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EMISSIONS RECALL BULLETIN

SUBJECT: No: EMR−05−001REVII
CATALYTIC CONVERTER OVERHEATING DATE: December, 2005
— EMISSIONS RECALL CAMPAIGN MODEL: 2002−05 Lancer
CIRCULATE TO: [ ] GENERAL MANAGER [X] PARTS MANAGER [X] TECHNICIAN
[X] SERVICE ADVISOR [X] SERVICE MANAGER [X] WARRANTY PROCESSOR [ ] SALES MANAGER

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.

S For all affected vehicles, reprogram the PCM as described in this bulletin, regardless of the age
or mileage of the vehicle.

S 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 appears later 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.

FILE UNDER:
Emission Recall Bulletins in the Dealer Service Information Binder (2973)
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EMR−05−001REVII

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.”

b. Select “Database File Display”. The database version is displayed in the top right corner of the
screen. Make sure the database version is N05111 or greater.
c. If the database version is less than N05111, go to Step 5.
d. If the database version is N05111 or greater, go to Step 8.

5. Turn the ignition key to OFF and disconnect the MUT−III.

6. Gather the following reprogramming equipment:

− MUT−III / STV Reflash Update CD 12/05 or later

− Memory Card 128 MByte Compact Flash MB991853
− Memory Card Adapter PCMCIA MB991939
− “Engine Compartment/Control Module” Labels p/n MSSF−024G−00

UPDATE CD VCI MUT−III MAIN HARNESS

MUT−III LAPTOP

MEMORY CARD ADAPTER MEMORY CARD

7. Install Reflash Update CD 12/05 in the MUT−III laptop. Follow the CD installation instructions.

8. Transfer the reprogramming data from the laptop to the memory card.
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9. Remove the memory card from the laptop and install it in the VCI. Connect the VCI to the vehicle.
YOU MUST DISCONNECT THE MUT−III LAPTOP.

10. MODELS EQUIPPED WITH ABS: With the ignition key OFF, unplug the ABS fuse (7.5 amp fuse in
junction box in passenger compartment).

11. Reprogram the PCM, using automatic reprogramming. For reprogramming details, refer to
TSB−03−00−015. 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 below.
S If the ROM ID is the same as or higher than the ROM ID in the table, the PCM has been re-
programmed for this concern.
S If it is not, 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.

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.

a. After reprogramming is completed, the new ENG ROM ID and new A/T ROM ID will display
alternately with the message “Turn IG SW OFF” every four seconds. Note this information.
Verify that the new PCM part number and ROM IDs are the same as those listed in the table
below.
DISPLAY ON MUT−III SCREEN
AFTER REPROGRAMMING
MODEL PCM MUT−III ECU ROM ID VENDOR #
PART REFLASH PART
NUMBER DATABASE NUMBER
2002 Lancer M/T MR578519 VN0510A MR578519 987220 E6T34976H5
Fed. emissions
2002 Lancer A/T MR578521 VN0510B Eng: MR578521 Eng: 885621 E6T31083HS40
Fed. emissions A/T: MR578521 A/T: 852806
R15 tires
2002 Lancer A/T MR578490 VN0510C Eng: MR578490 Eng: 899021 E6T31081HS40
Fed. emissions A/T: MR578490 A/T: 864204
R14 tires
2002 Lancer M/T MR578518 VN0510G MR578518 986720 E6T34975H5
Calif. emissions
2002 Lancer A/T MR578520 VN0510H Eng: MR578520 Eng: 885421 E6T31082HS40
Calif. emissions A/T: MR578520 A/T: 852606
R15 tires
2002 Lancer A/T MR578489 VN0510I Eng: MR578489 Eng: 898921 E6T31080HS40
Calif. emissions A/T: MR578489 A/T: 864104
R14 tires
2003 Lancer M/T MR988330 VN05107 MR988330 918915 E6T34979H4
Fed. emissions
2003 Lancer A/T MR988331 VN05108 Eng: MR988331 Eng: 819016 E6T31087HS40
Fed. emissions A/T: MR988331 A/T: 875102
R15 tires
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2003 Lancer A/T MR988332 VN05109 Eng: MR988332 Eng: 819116 E6T31088HS40
Fed. emissions A/T: MR988332 A/T: 875202
R14 tires
2003 Lancer M/T MR988327 VN0510D MR988327 918616 E6T34978H4
Calif. emissions
2003 Lancer A/T MR988328 VN0510E Eng: MR988328 Eng: 818717 E6T31085HS40
Calif. emissions A/T: MR988328 A/T: 874902
R15 tires
2003 Lancer A/T MR988329 VN0510F Eng: MR988329 Eng:818817 E6T31086HS40
Calif. emissions A/T: MR988329 A/T:875002
R14 tires
2004 Lancer M/T MN132864 VN05104 MN132864 922923 E6T34983H5
2004 Lancer A/T MN132867 VN05105 Eng: MN132867 Eng:823024 E6T31095H50
R15 tires A/T: MN132867 A/T:876903
2004 Lancer A/T MN132868 VN05106 Eng:MN132868 Eng:823124 E6T31096H50
R14 tires A/T: MN132868 A/T:877001
2005 Lancer M/T 1860A067 VN05101 1860A067 966314 E6T34987H3
2005 Lancer A/T 1860A068 VN05102 Eng: 1860A068 Eng:866414 E6T42773H30
R15 tires A/T: 1860A068 A/T:802302
2005 Lancer A/T 1860A069 VN05103 Eng:1860A069 Eng:866514 E6T42774H30
R14 tires A/T: 1860A069 A/T:802402
2006 Lancer M/T 1860A417 VN05091 1860A417 882512 E6T34989H1
2006 Lancer A/T 1860A418 VN05092 Eng:1860A418 Eng:882612 E6T42777H10
R15 tires A/T:1860A418 A/T:812502
2006 Lancer A/T 1860A419 VN05093 Eng:1860A419 Eng:882712 E6T42778H10
R14 tires A/T:1860A419 A/T:812601

