Seat Side Airbag Module Replacement (TSB-07-52B-004)

SEAT SIDE AIRBAG MODULE REPLACEMENT

TECHNICAL SERVICE BULLETIN

PURPOSE

Some affected vehicles may exhibit the "SRS" warning light illuminated on the instrument panel and DTC B1421 Side Airbag Module (RH) (Squib) System Fault 2 or B1431 Side Airbag Module (LH) (Squib) System Fault 2 is recorded in the SRS ECU memory or DTC 72 / DTC 82 (2004 Endeavor without Advanced Airbag). If an affected vehicle has not been in a collision, and normal diagnostic procedures confirm that the side air bag is malfunctioning and should be replaced, the side air bag module can now be ordered and replaced separately. It is no longer necessary to replace the seatback assembly.

AFFECTED VEHICLES

• 2004 - 2008 Endeavor
• 2004 - 2008 Galant

PROCEDURE

Using the scan tool in "ALL DTCs" mode, scan the vehicle and record any DTCs that are displayed and in which ECU they are displayed in. Conduct regular troubleshooting steps outlined in the service manual for any DTCs and complete repairs for those faults (electrical connections, damaged wiring etc.) prior to replacing any components. 

Prior to starting repairs, record the customer's radio presets and disconnect the negative (-) battery post. Wait for a minimum of 60 seconds prior to making any disconnection of electrical connections related to the SRS system. Refer to section 52B of the service manual for additional details on SRS Service Precautions. 

1. Seat Removal and Disassembly 
   1. Refer to the the service manual, section 52A, and remove the applicable front seat from the vehicle. Place the removed seat on a clean workbench covered with a shop blanket or equivalent protection.
      NOTE: Plastic interior parts scratch easily. Protect the surrounding areas from damage when removing the seat from the vehicle.
   2. Remove the seatback panel to access the side air bag module connector and mounting nuts.
      NOTE: It is not necessary to remove the bottom seat cushion.

      Using a screw driver, probe behind the seatback panel and push the lower left and right side retaining clips towards the center of the seat to release them from the panel. There is one on each side of the seat.

      Fig 1: Releasing Clips From Seatback Panel

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   3. Pull out and downward on the bottom edge of the seat back panel and moderately strike the panel along the centerline as shown. This will release the upper retaining clips. Pull down to remove the seat back panel.
   Fig 2: Releasing Upper Retaining Clips
   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   4. Inspect all of the seat back retaining clips for damage. Replace any damaged clips (MR306977) and reinstall the lower clips to their mounting points on the seat back.
2. Air Bag Removal 
   1. Push the hooks retaining the side cover inwards to release them from the seat frame.
      Fig 3: Releasing Hooks From Seat Frame

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

      THIS STEP DOES NOT APPLY TO 2004 MODELS. 

   2. Release the bottom cover hook by pulling it up far enough to clear the lateral support rod and then push inward as indicated.
      Fig 4: Releasing Bottom Cover Hook

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   3. Using a needle nosed pliers, remove the safety hook from the frame anchor. Note that it is very strong and will require an effort to release it.
      NOTE: THE SAFETY HOOK IS A SAFETY ITEM. REMEMBER TO REINSTALL IT DURING ASSEMBLY.
      Fig 5: Removing Safety Hook From Frame Anchor

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   4. 2007 Models  - Cut the white wire tie securing the wiring harness to the bracket.
      Fig 6: Cutting White Wire Tie

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   5. Remove the airbag retaining nuts and keep them for installing the new airbag assembly. For 2004 - 2006 models, these nuts also secure the bracket that the safety hook attaches to.
      Fig 7: Identifying Airbag Retaining Nuts

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

      2004 - 2006 Models Only 

   6. Pull the airbag assembly part way out of the seat frame and work the safety hook bracket loose of the studs.
   7. With needle nosed pliers, squeeze the tangs on the airbag harness clip and remove it from the bracket.
      Fig 8: Removing Airbag Harness Clip

