Random Misfire

[Budrow01]

RANDOM MISFIRE (DTC P0300, P0301, P0302, P0303, OR P0304)
TECHNICAL SERVICE BULLETIN
Reference Number(s): TSB-06-13-004, Date of Issue: April 01, 2006
MITSUBISHI: 2003-2005 Lancer Evolution
Superceded Bulletin(s): TSB-05-13-003, Date of Issue: February 01, 2005
PURPOSE
NOTE: This TSB supercedes TSB-05-13-003, issued February, 2005, for new diagnosis and repair information.


If the Check Engine light comes on and DTC 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 (2003-2004 MODELS ONLY) and ATTACHMENT B (2005 MODELS ONLY).

AFFECTED VEHICLES
2003-2005 Lancer Evolution equipped with 5-speed transmission produced before 7/04

PROCEDURE
Connect the MUT-III scan tool. Confirm DTC P0300 (Random Misfire) or P0301, P0302, P0303, or P0304 is set in the PCM.
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%
If DTC set conditions do not match the above criteria:
2003-2004 Models : Do not continue with this bulletin procedure. Refer to the appropriate DTC diagnosis procedures in Group 13 of the service manual.
2005 Models : Go to Step 3.
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.
Use the MUT-III to check the PCM ROM ID:
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.
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.
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 MUT-III. Then go To Step 5 to perform the test drive.
2003 and 2004 Models Only:
If the ROM-ID is not JM941715 or above (2003 models) or JM964111 or above (2004 models), reprogram the PCM, using MUT-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 p/n 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.


DISPLAY - ON MUT-III AFTER REPROGRAMMING
DISPLAY ON MUT-III AFTER REPROGRAMMING
MODEL PCM PART NUMBER MUT-III REPROGRAMMING DATABASE ECU PART NUMBER ROM ID (Engine) VENDOR #
2004 Lancer Evolution MN191022 VN04122 MN191022 964111 E6T34888H3
2003 Lancer Evolution MN132874 VN04121 MN132874 941715 E6T34880H3


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).
Fig. 1: Identifying Control Module Label

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.
Affix the Control Module label to the PCM.
Models equipped with ABS: Reconnect the ABS fuse. Confirm no DTCs are set.
Continue with Step 5 to perform the test drive.
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.
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.
If the Check Engine light does NOT come on during the test drive, do not continue with this bulletin procedure.
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.
Replace both the input shaft and the input 5th gear, using the parts listed in the PARTS INFORMATION section of this bulletin. Refer to Group 22 in the service manual.
Install a new input shaft oil seal.
After parts replacement, repeat the test drive described in Step 5. Verify that the Check Engine light does not come on.
Fig. 2: Identifying Input Shaft Oil Seal

PARTS INFORMATION
Use the Genuine Mitsubishi Parts listed below:

PARTS INFORMATION
Description Part Number
Input Shaft MN107628
Input 5th Gear MN107624
Input shaft Oil Seal MD746516


WARRANTY INFORMATION
PCM Reprogramming for DTC P0300/P0301/P0302/P0303/P0304
Nature Code: 16D Cause Code: 490

Labor Operation No . 13850113 Time Allowance: 0.3 hr.

Warranty Coverage: 8 years / 80,000 miles Emissions warranty

Input Shaft and Input 5th Gear Replacement
Nature Code: 16D Cause Code: 150

Labor Operation No . 2220109G Time Allowance: 8.2 hrs.

Warranty Coverage: Powertrain coverage (5 years/60,0000 miles or 10 years/100,000 miles depending on model year, vehicle sale date, and if original owner.

ATTACHMENT A (2003-2004 MODELS ONLY)
Fig. 3: Freeze Frame Data Flow Chart (2003-2004 Models)

ATTACHMENT B (2005 MODELS ONLY)
Fig. 4: Freeze Frame Data Flow Chart (2005 Models)