SR-17-004REV
Service Bulletin Details
Public Details for: SR-17-004REV
This is a revised safety recall bulletin sent to dealers informing them of new takata inflator return procedures.
Models from 2004
2004 MITSUBISHI LANCER |
2004 MITSUBISHI LANCER EVOLUTION |
2004 MITSUBISHI LANCER SPORTBACK |
SAFETY RECALL BULLETIN SUBJECT: LANCER PASSENGER SIDE FRONTAL AIR BAG INFLATOR − SAFETY RECALL CAMPAIGN - REVISED No: SR−17−004 REV DATE: June 2023 2004−06 Lancer, Lancer Sportback, and Lancer Evolution MODEL: CIRCULATE TO: [ X ] GENERAL MANAGER [ X ] PARTS MANAGER [ X ] TECHNICIAN [ X ] SERVICE ADVISOR [ X ] SERVICE MANAGER [ X ] WARRANTY PROCESSOR [ X ] SALES MANAGER This bulletin supersedes SR-17-004 issued October 2017, to update the Inflator Returns section. Revisions are indicated by: PURPOSE This campaign bulletin instructs dealers to replace the passenger side frontal air bag inflator with one manufactured by a different supplier, and return the subject air bag inflator per the instructions at the end of this bulletin. BACKGROUND Based upon a Defect Information Report submitted to the National Highway Traffic Safety Administration by TK Holdings (Takata), MMNA is recalling certain 2004-2006 Lancer and Lancer Evolutions, and certain 2004 Lancer Sportback vehicles. Affected vehicles are equipped with a specific type of passenger side frontal air bag inflator provided by Takata that could be susceptible to rupture, due to excessive internal pressure, during a normal air bag deployment event. This condition is more likely to occur if the vehicle has been exposed to high levels of absolute humidity for an extended period of time. AFFECTED VEHICLES 2004 - 2006 Lancer vehicles built August 4, 2003 - August 28, 2006 2004 - 2006 Lancer Evolution vehicles built February 11, 2004 - September 1, 2006 2004 Lancer Sportback vehicles built August 4, 2003 - January 23, 2004 IMPORTANT Affected new or used inventory vehicles must be repaired before the vehicle is sold/delivered. Dealers must check their inventory vehicles’ VINs on the Warranty Super Screen to verify whether the vehicle is involved in this recall campaign. It is a violation of Federal law for a dealer to sell/ deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by the notification under a sale or lease until the defect or noncompliance is remedied. REQUIRED OPERATIONS Before starting this campaign procedure, CHECK THE WARRANTY SUPERSCREEN to verify if the vehicle is an affected VIN for this campaign and this campaign procedure has not already been completed. Copyright 2023, Mitsubishi Motors North America, Inc. Continued The information contained in this bulletin is subject to change. For the latest version of this document, go to the Mitsubishi Dealer Link, MEDIC, or the Mitsubishi Service Information website (www.mitsubishitechinfo.com). 6/23/2023 Page 1 of 22 (5323/4602) REQUIRED EQUIPMENT • Trim stick • VCI (Vehicle Communication Interface) or VCI Lite - MB991824 or MB992744. • MEDIC Laptop/Tablet with A/C power adapter - 520924, or 547708. • MUT-III main harness 'B' (red or black connector at the DLC end) - MB991911 or MB992746. • USB 2.0 cable - MB991827 or MB992747. REMOVAL PROCEDURE Never attempt to disassemble or repair the air bag modules. If faulty, replace ! WARNING it. Do not drop the air bag modules or allow contact with water, grease or oil. Replace it if a dent, crack, deformation or rust is detected. ! WARNING The air bag modules should be stored on a flat surface and facing upward. Do not place anything on top of it. ! WARNING ! WARNING Do not expose the air bag modules to temperatures over 93o C (200o F). INSULATING TAPE BATTERY 1. Record the radio station presets. Disconnect the negative (-) battery terminal and insulate the terminal with electrical tape. BATTERY CABLE (–) Wait at least 60 seconds after disconnecting the battery cable before doing any further work to prevent accidental air bag deployment. ! WARNING ! WARNING Battery posts, terminals, and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING. 2. 