Canada - Engine Control - Excessive Sulfur Dioxide Odor

Bulletin
TSB2004

Issue Date
June 21, 2004

Market
Canada

Title
EXCESSIVE SULFUR DIOXIDE ODOUR

Component
ENGINE ELECTRICAL

Models
'04 GX 470

Some customers may complain of excessive sulphur dioxide odour on 2004 model year GX 470 vehicles under the following conditions:
- Stop and Go Driving
- Heavy Acceleration

In order to reduce the sulphur dioxide odour, the Electronic Control Module (ECM) (SAE term: Powertrain Control Module/PCM) fuel cut control logic has been modified and a new catalyst is provided. Follow the repair procedure to reflash the ECM and replace the catalytic converter assembly.

NOTE:
For more complete understanding of the root cause, refer to TSB0594 "Sulphur Odour/Smell From Exhaust" dated February 21, 2002.

APPLICABLE VEHICLES:
- 2004 model year GX470 vehicles produced BEFORE the Production Change Effective VIN shown below.







PRODUCTION CHANGE INFORMATION:







WARRANTY INFORMATION:







PARTS INFORMATION:







REQUIRED SSTs:







ECM (PCM) IDENTIFICATION CHART:

NOTE:
2004 model year Sub Calibration ID will display YES as DONE on the Diagnostic Tester display.

ECM REPROGRAM PROCEDURE:
1. Check for the Authorized Modification Label affixed to the vehicle in the location as shown in Figure 2. If there is no label present, proceed to step 2.







2. Connect the Diagnostic Tester to the vehicle and select "CURRENT ECU CAL" from the "ECU REPROGRAM MAIN MENU." To determine the vehicle's current ECM calibration, see figure 1 shown.
3. Proceed to Flash Reprogram the ECM (PCM) by following the procedures outlined in TSB 0592, "HOW TO DOWNLOAD TDT SOFTWARE VERSIONS AND CALIBRATION FILES" dated Feb 4, 2003 and flash the ECM with new "Main" and "Sub" calibration file updates.

NOTE:
Errors during the flash reprogramming process can permanently damage the vehicle's ECM (PCM). In order to minimize this risk follow the steps below:
- Make sure that the current battery voltage is no less than 11.4 volts.
- Install a battery charger and set on a low setting to assure that the battery voltage DOES NOT FALL BELOW 11.4 VOLTS during the reprogramming.
- If battery's state of charge is in question, test with SST No. J-44350, "Midtronics battery Tester."
- Confirm that the engine hood is up, parking brake is set and all accessories are OFF (i.e., audio system, A/C, interior lights, Headlights, etc).
- DO NOT perform the reprogramming process until the engine room temperature is 70°C (158°F) or less.
- Confirm cable connections between the vehicle and the Diagnostic Tester are secured.
- In case of Error Message "Cannot Go To Reprogram Mode," refer to TSB 0449 titled "ECU Flash reprogramming Error Message."
- Do not interrupt the vehicle during the reprogramming process, keep all doors closed.

4. Select the proper ECM (PCM) calibration file for the model year vehicle and reprogram the ECM (PCM).
5. Start the engine and warm up the vehicle to normal operating temperatures before test-driving.
6. Test drive vehicle to confirm proper operation and to readjust the ECM (PCM) "Learned Values." Drive the vehicle using light to moderate acceleration in mostly stop and go type driving. Allow the vehicle to shift fully through all gears and at various shifter positions (D, 4, 3, 2, 1).







7. Enter the required information on the Authorized Modifications Label using a permanent marker and affix it to the vehicle at the location shown in Figure 2. The Authorized Modifications Label is available through the PDC, P/N 00451-00001-25.

Catalytic Converter Replacement Procedure
1. Refer to ETAS for 2003 or 2004 model year GX 470 Repair Manual:
Section: Exhaust

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.