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   8. Reposition the seat on the bench to allow access to the underside of the seat. Release the two clips securing the lower seat trim and fold the trim up and over the seat back to allow access to the airbag wiring harness on the underside of the seat.
      Fig 9: Locating Clips

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   9. Insert a screwdriver into the gray clip and twist the screwdriver to open the clip.
      Fig 10: Opening Clip

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   10. With needle nose pliers squeeze red harness clip and remove it from its bracket.
       Fig 11: Identifying Red Harness Clip

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   11. Insert a needle nosed pliers between the seat pan and the the seat cushion. Squeeze the retaining tabs of the black clip and pull it free of the seat pan.
       Fig 12: Inserting Needle Nosed Pliers Between Seat Pan And Seat Cushion

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   12. Locate the harness retaining ties on the underside of the seat assembly as illustrated. USING CARE, cut them to free the wiring harness.
       NOTE: For 2004 - 2006, Endeavor harness is black, Galant is yellow. For 2007 ALL harnesses are yellow.
       Fig 13: Identifying Seats Clips And Wire Ties

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
       CAUTION: USE CARE WHEN CUTTING THE HARNESS FREE. DO NOT CUT THE AIRBAG AND/OR SEAT BELT HARNESSES.
   13. Reposition the seat and remove the airbag module from the seat frame.

       Take note of the harness routing for positioning the harness when installing the new module. 

       Fig 14: Removing Airbag Module From Seat Frame

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
       WARNING: AIRBAG MODULES MUST BE PROPERLY DISPOSED OF. REFER GROUP TO 52B SUPPLEMENTAL RESTRAINT SYSTEMS - SRS OF THE SERVICE MANUAL FOR INSTRUCTIONS RELATING TO THE PROPER DISPOSAL OF AIRBAGS.
3. Airbag Module Installation 

   Install the new airbag module according to the following instructions. Installation is the reverse of removal.

   CAUTION: Confirm that you have the airbag for the correct seat application. The first letter of the serial number (L or R) relates to which seat the module is designed for. "L" is for the left hand seat and "R" is for the right hand seat.
   1. Route the connector of the airbag harness through the window in the seat frame.
      Fig 15: Routing Connector Of Airbag Harness Through Window In Seat Frame

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   2. Route the wiring harness from the new module in the same manner as the one you just removed.
      1. From the outside area of the frame, route the harness through the opening in the side rail and through the retaining bracket as shown.
      NOTE: THE AIRBAG MODULE MUST BE INSTALLED IN THE PROPER DIRECTION, WITH THE HARNESS PROTRUDING FROM THE TOP OF THE AIRBAG.
      Fig 16: Routing Wiring Harness From New Module

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   3. Route the harness between the inner plastic cover and the seat back assembly.
      Fig 17: Routing Harness Between Inner Plastic Cover And Seat Back Assembly

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   4. Align the air bag module mounting studs with the holes in the frame. If applicable, position the safety hook retaining bracket on the studs (2004 - 2006 models). Hand start the fastener nuts retained during removal of the air bag and and then torque them to specification. (17-26 Nm, 12.5-19 ft lb)
      Fig 18: Aligning Air Bag Module Mounting Studs With Holes In Frame

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   5. Attach the airbag harness to the safety bracket as shown.

      2004 - 2006 Models 

      Secure the harness by inserting the black clip into the hole in the harness bracket.

      Fig 19: Securing Harness (2004-06 Models)

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

      2007 Models 

      Secure the airbag harness to the frame bracket by looping a white tie under the frame bracket and around the harness. Pull the tie tight and cut off the excess.

