Pcm Reprogramming Service Campaign And Catalytic CONVERTOR (DTC P0420 May Be Set) Warranty Extension (SC-13-002)

PCM REPROGRAMMING SERVICE CAMPAIGN AND CATALYTIC CONVERTOR (DTC P0420 MAY BE SET) WARRANTY EXTENSION

SERVICE CAMPAIGN BULLETIN

PURPOSE

This service campaign bulletin provides instructions to reprogram the PCM with new software and, if necessary, replace the catalytic convertor. The new software will minimize continuous over-redline (abusive) operation by inducing the driver to up-shift or reduce throttle input.

A driver's continuous over-redline (abusive) operation can cause extremely high catalyst temperatures, which can damage the catalytic convertor. The damaged catalytic convertor may cause affected vehicles to exhibit MIL illumination with DTC P0420, "Warm Up Catalyst Efficiency Below Threshold" stored in the PCM.

Mitsubishi Motors North America, Inc. (MMNA) is also extending the catalytic convertor warranty on all affected vehicles to 5/31/2014 or until 100,000 miles, whichever is longer.  Refer to Warranty Bulletin WB 2014-003 for additional details. MMNA is also offering a $50 Mitsubishi fuel card to owners that have this service campaign completed. The card can be used at any gas station that accepts MasterCard®.

Warranty Coverage Application Examples: 

1. Until May 31, 2014: Regardless of a vehicle's mileage, a defective catalytic convertor will be warranty covered.
2. From June 1st, 2014: A defective catalytic convertor will be warranty covered up to 100,000 miles regardless of time. A vehicle beyond 100,000 miles will not be covered.

AFFECTED VEHICLES

2006 Lancer Evolution

CUSTOMER NOTIFICATION

A letter will be sent to all owners of affected vehicles requesting them to bring their vehicle to a local Authorized Mitsubishi dealership to have their ECM updated with the latest software. All owners who receive this product improvement  are eligible to receive a $50 Mitsubishi fuel card. The card will be made out to the owner's name on the campaign claim and mailed to the address on the claim. The owner will receive it 4-6 weeks after the campaign claim is processed. Please refer to the Warranty Information  section. A copy of the customer notification letter appears at the end of this bulletin.

REQUIRED OPERATIONS

Before starting this campaign procedure, CHECK THE VEHICLE INFORMATION SUPER SCREEN  to verify if the vehicle is an affected VIN for this campaign (C1305H) and this campaign procedure has not already been completed.

1. Conduct standard catalytic convertor inspection and DTC P0420 diagnosis.
   • If the catalytic convertor is damaged and the vehicle is within terms of the warranty extension, replace it using parts listed in the Parts Information  section before proceeding with step 2.
2. Reprogram the ECM with new parameters using the following equipment:
   • MEDIC laptop computer with A/C power adaptor - 520924, or MIT547708.
     • MEDIC 3 Update is at 038 or higher.
     • For Standalone MUT-III laptops, reprogramming database N11021 or higher.
   • VCI (Vehicle Communication Interface) - MB991824.
   • MUT-III main harness 'B' (RED  DLC connector & 12 pin reprogramming connector) - MB991911.
   • "Engine Compartment/Control Module" label - p/n MSSF024G00.
   • 128 Mb Compact Flash Memory Card - MB991853 (or equivalent)
   • PCMCIA Memory Card Adapter - MB991939 (or equivalent)
3. Explain to the customer what to expect from the new software. If their catalyst convertor was damaged, advise them the damage was due to continuous operation during over-redline fuel cut-off. After reprogramming, a vehicle operated in the over-redline, fuel cut range for several seconds will exhibit a much more pronounced fuel cut or power reduction (≈ 200 RPM) to induce the driver to either up-shift or reduce throttle input.
4. After reprogramming, perform a test drive to confirm repairs.

ECM REPROGRAMMING CHART

MODEL	CURRENT PART NO.	ROM ID	DISPLAY ON MUT-III AFTER REPROGRAMMING
			New Part No.	New ROM ID
06 Lancer Evolution 2.0L 5M/T & 6M/T	1860A465	885913 or 885914 or 885915	1860A465	885916

PROCEDURE

If inspection confirms the catalytic convertor is damaged, replace it using the part number shown in the Parts Information  section of this bulletin.

1. Gather the reprogramming equipment:
2. Check the underside of the hood to verify that there is no label previously installed to indicate the vehicle has already been reprogrammed for this service campaign bulletin, TSB-11-13-003, TSB-12-13-001 or TSB-12-13-001REV. If it has, no further reprogramming is necessary. Submit campaign claim using labor operation C1305H 0.3 hrs.
3. Verify the vehicle's PCM part number is listed in the ECM Reprogramming Chart that appears earlier in this bulletin.
   1. Connect the laptop to the VCI, and the VCI to the vehicle. Turn the ignition to the ON position.
   2. From the Main Menu, click on System Select.
   3. Select MFI.
   4. Select ECU Information
   5. Compare the ROM ID to the ECM Reprogramming Chart that appears earlier in this bulletin.
      • If the ROM ID listed is earlier (lower number) than what is listed in the table, go to step 4.
      • If the ROM ID listed is the same as, or later than (higher number), the ROM ID in the chart, the PCM has already been reprogrammed for this concern. No further reprogramming is necessary. Submit campaign claim using labor operation C1305H 0.3 hrs.
4. Use the MUT-III to erase all DTCs set in the PCM.
   • Click the UP arrow at the bottom left of the screen to return to the MFI menu, then select Read and Erase DTCs.

