Recall - Headlamp Inspection/Replacement: Overview
No: SR 12-002DATE: August, 2012
MODEL: See below
SUBJECT:
SERVICE PART HEADLAMPS - SAFETY RECALL
CAMPAIGN
PURPOSE
Certain service part headlamps installed as replacement parts on affected vehicles allow for horizontal adjustment. If the headlamp's horizontal adjustment mechanism is not disabled, the headlamp can be adjusted to either reduce the driver's visibility or blind oncoming traffic. Both
conditions increase the risk of a crash.
Dealers are instructed to inspect affected vehicles to see if replacement headlamps that allow for horizontal adjustments are installed. Affected 2001-2006 Montero vehicles equipped with noncompliant headlamps require installation of an aiming cap to seal and disable the horizontal adjustment mechanism. Affected 2008-2012 Lancer vehicles equipped with noncompliant headlamps require bending of a vertically extended tab located on the headlamp to seal and disable the horizontal adjustment mechanism.
AFFECTED VEHICLES
2001-2002 Montero (US and PR vehicles only)
2003-2006 Montero (Two US vehicles only)
2008-2012 Lancer, Lancer Evolution, Lancer Ralliart, Lancer Sportback, Lancer Sportback Ralliart
produced before April 6, 2012 (US vehicles only)
Important
Affected new or used inventory vehicles must be repaired before the vehicle is 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 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.
CUSTOMER NOTIFICATION
2001-2002 Montero
Dealers are instructed to inspect any 2001-2002 Montero brought in for service. Purchasers of affected headlamps could not be identified and will not be notified by mail. Advise customers of the recall before proceeding with the repairs.
2003-2006 Montero
The owners of the two affected 2003-2006 Montero have been identified and will be sent a customer letter, requesting them to bring their vehicle to a local Mitsubishi dealer to have their service part headlamps repaired. It is not necessary to inspect all 2003-2006 Montero brought in for service.
The only 2003-2006 Montero that need inspection/repair will be identified on the warranty superscreen and/or owner will present the letter. A copy of the customer notification letter appears at the end of this bulletin.
2008-2012 Lancer, Lancer Evolution, Lancer Ralliart, Lancer Sportback, Lancer Sportback Ralliart
A customer letter will be sent to owners of affected 2008-2012 Lancer vehicles that can be identified through part purchase records. A copy of the customer notification letter appears at the end of this bulletin. Not all vehicle owners that purchased affected headlamps could be identified and sent customer letters. Dealers are instructed to inspect any 2008-2012 Lancer vehicles brought in for service. Advise customers of the recall before proceeding with the repairs.
REQUIRED OPERATIONS
Before starting this campaign procedure, CHECK ON 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.
SERVICE PART HEADLAMP REPAIR PROCEDURE
For 2001-2006 Montero
1. Check if a headlamp aiming cap is installed on the back of the headlamp as shown below. If not, install the cap according to the following procedure.
2. Aiming cap installation procedure
a. Make sure the aiming cap is mounted on the headlamp aiming adjustment access port.
b. With your fingers, push the aiming cap until it is secured onto the headlamp aiming adjustment access port. (Please note the direction of the aiming cap with the flat section pointed up.)
For 2008-2012 Lancer (Equipped with HID or Halogen Headlamps)
1. With an automotive inspection mirror and light source, check if the tab is properly sealed on the back of the headlamp as shown in Step 2e. If not properly sealed, proceed with the following procedure to seal the headlamp.
(You may access the open area between the fender and upper rail to assist in your inspection as shown in the photo.)
2. Headlamp sealing procedure
(If the repair is being completed on a Lancer Evolution, Lancer Ralliart, or Lancer Sportback Ralliart, you may remove the Coolant Tank located behind the right headlamp and the A/C Relay Assembly located behind the left headlamp to gain additional access area as shown.
a. Place a screwdriver through the open area between the headlamp and front fender as shown in Step 2e.
b. With your finger, locate the tab and slightly push the tab towards the front of the vehicle.
Apply pressure on the screwdriver to flatten the tab against the headlamp.
c. Continue to apply pressure on the screwdriver until you hear two distinct clicks. The headlamp horizontal mechanism is now properly sealed.
d. With an automotive inspection mirror and light source, check if the tab is sealed on the headlamp.
e. Make sure the sealing operation has been completed.
PARTS INFORMATION
Use the genuine Mitsubishi Part listed:
An initial supply of parts will be allocated to dealers in U.S. and Puerto Rico. Determine your dealership's actual needs before ordering additional parts.