      Fig 20: Securing Harness (2007 Models)

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   6. Reattach the safety hook and the 4 metal and 2 plastic seat cover hooks to the seat frame as shown. Install the bottom plastic seat cover hook first. Remember that the bottom hook must be installed above the lateral support rod and slid down into position. It may be necessary to tap the hooks with a rubber mallet to ensure proper attachment.
      NOTE: THE SAFETY HOOK MUST BE SECURELY SEATED TO ITS ANCHOR STRAP. IT MAY BE NECESSARY TO TAP IT INTO PLACE USING A RUBBER MALLET.
      Fig 21: Attaching Safety Hook And Metal And Plastic Seat Cover Hooks To Seat Frame

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   7. Place the seat on its back. If the seat is equipped with a seat heater, route the airbag module harness under the seat heater harness and secure the harnesses together as shown using a black tie clip.
      NOTE: If the seat is not equipped with a seat heater, secure the airbag module harness to the seat cushion pan with a black tie clip.
      Fig 22: Securing Harnesses Together

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   8. Position and insert the red airbag harness connector to the adjuster bracket.
      Fig 23: Inserting Red Airbag Harness Connector To Adjuster Bracket

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   9. Snap the gray connector closed to secure the air bag harness.
      Fig 24: Identifying Gray Connector

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   10. Route and secure the harness as shown.
       CAUTION: Do not tie the seat power harness with the other harnesses.
       Fig 25: Routing Harness

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   11. Wrap the bottom cloth around the seat and secure the clips to the second seat cushion support wire.
       Fig 26: Identifying Clips

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
4. Seat Reassembly and Installation 
   1. 12. Place the seat upright. Check the condition and location of the rear cover retaining clips. Secure the rear cover to the back of the seatback.
   2. 13. Reinstall the seat into the vehicle, torquing all fasteners to spec. Refer to Group 52 - Interior of the service manual for details.
   3. 14. Insure all electrical connections are secure.
   4. 15. Reconnect the battery and reset radio memory.
   5. 16. Using the scan tool, conduct "Occupant Classification Accuracy Check" as per the service manual. (Except Endeavor without  advanced airbag). Refer to "Accuracy Check of the Occupant Classification Sensor" under "On Vehicle Service" in Group 52B Supplemental Restraint System - SRS.
   6. 17. Using the scan tool, perform Erase and Read All DTCs". Diagnose and repair any DTCs that recur.
   7. 18. Test drive the vehicle to insure that no seat operation conditions or BSR issues have been created.

PARTS INFORMATION

Use the genuine Mitsubishi Part listed below.

Description	Part Number	Application
Side Airbag LH	7030A097	2007 Galant, Endeavor
Side Airbag RH	7030A098	2007 Galant, Endeavor
Side Airbag LH	MR595823	2004-06 Endeavor
Side Airbag RH	MR595824	2004-06 Endeavor
Side Airbag LH	MN121355	2004 Galant
Side Airbag RH	MN121356	2004 Galant
Side Airbag LH	7030A049	2005-06 Galant
Side Airbag RH	7030A050	2005-06 Galant
Hook, Frt Seat	MR306977	All Galant and Endeavor
Band, Frt. Seat White (Wire tie)	MR347763 (or equivalent)	As req'd
Band, Frt Seat Black (Wire Tie)	MB953180 (or equivalent)	As req'd

WARRANTY INFORMATION

This bulletin is supplied as technical information only and is not an authorization to repair.

If an affected vehicle is observed with the above condition, repair as described in this bulletin and submit a normal warranty claim as follows.

Seat Air Bag Module Replacement 

Nature Code:  260	Cause Code:  59D
Labor Operation No. LH.  52113095	Time Allowance:  0.8 hr.
Labor Operation No. RH  52123095	Time Allowance:  0.8 hr.

Warranty Coverage: 

Special Warranty Information: Normal warranty procedures apply.

Warranty Coverage: 

Restraint System Coverage Terms:

5 years/60,000 miles

Replaced Part Retention Requirements 

Retain all warranty replaced air bag modules for a period of 5 days from the claim payment date. If requested, parts must be returned to the requested address adherent to hazardous material shipping requirements. See Section 10 of the Warranty Policy and Procedures Manual for Hazardous Materials shipping information. 

If not requested to be returned after 5 days from claim payment date have elapsed, warranty replaced airbag modules may be properly disposed of locally. Refer to Section 52B - Supplemental Restraint System (SRS), of the service manual for instructions relating to the proper disposal of airbags.