Recall - Driver's Air Bag Over-Pressurization

08-093

February 29, 2012

Applies To:
See VEHICLES AFFECTED

Safety Recall: Driver's Airbag Inflator Can Be Over-Pressurized (Supersedes 08-093, dated December 21, 2011, to revise the information marked by asterisks)

REVISION SUMMARY

*Under VEHICLES AFFECTED, the 2001 Odysseys were removed.*

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.

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.

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.

CORRECTIVE ACTION

Install a driver's airbag inflator kit, then return the original, undeployed inflator as directed.

PARTS INFORMATION

Driver's Airbag Inflator Kit:
P/N 04770-S5A-308**
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.

^ 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 for Fed Ex Air shipping documents and instructions; do not use the documentation included in the airbag inflator kit.

WARRANTY CLAIM INFORMATION

NOTE:
^ To avoid non-payment of warranty claims, the 13-digit 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 original, undeployed inflator must be returned to its supplier. For more information, refer to INFLATOR PACKING AND GROUND SHIPPING INSTRUCTIONS: DEALERS IN THE 48 CONTIGUOUS STATES or INFLATOR PACKING AND AIR SHIPPING INSTRUCTIONS: DEALERS IN ALASKA AND HAWAII.

Operation Number: 7521F4

Flat Rate Time: 0.5 hour

Failed Part: P/N 06770-S84-A11ZA

Defect Code: 5SZ00

Symptom Code: Q9600

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.

4. Remove the four horn plate mounting bolts, the mounting bolt felt washers, and the horn plate. The felt washers will not be reused.

5. Remove and discard the felt tape covering the lower two inflator locknuts.

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 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 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).

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 55A inflator is slightly taller than the S84 inflator, but they are still interchangeable.

10. Cover the lower two inflator locknuts with new felt tape.

11. 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.

12. 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.

13. Center-punch a completion mark below the third character of the engine compartment VIN:

14. Give your warranty clerk the 13-digit inflator serial number you wrote down in step 1. For the warranty claim to be paid, your warranty clerk must enter the appropriate 13-digit serial number in the Diagnostic Trouble Codes field on the warranty claim.

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.

1. Write down the 13-digit 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 13-digit serial number in the Diagnostic Trouble Codes field on the warranty claim.

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.

4. 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.

5. 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 (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).

6. Turn over the airbag (inflator side down), and shake it to remove any debris from the inflator opening.

7. 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 55A inflator is slightly taller than the S84 inflator, but they are still interchangeable.

8. 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.

9. Center-punch a completion mark below the third character of the engine compartment VIN:

10. Give your warranty clerk the 13-digit inflator serial number you wrote down in step 1. For the warranty claim to be paid, your warranty clerk must enter the appropriate 13-digit serial number in the Diagnostic Trouble Codes field on the warranty claim.

INFLATOR PACKING AND GROUND SHIPPING INSTRUCTIONS: DEALERS IN THE 48 CONTIGUOUS STATES

NOTE:

^ Do not deploy the original inflator. Claims for deployed inflators will be charged back to your dealership.

^ There is a 48-hour return shipment objective for the inflator.

^ The following ground shipping instructions are also in the return shipping box (the box the new inflator came in) from kit P/N 04770-55A-308. If you're a dealer in Alaska or Hawaii, call the WPI administrative office for Fed Ex Air shipping documents and instructions.

1. Carefully insert the original inflator into the round opening in the return shipping box (the box that the new inflator came in). Also place a copy ofthe repair order in the box.

2. Close the top flap on the box, then double-tape the the box closed with 2-inch clear packing tape on the entire front seam and the side seams. Press down on the tape for good adhesion.

3. Fill out the FedEx Ground paperwork, and handle it as indicated below:

^ OP-950 Hazardous Materials Certification form:

- At the top, fill in the shipper name, address, and date.

- At the bottom, sign your name on the signature line.