6/23/2023 Remove the front left and right A-pillar trims. Page 2 of 22 (5323/4602) 3. Remove the instrument panel. 6/23/2023 Page 3 of 22 (5323/4602) CLIP AND CLAW POSITION NOTE (1) •: CLIP P OSITIONS (2) ¢: CLAW P OSITIONS CLIP D COLUMN COVER � INSTRUMENT PANEL CLAW CLAW -- INSTRUMENT PANEL SECTION E-E SECTION D-D � �l SECTION F-F CLIP P'c�w CLIP �\ � CLAW G >-_ :STRUMENTPANEL INSTRUMENT PANEL � INSTRUMENT PANEL SECTION G-G SECTION H -H CLIP � II SECTION 1-1 INSTRUMENTPANEL bd 6/23/2023 SECTION C-C SECTION B-B SECTION A-A STRUMENTPANEL � /� INSTRUMENT PANEL CLAW Page 4 of 22 CLIP � (5323/4602) 4. Remove the distribution duct from the instrument panel. ! CAUTION removal. Do not damage the air bag or the instrument panel during air bag module 5. The front passenger side air bag module is secured to the instrument panel in a flexible plastic enclosure. Insert a flat head screwdriver and disengage the mounting hooks to dislodge the module from the enclosure. 6/23/2023 Page 5 of 22 (5323/4602) AIR BAG INFLATOR REPLACEMENT PROCEDURE 1. Place the air bag module on a clean work bench covered with a new, clean cloth/sheet with the air bag facing down. NOTE: The airbag module (especially the air bag) must be protected from adhesives, dirt, dust, and sharp objects. NOTE: The protective foam on the air bag module may be brittle. Ensure foam debris is immediately removed from the work area to maintain a contaminant-free work environment. clip 6/23/2023 2. Use pliers to pinch the hooks and remove the wiring clip from the bracket. 3. Remove and discard the 2 circled nuts. Page 6 of 22 (5323/4602) 4. Stopper plate ! CAUTION Remove and keep the stopper plate for reuse. To avoid accidental dropping of the airbag, do not remove the nuts in Step 5. 5. Loosen, but do not remove, the circled nuts. 6. Gently pull and straighten the wires so it is in line with the inflator. This will prevent the wire from contacting the edges of the inflator housing during removal. of wiring ! CAUTION 6/23/2023 Do not damage the wiring harness during inflator removal. Page 7 of 22 (5323/4602) 7. Gently push the inflator with your finger in the indicated direction while gently pulling (straightening) the wire to remove the inflator. Do not detach the wiring harness from the inflator to avoid the risk of accidental air bag deployment. ! WARNING Unpackage the air bag inflator kit, remove and verify the contents: a. (1) Replacement inflator with tapes and cloth cover. b. (6) Felt tapes c. (1) Replacement wiring harness d. (1) Caution label e. (1) Old stopper plate (not in box) from Step 4 f. (4) Replacement nuts - M5 g. (1) CE certification label 9. Package the old inflator, with its wiring harness still attached, into the box. Ensure the items are correctly wrapped with the old wrapping to protect from damage during shipping. 8. a b c d g e 6/23/2023 Page 8 of 22 (5323/4602) connector 10. Begin insertion of the replacement inflator into the housing as shown, with the electrical connector side going in first. NOTE: Make sure that the rib faces down. NOTE: Make sure that the cloth and tapes do not fall off. direction Rib NG Rib NG 11. Fully insert the inflator. Non-connector side plate ! CAUTION 6/23/2023 12. Ensure that the inflator makes complete contact with the housing plate. If needed, rotate the inflator so that the inflator's flat section is parallel with the housing plate. 13. Reinstall the stopper plate. 14. Ensure the inflator is seated correctly in the housing, and there are no gaps on either end. plate Stopper plate CAUTION: Do NOT incorrectly insert the inflator. plate Do not reuse the old nuts. Page 9 of 22 (5323/4602) 15. Install and lightly tighten the (2) nuts holding the stopper plate. 