   MEDIC 3 USERS (Stand-alone MUT-III users go to step   7 .) 

5. Verify that your MEDIC 3 has the most current version of the reprogramming database. Starting on the MEDIC 3 main page confirm your MEDIC 3  update is at 038 or greater. 
6. If your MEDIC 3 is not to the required level, click the "Admin" tab and select "Updates." Follow the onscreen instructions to update your MEDIC and download the latest reflash database.

   STAND-ALONE MUT-III USERS 

7. Verify your MUT-III has the most current version of the reprogramming database. Starting on the MUT-III main page:
   1. Select "Special Function", then select "ECU Reprogramming."
   2. Select "Database File Display (K-line)". The database version is displayed in the top right corner of the screen. Make sure the database version is N11021 or greater. 
      • If the database version is N11021 or greater,  continue with "Updating the VCI.".
      • If the database version is less than N11021,  install the latest reflash database from the YELLOW reflash CD 2/11 issued 12/2011.
        NOTE: Updating with CD 2/11 will bring your database version to N11121.
        1. From the MUT-III Main Menu, select Special Function.
        2. Select Database File Display.
        3. When the Installation Check window appears, click the check mark.
        4. After the update completes, remove the Reflash Update CD from the PC's DVD-ROM drive and continue to "Updating the VCI."
        5. Click the "up" arrow in the lower left corner of the screen to return to the ECU Reprogramming menu.

        UPDATING THE VCI 

        NOTE: You only have to transfer a reprogramming database to the VCI once. It is not necessary to update again until a new reprogramming database is released.
        1. Install the memory card into the card adaptor.
        2. Install the card adapter into one of the PC card slots. (You can use either slot for the card adapter.)

           A "Found New Hardware" message displays on the monitor. Wait for the message to disappear.

        3. Select "Memory card transfer" (Do not remove the memory card from the PC).
        4. Select the the drive with "\Removable Disk" and press the check mark button.

           Stand-alone MUT-III (IBM laptop) will be drive E:\ MEDIC (Panasonic laptop) will be drive F:\

        5. When the message "Check of Operation - It transfers data to the memory card. Are you ready?" displays, press the check mark button.
        6. A progress monitor displays during data transfer to the memory card.
        7. When the message "Transfer is complete" appears, press the check mark button.
           NOTE: Data transfer will take 10 minutes or more.

           To remove the memory card:

        8. Click the "safely remove hardware" icon in the lower right corner of the screen.
        9. Select "PCMCIA IDE/ATAPI Controller," then click the Stop button.

           When the message "The device can now be safely removed from the system" displays, remove the memory card (press the button next to the PC card slot) and "Close" the Safely Remove Hardware window.

        10. Install the memory card adaptor in the slot at the bottom of the VCI.

REPROGRAMMING PROCEDURE

CONNECT A BATTERY CHARGER TO THE VEHICLE'S BATTERY DURING THE REPROGRAMMING PROCEDURE. DO NOT ALLOW THE BATTERY CHARGER TO TIME OUT. BATTERY VOLTAGE (AS MEASURED AT THE BATTERY POSTS WITHOUT ELECTRICAL LOAD) MUST BE KEPT AT 12.4V OR HIGHER IN ORDER TO REPROGRAM THE ECM. MEASURE THE BATTERY VOLTAGE AND CHARGE AS NECESSARY. 

1. MAKE SURE THE USB CABLE IS DISCONNECTED FROM THE VCI. 
2. Connect the VCI to the vehicle.
   IMPORTANT: Both connectors of the MUT-III main harness must be connected to the vehicle to perform reprogramming.
   CAUTION: DO NOT DISTURB THE HARNESS CABLES OR CONNECTIONS. INTERRUPTION DURING THE PROGRAMMING PROCESS COULD CAUSE THE PCM TO LOSE DATA OR PREVENT FUTURE REPROGRAMMING.
3. On the VCI, select "1. Automatic rpg." For reprogramming details, refer to TSB-06-00-004  . It will take up to 20 minutes to complete the reprogramming.
   NOTE: If the message "ECU at Current Level of VCI" appears, the PCM did not reprogram. Verify that the ROM ID is the same as the ROM ID listed in the table  on .
   • If the ROM ID is the same as or higher  than the ROM ID in the table, the PCM has already been reprogrammed for this concern. No further reprogramming is necessary. Submit campaign claim using labor operation C1305H 0.3 hrs.
   • If the ROM ID is lower, verify that the correct database update is in the MUT-III and was transferred to the memory card, and that the memory card is properly installed in the VCI.
4. After reprogramming completes, the new PCM p/n and ROM ID are displayed with the message "Turn IG SW OFF". Verify the new information is the same as listed in the table  on .
5. Check for DTCs recorded in PCM memory. Diagnose and repair as necessary.
6. Using a ball-point pen, enter the appropriate PCM part number, vendor number, ROM ID#, this service campaign number (SC-13-002), your dealer code, and the current date on the Engine Compartment / Control Module Label (part no. MSSF024G00).

The Control Module Label is NOT used for this reflash. It should be discarded. 

PARTS INFORMATION

Use only the Genuine Mitsubishi Parts listed below. Please refer to Parts Bulletin 15-LE-01-13 for additional information.

Description	Part Number
Label, Engine Compartment	MSSF024G00
Kit, Catalytic Convertor	1584A903