SR-18-005REV

SAFETY RECALL BULLETIN
SUBJECT:
LANCER PASSENGER SIDE FRONTAL AIR BAG
INFLATOR −SAFETY RECALL CAMPAIGN - REVISED
No:
SR−18−005 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-18-005 issued April 2018, 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 those that previously received a like-for-like passenger side frontal air bag
inflator under recall SR-14-012 as an interim remedy. Those vehicles are still 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).
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REQUIRED EQUIPMENT
•
•
•
•
•
Trim stick
VCI (Vehicle Communication Interface) or VCI Lite - MB991824 or MB992744V.
MEDIC Laptop/Tablet with A/C power adapter - MIT540031 or FZG1MK2.
MUT-III main harness 'A' (blue connector at the DLC end) or MUT-III main harness 'B' (black
connector at the DLC end) - MB992745V or MB992746V.
USB 2.0 cable - RRAR1MBR108GL.
REMOVAL PROCEDURE
Never attempt to disassemble or repair the air bag modules. If faulty,
replace it.
! WARNING
! WARNING
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.
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
Battery posts, terminals, and related accessories contain lead and lead
compounds. WASH HANDS AFTER HANDLING.
! WARNING
2.
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Remove the front left and right A-pillar trims.
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3.
Remove the instrument panel.
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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.
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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
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2.
Use pliers to pinch the hooks and remove the wiring
clip from the bracket.
3.
Remove and discard the 2 circled nuts.
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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
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Do not damage the wiring harness during inflator removal.
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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
8.
a
b
c
d
g
e
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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 that previously contained the
new inflator. Ensure the old inflator is correctly
wrapped, using the wrapping that came with the new
inflator, to protect the old inflator from damage during
shipping.
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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
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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.
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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.
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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
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CAUTION: Do not connect the wiring harness in the
incorrect direction.
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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.
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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
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B
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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.
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•
•
•
•
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
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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.
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!! 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.
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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
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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
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RECALL 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
C1807A01
1.6 hours
7030A950
Claim Header Section: Passenger Side Air Bag Inflator Replacement
C1807A.
C1807A_ _
This campaign is for the replacement of the air bag inflator on certain
2004-2006 MY Lancers (Lancer, EVO, and Wagon).
64500
JA…………..….
Check the Open Campaign area of the Superscreen each
time to be certain of a vehicles eligibility. Only VINs showing C1807A
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.
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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 C1807A01 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.
NOTE: Rental cars applicable in the US and Puerto Rico only.
PARTS RETURN:
Follow the instructions in this TSB in regards to returning replaced air bag inflators. DO NOT
return the replaced parts to MMNA.
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