Pcm Reprogramming For Catalytic Converter Overheating - Emissions Recall Campaign (EMR-06-003)

PCM REPROGRAMMING FOR CATALYTIC CONVERTER OVERHEATING - EMISSIONS RECALL CAMPAIGN

SERVICE CAMPAIGN BULLETIN

PURPOSE

Some affected vehicles have incorrect parameters in the Powertrain Control Module (PCM) software that may cause the warm-up catalytic converter to overheat and deteriorate when the vehicle is repeatedly driven in an aggressive manner.

• For all affected vehicles, check and note any DTCs set and reprogram the PCM as described in this bulletin, regardless of the age or mileage of the vehicle.
• If an affected vehicle has a Service Engine Soon (SES) lamp on and DTC P0421 and/or P0431 set (before reprogramming the PCM), also replace the warm-up catalytic converter, using an exhaust manifold repair kit.

AFFECTED VEHICLES

2004-2005 Galant models equipped with 2.4L MIVEC engine for California and Federal Emissions

CUSTOMER NOTIFICATION

A letter will be sent to all owners of affected vehicles, telling them to bring their vehicle to a Mitsubishi Motors dealer to have the PCM reprogrammed at no charge. If their vehicle has a SES lamp on for failure of the warm-up catalytic converter (DTC P0421 and/or P0431), before reprogramming the PCM, a new warm-up catalytic converter must be installed.

REQUIRED OPERATIONS

Before starting this campaign procedure, CHECK ON THE WARRANTY SUPERSCREEN  to verify that the vehicle is an affected VIN for this campaign and that this campaign procedure has not already been completed.

1. Check the underside of the hood to verify that there is no label previously installed to indicate that this Emissions Recall reprogramming has already been done.
2. Using the MUT-III, verify that the vehicle's ECU part number is listed in the table in Step 7.
3. Note any DTCs set in the PCM. Then use the MUT-III to erase all DTCs.
4. MEDIC-II ONLY  . Verify that your MEDIC-II is at download M136 or higher.
   IMPORTANT: Dealers using MEDIC-II will not receive a reflash CD. The reflash data will be sent electronically.
   1. If the download is M136 or higher, GO TO STEP 6. 
   2. If the download version is less than M136, force a download to the MEDIC-II as follows:
   1. On the MEDIC-II main screen, click on "Maintenance".
   2. Click on "Download". After the download completes, GO TO STEP 6. 
5. Scan Tool Viewer (STV) ONLY (MEDIC-II USERS GO TO STEP 6).  Verify that your MUT-III is at STV Version 15 or higher, and that it has the most current version of the reprogramming database:
   1. Select "Special Function", then select "ECU Reprogramming."
   2. Select "Database File Display". The database version is displayed in the top right corner of the screen. Make sure the database version is N06112 or greater  .
   3. If the database version is N06112 or greater  , reprogram the PCM as described in Step 6  .
   4. If the database version is less than N06112  , you must transfer the new reprogramming data from the Reflash Update CD 12/06  to the MUT-III hard drive as follows:
   1. Install Reflash Update CD 12/06  into the PC's DVD-ROM drive.
   2. Follow the instructions on the screen. The system will automatically transfer the reprogramming data onto the PC's hard drive.
6. Reprogram the PCM as follows:
   1. Transfer the reprogramming data from the laptop to the memory card. (Use the port on the left side of the laptop.) Select ECU Reprogramming, then Memory Card Transfer. A status bar will display while the data is loading into the memory card  .

      When the memory card data transfer is complete, remove the memory card from the laptop and install it in the VCI.

   2. Connect the following equipment:
      • VCI (Vehicle Communication Interface) - MB991824
      • MUT-III main harness A (Blue) - MB991910
   3. Reprogram the PCM, using "Automatic reprogramming"  on the VCI. It will take up to 20 minutes to complete the 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 PCM REPROGRAMMING.

   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 in Step 7.

