Recall - Air Bag Sensor Replacement: Overview
No: SR-12-003DATE: August, 2012
MODEL: 2012 i-MiEV
SUBJECT:
2012 I-MIEV AIRBAG SENSORS - SAFETY RECALL
CAMPAIGN
PURPOSE
Certain airbag sensors equipped on 2012 i-MiEV vehicles built between November 4, 2011 - December 22, 2011, are incompatible with the self diagnostic software used by the SRS. This incompatibility may be detected during the initial SRS diagnostic check when the ignition is turned ON. If this incompatibility is detected, the SRS warning lamp will illuminate. If the vehicle were to be involved in a collision while
the SRS warning lamp is illuminated, the side and curtain airbags may not deploy or the frontal airbags may deploy late, increasing the risk of personal injury.
Replacing all (4) airbag sensors equipped on affected vehicles with new sensors will resolve this potential condition.
AFFECTED VEHICLES
Certain 2012 i-MiEV vehicles built between November 4, 2011 - December 22, 2011
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
A letter will be sent to all owners of affected vehicles requesting them to bring their vehicle to a local certified Mitsubishi i-MiEV dealer to have their airbag sensors replaced. A copy of the customer notification letter appears at the end of this bulletin.
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.
Repairs must be completed by a certified i-MiEV technician.
IMPORTANT
Please ensure the main drive battery is fully charged prior to vehicle delivery. If the vehicle cannot be immediately repaired, the main drive battery should be charged while the vehicle is waiting for repairs. This will limit customer inconvenience and maximize customer satisfaction.
AIRBAG SENSOR REPLACEMENT PROCEDURE
1. Remove the 12V battery cover and disconnect (-) terminal of the battery. Wait at least 60 seconds. Insulate disconnected (-) terminal with electrical tape.
REMINDER: If the vehicle is not equipped with the optional OEM navigation unit, please record all radio station presets and reprogram when repair is completed.
Caution!
The condenser installed in the SRS-ECU keeps a required voltage to deploy airbags for a certain period of time even after the electric motor switch is turned OFF. Do not perform any operation during this period as incidental airbag deployment may occur.
2. Remove 2 bolts and 5 fasteners as shown below on both left front and right front splash shields to access the fog light and front combination light assembly connectors.
Note:
Arrows indicate fastener locations. Bolts are circled in red.
3. Disconnect the fog light and front combination light assembly connectors.
4. Remove 8 fasteners as shown in the following illustration. Unhook the claws located at the upper left and upper right corners of the front bumper (see Section A -A).
5. Refer to the following illustration to complete front bumper assembly removal.
Caution!
Handle the front impact sensors with extreme care as they are fragile. The impact sensor must be replaced If it is dropped or damaged. If a replacement impact sensor is discovered to be dented, cracked, deformed, or rusted, obtain a new part to complete the repair.
6. Disconnect both front impact sensor connectors.
Slide the connector lock (outer sleeve) of the front impact sensor harness connector towards the center of the vehicle. Unlock and disconnect the connector. Repeat this procedure for the other impact sensor.
Outer Sleeve (driver side sensor) shown.
7. Replace both front impact sensors.
To ensure proper installation, position the front impact sensor with the side marked "F" facing towards you (circled in yellow in the first illustration below). There is also a tab located on the back of the impact sensor that slots into the mounting surface. Make sure the tab is aligned with the mounting surface (shown in the second illustration).
Caution!
Use only hand tools when removing or installing front impact sensors. Torque to the proper specification to prevent damage (97 + 26 in-lb) (11+ 3 N-m).
Caution!
The SRS may not operate properly if a front impact sensor is not installed correctly, increasing the risk of personal injury.
Caution!
Make sure the old impact sensors and new impact sensors are kept separate. In order to distinguish the two, the torque mark on the old sensor is located near the hole. For new sensors, the mark is located near the part number. (Marks are circled in red in the first illustration.)
8. Reconnect and lock both front impact sensor connectors.
9. Reinstall the front bumper assembly.
In order to reinstall the bumper, you must align the mounting tab first (shown in Step 4).
10. Reconnect the fog light and front combination light assembly connectors.
11. Reinstall the bolts and fasteners on both left front and right front splash shield. Torque specification is 44 + 17 in-lb (5 + 2 N-m).
12. Remove the rear seat cushion pad and cover.
Pull the rear seat hook forward to unlock the rear seat cushion. Remove the rear seat cushion pad and cover by lifting it upward while simultaneously pulling the rear seat hook forward.
13. Remove the left front and rear scuff plate and front seat belt lower anchor bolt.
The front scuff plate is held on by 10 claws. The rear scuff plate is held on by 4 claws and 1 clip.
Carefully remove the claws from its slot as indicated by the white arrows. Carefully detach the clip as indicated by the black arrow.
14. Remove the left center pillar lower trim (it is not secured by any claws/clips).
15. Disconnect the left side impact sensor connector.
Slide the connector lock (outer sleeve) of the side impact sensor harness connector away from the sensor. Unlock and disconnect the connector.
16. Replace the left side impact sensor (ensure operation is completed on both sides).
To ensure proper installation, position the side impact sensor with the side marked "F" facing towards you. There is also a tab located on the back of the impact sensor that slots into the mounting surface. Make sure the tab is aligned with the mounting surface (shown in Step 7).
Caution!
Use only hand tools when removing or installing side impact sensors. Torque to the proper specification to prevent damage (97 + 26 in-lb) (11+ 3 N-m).
Caution!
The SRS may not operate properly if a side impact sensor is not installed correctly, increasing
the risk of personal injury.
Caution!
Make sure the old impact sensors and new impact sensors are kept separate. In order to
distinguish the two, the torque mark on the old sensor is located near the hole. For new sensors, the mark is located near the part number (shown in Step 7).
17. Connect and lock the left side impact sensor connector.
18. Reinstall the left center pillar lower trim.
19. Reinstall and tighten the left front seat belt lower anchor bolt.
Torque specification is 30 +/- 7 ft-lb (40 +/- 10 N-m)
20. Reinstall the left front and rear scuff plate.
21. Repeat Steps (13) - (20) on the right side.
22. Reinstall the rear seat cushion pad and cover.
23. Remove tape and connect the negative (-) terminal of the 12V battery. Reinstall battery cover.
Torque specification for negative (-) terminal is 44 +/- 8 in-lb (5 +/- 1 N-m).
24. Perform POST-INSTALLATION INSPECTION to verify repair has been completed.
a. Turn on the electric motor switch.
b. Check if the SRS warning light is illuminated for 6 to 8 seconds, and extinguished afterwards.
c. If the light does not extinguish, perform troubleshooting as shown in the Service Manual Group 52B Supplemental Restraint System (SRS) - SRS Airbag Diagnosis - Check Chart for Diagnostic Trouble Codes.
25. Fully charge the i-MiEV Main drive lithium-ion battery. If applicable, set the clock and radio station presets before returning the vehicle to the customer.
PARTS INFORMATION
Use the genuine Mitsubishi Part listed:
Dealers will automatically receive an initial quantity of parts to complete the recall on in-stock dealer units, shipped the week of August 13, 2012. We will also be contacting owners directly to coordinate their return to a local certified i-MiEV dealer. If we can confirm their return, we will ship the necessary repair kit(s) to the dealer automatically.