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

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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 began February 12, 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

 


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.

 

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

 


For Immediate Release

 

Statement by American Honda Regarding
Hybrid Power Control Unit Software Recall: 2020 Honda Accord Hybrid, 2020
Honda CR-V Hybrid and 2020-2021 Honda Insight 

 

  • 27,838 vehicles are affected in the United States
  • Hybrid PCU software will be updated, for free
  • No reported crashes or injuries related to this issue

 

TORRANCE, Calif. – Dec. 22, 2020 – Honda will voluntarily recall 27,838 model-year

2020 Accord Hybrid, 2020 CR-V Hybrid and 2020-2021 Insight vehicles in the United States to update software in the Hybrid Power Control Unit (PCU). Under certain circumstances, the portion of the PCU that controls charging of the 12 volt accessory battery may malfunction, sending the PCU into a “fail safe” mode, preventing battery charging and activating warning displays for the driver. Since a charged 12 volt battery is required for proper vehicle function, this condition may cause a vehicle to stall while driving, potentially increasing the risk of a crash. Honda has received no reports of crashes or injuries related to this issue.

Honda is announcing this recall to encourage each owner of an affected vehicle to take it to an authorized dealer as soon as they receive notification of this recall from Honda. Mailed notification to owners will begin in late-Feb. 2021. Owners can also

determine if their specific vehicles are included in the recall by visiting www.recalls.honda.com or by calling (888) 234-2138.

# # #

 

Honda ● 1919 Torrance Blvd. ● Torrance, California 90501-2746 ● Phone (310) 783-3170 ● Fax (310) 783-3622
Media Web Site: www.hondanews.com  Consumer Web Site: www.honda.com

 


 

Defect Information Report

 

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

 

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

 

Total number of potentially affected vehicles: 27,838

 

Percentage of affected vehicles that contain the defect: 2%  

 

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.

 

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.

 

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

 

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.

 

Manufacturer’s campaign number: K9E

 


 


4 Affected Products

Vehicles

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

 


9 Associated Documents

Miscellaneous Document – Media Statement

RMISC-20V798-4871.pdf 74.741KB

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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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Recall Quarterly Report #1, 2021-1

RCLQRT-20V798-8181.PDF 211.161KB

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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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ISSUED Owner Notification Letter(Part 577)

RCONL-20V798-9204.pdf 265.505KB

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Recall Quarterly Report #2, 2021-2

RCLQRT-20V798-9144.PDF 211.265KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

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

 


 

Reprogramming

i-HDS Diagnostic Software and J2534 Reprogramming Software

 

Honda J2534 Pass-Thru User Guide

Honda J2534 Pass-Thru Software Download

Latest ECU Software

 

i-HDS Diagnostic Software and J2534 Reprogramming Software

American Honda Motor Co., Inc. ("Honda") offers the i-HDS (Honda Diagnostic System) software suite for the diagnosis and repair of electronic systems on Honda and Acura automobiles, and for the reprogramming of electronic control units (including, but not limited to, ECMs and PCMs). This software provides access to all Honda and Acura vehicle systems (access to the immobilizer security system requires a Security Professional level software subscription and Vehicle Security Professional [VSP] registration with NASTF). To use the i-HDS software, you need to purchase one of our convenient subscription options. In addition, you will need a pass-thru Vehicle Communication Device (VCI) that is compliant with SAE J2534-1 and J2534-2 in order to communicate with the vehicle

 

Vehicle Communication Interfaces (VCI)

The i-HDS software supports the use of a generic pass-thru VCI that is compliant with SAE J2534-1 and J2534-2. However, Honda recommends the Denso DST-i or the Bosch MVCI for use on Honda and Acura vehicles, as Honda has worked closely with these manufacturers to ensure their hardware and our software interact safely and within the J2534-1 and -2 specifications, for both diagnostics and reprogramming. If you choose to use a generic VCI, please carefully consider the customer and technical support options you will receive from your chosen device supplier. Honda does not provide technical or customer support for generic VCI devices.

The VCI Application Table below lists devices that either are approved and supported by Honda or are known to have completed and passed an independent, exhaustive validation program with our i-HDS software suite.

VCI Name Manufacturer Version Information Notes
Firmware J2534 API
DST-i DENSO 2.02.0002* 04.04 This is the current generation VCI used by Honda and Acura dealers. Honda routinely validates the functionality and provides customer support for this device.
DST-nano DENSO 2.02.0002* 04.04 This is the current generation VCI used by Honda Canada Inc. Honda and Acura dealers. Honda routinely validates the functionality and provides customer support for this device.
MVCI Bosch 3.01.60* 04.04 This is the previous generation VCI used by Honda and Acura dealers. Honda routinely validates the functionality and provides customer support for this device.
MongoosePro Honda Safety Recall: Multi-Model Hybrid DC-DC Converter PCU Software Update - 2020-2021 Honda | small light Drew Technologies 1.9.5** 04.04 This company has completed an independent i-HDS validation and claims it to function with the i-HDS software. Honda does not provide ongoing validation, nor customer support for this device.
d-briDGe Pro Dearborn Group 3.303** 04.04 This company has completed an independent i-HDS validation and claims it to function with the i-HDS software. Honda does not provide ongoing validation, nor customer support for this device.

* These versions may have been superseded. Honda provides the latest supported versions to current i-HDS subscribers.
** Version used in validation program. See Terms and Conditions and Important Notice Regarding Reprogramming below for more details.

 

Reprogramming with the J2534 Rewrite Application in i-HDS

Included in the i-HDS software suite is a new reprogramming application called J2534 Rewrite. This application is made available to all subscribers of the i-HDS software suite and replaces the previous generation software, J2534 Honda Pass-thru Reprogramming Software.

This new application is compatible with generic VCIs that comply with SAE J2534. It must be used to reprogram any Honda/Acura vehicle equipped with ECUs that support reprogramming. Refer to the table below for legacy applicability for the programming of ECMs and PCMs. Though system dependent, late-model vehicles may be equipped with other ECUs that support reprogramming as well, e.g. ABS or VSA. J2534 Rewrite must be used to reprogram these control modules, as instructed in an applicable service bulletin.

As shown in this table, not all legacy Honda/Acura models are equipped with a reprogrammable ECM/PCM. Furthermore, all 2007 and later models not listed in the table are fully supported with this application.

Safety Recall: Multi-Model Hybrid DC-DC Converter PCU Software Update - 2020-2021 Honda | small light CarDAQ-Plus 2 Diagnostic Code Reader and J2534 Programming Tool
Safety Recall: Multi-Model Hybrid DC-DC Converter PCU Software Update - 2020-2021 Honda | small light Drew Technologies (DRWCDPLUSKIT) CarDAQ-Plus J2534 Flash Reprogramming Kit
Safety Recall: Multi-Model Hybrid DC-DC Converter PCU Software Update - 2020-2021 Honda | small light CarDAQ-M Modular PassThru J2534 Vehicle Reflash Hardware
Safety Recall: Multi-Model Hybrid DC-DC Converter PCU Software Update - 2020-2021 Honda | small light VSI J2534 ECU Reprogrammer & Diagnostic Adapter
Safety Recall: Multi-Model Hybrid DC-DC Converter PCU Software Update - 2020-2021 Honda | small light MAXIFLASH PRO (ALT-MF2534)

 

DST-i Information:

MVCI Information:

 

techinfo.honda.com

 


 

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