Lancer LS L4-2.0L SOHC (2002)
Technical Service Bulletin # EMR-05-001R2
Date: 051201
Recall - PCM Update for Warm-Up Cat. Converter Melt Down
No: EMR-05-001REVII
DATE: December, 2005
MODEL:
2002-05 Lancer
CATALYTIC CONVERTER - OVERHEATING - EMISSIONS
RECALL CAMPAIGN
This TSB supercedes EMR-05-001REV, issued October 2005, to update the PCM reprogramming database, which eliminates TPS reinitialization, and
to update the warranty labor time.
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 melt when the vehicle is repeatedly driven at wide-open throttle. For certain 2002-2003 vehicles, new warranty limits will apply to the
warm-up catalytic converter, which are described in the CUSTOMER NOTIFICATION and WARRANTY INFORMATION sections of this bulletin.
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For all affected vehicles, reprogram the PCM as described in this bulletin, regardless of the age or mileage of the vehicle.
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If an affected vehicle has a Service Engine Soon (SES) lamp on and DTC P0421 set, also replace the warm-up catalytic converter, using an exhaust
manifold repair kit. See warranty details below.
AFFECTED VEHICLES
2002-2005 Lancer models equipped with 2.0L engine (approximately 195,000 vehicles)
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, and that if their vehicle has a SES lamp on for failure of the warm-up catalytic converter (DTC P0421), they will also receive a new
warm-up catalytic converter.
In addition, owners will be advised that the new warranty coverage for the warm-up catalytic converter will be extended from 8 years/80,000 miles to a
limit of 8 years/100,000 miles. Until February 28, 2006, replacement of the warm-up catalytic converter will be free of charge, regardless of vehicle
mileage.
After February 28, 2006, all owners (regardless of vehicle mileage) will be entitled to the PCM reflash free of charge. However, warm-up catalytic
converter replacement will not be covered under the warranty if a 2002-2003 model has over 100,000 miles (over 80,000 miles for 2004-2005 models).
A copy of the customer notification letter is shown in this bulletin.
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.
CAUTION
BATTERY VOLTAGE (AS MEASURED AT THE BATTERY POSTS WITHOUT ELECTRICAL LOAD) MUST BE 12.4V OR HIGHER
IN ORDER TO REPROGRAM THE PCM.
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.
Verify that the vehicle's PCM part number is listed in the table in Step 11 of this bulletin.
a.
Verify whether the ROM ID is the same as the ROM ID listed in the table in Step 11. 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.
3.
Note any DTCs set in the PCM. Then use the MUT-III to erase all DTCs.
4.
Verify that your MUT-III has the most current version of the reprogramming database:
a.
Select "Special Function", then select "ECU Reprogramming."
