Safety Recall: Multi-Model Hybrid DC-DC Converter PCU Software Update – 2020-2021 Honda

December 17, 2020 NHTSA CAMPAIGN NUMBER: 20V798000

Loss of Drive Power from DC-DC Converter Shutdown

A loss of drive power can increase the risk of a crash.

 

NHTSA Campaign Number: 20V798

Manufacturer Honda (American Honda Motor Co.)

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 27,838

 

Summary

Honda (American Honda Motor Co.) is recalling certain 2020 CR-V Hybrid, Accord Hybrid, and 2020-2021 Insight vehicles. The DC-DC converter may shut down and prevent the 12-volt battery from recharging, possibly resulting in a loss of drive power.

 

Remedy

Honda will notify owners, and dealers will update the power converter unit (PCU) software, free of charge. The recall is expected to begin February 25, 2021. Owners can contact Honda customer service at 1-888-234-2138. Honda’s number for this recall is K9E.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Honda has a Recall

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Service Bulletin

A20-124
December 18, 2020
Version 1

 

Safety Recall: Multi-Model Hybrid DC-DC Converter PCU Software Update

 

AFFECTED VEHICLES

Year	Model	Trim Level	VIN Range
2020	Accord Hybrid	ALL	Check the iN VIN status for eligibility.
2020	CR-V Hybrid	ALL	Check the iN VIN status for eligibility.
2020-21	Insight	ALL	Check the iN VIN status for eligibility.

 

BACKGROUND

Due to programming issues in the Power Control Unit (PCU), the DC-DC converter unit may generate excessive voltage, triggering the failsafe mode in the power supply control program. In this condition, the DC-DC converter unit is unable to supply power to the 12V battery, which may result in the illumination of the 12V battery warning light and a warning message to be displayed. If the vehicle continues to be driven in this condition, it may decrease driver assistance and could eventually stop running.

 

CUSTOMER NOTIFICATION

Owners of affected vehicles will be sent a notification of this campaign.

Do an iN VIN status inquiry to make sure the vehicle is shown as eligible.

Some vehicles affected by this campaign may be in your new or used vehicle inventory.

Failure to repair a vehicle subject to a recall or campaign may subject your dealership to claims or lawsuits from the customer or anyone else harmed as a result of such failure. Before selling a vehicle in inventory, always check if it is affected by a safety recall by conducting a VIN status inquiry.

 

CORRECTIVE ACTION

Update the PCU (EV/HEV/IMA Motor System) software.

 

WARRANTY CLAIM INFORMATION

Operation Number	Description	Flat Rate Time	Defect Code	Symptom Code	Template ID	Failed Part Number
1185B6	Update the PCU software (includes CKP pattern learn).	0.3 hr	6PU00	K9E00	A20124A	1B000-6L2-A21

Skill Level: Repair Technician

 

SOFTWARE INFORMATION

NOTE

Unnecessary or incorrect repairs resulting from a failure to update the diagnostic and reprogramming software are not covered under warranty.

Before beginning the repair, make sure all diagnostic and reprogramming software are updated as listed.

i-HDS Software Version	1.006.013 or later
HDS Software Version	3.104.014 or later
J2534 Rewrite Software Information
PC Application Version	1.2.1.1
Database Update	10-DEC-2020 or later
NoticeDB Version	09-DEC-2020 or later

Update only the systems and software listed in this service bulletin.

American Honda has validated and approved the Denso DST-i as the vehicle communication interface (VCI) to support this service bulletin.

For more information about updating vehicle systems, refer to service bulletin 01-023, Updating Control Units/Modules.

Year/Model	Vehicle System	Program ID (or later)
2020 CR-V Hybrid	PCU	1K021-5RD-A020
2020 Accord Hybrid	PCU	1K021-6C2-A220
2020 Insight	PCU	1K021-6L2-A220
2021 Insight	PCU	1K021-6L2-A420

 

REPAIR PROCEDURE

NOTICE

• Make sure the 12-volt battery is fully charged before starting an update.
• Connect a fully charged jumper battery to the vehicle, and leave it connected during the entire procedure to maintain steady voltage.
• Do not use the GR8 because the vehicle requires a steady electrical current.
• Control module failure caused by the improper completion of a software update (early key cycle, low battery voltage, disconnected DLC cable, etc.) is not covered by warranty.
• If an error occurs during the update or the i-HDS freezes, do not disconnect the battery or turn the ignition to OFF. Reboot the i-HDS, and start over.
• To prevent control unit damage, do not operate anything electrical (headlights, audio system, brakes, A/C, power windows, door locks, etc.) during the update.
• Warranty reimbursement for technician labor is not allowed for routine checking/installation of any available software update.

 

NOTE

This update will not require entering a service bulletin number.

1. Update the PCU software using the J2534 Rewrite software with the DST-i. Refer to service bulletin 01-023, Updating Control Units/Modules.
2. Do the CKP pattern learn procedure. Refer to the service information.

 

END

 

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December 17, 2020

 

Mr. Jeffrey Giuseppe
Associate Administrator for Enforcement
National Highway Traffic Safety Administration
Attn: Recall Management Division (NVS-215)
1200 New Jersey Avenue, SE
Washington, D.C. 20590

 

Re:
Part 573, Defect Information Report
2020 Model Year Honda Accord Hybrid
2020 Model Year Honda CR-V Hybrid
2020-2021 Model Year Honda Insight
Power Converter Unit / DC-DC Converter

 

Dear Mr. Giuseppe:

In accordance with the National Traffic and Motor Vehicle Safety Act and 49 CFR Part 573 Defect and Noncompliance and Responsibility Reports, Honda is submitting the enclosed Defect Information Report regarding a safety recall of certain 2020-2021 model year Honda Accord Hybrid, CR-V Hybrid, and Insight vehicles to address a defect with the power converter unit / DC-DC converter.

