Campaign - O2 Sensor Replacement/PROM Update
VOLUME3
GROUP
Campaign
NUMBER
037
MODEL
Optima
DATE
March 2004
SUBJECT
Service Campaign: ECM Reprogramming 2.5L & 2.7L V6 Engine 02 Sensor
This bulletin provides information relating to a service campaign for possible 02 sensor MIL illumination. Some 2001MY 2.5L and 2002MY 2.7L Optima V6 engines may experience the following conditions:
^ Malfunction Indicator Light (MIL) illumination
^ One or more of the following Diagnostic Trouble Codes (DTC) stored in the Engine Control Module (ECM)
^ B1/S1: Bank 1 (RH, bulkhead side) Sensor 1 (upstream)
- P0133: H025 Circuit slow response B1S1
- P0134: H025 Circuit no activity detected B1S1
- P1134: H025 Circuit-transition switch time malfunction B1S1
^ B2151: Bank 2 (LH, radiator side) Sensor 1 (upstream)
- P0153: H025 Circuit slow response B251
- P0154: H025 Circuit no activity detected B251
- P1154: H025 Circuit - transition switch time malfunction B251
To reduce the incidence of MIL illumination, perform this service campaign as follows:
1. 2001 MY Optimas: Install improved 02 Sensors, if they were not installed in Campaign SC028, Optima Oxygen Sensors, published March 2003. Follow the Replacement Procedure for 2001 MY 02 Sensors in this campaign and then reprogram ECM following the Reprogramming Procedure for 2001 MY and 2002MY ECM in this campaign.
2. 2001 MY Optimas: If Campaign SC028, Optima Oxygen Sensors, published March 2003 was previously completed, then reprogram ECM following the Reprogramming Procedure for 2001 MY and 2002MY ECM in this campaign.
3. 2002MY Optimas: Reprogram the ECM following the Reprogramming Procedure for 2001 MY and 2002MY ECM in this campaign.
NOTICE
There is no charge to the customer for this repair. Under applicable law, you may not sell or otherwise deliver any affected 2001-2002MY Optima until it has been repaired, pursuant to the procedures set forth in this bulletin.
Campaign Parts Information:
There are no vehicle parts required for 2002MY vehicles. Some 2001MY vehicles will require new 02 sensors. For additional part number information.
ROM ID INFORMATION TABLE
INSPECTION PROCEDURE:
Open hood and check for a SC037 Campaign Completion Label on the bulkhead above the master cylinder.
^ If label exists, NO FURTHER ACTION IS REQUIRED.
^ If label DOES NOT EXIST, continue on to appropriate procedure for specific model year as indicated in numbers 1 - 3 in this campaign.
REPLACEMENT PROCEDURE: FOR 2001MY 02 SENSORS
^ For 2001 MY vehicles, check Dealer DCS System under the Warranty main menu, number 8, for open Service Campaign SC028. If campaign has been completed, reprogram ECM only. If SC028 has NOT been completed, REPLACE UPSTREAM 02 SENSORS (B1S1, B251) AND REPROGRAM ECM.
REPAIR PROCEDURE:
1. Position vehicle on a hoist but do not raise.
2. Open hood, disconnect bank 2 sensor 1 connector at front corner of left cylinder head and remove connector from bracket.
3. Disconnect bank 1 sensor 1 connector at rear corner of right cylinder head and remove connector from bracket.
4. Raise vehicle on hoist and using suitable 02 sensor socket, remove both front (pre-catalyst) oxygen sensors.
5. Install new oxygen sensors, black wire sensor on bank 1 (bulkhead side) and gray wire sensor on bank 2 (radiator side). Torque to 29 - 36 lb-ft (40 - 50 Nm).
6. Lower vehicle and reconnect sensor connectors, reinstall connectors onto brackets.
REPROGRAMMING PROCEDURE FOR 2001MY AND 2002MY ECM:
NOTICE
Clear any stored Diagnostic Trouble Codes (DTCS) before reprogramming ECM.
