Recall - Air In VSA Modulator Assembly
10-017May 14, 2010
Applies To:
2007 Element - ALL
2008 Element 2WD - From VIN 5J6YH1...8L000001 thru 5J6YH1...8L015906
2008 Element 4WD - From VIN 5J6YH2...8L000001 thru 5J6YH2...8L018137
2007-08 Odyssey - ALL
Safety Recall:
Air In VSA Modulator-Control Unit Causes Low/Soft Brake Pedal
(Supersedes 10-017, dated April 17, 2010, to revise the information marked by the black bars and asterisks)
REVISION SUMMARY
*^ Under WARRANTY CLAIM INFORMATION, the flat rate times were changed to reflect HDS use with software version 2.021.019 (CM database update 08-APRIL-2010) or later.
^ Under REPAIR PROCEDURE, a note was added, and step 4 was changed to reflect HDS use with software version 2.021.019 (CM database update 08-APRIL-2010) or later.*
BACKGROUND
The two plugs that seal the sides of the VSA modulator-control unit may allow a small amount of air to enter the brake system after system initialization. Over time, enough air can enter the modulator to make the brake pedal lower and softer than normal. In rare cases, excessive air entering the VSA modulator-control unit could lower the vehicle's braking performance, increasing the risk of a crash.
CUSTOMER NOTIFICATION
Owners of affected vehicles will receive a notification of this campaign. An example of the customer notification is at the end of this service bulletin.
Not all vehicles in the Applies To range are affected by this campaign. To verify vehicle eligibility, you must check at least one of these items:
^ The customer has a notification letter.
^ The vehicle is shown as eligible on a VIN status inquiry.
In addition, check for a punch mark above the fifth 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. As a matter of federal law, 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
Bleed the brake system using the special procedure in this service bulletin, then install two modulator sealing caps over the two plugs on the sides of the VSA modulator-control unit.
PARTS INFORMATION
Modulator Sealing Cap (two required):
P/N 57119-SHJ-305
TOOL INFORMATION
Modulator Sealing Cap Installer: T/N 07AAB-SHJ-A120
(Includes two tools)
These tools were sent to all dealers in April 2010.
To order more modulator sealing cap installers, use
normal parts ordering procedures.
REQUIRED MATERIALS
Honda Genuine DOT 3 Brake Fluid:
P/N 08798-9008
(One bottle repairs one vehicle.)
Dow Corning Toray SE 9186 White RTV Silicone:
P/N 08734-0012
(One tube repairs about 40 vehicles.)
Isopropyl Alcohol (commercially available)
WARRANTY CLAIM INFORMATION
Failed Part: Element P/N 57110-SCV-A11
Odyssey: P/N 57110-SHJ-964
Defect Code: 5VM00
Symptom Code: R3000
Template ID: 10-017A (Element)
10-017B (Odyssey)
Skill Level: Repair Technician
REPAIR PROCEDURE
NOTE:
^ Before you do steps 1 thru 4, make sure the vehicle's battery is fully charged and in good condition. If needed, attach a battery charger.
^ Top-off the brake fluid reservoir as needed during the bleeding procedures (steps 3, 4, and 5). Never let the brake fluid reservoir go dry.
* ^ Make sure the HDS is loaded with software version 2.021.019 (CM database update 08-APRIL-2010), or later.*
1. Connect the HDS to the vehicle's DLC.
2. On the HDS, go to the ABS/TCS/VSA Functional Tests screen.
3. Prime the VSA modulator pump:
^ Press and hold the brake pedal.
^ Select Left Front VSA on the HDS, and continue holding the brake pedal until the test is finished.
- During the test, you don't need to be close to the wheel, and you don't need to rotate the LF wheel. When these screen prompts appear on the HDS, just press the ENTER button.
^ Press and hold the brake pedal again.
^ Select Right Front VSA on the HDS, and continue holding the brake pedal until the test is finished.
- During the test, you don't need to be close to the wheel, and you don't need to rotate the RF wheel. When these screen prompts appear on the HDS, just press the ENTER button.
4. Bleed the VSA modulator:
NOTE:
Do not press the brake pedal during this step.
^ Raise the vehicle, then remove the front wheels.
* ^ Select Modulator Bleed Function Test or Modulator Bleed on the HDS, then follow the HDS screen prompts to bleed the VSA modulator.*
5. Manually bleed the brake system:
^ With the help of an assistant, manually bleed the front brake calipers until you get clear fluid and no bubbles. This usually takes at least two bleeding procedures.
^ Manually bleed the rear brake calipers until you get clear fluid and no bubbles. This usually takes at least five bleeding procedures.
^ Reinstall the front wheels, then lower the vehicle.
6. Odyssey only: Remove the air cleaner housing:
^ Disconnect the MAF sensor 5P connector.
^ Remove the bolts and the harness clamps.
^ Remove the housing.
7. Element only: Detach the power steering reservoir from its mount on the fender, then move it out of the way.
8. Disconnect the VSA modulator-control unit 47P connector by pressing the release tab, and then pulling down (Odyssey) or up (Element) on the orange release lever; the connector then disconnects itself.
NOTE:
^ Do not force the lever; if you break it, you need to replace the entire engine wire harness.
^ If the lever won't move, make sure to press the release tab before trying to move it. If needed, wiggle the connector while moving the lever to free up the white slides on the connector.
9. Moisten a clean shop towel with isopropyl alcohol, then use the towel to thoroughly clean the two plugs and the surrounding areas on the sides of the VSA modulator-control unit. Allow the alcohol to dry before you continue.
NOTE:
If there is corrosion on or near the modulator plugs, remove it with a scouring pad, then thoroughly clean the area with a shop towel moistened with isopropyl alcohol. Allow the alcohol to dry before you continue.
10. Insert a sealing cap into the end of the sealing cap installer, with the cupped side of the cap facing up.
11. Fill the sealing cap half full with Dow Corning bray SE 9186 White RTV Silicone.
NOTE:
^ Dow Corning bray SE 9186 White RTV Silicone is the only sealant approved for this repair. Do not use any other type or brand of sealant.
^ Keep the silicone sealant tube capped when it's not being used.
12. Center the sealing cap installer over the front plug on the VSA Modulator-control unit, and quickly press the cap squarely onto the plug.
13. Carefully tilt the installer down at an angle to remove it from the cap.
14. Inspect the cap installation:
^ The cap should fit squarely on the plug, flush to the modulator body.
^ Make sure there's a continuous bead of silicone sealant around the cap.
^ If any sealant runs from the cap, wipe off the run, but do not wipe off the cap.
^ If the sealant gets on any other parts, wipe it off immediately.
15. Repeat steps 10 thru 14 to install the second cap on the rear plug of the VSA modulator-control unit.
NOTE:
Allow the silicone sealant to cure for 15 minutes before driving the vehicle. Do not touch the caps when the sealant is curing.
16. Reconnect the VSA modulator-control unit 47P connector:
^ Align the connecting surface of the connector and the VSA modulator-control unit, and press the connector against the modulator.
^ Pull up (Odyssey) or down (Element) on the orange release lever until it clicks into place.
^ Make sure the connector is fully seated.
17. Element only: Reattach the power steering reservoir to its mount on the fender.
18. Odyssey only: Reinstall the air cleaner housing.
19. Center-punch a completion mark above the fifth character of the engine compartment VIN:
Disclaimer