Model - Dates of Manufacture
Honda Insight 2020 10/21/2019 to 05/13/2020
Honda Insight 2021 05/18/2020 to 06/01/2020
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.
Percentage of affected vehicles that contain the defect:
2%
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 over voltage and shut down the DC-DC converter.
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 re-creation testing in different hybrid electric vehicle models installed with the same PCU and DC-DC converter.
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.
The dealer will update the PCU software program for free. Software update is available as of December 17, 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).
hondanews.com