1. Connect OBDII cable to the Hi-Scan Pro.
2. Remove the program card from the upper slot on the Hi-Scan Pro and insert the reprogramming card.
3. Connect the Hi-Scan Pro to the vehicle OBDII connector located under the dash on the driver's side.
NOTICE
Any interruptions will prevent proper reprogramming. Make sure all connections are secure. Leave the ignition key in the ON position during reprogramming. If reprogramming is interrupted - go to Manual Reprogramming Procedure.
4. Turn the ignition key to the "ON" position.
5. Turn the Hi-Scan Pro on and select "15. Optima 2.5&2.7 TiO2S HEATING" and press the "ENTER" key.
6. Select "01. MS 2.5&2.7 TiO2S HEATING [AUTO]" and press the "ENTER" key.
7. At the prompt, enter your password "0525" and press the "ENTER" key.
8. Reprogramming will proceed automatically as shown.
9. When "REPROGRAMMING COMPLETED" message is displayed, turn the Hi-Scan Pro off and disconnect from vehicle. Turn the ignition key to the "OFF" position for 20 seconds, start engine and verify normal operation.
10. Check for DTC using the Hi-Scan Pro with system program card and erase any stored DTC.
11. Install SC037 Campaign Completion Label onto bulkhead above master cylinder.
NOTICE
If reprogramming did NOT complete properly or was interrupted, repeat process using the following procedure.
MANUAL REPROGRAMMING
PROCEDURE:
1. Turn the ignition key to the "ON" position.
2. Turn the Hi-Scan Pro on and select "15. Optima 2.5&2.7 TiO2S HEATING" and press the "ENTER" key.
3. Select "02. MS 2.5&2.7 Ti025 HEATING [ERROR]" and press the "ENTER" key.
4. Select option that matches the model year and engine, and press the "ENTER" key.
5. At the prompt, enter your password from the chart and press the "ENTER" key.
6. Reprogramming will proceed automatically as shown.
7. When "REPROGRAMMING COMPLETED" message is displayed, turn the Hi-Scan Pro off and disconnect from vehicle. Turn the ignition key to the "OFF" position for 20 seconds, start engine and verify normal operation.
8. Check for DTC using the Hi-Scan Pro with system program card and erase any stored DTC.
9. Install SC037 Campaign Completion Label onto bulkhead above master cylinder.
FOR CALIFORNIA, MASSACHUSETTS, VERMONT; AND MAINE DEALERS:
VEHICLE EMISSION RECALL - PROOF OF CORRECTION CARD
A Vehicle Emission Recall - Proof of Correction card must be filled out for all vehicles registered in California, Massachusetts, Vermont, and Maine.
California, Massachusetts, Vermont, and Maine residents who own an affected vehicle will be required to possess a Vehicle Emission Recall - Proof of Correction card as evidence of voluntary service campaign completion when they apply for vehicle registration renewal.
WHAT TO DO WITH THE CARD:
Each customer whose vehicle is registered in California, Massachusetts, Vermont, and Maine must be given a completed Vehicle Emission Recall - Proof of Correction card after the voluntary service campaign has been completed.
Note:
This card MUST be completed by the Dealership's Service Manager using a permanent ink pen. A fine point pen is recommended. When filling in the information, copy the information directly from the vehicle, NOT the repair order. ALL INFORMATION MUST BE PRINTED AND NEAT.
DO NOT COMPLETE THE CARD UNLESS THE VOLUNTARY SERVICE CAMPAIGN WORK IS COMPLETED!
The copy of the card shown below indicates the areas to be filled in.
Each area must be filled in.
AFFECTED PRODUCTION RANGE:
All 2001MY Optima 2.5L and 2002MY Optima 2.7L V6 engines.
PART NUMBER INFORMATION:
WARRANTY INFORMATION:
NOTICE
02 Sensor replacement is ONLY necessary for 2001 MY vehicles that did NOT have Campaign SC028 (Service Campaign: Optima Oxygen Sensors, published March 2003) completed. Check for Campaign SC028 completion by accessing the Dealer DCS System under the Warranty menu, number 8, campaign list by VIN No. After entering the vehicle's VIN No. you will see a list of completed and open campaigns. If Campaign SC028 has NOT been completed on the vehicle, continue to Replacement Procedure: For 2001 MY 02 Sensors in this campaign. If Campaign SC028 has been completed continue to Reprogramming Procedure for 2001 MY and 2002MY ECM in this campaign.