Canada - Engine Controls - Sulfur Odors/MIL ON/DTC P0420

Bulletin
2021

Issue Date
June 23, 2004

Market
Canada

Title:
EXCESSIVE SULPHUR DIOXIDE ODOUR

Model
'03 - '04 Corolla

Some 2003 -- 2004 model year Corolla vehicles equipped with a 1ZZ--FE engine may exhibit a M.I.L. "ON" condition with Diagnostic Trouble Code P0420 (Catalyst System Efficiency below Threshold) stored in the Engine Control Module (ECM) (SAE term: Powertrain Control Module/PCM). Follow the repair procedure to reflash the ECM (PCM) and replace the catalytic converter assembly.

Note:
For more complete understanding of the root cause, refer to TSB1212 "Sulphur Odour from Exhaust" dated March 4, 2003

APPLICABLE VEHICLES:
- 2003 - 2004 model year Corolla vehicles equipped with 1ZZ-FE engine produced BEFORE the Production Change Effective VIN shown below.







PRODUCTION CHANGE INFORMATION :







PARTS INFORMATION:







PARTS INFORMATION:

* The original part (17410 - 0D150 or 17410 - 22470) is currently used in vehicle production and is still available as a service part. The repair part (17410 - 0D360) should be used when the customer complains of sulphur dioxide odour and/or M.I.L. "ON" DTC P0420.







REQUIRED SSTS:







WARRANTY INFORMATION:











ECM (PCM) IDENTIFICATION CHART:

Note:
Some 2003 model year Corolla ATM vehicles with Delco ECM (P/N 89666 - 02150) are not reprogrammable. If the Diagnostic Tester displays an error message confirm part number and then refer to the ECM/PCM replacement procedure of this TSB.

ECM REPROGRAM PROCEDURE:
1. Check for the Authorized Modification Label affixed to the vehicle in the location 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, Figure 1 shown.

3. Proceed to Flash Reprogram the ECM (PCM) by following the procedures in TSB #941 titled "ECU Flash Reprogramming Process", for 2001 and late applicable models

Note:
Errors during the flash reprogramming process can PERMANENTLY DAMAGE the vehicles ECM (PCM). In order to minimize this risk follow the steps below:
- Make sure that the 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, ect.)
- DO NOT perform the reprogramming process until the engine room temperature is 70�C or less.
- Confirm cable connections between the vehicle and Diagnostic Tester are secured.
- In case of Error Message "Cannot go to Reprogram Mode," refer to TSB #0959 "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.







7. Enter the following information on the Authorized Modification Label shown in Figure 2 using a permanent maker.
- ECM (PCM) part number
- New ECM (PCM) calibration number
- Your Dealer code
- Reprogramming date

ECM (PCM) REPLACEMENT PROCEDURE:
1. 2003 model year Corolla ATM vehicles equipped with Delco ECM (PCM) "P/N 89666 - 02150 are not reprogrammable.
2. For the location of the ECM (PCM) refer to E-TAS 2003 or 2004 model year Matrix Repair Manual Section: Diagnostics
Sub Section: SFI

CATALYTIC CONVERTER REPLACEMENT PROCEDURE:
Refer to E-TAS 2003 or 2004 model year Corolla Repair Manual:
Section: Exhaust
Subsection: Exhaust Pipe Assy; Removal and Installation and Disassembly and Reassembly (Corolla).

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.