16. Remove and discard (2) nuts near the housing plate side. 17. Install (2) new nuts and lightly tighten them. Stopper plate plate 18. In the illustrated order, torque all (4) nuts to 34.5 + 3.5 in-lb (3.9 + 0.4 Nm). 19. Match the wiring harness connector's plug with the shape in the electrical connector socket. ! WARNING Do not touch the inflator’s electrical connector. ! WARNING Do not reuse the old wiring harness. 6/23/2023 Page 10 of 22 (5323/4602) 20. Press the wiring harness connector firmly into the electrical connector socket. NOTE: A faint click will be heard when the connector is inserted correctly. Harness connector 21. Ensure the harness connector is completely inserted into the electrical connector socket by gently pulling on the harness connector. Measure the distance between the inflator and the harness connector to ensure it is less than 1 mm. If the distance is more than 1 mm, the connection is NG. 22. Clip the wiring harness to the mounting bracket as shown. NG 6/23/2023 CAUTION: Do not connect the wiring harness in the incorrect direction. Page 11 of 22 (5323/4602) 23. Confirm that the wiring harness clip has been fully inserted. 24. Use a clean, dry cloth or towel to wipe the old caution label. 25. Affix the new caution label directly over the old caution label. 6/23/2023 Page 12 of 22 (5323/4602) 26. Apply degreaser onto a cloth or towel and wipe the outlined area. 27. Affix the CE certification label on the degreased area. 28. Prepare felt tapes for application to the outlined locations. A B a. Note the taping area for Position A and Position B. A A 6/23/2023 B Page 13 of 22 (5323/4602) b. Tape (4) Position A as illustrated. c. d a d b g REINSTALLATION PROCEDURE Tape (2) Position B as illustrated. 29. Confirm the following items: a. There is no gap between the inflator and housing plate or stopper plate. b. Inflator flat section is parallel with housing plate. c. Harness connector correctly connected to inflator. d. The nuts (silver finish) are properly torqued to 34.5 + 3.5 in-lb (3.9 + 0.4 N-m). e. Caution label correctly affixed. f. CE certification label affixed. g. (6) felt tapes applied. h. (4) old nuts discarded. i. There are no scratches or debris/dirt on the air bag. j. Harness connector correctly clipped. e 1. 2. Reinstall the passenger air bag module to the instrument panel. Reinstall the distribution duct to the instrument panel. 3. 4. Reinstall the instrument panel. Remove the electrical tape and reconnect the negative (-) battery terminal. Tighten the clamp nut securely. NOTE: Reinstall the center bolts first to align the distribution duct. 5. Turn the ignition switch to the “ON” position. If the “SRS” warning light illuminates continuously (does not extinguish after seven seconds), troubleshoot per the applicable service manual, Group 52B Supplemental Restraint System (SRS) > SRS Air Bag Diagnosis > SRS Warning Light Check. 6. Input radio station presets and set the clock, if applicable. ERASE AND READ DTCs FROM ALL ECUs 7. Connect the equipment as follows: • Turn the laptop computer/tablet on. 6/23/2023 Page 14 of 22 (5323/4602) • • • • Connect the USB cable to the VCI/VCI Lite. When the laptop displays the MUT-III main screen, connect the USB cable to the laptop. Connect the MUT-III main harness 'B' with the red or black DLC connector to the VCI/VCI Lite. Connect the red or black connector of the MUT-III main harness 'B' to the vehicle's data link connector. NOTE: VCI and laptop shown for illustration purposes only. MEDIC-3 MUT-III MAIN HARNESS MEDIC 3 / MUT-III LAPTOP VCI - LAPTOP RED END VCI 8. Turn the ignition switch to the “ON” position. 