Click on Service Bay.
• Click on Airbag inflator recall SB 10-039.
• Enter the VIN and the airbag serial number.
The iN will indicate if the airbag is OK or if the
airbag inflator must be replaced. If the airbag is OK,
go to REPAIR PROCEDURE A. If the airbag
inflator must be replaced, go to REPAIR
PROCEDURE B.
REPAIR PROCEDURE B – ACCORD ONLY
NOTE: Be careful not to damage any parts when
replacing the inflator, and follow the procedure exactly.
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
SERIAL NUMBER
TAKATA
SRS
*HQL41V897*
M/D-1000
77800-S5A-A813-M1
7917
Q4
Locate serial
number here.
2. Place the airbag, face down, on a clean shop towel.
REPAIR PROCEDURE A
1. Reinstall the airbag using new Torx bolts, and
torque the bolts to 10 N.m (7.0 lb-ft).
2. Center-punch a completion mark below the fifth
character of the engine compartment VIN:
1HGCXXXXXXXXXXXXX
Center-punch here.
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3. Remove the four horn plate mounting bolts, the
mounting bolt felt washers, and the horn plate. The
felt washers will not be reused.
5. 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 6.
HORN PLATE
MOUNTING BOLTS
MOUNTING BOLT
FELT WASHERS
LOCKNUTS
(Discard.)
(Discard.)
INFLATOR
(Return to
manufacturer.)
AIRBAG
HORN PLATE
FELT TAPE
(Discard.)
6. Use shop air to clean any debris that may be on the
inflator, then remove the inflator from the airbag.
4. 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.
7. Turn over the airbag (inflator side down), and shake
it to remove any debris from the inflator opening.
8. 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.
9. Cover the lower two inflator locknuts with new felt
tape.
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10. 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.
11. 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.
12. Center-punch a completion mark below the fifth
character of the engine compartment VIN:
1HGCXXXXXXXXXXXXX
3. 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 4.
LOCKNUTS
(Discard.)
INFLATOR
(Return to
manufacturer.)
Center-punch here.
13. Give your warranty clerk the inflator 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.
AIRBAG
REPAIR PROCEDURE B – CIVIC, CIVIC HYBRID,
CR-V, AND ODYSSEY
NOTE: Be careful not to damage any parts when
replacing the inflator, and follow the procedure exactly.
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
SERIAL NUMBER
4. 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.
5. Turn over the airbag (inflator side down), and shake
it to remove any debris from the inflator opening.
6. 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).
2. Place the airbag, face down, on a clean shop towel.
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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.
10-039
7. 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.
8. Center-punch a completion mark below the fifth
character of the engine compartment VIN:
1HGCXXXXXXXXXXXXX
Center-punch here.
9. Give your warranty clerk the inflator 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 2002 model year
Odyssey vehicles, 2002–2003 model year Civic
vehicles, 2003 model year Civic Hybrid vehicles and
2002–2004 CR-V 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?
Call any authorized Honda dealer and make an
appointment to have your vehicle inspected. The
dealer will inspect and, if necessary, replace the
driver's airbag inflator. The inspection 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.
10-039
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
Or 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 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 and Civic vehicles, 2002 model year Odyssey
and 2002–2003 CR-V 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.
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What should you do?
You must have your vehicle's driver's airbag inflator
inspected again and, if necessary, replaced; this work
will be done free of charge. Even though you
previously had the driver's airbag inflator inspected,
you must have it inspected again as we have
determined that the prior inspection criteria were
insufficient and your inflator may, in fact, need to be
replaced to avoid the possibility of an over-pressurized
deployment. Call any authorized Honda dealer and
make an appointment to have your vehicle inspected.
The dealer will inspect, and if necessary replace the
driver's airbag inflator. The inspection 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. We apologize for any inconvenience this
may cause, but it is necessary for your safety.
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
Or 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
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