   • If the ROM ID is the same or higher than the ROM ID in the table, the PCM has already been reprogrammed for this concern. Do not continue with this reprogramming procedure.
   • If it is not, verify that the correct database update is in the MUT-III. Verify the correct database was transferred to the memory card, and that the memory card is properly installed in the VCI.
7. After reprogramming, the new ECU part number and software part number will display. Verify that they are the same as those listed below. Note this information.
   ECU PART NUMBER INFORMATION
   
   

   			DISPLAY ON MUT-III SCREEN AFTER REPROGRAMMING
   MODEL	PCM PART NUMBER	MUT-III REFLASH DATABASE	ECU PART NUMBER	ROM ID	VENDOR #
   2004 Galant 2.4L MIVEC Calif. emissions	MN156501	VN06091	MN156501	ENG: B48853 A/T: B73018	E6T41676W042
   2004 Galant 2.4L MIVEC Fed. emissions	MN147173	VN06092	MN147173	ENG: B43053 A/T: B74513	E6T41675W042
   2004 Galant 2.4L MIVEC Calif. emissions	1860A225	VN06093	1860A225	ENG: B48827 A/T: B07201	E6T41680W031
   2004 Galant 2.4L MIVEC Fed. emissions	1860A226	VN06094	1860A226	ENG: B43033 A/T: B07301	E6T41681W031
   2005 Galant 2.4L MIVEC Calif. emissions	1860A057	VN06075	1860A057	ENG: 365825 A/T: 302905	E6T41679H82
   2005 Galant 2.4L MIVEC Fed. emissions	1860A056	VN06076	1860A056	ENG: 365725 A/T: 302805	E6T41678H82

8. If DTC P0421 and/or P0431 were set in the PCM as a result of confirmation for any DTCs in Step 3, replace the warm-up catalytic converter, using the exhaust manifold repair kit listed in the PARTS INFORMATION section of this bulletin. Refer to Group 15 in the appropriate service manual for installation instructions.
9. Using a ball-point pen, enter the appropriate PCM part number, vendor number, ROM ID#, this recall bulletin number (EMR-06-003  ), your dealer code, and the current date on the Engine Compartment/Control Module Label (p/n MSSF-024G-00).
10. Carefully remove all dirt and oil from a vacant area near the VECI label on the underside of the hood, and affix the Engine Compartment label.
11. Affix the Control Module label to the PCM.
12. FOR VEHICLES REGISTERED IN CALIFORNIA ONLY  : Complete a "VEHICLE EMISSION RECALL - PROOF OF CORRECTION" form (p/n MSSF-106D-00). Give the completed form to the vehicle owner.
    NOTE: These forms are available from Workflow One at 1-866-980-7000.

PARTS INFORMATION

Use the Genuine Mitsubishi Parts listed below.

Description	Model	Part Number
Exhaust Manifold Repair Kit (includes manifold with catalytic converter, gasket, and nuts)	Federal emissions	1555A410
Exhaust Manifold Repair Kit (includes manifold with catalytic converter, gasket, and nuts)	California emissions	1555A411

WARRANTY INFORMATION

Claims for this campaign must be entered as recall Type "C" claims in the Mitsubishi Dealer Link (MDL).

Campaign Operation: C0608BXX 

Labor Time: 

0.3 hrs. for PCM Reprogramming OR 

1.2 hrs. for PCM Reprogramming and ONLY IF NEEDED, Catalytic Converter Replacement 

Sample claim screens are shown on the following pages.

Replacement Parts Storage and Retention: 

Retain all replaced catalytic converters for at least five (5) days after the payment of the related campaign claim.  The five days begins the day after the claim appears in the "Paid" section of your warranty claim statement. If the part is requested during those five days, you must return the part as indicated on the parts return request letter.

If you do not receive a request after five days from the claim payment date, you may scrap the replaced catalytic converter.

Header Section 2004 and 2005 Galant 2.4L MIVEC Emissions Recall 

SCENARIO 1: UPON INSPECTION ONLY PCM REPROGRAMMING IS NEEDED 

PARTS SECTION: No Parts Are Allowed For Reprogramming Only Claims 

LABOR SECTION: PCM REPROGRAMMING ONLY 

SCENARIO 2: PARTS SECTION: REPROGRAMMING AND CATALYTIC CONVERTER REPLACEMENT 

LABOR SECTION: PCM REPROGRAMMING AND, ONLY IF NEEDED, CATALYTIC CONVERTER REPLACEMENT (Note: Cat Con is integrated with the exhaust manifold)