9. From the MEDIC main page, a. Click on MUT-III b. Select “Special Function” c. Select “All DTCs” d. If any DTCs appear, troubleshoot per the applicable service manual. NOTE: Ensure all accessories are off (e.g. lights, heating and AC system, audio/navi unit, etc…). PARTS INFORMATION Use the genuine Mitsubishi Part listed below: Description Part Number Quantity Kit, Air Bag Inflator 7030A950 1 6/23/2023 Page 15 of 22 (5323/4602) INFLATOR RETURNS Do NOT deploy any inflator. Fill out the form on page 19 and contact the appropriate Takata USA representatives below to obtain return shipping documents. !! IMPORTANT !! US - 48 Contiguous States RXO Logistics Customer Service Rep Email: [email protected] Hawaii, Alaska, US Virgin Islands, Puerto Rico and Other US Territories RXO Logistics Representative Email:: [email protected] If a response is not received within 2 to 3 days, call 210-317-6436 to escalate . In most cases, the replaced Takata air bag inflators will be picked up within 3 buisness days. The removed air bag inflator modules must be returned to Takata. If you have NOT accumulated inflator modules after two weeks, follow the return procedures on page 17. If you have accumulated 7 or more inflator modules after two weeks, follow the inflator return procedures on page 18. There will not be a system generated aterial return request. Regardless, the campaign claim is subject to chargeback if the replaced air bag inflator is not returned to Takata. Please make sure you keep a copy of proof of shipment with the repair order. As the shipper, you are responsible for proper packing and document completion. The person packaging the inflator must have received hazardous material training per 49 CFR 172.702, and the training records must be on file at your dealership. The US Department of Transportation will impose substantial fines and/or penalties on the shipper if either packaging, labeling or documentation is not properly prepared and Customer Copy of OP 900PRP form is not kept on file for a minimum of 2 years. RXO LOGISTICS RETURN POLICY ON TAKATA AIRBAGS/INFLATORS 1.Begin to stack the pallet, ensuring NOTHING exceeds the edges of the pallet and less than 5 ft high so the pallet will be structurally safe for transport. 2.Keep a count of how many Driver and Passenger side airbags/inflators you have on that pallet (THIS IS REQUIRED TO SCHEDULE YOUR PICKUP). You can also send back multiple pallets if you have the capacity and ability to do so. 3.Once the pallet is ready and secure (WRAPPED OR TIED DOWN), you can email your request to RXO Logistics to schedule the LTL pickup. After all the above is completed, RXO Logistics will contact and schedule the appropriate carrier for your pickup. They will request the pickup for the next business day but may take up to 72 business hours depending on truck availability. At this point, RXO Logistics will email you five documents: a) Bill of Lading b) Overpack c) ERG 171 d) TK Holdings address label e) these return instructions DO NOT SHIP REPLACED INFLATORS TO MMNA. SHIP ONLY TO RXO LOGISTICS/TAKATA. 6/23/2023 Page 16 of 22 (5323/4602) !! IMPORTANT !! Use these instructions if there are LESS THAN 7 inflators being returned. 48 STATE FEDEX PRP SHIPMENT PREPARATION 1. 4. Shipping Documentation Instructions Shipping Instructions If 7 Kits have not been accumulated within a week, please follow the instructions below a) Separate the bottom 4 labels (OP 900PRP form), place them in the FedEx Ground envelope, remove the backing and firmly place on bottom side of box. a) Email RXO Logistics for direction at [email protected] b) Peel off the Box Copy of the OP 900PRP form and firmly apply to the front side of the box. 1.a Shipping Documents OP 900PRP Hazardous Materials Certification Form FedEx Ground Shipping Label 5. Shipping Documentation Instructions (Cont.) a) Peel off the SHIPPER RECEIPT from the top of the FedEx Ground PRP Shipping label, place it in the Tracking ID box on the Customer Copy of the OP 900PRP form. 3) FedEx Ground Shipping Envelope b) Peel off the RECEIPT & SHIPPER