Pcm Reprogramming And Catalytic CONVERTOR Replacement (DTC P0420 May Be Set) (TSB-12-13-001REV)

PCM REPROGRAMMING AND CATALYTIC CONVERTOR REPLACEMENT (DTC P0420 MAY BE SET)

TECHNICAL SERVICE BULLETIN

REVISION HISTORY

PURPOSE

This TSB 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. 

AFFECTED VEHICLES

2006 Lancer Evolution

REQUIRED OPERATIONS

1. Conduct standard catalytic convertor inspection and DTC P0420 diagnosis.
   • If the catalytic convertor is damaged, replace it using parts listed in ASA-CAPS 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 caused MIL illumination and what to expect from the new software. Advise them their catalytic convertor was damaged 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 shift up or reduce throttle input.
4. After reprogramming, perform a test drive to confirm repairs.

ECM REPROGRAMMING CHART

PROCEDURE

If inspection confirms the catalytic convertor is damaged, replace it using the part number shown in the Parts Information section of this TSB, or refer to ASA CAPS.

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 TSB, TSB-11-13-003, or TSB 12-13-001. If it has, this TSB does not apply. Conduct normal P0420 diagnosis.
3. Verify the vehicle's PCM part number is listed in the ECM Reprogramming Chart that appears earlier in this TSB.
   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 TSB.
      • 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. This TSB does not apply. Conduct normal P0420 diagnosis.
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 037 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.

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 .
   • 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. This TSB does not apply. Conduct normal P0420 diagnosis.
   • 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 .
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 TSB number (TSB-12-13-001REV  ), 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.

WARRANTY INFORMATION

If an affected vehicle is repaired for the described condition, submit a normal warranty claim using the following information.