Canada - Engine Controls - MIL ON/DTC P0420 Set

Bulletin
TSB2065

Issue Date
August 16, 2004

Market
Canada



Title
M.I.L. .ON. DTC P0420

Component
ENGINE ELECTRICAL

Models
'03 - '04 Matrix (1ZZ-FE)

Some 2003 -- 2004 model year Matrix vehicles equipped with the 4 cylinder (1ZZ--FE) engine may exhibit a M.I.L. "ON" condition with Diagnostic Trouble Code (DTC) P0420 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:
The repair procedure in this TSB is the same as TSB No. 2020 "Excessive Sulfur Dioxide Odor." This repair should only be performed once.

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






PRODUCTION CHANGE INFORMATION:






WARRANTY INFORMATION:











PARTS INFORMATION:






REQUIRED SSTS:






ECM (PCM) IDENTIFICATION CHART:

NOTE:
Some 2003 model year Matrix ATM vehicles with Delco ECM (P/N 89666--02160) 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 later 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 Matrix 2WD ATM vehicles equipped with Delco ECM (PCM) P/N 89666 - 02160 are not reprogrammable.
2. For the location of the ECM (PCM) refer to ETAS 2003 or 2004 model year Matrix Repair Manual:
Section: SFI (1ZZ-FE);
Subsection: Location (Matrix/Corolla)

CATALYTIC CONVERTER REPLACEMENT PROCEDURE:

Refer to ETAS for 2003 or 2004 model year Matrix Repair Manual:
Section: Exhaust Pipe Assy (1ZZ-FE);
Subsection: Removal & Installation & Disassembly & Reassembly (Matrix/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.