Engine Controls - MIL ON/DTC's P0300 or P0301-P0304 Set
No: TSB-06-13-004DATE: April, 2006
MODEL: See below
SUBJECT:
RANDOM MISFIRE (DTC P0300, P0301, P0302, P0303, OR P0304)
This TSB supercedes TSB-05-13-003, issued February, 2005, for new diagnosis and repair information.
PURPOSE
If the Check Engine light comes on and DIG P0300 (Random Misfire) or P0301, P0302, P0303, or P0304 is set in the PCM, the cause may be one of the following:
^ Fuel injection/Ignition system
^ PCM software
^ Worn input shaft 5th gear spline, misjudged by the PCM as a misfire
To eliminate this condition, follow the diagnosis and repair procedures described below. These procedures are outlined in flowcharts in Attachment A (for 2003-2004 models) and Attachment B (for 2005 models) of this bulletin.
AFFECTED VEHICLES
2003-2005 Lancer Evolution equipped with 5-speed transmission produced before 7/04
PROCEDURE
1. Connect the MUT-III scan tool. Confirm DTC P0300 (Random Misfire) or P0301, P0302, P0303, or P0304 is set in the PCM.
2. Read and record the freeze frame data for coolant temperature, engine rpm, vehicle speed, and engine load when the DTC was set.
^ Coolant temperature higher than 167 degrees F (75 degrees C)
^ Engine rpm more than 2500 rpm
^ Vehicle speed more than 60 mph
^ Engine load less than 80%
a. If DIG set conditions do not match the above criteria:
^ 2003-2004 Models: Do not continue with this bulletin procedure. Refer to the appropriate DIG diagnosis procedures in Group 13 of the service manual.
^ 2005 Models: Go to Step 3.
b. If the DTC set conditions match the above criteria:
^ 2003-2004 Models: Erase the DTC and then go to Step 3.
^ 2005 Models: Go to Step 6 for parts replacement.
3. Use the MUI-III to check the PCM ROM ID:
a. 2003 Models:
^ If the ROM ID is JM941715 or above, go to Step 6 for parts replacement.
^ If the ROM ID is NOT JM941715 or above, reprogram the PCM as described in Step 4 below.
b. 2004 Models:
^ If the ROM ID is JM964111 or above, go to Step 6 for parts replacement.
^ If the ROM ID is NOT JM964111 or above, reprogram the PCM as described in Step 4 below.
c. 2005 Models:
^ If the ROM ID is 969313 or above. go to Step 5 to perform a test drive.
^ If the ROM ID is NOT 969313 or above, reprogram the PCM as described in TSB-06-13-005. This will enable all freeze frame data to be read by the MUI-III. Then go to Step 5 to perform the test drive.
4. 2003 and 2004 Models Only:
a. If the ROM-ID is not JM941715 or above (2003 models) or JM964III or above (2004 models), reprogram the PCM, using MUI-III database version N06031 or greater. After reprogramming is completed, the new ROM ID will display. Note this information, and verify that the new PCM pin and ROM ID are the same as those listed below.
IMPORTANT!
Models equipped with ABS: With the ignition key OFF, unplug the ABS fuse (7.5 amp fuse in the junction box in the passenger compartment). Refer to the service manual for exact fuse location in the box.
b. Using a ball-point pen, enter the appropriate PCM part number, vendor number, ROM ID #, this TSB number (TSB-06-13-004), your dealer code, and the current date on the Engine Compartment / Control Module Label (part no. MSSF-024G-00).
c. 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.
d. Affix the Control Module label to the PCM.
e. Models equipped with ABS: Reconnect the ABS fuse. Confirm no DTCs are set.
f. Continue with Step 5 to perform the test drive.
5. TEST DRIVE
Test drive the vehicle in both 4th gear and 5th gear at highway speeds as follows:
NOTE:
Disengaging the clutch during the test drive will change the phasing between the engine and the transmission, and indicate a possible input shaft problem.
a. In 4th gear, drive above 60 mph, or as fast as local regulations permit. Then slightly release the accelerator pedal for 10 seconds. During the 10 seconds, press and quickly release the clutch. Repeat this at least two times.
b. In 5th gear, drive above 60 mph, or as fast as local regulations permit. Then slightly release the accelerator pedal for 10 seconds. During the 10 seconds, press and quickly release the clutch. Repeat this at least two times.
c. If the Check Engine light does NOT come on during the test drive, do not continue with this bulletin procedure.
d. If the Check Engine light comes on during the test drive, read the DTCs and freeze-frame data:
^ If a misfire DTC is set and the freeze-frame data matches the criteria in Step 2, go to Step 6 for parts replacement.
^ If the freeze-frame data does NOT match the criteria in Step 2, refer to Group 13 of the service manual for diagnosis of the DTC that was originally set. Do not continue with this bulletin procedure.
6. Replace both the input shaft and the input 5th gear, using the parts listed in the PARIS INFORMATION section of this bulletin. Refer to Group 22 in the service manual.
a. Install a new input shaft oil seal.
b. After parts replacement, repeat the test drive described in Step 5. Verify that the Check Engine light does not come on.
PARTS INFORMATION
Use the Genuine Mitsubishi Parts listed below:
WARRANTY INFORMATION
Attachment A
Attachment B