Service Bulletin 10-039

Service BulletinApplies To:10-0392001–02 Accord – Check the iN VIN status for eligibility2001–03 Civic – Check the iN VIN status for eligibility2003 Civic Hybrid – Check the iN VIN status for eligibility2002–04 CR-V – Check the iN VIN status for eligibility2002 Odyssey – Check the iN VIN status for eligibilitySeptember 12, 2014Safety Recall: Replacement Driver’s Airbag Inflator Can BeOver-Pressurized(Supersedes 10-039, dated December 21, 2011, to revise the information marked by the black bars)REVISION SUMMARY Under PARTS INFORMATION, part numbers werechanged. Under INSPECTION PROCEDURE, a step and notewere added.BACKGROUNDA small number of airbag modules with defectiveinflators were sold as replacement parts to replacedeployed or damaged airbags.A manufacturing error can produce over-pressurizationof some replacement driver’s (front) airbag inflatorsduring airbag deployment. If an affected airbagdeploys, the increased internal pressure may causethe inflator casing to rupture. Metal fragments couldpass through the airbag cushion material, possiblycausing an injury or fatality to vehicle occupants.CUSTOMER NOTIFICATIONAll owners of affected vehicles will be sent anotification of this campaign. An example of thecustomer notification is included at the end of thisservice bulletin.Do an iN VIN status inquiry to make sure the vehicleis shown as eligible.In addition, check for a punch mark below the 5thcharacter of the engine compartment VIN. A punchmark in that location means this campaign has alreadybeen completed.Some vehicles affected by this campaign may be inyour used vehicle inventory. These vehicles must berepaired before they are sold.Should a dealership sell an unrepaired vehicle thatsubsequently causes an injury or damage because ofthe recalled item, the dealership will be solelyresponsible to the damaged party, and will be requiredto defend and indemnify American Honda for anyresulting claims. To see if a vehicle in inventory isaffected by this campaign, do a VIN status inquirybefore selling it.CORRECTIVE ACTIONMost vehicles will require an inspection only. Do theINSPECTION PROCEDURE and, if needed, install adriver’s airbag inflator kit, then return the defective,undeployed inflator as directed. 2014 American Honda Motor Co., Inc. – All Rights ReservedATB 46168-52548 (1409)1 of 8CUSTOMER 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 assumethis bulletin applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact anauthorized Honda automobile dealer.

PARTS INFORMATIONNOTE: All the vehicles involved in this campaign requireinspection. However, only a very small number ofthese vehicles require replacement of the airbaginflator compared to the large number of vehiclesthat will require an inspection. Order an airbaginflator kit only if the inspection shows that theinflator must be replaced. Always use new Torx bolts to reinstall theairbags, even on vehicles that do not need a newinflator. The new Torx bolts are coated withthreadlock 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), felttape, felt washers (4), Torx bolts (2), and shippinginstructions.NOTE: The felt tape and the felt washers are usedonly 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 oldinflator to its supplier, ideally within 48 hours of therepair. 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 chargedback to your dealership.*The kit contains FedEx Ground shipping documentsand instructions for the airbag inflator. If you are adealer in Alaska or Hawaii, call the WPI administrativeoffice at 937-642-2737 for FedEx Air shippingdocuments and instructions; do not use thedocumentation included in the airbag inflator kit.2 of 8WARRANTY CLAIM INFORMATIONNOTE: If the airbag inflator is replaced, to avoidnon-payment of warranty claims, the 13-digit serialnumber on the box of the new airbag inflator must beentered in the Diagnostic Trouble Codes field oneach warranty claim. For more information, refer tostep 1 of REPAIR PROCEDURE B. To avoid a warranty claim being charged back toyour dealership, the defective, undeployed inflatormust be returned to its supplier. For moreinformation, refer to INFLATOR PACKING ANDGROUND SHIPPING INSTRUCTIONS: DEALERSIN THE 48 CONTIGUOUS STATES or INFLATORPACKING AND AIR SHIPPING INSTRUCTIONS:DEALERS IN ALASKA AND HAWAII.OP#DescriptionFRT7525A5Remove the driver’s airbag, check theinflator serial number, and reinstall theoriginal airbag.0.37525A6Remove the driver’s airbag, check theinflator serial number, and REPLACE theairbag inflator.0.5Failed Part:Defect Code:Symptom Code:Skill Level:P/N 06770-S84-A11ZA5US00R5400Repair TechnicianINSPECTION PROCEDURENOTE: If, before removing the airbag, you suspect thatit may not be the correct airbag for the vehicle or acounterfeit, do not remove the airbag. Contact yourDPSM for assistance.1. Remove the driver’s airbag: Refer to page 23-278 of the 1998–2002 AccordService Manual, or Refer to page 23-137 of the 2001–2005 CivicService Manual, or Refer to page 23-112 of the 2003–2004 CivicHybrid Service Manual, or Refer to page 23-131 of the 2002–2004 CR-VService Manual, or Refer to page 23-368 of the 1999–2004 OdysseyService Manual, or Online, enter keywords DRIVER AIR, and selectDriver’s Airbag Replacement from the list.10-039