NUMBER from the top of the FedEx Ground PRP Shipping label, and place it in the Tracking ID box on the FedEx copy. 4) 4) 3) 2. Packing Instructions 6. Shipping Documentation Instructions (Cont.) a) Confirm box is in acceptable condition. If a new box is needed, follow the New Box instructions located on the next page. a) Separate the FedEx Copy and Customer Copy of the OP 900PRP form. Keep the FedEx copy with the box. Attach the Customer Copy to the Repair Order. b) Place the un-deployed air bag inflator in the box. Note: Dealers must retain the Customer Copy of OP 900PRP form in their records for 2 years. Dealership Copy 7. FedEx Ground PRP Shipping label 3. Closure Instructions a) Close the top box flap, per box closure instructions located on front panel of box. a) Fill in Shipper Name & Address in the upper section of the FedEx Ground Shipping label. Note: (RMA# is not required). 1) b) Peel off the backing of the FedEx Ground PRP Shipping label and affix to the back side of the box. 2) c) Provide the package and the FedEx Copy of The OP 900PRP form to the FedEx Ground Driver. 1) 2) Note: If you don’t receive regular pickups from Fed-Ex, call 800-463-3339 to schedule a pickup of the package. 6/23/2023 Page 17 of 22 (5323/4602) INFLATOR RETURNS International Shipping Return Instructions NOTE: ALL International Locations outside of the United States (APAC, EMEA, Hawaii, Alaska, Puerto Rico, and US Virgin Islands dealers) please follow below shipping instructions. Dealerships in these locations MUST contact the following Takata / RXO representative directly for shipping instructions primarily via New Email at: [email protected] Escalation Contact: Miguel Prigadaa Phone: 210-317-6436 If dealers are in need of additional boxes, please send your request to the same email address: [email protected] and make sure to indicate how many boxes you need, as well as the model, part number and include pictures if possible. (please consider that shipping additional boxes will take a few weeks to get process depending in the area/country you are located) 1. Shipping Documents 3. Shipping Instructions – Prepare the Pallet a) Box Label • Supplied with each Kit • To be affixed to each box a) Accumulate and palletize Kits b) Arrange Kits on Pallet • A minimum of 25 boxes and maximum of 200 boxes per pallet . c) Shrink-wrap Kits to Pallet d) Prepare to ship per IATA International regulations e) Affix Over-pack Label and Pallet Label on (1) side of Pallet F) (Not Please on Top)hold as many Airbags as possible in order to accumulate as many as possible and limit the number of pickups to at least 1 per month. b) Over-pack Label • To be supplied by RXO • To be affixed to the outside of each pallet c) Bill of Lading • To be supplied by the local carrier. • Print 2 copies: 1 for Dealer Records, 1 for the local pickup Driver d) Commercial Invoice • To be dealer provided by the if possible. 2. Packing Instructions 4. Shipping Instructions – Schedule Intl Pickup **DO NOT DEPLOY THE INFLATOR** a) When ready to ship • Email RXO at [email protected] • EXCALATION PURPOSES Contact: Miguel Prigadaa Phone: 210-317-6436 • b) Fill out the International Pickup Template with all details: • Dealer/Pickup contact Information including hours of operations • Quantity of boxes/Pallets • Weight and Dimensions • Email Address Confirm box is in acceptable condition. Box should be in good condition with no visible signs of damage and should be capable of withstanding additional transportation. d) Place the un-deployed air bag inflator in the “cradle” of the box insert. 