 

If you have any questions about this report, please feel free to contact me.

 

Sincerely,

 

AMERICAN HONDA MOTOR CO., INC.

 

Jeff Chang
Senior Manager
Product Regulatory Office

JC:wvt

 

Defect Information Report

 

573.6(c)(1)

Name of manufacturer:

Honda Manufacturing of Indiana, LLC
Honda of America Mfg., Inc.

 

Manufacturer’s agent:

Jeff Chang
American Honda Motor Co., Inc.
1919 Torrance Blvd.
Torrance, CA  90501-2746

 

573.6(c)(2)

Identification of potentially affected vehicles:

Make/Model	Model Year	Dates of Manufacture	Number of Vehicles
Honda Accord Hybrid	2020	10/21/2019 to 06/11/2020	10,385
Honda CR-V Hybrid	2020	01/16/2020 to 06/05/2020	4,728
Honda Insight	2020	10/21/2019 to 05/13/2020	12,601
Honda Insight	2021	05/18/2020 to 06/01/2020	124

 

Description of the basis for the determination of the recall population:

The recall population was determined based on manufacturing records. The manufacturing range reflects all possible vehicles that could potentially experience the problem.

 

Description of how the vehicles being recalled differ from similar vehicles not included in the recall:

Only certain vehicles with a power converter unit (PCU) installed that contains transistors with a high concentration of dopant injections are included in the recall. Similar vehicles not included in the recall had PCUs installed that contain transistors with an appropriate concentration of dopant injections.

 

Identification of affected component:

Component: PCU Assy.

 

Part No.:

Accord Hybrid	2020	1B000-6C2-A21	1B000-6C2-C21
CR-V Hybrid	2020	1B000-5RD-A02
Insight	2020	1B000-6L2-A21	1B000-6L2-C21
	2021	1B000-6LS-A41	1B000-6LS-C41

 

Country of Origin: Japan

Manufacturer: Mitsubishi Electric Corporation

 

573.6(c)(3)

Total number of potentially affected vehicles: 27,838

 

573.6(c)(4)

Percentage of affected vehicles that contain the defect: 2%  

 

573.6(c)(5)

Defect description:

The DC-DC converter on certain PCUs contain transistors with a high concentration of dopant injections. The increased doping, along with cold ambient temperatures, could amplify the voltage output and shut down the DC-DC converter due to overvoltage, which prevents the 12volt battery from recharging. If vehicle operation continues after illumination of the 12-volt battery system charging indicator, a depleted 12-volt battery can restrict or eliminate motive power, increasing the risk of a crash.

 

573.6(c)(6)

Chronology:

November 2019 to March 2020

Honda launched investigations in the U.S. and several global markets that received reports of

DC-DC converter failure. The supplier’s assembly processes were evaluated, and Honda found that there were no specifications for the application of dopant injections to the transistors on the DC-DC converter. The supplier began monitoring for high concentrations of dopant injections in the transistors, which Honda identified to be the cause of the increased voltage in the DC-DC converter in low ambient temperatures. The increased voltage inadvertently activated a test circuit only used during vehicle manufacturing, which amplified the DC-DC converter voltage output. Voltage output above the system’s threshold could result in overvoltage and shut down the DC-DC converter.

 

July to November 2020

Honda examined the multitude of scenarios potentially occurring due to DC-DC converter failure and the inability to recharge the 12-volt battery. The failure mode was also confirmed during recreation testing in different hybrid electric vehicle models installed with the same PCU and DCDC converter.

 

December 10, 2020

Honda determined that a defect related to motor vehicle safety existed and decided to conduct a safety recall.

As of December 10, 2020, Honda has received 53 warranty claims, 65 field reports, and no reports of crashes or injuries related to this issue.

 

573.6(c)(8)(i)

Program for remedying the defect:

Registered owners of all affected vehicles will be contacted by mail and asked to take their vehicle to an authorized Honda dealer. The dealer will update the PCU software program for free. Owners who have paid to have these repairs completed at their own expense will be eligible for reimbursement, in accord with the recall reimbursement plan on file with NHTSA.  573.6(c)(8)(ii)

The estimated date to start notification to dealers: December 18, 2020

The estimated date to start notifications to owners: February 25, 2021

 

573.6(c)(10)

Representative copies of all notices, bulletins and other communications:

A copy of the dealer service bulletin, the final customer notification letter, and other dealer communications will be submitted to your office as soon as possible.

A draft of the owner notification letter will be submitted to your office as soon as possible.

 

573.6(c)(11)

Manufacturer’s campaign number: K9E

 

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4 Affected Products

Vehicles

MAKE	MODEL	YEAR
HONDA	ACCORD HYBRID	2020
HONDA	CR-V HYBRID	2020
HONDA	INSIGHT	2020-2021

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5 Associated Documents

Defect Notice 573 Report

RCLRPT-20V798-5921.PDF 216.921KB

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Manufacturer Notices(to Dealers,etc) – Stop Sale/Safety Recall: 2020-2021 Multi-Model DC-DC Converter

RCMN-20V798-1078.pdf 194.934KB

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Miscellaneous Document – Part 573 Defect Information Report

RMISC-20V798-7476.pdf 357.168KB

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Remedy Instructions and TSB

RCRIT-20V798-4148.pdf 75.149KB

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Recall Acknowledgement

RCAK-20V798-1007.pdf 244.882KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V798&docType=RCL

For the most up to date documents from NHTSA for this Recall, click the lick above

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Last update on 2021-04-09 / Affiliate links / Images from Amazon Product Advertising API