2. Visually inspect the airbag and the inflator for anyunusual writing or markings. If there is nothing unusual about the airbag or theinflator, go to step 3. If there is unusual markings, like an incorrectlabel or a model year written in marker, theairbag and inflator may not be the correct airbagand/or inflator for the vehicle or it may be acounterfeit part. For more information aboutcounterfeit airbags, you can refer to safercar.gov,enter keywords MANAGING COUNTERFEIT,and select Recommended Dealer Guidance forManaging Counterfeit Air Bags from the list. Ifyou suspect that the airbag or inflator iscounterfeit, do not continue this procedure.Contact your DPSM for assistance.3. Determine if the airbag is made by Autoliv orTakata by comparing inflators to those in theimages below.NOTE: The Autoliv serial number label is differentfrom the Takata label.AUTOLIV (not 3-M17917Q4Locate serialnumber here. If the airbag is made by Autoliv, the airbag is OK.Go to REPAIR PROCEDURE A. If the airbag is made by Takata, go to step 3.10-0393 of 8

4. Locate the serial number on the bottom of theairbag. Make sure you also have the VIN, then goto 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 theairbag inflator must be replaced. If the airbag is OK,go to REPAIR PROCEDURE A. If the airbaginflator must be replaced, go to REPAIRPROCEDURE B.REPAIR PROCEDURE B – ACCORD ONLYNOTE: Be careful not to damage any parts whenreplacing the inflator, and follow the procedure exactly.1. Write down the 13-digit serial number located onthe right side of the new inflator’s box. For thewarranty claim to be paid, your warranty clerk mustenter this 13-digit serial number in the DiagnosticTrouble Codes field on the warranty claim.INFLATOR BOX13-DIGIT SERIAL 17917Q4Locate serialnumber here.2. Place the airbag, face down, on a clean shop towel.REPAIR PROCEDURE A1. Reinstall the airbag using new Torx bolts, andtorque the bolts to 10 N.m (7.0 lb-ft).2. Center-punch a completion mark below the fifthcharacter of the engine compartment VIN:1HGCXXXXXXXXXXXXXCenter-punch here.4 of 810-039

3. Remove the four horn plate mounting bolts, themounting bolt felt washers, and the horn plate. Thefelt washers will not be reused.5. Using needle-nose Vise Grips, remove the fourlocknuts from the inflator. The locknuts will not bereused.NOTE: Do not remove the inflator from the airbaguntil you complete step 6.HORN PLATEMOUNTING BOLTSMOUNTING BOLTFELT WASHERSLOCKNUTS(Discard.)(Discard.)INFLATOR(Return tomanufacturer.)AIRBAGHORN PLATEFELT TAPE(Discard.)6. Use shop air to clean any debris that may be on theinflator, then remove the inflator from the airbag.4. Remove and discard the felt tape covering thelower two inflator locknuts.NOTE: Do not allow any debris to enter the inflatoropening in the airbag. Do not deploy the inflator. The inflator must bereturned to its supplier in the box the new inflatorcame in (see INFLATOR PACKING ANDGROUND SHIPPING INSTRUCTIONS:DEALERS IN THE 48 CONTIGUOUS STATESor INFLATOR PACKING AND AIR SHIPPINGINSTRUCTIONS: DEALERS IN ALASKA ANDHAWAII).7. Turn over the airbag (inflator side down), and shakeit to remove any debris from the inflator opening.8. Install the new inflator in the airbag with newlocknuts. Torque the locknuts to 3.9 N.m (2.8 lb-ft,34 lb-in).NOTE: The new inflator is slightly taller than theoriginal inflator, but they are still interchangeable.9. Cover the lower two inflator locknuts with new felttape.10-0395 of 8

10. Reinstall the horn plate with new felt washers on itsmounting bolts. Torque the mounting bolts to3.4 N.m (2.5 lb-ft, 30 lb-in), then make sure thehorn 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 selectDriver’s Airbag Replacement from the list.12. Center-punch a completion mark below the fifthcharacter of the engine compartment VIN:1HGCXXXXXXXXXXXXX3. Using needle-nose Vise Grips, remove the fourlocknuts from the inflator. The locknuts will not bereused.NOTE: Do not remove the inflator from the airbaguntil you complete step 4.LOCKNUTS(Discard.)INFLATOR(Return tomanufacturer.)Center-punch here.13. Give your warranty clerk the 13-digit inflator serialnumber you wrote down in step 1. For the warrantyclaim to be paid, your warranty clerk must enter theappropriate 13-digit serial number in theDiagnostic Trouble Codes field on the warrantyclaim.AIRBAGREPAIR PROCEDURE B – CIVIC, CIVIC HYBRID,CR-V, AND ODYSSEYNOTE: Be careful not to damage any parts whenreplacing the inflator, and follow the procedure exactly.1. Write down the 13-digit serial number located onthe right side of the new inflator’s box. For thewarranty claim to be paid, your warranty clerk mustenter this 13-digit serial number in the DiagnosticTrouble Codes field on the warranty claim.INFLATOR BOX13-DIGIT SERIAL NUMBER4. Use shop air to clean any debris that may be on theinflator, then remove the inflator from the airbag.NOTE: Do not allow any foreign objects to enter theinflator opening in the airbag. Do not deploy the inflator. The inflator must bereturned to its supplier in the box the new inflatorcame in (see INFLATOR PACKING ANDGROUND SHIPPING INSTRUCTIONS:DEALERS IN THE 48 CONTIGUOUS STATESor INFLATOR PACKING AND AIR SHIPPINGINSTRUCTIONS: DEALERS IN ALASKA ANDHAWAII).5. Turn over the airbag (inflator side down), and shakeit to remove any debris from the inflator opening.2. Place the airbag, face down, on a clean shop towel.6. Install the new inflator in the airbag with newlocknuts. Torque the locknuts to 3.9 N.m (2.8 lb-ft,34 lb-in).NOTE: The new inflator is slightly taller than theoriginal inflator, but they are still interchangeable.6 of 810-039