5. Shipping Instructions – Ship 2.1 Closure Instructions a) Close the top box flap, per box closure instructions located on front panel of box using a 2” wide by 4” long piece of tape to securely Close the box. a) Give 1 Copy of BOL and 1 Copy of ERG to Driver b) Retain 1 Copy of BOL for Dealership records and archive for 2 Years 6. Requesting a New Box If a new box or replacement boxes are needed, please contact the representative listed below by phone or email to request replacement materials. E-Mail: [email protected] To help expedite your request, please be prepared to provide the following information: a) What Type of shipping material needed • Number of Replacement Boxes needed • Part Return Label • Airbag Model • Pictures (of the airbag if possible) b) Dealer Shipping Information • Contact name • Dealer Address • Phone Number 6/23/2023 Page 18 of 22 (5323/4602) PALLET (S) MUST BE READY BEFORE SENDING IN THE TEMPLATE. ALL FIELDS PERTAINING TO YOUR LOAD MUST BE FILLED IN AND SENT TO [email protected] ESCALATION PHONE NUMBER 210-317-6436 MIGUEL PRIGAADA Dealer Code Dealer or Business Name Pickup Address City, State & Zip Physical Address (if different from pickup address) City, State & Zip Hours Available for Pickup YOUR Name & Phone # Days/hours pickup is not allowed (lunch hour if shut down) Email address for BOL Do you need a truck with lift gate and pallet jack? Where can the driver expect to find pallet on property? Please give clear directions Special instructions or notes that will help driver locate pallet on site LTL YES NO Pallet #1 Pallet #2 Pallet #3 Pallet #4 Pallet #5 Pallet #6 Pallet #7 Pallet #8 Pallet #9 Pallet #10 Pallet #11 Pallet #12 Pallet #13 Pallet #14 Total Boxes 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Driver Side Count Passenger Side Count Total 6/23/2023 Page 19 of 22 (5323/4602) WARRANTY INFORMATION There is only one repair scenario for this campaign. # Repair Procedure Campaign Operation Labor Time Allowance Part Number 1 Replace air bag inflator kit C1704A01 1.6 hours 7030A950 WARRANTY / RECALL CAMPAIGN CLAIM INFORMATION Enter all claims as claim type “C” - Recall/Campaign Claims Please follow the campaign instructions when entering each claim in order to select the operation codes that correctly match up with the work that was actually performed. A claim example is provided below. Certain 2004-2006MY - Lancer models (Lancer, Lancer EVO, and Lancer Wagon) Required Operation to be performed by model year 1. 2004-2006MY Lancer - Replace Air Bag Inflator Kit 6/23/2023 Page 20 of 22 Labor Operation C1704A01 Labor Time 1.6 hrs. (5323/4602) Claim Header Section: Passenger Side Air Bag Inflator Replacement C1704A. C1704A_ _ 64500 JA…………..…. This campaign is for the replacement of the air bag inflator on certain 2004-2006 MY Lancers (Lancer, EVO, and Wagon). Check the Open Campaign area of the Superscreen each time to be certain of a vehicles eligibility. Only VINs showing C1704A as open are involved. After entering the required customer data, vehicle information and applicable campaign operation number, hitting the “Save and Continue” button will automatically fill-in several fields. Please note there is only 1 possible repair scenario for this campaign. 6/23/2023 Page 21 of 22 (5323/4602) Recall Campaign Claim Example: Follow these instructions to claim for performing the replacement of the air bag inflator. PARTS: There is only one repair scenario and it requires replacement of ONLY this air bag inflator. Scenario #1 - on 2004-06MY Lancer vehicles - replace the air bag inflator kit. Part# 7030A950 LABOR: The full recall campaign labor operation number is C1704A01 and the allowed labor time of 1.6 hours will be automatically entered as a result of the 'Repair Performed' scenario selected from the “Vehicle” page. RENTAL CARS: If there is a need to provide the owner with a rental car, claim the applicable charges in this section of the claim on the lower portion of the labor entry screen. PARTS RETURN: Follow the instructions in this TSB in regards to returning replaced air bag inflators. DO NOT return the replaced parts to MMNA. 6/23/2023 Page 22 of 22 (5323/4602)