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SB-10057899-5513

SERVICE CAMPAIGN BULLETIN
SUBJECT:

i−MiEV UNDERCARRIAGE RUST −
SERVICE CAMPAIGN − REVISED

No:

SC−14−003REV

DATE:

April, 2015

MODEL:

2012 i−MiEV

CIRCULATE TO:

[X] GENERAL MANAGER

[X] PARTS MANAGER

[X] TECHNICIAN

[X] SERVICE ADVISOR

[X] SERVICE MANAGER

[X] WARRANTY PROCESSOR

[X] SALES MANAGER

This bulletin supercedes SC−14−003, issued October, 2014, to clarify the repair procedures and
require photos be uploaded to the PRC prior to under cover replacement. Changes are italicized
and indicated by A.

PURPOSE
The undercarriage on certain 2012 i−MiEV vehicles, along with the bolts securing the Main Drive
Lithium−ion battery under covers and non−essential ground connections, may be susceptible to rust.

2012 i−MiEV built October 28, 2011 − July 2, 2012

CUSTOMER NOTIFICATIONS
A letter will be sent to all owners of affected vehicles requesting them to bring their vehicle to a local
Certified Mitsubishi Motors i−MiEV dealer to have this product improvement performed. A copy of the
customer notification letter appears at the end of this bulletin.

REQUIRED OPERATIONS
D

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.

D

Record the vehicle’s production date. This information will be needed during the Repair Procedure.

D

Repairs must be completed by a certified i−MiEV technician. Please ensure the Main Drive battery’s charge is properly maintained while the vehicle is not being serviced.

IMPORTANT
To maximize customer satisfaction with the quality of their vehicle, affected new or used
inventory vehicles should be remedied 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 service campaign.
Copyright 2015, 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).
(4272)

"

AFFECTED VEHICLES

"

This campaign bulletin instructs dealers to inspect the non−essential ground connection bolts and
undercarriage. If the bolts are not broken, the dealer will remove any undercarriage rust, apply
anti−corrosion wax to the frame, reinstall the under covers, and replace the bolts. If the bolts are
broken, upload photos of the broken bolt to the PRC for Techline review. Once approved, the “209 −
Product Support” parts restriction on the under covers are removed and the order will process. The
dealer will then remove any undercarriage rust, apply anti−corrosion wax to the frame, and replace the
under covers with new covers that use ground bus bars.

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SC−14−003REV

IMPORTANT
Please ensure the Main Drive battery is fully charged prior to vehicle delivery. If the vehicle
cannot be immediately remedied, the Main Drive battery should be charged while the vehicle
is waiting for the product improvement. This will limit customer inconvenience and maximize
customer satisfaction.

PROCESS FLOW CHART

"

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SC−14−003REV

WARNING

Wear safety goggles, gloves, and a face mask while performing this repair.

REPAIR PROCEDURE
1. Place the vehicle on a lift, shift the selector to PARK, set the parking brake, and turn the electric motor
switch to the OFF position. Raise the vehicle.
2. Remove the front and rear plug covers (#3 and #6 − refer to the diagram below) and the non−essential
ground bolts (#4 and #7 − refer to the diagram below).
3. Remove the front under cover (#5 − refer to the diagram below), then remove the rear under cover
(#8 − refer to the diagram below).

Ground Bolts #4 and #7

"

4. If the non−essential ground bolts are broken, upload photos of the broken bolt to the PRC. Once
approved by Techline, the “209 − Product Support” parts restriction on the under covers are removed
and the order will process. Skip Step 5 and go to Step 6.

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SC−14−003REV

a. Use a high pressure air hose to remove dirt from the under covers.
b. Remove any rust on the under covers with a wire brush until the surface is smooth.
Before Brushing

Circled Area
After Brushing

6. Inspect Crossmember A. If rust is present, remove 50% or more of the rust using hand tools such
as a wire brush, flat head screwdriver and a scraper.
Front of Vehicle

Crossmember A

Crossmember B

Crossmember C

Crossmember D

"

5. If the non−essential ground bolts are not broken:

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SC−14−003REV

Using Wire
Brush

Using Scraper

Before Rust Removal

After Rust Removal

7. Repeat Step 6 for Crossmember B, C, and D and remove rust if required.

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SC−14−003REV

8. Install (9) washers to the frame with super glue or epoxy in the attachment points indicated below.
IMPORTANT

Apply pressure to each washer for at least 1 minute to ensure proper bonding.

