SR-17-004 – LANCER PASSENGER SIDE FRONTAL AIR BAG INFLATOR – SAFETY RECALL CAMPAIGN – 2004-2006 Mitsubishi Lancer – Mitsubishi

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NHTSA Campaign Number: 17V569
Manufacturer Mitsubishi Motors North America, Inc.
Components AIR BAGS
Potential Number of Units Affected 66,001

Passenger Side Front Air Bag Inflator may Rupture

In the event of a crash necessitating deployment of the passenger’s frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.

Summary

Mitsubishi Motors North America, Inc. (Mitsubishi) is recalling certain 2004-2006 Lancer and Lancer Evolution vehicles and 2004 Lancer Sportback vehicles. These vehicles are equipped with a passenger side frontal air bag that may be susceptible to moisture intrusion which, over time, could cause the inflator to rupture.

Remedy

Mitsubishi will notify owners, and dealers will replace the front passenger air bag inflator with a different inflator, free of charge. The recall began on October 12, 2017. Owners may contact Mitsubishi customer service at 1-888-648-7820. Mitsubishi’s number for this recall is SR-17-001. Note: This recall supersedes recall 15V-321.

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 Mitsubishi has a Recall

SUBJECT:

LANCER PASSENGER SIDE FRONTAL AIR BAG INFLATOR – SAFETY RECALL CAMPAIGN

No: SR-17-004

DATE: October 2017

MODEL: 2004-06 Lancer, Lancer Sportback, and Lancer Evolution

CIRCULATE TO:

[ X ] GENERAL MANAGER

[ X ] PARTS MANAGER

[ X ] TECHNICIAN

[ X ] SERVICE ADVISOR

[ X ] SERVICE MANAGER

[ X ] WARRANTY PROCESSOR

[ X ] SALES MANAGER

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

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.

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 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.

The air bag modules should be stored on a flat surface and facing upward. Do not place anything on top of it.

Do not expose the air bag modules to temperatures over 93^oC (200^o F).

Record the radio station presets. Disconnect the negative (-) battery terminal and insulate the terminal with electrical tape.

Wait at least 60 seconds after disconnecting the battery cable before doing any further work to prevent accidental air bag deployment.

Battery posts, terminals, and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

Remove the front left and right A-pillar trims.

Remove the instrument panel.

Remove the distribution duct from the instrument panel.

Do not damage the air bag or the instrument panel during air bag module removal.

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.

AIR BAG INFLATOR REPLACEMENT PROCEDURE

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.

Use pliers to pinch the hooks and remove the wiring clip from the bracket.

Remove and discard the 2 circled nuts.

Remove and keep the stopper plate for reuse.

To avoid accidental dropping of the airbag, do not remove the nuts in Step 5.

	Loosen, but do not remove, the circled nuts.
	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.

Do not damage the wiring harness during inflator removal.

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.

	Unpackage the air bag inflator kit, remove and verify the contents: (1) Replacement inflator with tapes and cloth cover. (6) Felt tapes (1) Replacement wiring harness (1) Caution label (1) Old stopper plate (not in box) from Step 4 (4) Replacement nuts – M5 (1) CE certification label
	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.
	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.
	CAUTION: Do NOT incorrectly insert the inflator.
	Fully insert the inflator.
	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.
	Reinstall the stopper plate. Ensure the inflator is seated correctly in the housing, and there are no gaps on either end.

Do not reuse the old nuts.

	Install and lightly tighten the (2) nuts holding the stopper plate.
	Remove and discard (2) nuts near the housing plate side. Install (2) new nuts and lightly tighten them.
	In the illustrated order, torque all (4) nuts to 34.5 + 3.5 in-lb (3.9 + 0.4 Nm).
	Match the wiring harness connector’s plug with the shape in the electrical connector socket.

Do not touch the inflator’s electrical connector.

Do not reuse the old wiring harness.

	Press the wiring harness connector firmly into the electrical connector socket. NOTE: A faint click will be heard when the connector is inserted correctly.
	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.
	Clip the wiring harness to the mounting bracket as shown.
	CAUTION: Do not connect the wiring harness in the incorrect direction.

	Confirm that the wiring harness clip has been fully inserted.
	Use a clean, dry cloth or towel to wipe the old caution label. Affix the new caution label directly over the old caution label.

	Apply degreaser onto a cloth or towel and wipe the outlined area.
	Affix the CE certification label on the degreased area.
	Prepare felt tapes for application to the outlined locations.
	Note the taping area for Position A and Position B.
	Tape (4) Position A as illustrated.
	Tape (2) Position B as illustrated.
	Confirm the following items: There is no gap between the inflator and housing plate or stopper plate. Inflator flat section is parallel with housing plate. Harness connector correctly connected to inflator. The nuts (silver finish) are properly torqued to 34.5 + 3.5 in-lb (3.9 + 0.4 N-m). Caution label correctly affixed. CE certification label affixed. (6) felt tapes applied. (4) old nuts discarded. There are no scratches or debris/dirt on the air bag. Harness connector correctly clipped.

REINSTALLATION PROCEDURE

Reinstall the passenger air bag module to the instrument panel.
Reinstall the distribution duct to the instrument panel.

NOTE: Reinstall the center bolts first to align the distribution duct.

Reinstall the instrument panel.
Remove the electrical tape and reconnect the negative (-) battery terminal. Tighten the clamp nut securely.
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.
Input radio station presets and set the clock, if applicable.

ERASE AND READ DTCs FROM ALL ECUs

Connect the equipment as follows:

Turn the laptop computer/tablet on.
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.

Turn the ignition switch to the “ON” position.

NOTE: Ensure all accessories are off (e.g. lights, heating and AC system, audio/navi unit, etc…).

From the MEDIC main page,
1. Click on MUT-III
2. Select “Special Function”
3. Select “All DTCs”
4. If any DTCs appear, troubleshoot per the applicable service manual.

PARTS INFORMATION

Use the genuine Mitsubishi Part listed below:

Description	Part Number	Quantity
Kit, Air Bag Inflator	7030A950	1

INFLATOR RETURNS

Do NOT deploy any inflator.

Contact the appropriate Takata USA representatives below to obtain return shipping documents.

US – 48 Contiguous States
XPO Customer Service Rep
Phone: 888-708-5712
Email: SCFieldaction.14305@xpo.com

Puerto Rico
Forwarder: Crane Worldwide
Contact Person: Juan Armstrong
Email: Juan.Armstrong@craneww.com
Phone: (787) 410-6777

Hawaii, Alaska, US Virgin Islands, and Other US Territories
XPO Representative
Phone: 210-250-5061
Email: SCTakataRestraints_International@XPO.com

The removed air bag inflator modules are to be returned to Takata once per week. If you have NOT accumulated 6 inflator modules after one week, follow the return procedures on page 17. If you have accumulated 6 or more inflator modules after one week, follow the inflator return procedures on page 18.

There will not be a system generated material 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.

DO NOT SHIP REPLACED INFLATORS TO MMNA. SHIP ONLY TO TAKATA.

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 Labor Operation Labor Time

2004-2006MY Lancer – Replace Air Bag Inflator Kit C1704A01 1.6 hrs.

Claim Header Section: Passenger Side Air Bag Inflator Replacement

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.

Recall Campaign Claim Example:

Follow these instructions to claim for performing the replacement of the air bag inflator.

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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

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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.