Recall - Brake Booster Check Valve Replacement: Overview
No: SR-09-002DATE: April, 2009
MODEL:
2008-09 Lancer
2008-09 Outlander
SUBJECT:
BRAKE BOOSTER CHECK VALVE REPLACEMENT SAFETY RECALL CAMPAIGN
PURPOSE
On some affected vehicles equipped with automatic transmissions (including CVT), the brake booster check valve may stick closed when the engine is shut off. Under certain conditions (very slow vehicle maneuvers after a restart) there may be insufficient initial brake assist, which may temporarily increase the stopping distance of the vehicle and therefore increase the risk of a crash.
This Safety Recall Bulletin contains instructions for replacing the brake booster check valve. A new check valve must be installed. Refer to the Parts Information section of this bulletin for additional information.
AFFECTED VEHICLE(S)
U.S. - 2008-09 Lancer and Outlander built between October 23, 2007 and January 22, 2009.
CANADA - 2008-09 Lancer built between October 24, 2007 and January 22, 2009.
- 2008-09 Outlander built between October 23, 2007 and December 1, 2008.
Vehicles equipped with automatic transmission or CVT only.
CUSTOMER NOTIFICATION
A letter will be sent to all owners of affected vehicles telling them to bring their vehicle to their Mitsubishi Motors dealer to have the brake booster check valve replaced. A copy of the customer notification letter is shown in this bulletin.
REQUIRED OPERATIONS
Before starting this recall campaign procedure, CHECK THE WARRANTY SUPERSCREEN to verify that the vehicle is an affected VIN for this campaign and that this campaign procedure has not already been completed.
Following the instructions in this recall bulletin, replace the brake booster check valve. Refer to the Parts Information section later in this recall campaign bulletin for the brake booster check valve part number and related information.
PROCEDURE
1. Open the hood and support it with the hood support rod.
OUTLANDER V6 - For all others, go to step 5
AIR INTAKE HOSE REMOVAL
2. Using pliers, compress the clamp securing the breather hose retaining clip and slide the clamp away from the fitting on the air intake hose.
3. Remove the breather hose from the air intake hose.
NOTE:
If the fitting comes out of the air intake hose, reinstall it and continue with the next step.
4. Loosen 2 band clamps and remove the air intake hose.
5. Locate the brake booster.
6. Using pliers, compress the clamp securing the brake booster hose to the brake booster check valve and slide the clamp away from the valve.
7. Remove the hose from the check valve.
8. Take note of the direction the check valve is facing.
9. Remove the check valve from the brake booster.
10. Insure that the grommet is in position and flush to the booster surface prior to installing the new check valve.
11. Install a new brake booster check valve facing the same direction as the one you removed. Insure that the check valve is completely inserted and that no gap exists between the valve and the grommet (see photos above).
CAUTION
Insure the check valve fits flush to the grommet. There must not be a gap between the base of the check valve and the grommet.
NOTE:
If necessary, you may use ETHANOL ONLY (ethyl alcohol) as a lubricant by coating only the bevelled surface of the check valve before inserting it into the grommet.
!! CAUTION!!
^ Do not use any other agent as a lubricant.
^ Do not use mineral-oil-based lubricants or engine oil as these could cause the grommet to swell.
^ Do not use neutral detergents as they are low volatility and may not evaporate and remain in the valve.
Reinstallation of the air intake hose is the reverse of removal. Refer to the illustration accompanying step 2 and torque the band clamps to the specification shown.
12. Reinstall the breather hose and secure it with the clamp.
13. For V6 vehicles, reinstall the air intake and breather hoses in the reverse order of removal (refer to air intake hose removal steps).
14. Perform the brake booster operation check procedure.
BRAKE BOOSTER OPERATION CHECK
PARTS INFORMATION
RECALL CLAIM INFORMATION
Campaign Labor Operation: C0903S01
Labor Time: 0.3 hr.
Required Part Numbers
Each repair requires the use of one Check Valve. Only one of this part number will be allowed on a claim. Check the part number against the part number on the related repair order.
Claim only the one applicable part number from the "Required Parts" listed in the Parts Information Section.
Please follow the service claim examples shown above.