- List the Tracking ID on the right side column of both copies. (The 15-digit Tracking ID is found on the PRP Shipping Label beneath the large bar code to the right of the parenthesis.)

- Keep one copy for dealer records and retain it for 1 year; give the second copy to the Fed Ex Ground driver.

^ Fed Ex Ground PRP Shipping Label:

- Complete all fields in the upper section of the label. (The RA number is not required.)

- Review the instructions on the back and, when the shipment is ready, call for Fed Ex Ground pick up for business locations at 888-777-6040.

^ OP-900 Hazardous Materials form:

- This form requires no further completion; attach the six-part label to the box.

4. Prepare the box and the labels:

^ Remove or black-out any old shipping labels, including the original bar code. Do not remove or black-out any of the hazard marks or labels.

^ Remove the adhesive backing from the PRP and the OP-900 labels, and attach them firmly to the box. Do not cover any of the hazard marks or labels.

NOTE:
Multiple boxes cannot be bundled together.

5. Prior to shipment, make sure that all steps have been properly completed. All boxes must be prepared in accordance with all U.S. Department of Transportation (D~ and FedEx Ground requirements. Incomplete or missing information will result in return to sender and delay of return credit.

6. Retain your copy ofthe OP-950 Hazardous Materials Certification form for at least 1 year. This is required per DOT regulations and for your proof of shipment via Tracking ID.

INFLATOR PACKING AND AIR SHIPPING INSTRUCTIONS: DEALERS IN ALASKA AND HAWAII

NOTE:

^ Do not deploy the original inflator. Claims for deployed inflators will be charged back to your dealership.

^ There is a 48-hour return shipment objective for the inflator.

^ Dealers in Alaska and Hawaii require FedEx Air shipping documents and instructions. Call the WPI administrative office for the documents and instructions.

1. Carefully insert the original inflator into the round opening in the return shipping box (the box that the new inflator came in).

2. Close the top flap on the box, then double4ape the the box closed with 2-inch clear packing tape on the entire front seam and the side seams. Press down on the tape for good adhesion.

3. Fill in this information on the FedEx airbill:

^ In the From section, add your name, address, and telephone number.

^ In the Your Internal Billing Reference section, add your 6-digit dealer number and the VIN.

^ In the Does this shipment contain dangerous goods? section, check the box next to Yes per attached Shipper's Declaration.

^ In the Total Declared Value section, do not add an amount.

4. Fill in this information on the SHIPPER'S DECLARATION FOR DANGEROUS GOODS form:

NOTE:
If not already done, cross out the words CARGO AIRCRAFT ONLY in the TRANSPORTATION DETAILS box at the top left of the form. The shipper may reject your shipment if CARGO AIRCRAFT ONLY is not crossed out.

^ In the Shipper section, add your name and address.

^ In the Air Waybill No. section, add the 12-digit tracking number from the top of the airbill.

^ In the Page of Pages section, add 1 of 1.

^ In the lower right corner of the form, print your name and title, your city, state, and the shipment date. Then add your signature.

5. For your records, keep one copy of the shipper's declaration and the senders copy of the airbill. Insert the completed shippers declaration and the airbill into an adhesive Fed Ex envelope, then attach the envelope to the box, most likely on the bottom. Do not cover any of the hazard markings or labels on the box.

6. Attach a From label (your dealership address) and a To label CFK Holdings, Inc., as listed on the airbill) to the outside of the box. Do not cover any of the hazard markings or labels on the box.

7. Before shipment, make sure steps 1 thru 6 have been completed. Incomplete or missing information may cause the box to be returned to you.

NOTE:
You (the shipper) are responsible for proper packing and document completion before shipping this box. The DOT (U.S. Department of Transportation) will impose substantial fines and/or penalties on the shipper (you) if the packaging, labeling, and/or documentation is/are not properly prepared. The person signing the document must be trained, and the training records must be on file at your place of business. Retain all documents for at least 2 years.

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