Engine Controls - Cold Start Roughness/Misfire/MIL/DTC's
GROUP ENGINENUMBER 033 [REVISED 3]
MODEL 06-07MY RIO/RIO 5
DATE APRIL 2010
UPGRADED INFORMATION IS SHOWN WITH ASTERISKS AND BLACK BARS.
SUBJECT
ECM UPGRADE FOR MULTIPLE DTC's LISTED (P0300, P0128, P0140, P0442, P0451, P0461) DTC LOGIC IMPROVEMENT
*This bulletin provides the procedure to upgrade the Engine Control Module (ECM) of some 2006-2007 RIO/RIO5 (JB) 1.6L vehicles produced February 20, 2005 to June 11, 2007 which may experience a rough idle during initial cold start-up period and/or illuminate the MIL with DTC's below. The ECM update addresses engine roughness/misfire that may occur in the first minute of idle after cold start with coolant temperature ranging from 30-70°F and other indicated upgrades referenced below. If the engine misfire continues beyond this period refer to service manual diagnostic procedures involving engine mechanical and engine control hardware issues. For confirmation that the latest reflash has been done to a vehicle you are working on, verify ROM ID using the tables in this TSB. This TSB supercedes all previous Rio Mis-fire P0300 publications except SA032 and SA036. Please discard any paper copies printed prior to April 2010 to ensure correct ROM ID is installed.*
^ P0300: Random/multiple Cylinder Misfire Detected and/or rough idle state
^ P0128: Thermostat Monitoring
^ P0140: O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2, stored in memory)
^ P0442: Evaporative Emission System - Leak detected
^ P0451: Evaporative Emission System Pressure Sensor/Switch Range Performance
^ P0461: Fuel Level Sensor "A" Circuit Range/Performance
To correct this condition, the ECM should be reprogrammed using the GDS download as described in this bulletin.
NOTICE
Do NOT replace the engine control parts related to misfire such as ignition coil, spark plug and oxygen sensor unless it can be proven the part is defective.
^ A fully charged battery is necessary before ECU upgrade can take place. DO NOT connect a battery charger to the vehicle during ECU upgrade. Make sure the blower motor is "OFF" during ECU upgrade.
^ All ECU upgrades must be done with the ignition key in the "ON" position.
^ Be careful not to disconnect any cables connected to the vehicle or GDS during the ECU upgrade procedure.
^ DO NOT start the engine during ECU upgrade.
^ DO NOT turn the ignition key "OFF" or interrupt the power supply during ECU upgrade.
^ When the ECU upgrade is completed, turn the ignition key "OFF" and wait 20 seconds before starting the engine.
^ ONLY use approved ECU upgrade software designated for the correct model, year and engine size. Failure to do so may create other driveability issues due to the use of the incorrect ECM/PCM calibration.
UPGRADE EVENT NAME
ROM TABLES
1. Connect the power supply cable to the GDS tool.
NOTICE
If attempting to perform the ECU with the power supply cable disconnected from the GDS tool, be sure to check that the GDS tool is fully charged before ECU upgrade. If the GDS tool is not fully charged, failure to preform the ECU upgrade may occur. Therefore, it is strongly recommended that the power supply connector be connected to the GDS tool.
2. Connect the USB cable between the VCI and the GDS tool.
NOTICE
When performing the ECU upgrade using the GDS tool, wireless communication between the VCI and GDS tool is not available. Therefore, be sure to connect the USB cable between the VCI and the GDS tool.
3. Connect the main 16-pin DLC cable (GHDM - 241000) to VCI.
4. Connect the Main 16-pin DLC cable (GHDM - 241000) to the OBD-II connector, located under the driver's side of the instrument panel.
5. With the ignition key ON, turn ON the VCI and GDS tool. Access the GDS vehicle identification number (VIN) screen and configure the vehicle using the VIN AUTO DETECT Function.
6. Once back at the GDS Main Screen, select ECU upgrade from the bottom right-hand corner. Next select Auto Mode, Engine. Perform the ECU upgrade in accordance with normal GDS tool ECU upgrade procedures.
NOTICE
Do NOT attempt to perform a Manual Mode PCM upgrade unless Auto Mode fails. Always follow the instructions given on the GDS tool in either Auto or Manual mode. See table for Manual Mode passwords. In addition, a PCM reset is required if Auto Mode fails; refer to the table below for procedure.
MANUAL MODE ECU UPGRADE PASSWORDS
7. When the GDS tool reports that the ECU upgrade has been successfully completed, click OK, turn OFF the ignition key, and wait at least 10 seconds before attempting to start the engine.
8. Check for Diagnostic Trouble Codes using the GDS and erase any DTC's store.
AFFECTED PRODUCTION RANGE
WARRANTY CLAIM INFORMATION