12. If DTC P0421 was set in the PCM, replace the warm−up catalytic converter, using the exhaust
manifold repair kit listed in the PARTS INFORMATION section of this bulletin. Refer to Group
17 (for California emissions vehicles) or Group 15 (except California emissions vehicles) in the
appropriate service manual for installation instructions.

13. Using a ball−point pen, enter the appropriate PCM part number, vendor number, ROM ID#, this
recall bulletin number (EMR−05−001), your dealer code, and the current date on the Engine
Compartment / Control Module Label (p/n MSSF−024G−00).

14. 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.
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15. Affix the Control Module label to the PCM.

16. MODELS EQUIPPED WITH ABS: Reinstall the ABS fuse.

17. 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 Relizon at
1−866−980−7000.

PARTS INFORMATION
Use the Genuine Mitsubishi Parts listed below.

Description Model Part Number

Exhaust Manifold Repair Kit 2002−2003 Lancer 2.0L MN195801
(includes manifold with catalytic converter,
gasket, and nuts)
Exhaust Manifold Repair Kit 2004 Lancer 2.0L MN195802
(includes manifold with catalytic converter,
gasket, and nuts)
Exhaust Manifold Repair Kit 2005 Lancer 2.0L MN195803
(includes manifold with catalytic converter,
gasket, and nuts)

WARRANTY INFORMATION
Refer to the flowchart on the following page.
Claims for this campaign must be entered as recall Type “C” claims in the Mitsubishi Dealer
Network (MDL).

Campaign Operation: C0505JXX

Labor Time:

0.3 hrs. for PCM Reprogramming OR

1.9 hrs. for PCM Reprogramming and 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.
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Mitsubishi Motors North America, Inc.

The information contained in this bulletin is subject to change. For the latest version of this document, go to the
Mitsubishi Dealer Link, MEDIC, or the Mitsubishi Service Information website (www.mitsubishitechinfo.com).
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2002−2005 Lancers Equipped with 2.0L Engine

Catalytic Converter Overheating − Emissions Recall Campaign

Header Section
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Parts Section − If ONLY PCM Reflash is needed

Labor Section − If ONLY PCM Reflash is needed

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Parts Section − If both PCM Reflash and Catalytic Converter replacement are needed

2005 models − p/n MN195803

2004 models − p/n MN195802
2002−2003 models − p/n MN195801

Labor Section − If both PCM Reflash and Catalytic Converter replacement are needed
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