IMPORTANT

Ensure rust is removed from the indicated attachment points before washer adhesion.

IMPORTANT

Ensure the washers and frame are clean before installation.

IMPORTANT

Do not cover the bolt holes with the washer.

IMPORTANT

Do not apply super glue or epoxy to the bolt hole threads.

FR

= Front

DS = Driver
Side
DS
FR

NOTE: Apply adhesives to each washer as shown in the left
illustration.

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SC−14−003REV

9. To prevent anti−corrosion wax from contacting the resin undercarriage components (harness, battery
tray, etc…), mask the indicated areas below with shipping/packaging paper or plastic covers.

Areas to be
masked
Masked areas
where wax will
be brushed on
after masking
is removed

DS
FR
FR

= Front

DS = Driver
Side

Without proper masking, wax may adhere to the battery
tray through the holes
Vehicle Rear

Vehicle Front

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SC−14−003REV

10. In one continuous motion, spray anti−corrosion wax on the frame in the areas indicated with red
arrows shown below. After the initial application, immediately apply 2−3 more coatings. The
anti−corrosion wax coating must be thicker than the existing frame undercoating.
IMPORTANT

Dealers in Oregon and Washington must use Dinitrol anti−corrosion wax Part
No. 1117901 and anti−corrosion wax applicator Part No. 1700700. Dealers in all
other states must use Three Bond anti−corrosion wax Part No. MZ320725.

IMPORTANT

If Dinitrol applicator Part No. 1700700 is required, set shop air to 29−58 psi.
Clean after every use with mineral spirits or similar solvent.

CAUTION

Familiarize yourself with the DANGER, PRECAUTIONS, and WARNING labels
on the can before applying the anti−corrosion wax.

WARNING

Do not apply anti−corrosion wax to the high voltage wiring or resin
components.

NOTE: Ensure the area is clean before applying anti−corrosion wax.

Sample of Spray

Sample of Waxing
FR

= Front

DS = Driver
Side
DS
FR

Brush on wax after
masking removal

Spray wax in one continuous
motion with masking applied

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SC−14−003REV

CAUTION

To avoid applying anti−corrosion wax to the resin components, and the bolt and
clip mounting locations, spray the wax onto a brush and apply to the indicated
areas.

11. Remove the masking. Spray anti−corrosion wax onto a brush and brush areas indicated with blue
arrows shown in the illustration in Step 10.

NOTE: In the indicated area below, the method of brushing depends on the vehicle’s build date.

D

For vehicles built in October 2011 and earlier, apply wax according to Figure A.

D

For vehicles built in November 2011 and after, apply wax according to Figure B.

Figure A

Figure B

DS
FR

12. Allow 30 minutes for the anti−corrosion wax to dry.
13. If the ground bolts from Step 2 are not broken, reinstall the old under covers (do not reinstall the plug
covers) and replace the ground bolts with new ones. Torque ground bolts to 80 + 17 in−lb (9 + 2 N−m)
and the under cover bolts to 44 + 17 in−lb (5 + 2 N−m). Proceed directly to the Continuity Check
Procedure section below.

"

If the ground bolts from Step 2 are broken, and the order for the under covers is approved by Techline,
proceed to Step 14.

"

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SC−14−003REV

14. Discard the old under covers. Install the bus bar assembly to the new rear under cover as shown,
then install the under cover to the vehicle.
NOTE: Do not install the plug covers until the Continuity Check Procedure has been completed.

Front

Rear

B

B
A

A

a. Install, but do not torque, the ground nut (A).
b. Install, but do not torque, the frame bolt (B).
c. Torque ground nut (A) to 17.5−35 in−lbs (2−4 N−m).
d. Torque frame bolt (B) to 26.5 − 62 in−lbs (3−7 N−m).
15. Repeat Step 14 for the new front under cover, and ensure the driver side and passenger side mounting
tabs are properly mounted into the frame.