Engine Controls - PCM Reprogramming Procedure

No: TSB-03-00-015
DATE: September, 2003
MODEL: All models
SUBJECT:
REPROGRAMMING WITH THE MUT-III

PURPOSE

This bulletin contains general instructions for reprogramming a vehicle PCM using the
MUT-Ill vehicle communication interface (VCI) unit. Before beginning reprogramming,
you must first transfer the reprogramming data to a PC memory card adapter equipped
with a compact flash memory chip. New data is transferred from a DVD to the PC hard
drive, then to the PC memory card. After data is in the memory card, it can be
downloaded to the VCI, then to the vehicle's PCM (ECU).

The MUT-III is capable of both automatic reprogramming (it automatically selects the
appropriate database) and manual reprogramming (you select the database). Automatic
reprogramming is recommended for most typical reprogramming situations. If automatic
reprogramming is not successful, try manual reprogramming.

AFFECTED VEHICLES
All models capable of PCM reprogramming, except 1995-99 Eclipse 2.0L non-turbo (For
1995-99 Eclipse 2.0L non-turbo models, use M1T992000-A and refer to the applicable
TSB.)

I. Transferring Reprogramming Data to Memory Card

Before beginning reprogramming, you must first transfer new reprogramming data from a
DVD to a PC memory card adapter equipped with a compact flash memory chip. The
data is transferred from the DVD-ROM to the PC hard drive, then to the PC memory
card.

Components

MUT-III personal computer

Reprogramming database on DVD-ROM
Memory card (MB991853)128 MByte Compact Flash (CF) *
Memory card adapter (MB991939) PCMCIA *
* Replacement generic memory and adapters can be ordered from SPX/OTC, or
purchased locally.

Procedure

1. Start the MUT-III personal computer.

2. Start the MUT-III system.

3. Install the memory card into the card adaptor.

4. Install the card adapter into the PC card slot. (There are two PC card slots. You can
 use either slot for the card adapter.)

A "Found New Hardware" message displays on the monitor. Wait for the message to
disappear.
5. When you receive new reprogramming data, install the reprogramming DVD-ROM
into the PC's DVD-ROM drive.
6. Select "Special function".
7. Select "ECU reprogramming".
8. If a "Please update to a new database file" message displays, press the check mark
button.
9. A "Please wait!" message displays. When the transfer is complete, the message
disappears. Then remove the DVD-ROM from the PC.
10. Select "Memory card transfer". (Do not remove the memory card from the PC.)
11. Select memory card "E:\" and press the check mark button.
12. When the message "It transfers data to the memory card. Are you ready?" displays,
press the check mark button.
13. A progress monitor displays during data transfer to the memory card.
14. When the message "Transfer is complete" appears, press the check mark button.

To remove the memory card:

15. Double-click the removal icon in the lower right corner of the screen.
16. Select "PCMCIA IDE/ATAPI Controller" . Then press the Stop button.
17. Verify that the correct item is selected, then press the OK button.

When the message "The device can now be safely removed from the system" displays,
remove the memory card (press the button next to the PC card slot).

II. Reprogramming A Vehicle ECU With the Vci

After data is in the memory card, it can be downloaded to the VCI, then to the vehicles
PCM (ECU). NOTE : Whenever the ECU is reprogrammed, a reprogramming label (p/n
MSSF-024G-00) must be completed and affixed to the vehicle. Refer to the applicable
reprogramming TSB for specific information that must be entered on the label.

VCI COMPONENTS
These components are required:

CONNECTING COMPONENTS
1. Insert the memory card into the PC card adapter. Then install into the VCI main unit.
2. Connect the MUT-III main harness A or B to the VCI main unit.
3. With the ignition switch in the OFF position, connect the MUT-III main harness to the
data link connector.
NOTE :For Outlander and 2002-on Montero models, use 12-pin to 13-pin adapter
harness MB991855 to connect the main harness to the data link connector.
4. Turn the ignition switch to the ON position.

MAIN MENU

Turn the ignition key to ON. When the VCI unit is turned on, the main menu displays:

IMPORTANT

^ When connecting and disconnecting, do not pull on the harness wires. Pull only on the
connectors.
^ During reprogramming, the ignition switch must remain ON.
^ Do not disturb the MUT-III main harness during reprogramming. After reprogramming,
start the engine to verify operation.

Automatic reprogramming is recommended for most typical reprogramming situations. If

automatic reprogramming is not successful, try manual reprogramming.

AUTOMATIC REPROGRAMMING

1. In the VCI main menu. select "Automatic RPG". Then press ENTER.

The available data will display.

2. Press ENTER. If the PCM requires reprogramming, the MUT-Ill will automatically
identify the appropriate database. Press ENTER again to transfer the reprogramming
data to the VCI.

a. If the PCM does NOT require reprogramming, this message displays. Press ENTER to
return to the main menu.

b. If there is no data for reprogramming this PCM, this message displays and no data is
transferred. Press ENTER to return to the main menu.

3. A progress monitor displays during data transfer to the VCI internal memory.
4. When data transfer is complete, ECU reprogramming automatically begins.

5. The ECU part number and ROM ID are displayed. Press ENTER to continue with
reprogramming.

6. If the database you selected does not apply to the vehicle's PCM, this message will
display. Press ENTER to return to the VCI main menu. Confirm PCM part number and
appropriate reprogramming database number.
7. If the PCM has already been reprogrammed with this database, or if the MUT-III main
harness is not properly connected to the VCI unit, this message displays and
reprogramming will not continue.

8. Verify that the harness is connected properly, then press ENTER. The VCI will retry
reprogramming.
9. A monitor indicates that reprogramming is in progress.

There are five phases in the reprogramming process. The VCI will continue with the
process automatically. Do not press any key.

Step 1: Saves data to the back-up memory.

Step 2: Erases data in the ECU.

Step 3: Writes new data in the ECU.

Step 4: Verifies the new data is transferred.

Step 5: Erases diagnosis and back-up memory.

10. The new ECU part number and ROM-ID display.

You must turn the ignition switch to OFF to complete the reprogramming process.

11. Start the engine and disconnect the MUT-III.

MANUAL REPROGRAMMING

1. In the main menu, select "Load RPG file". Then press ENTER.
2. Select the reprogramming database by using the down arrow. Then press ENTER.

3. If the correct database is selected, press ENTER. If not, press ESC to cancel and return
to the main menu.

4. A progress monitor displays during data transfer to the PC memory card.

5. After the data has been transferred to the PC memory card, this message displays.
6. The ECU part number and ROM ID are displayed. Press ENTER to continue with
reprogramming.

7. If the database you selected does not apply to the vehicle's PCM, this message will
display.

Press ENTER to return to the VCI main menu. Confirm PCM part number and
appropriate reprogramming database number.
8. If the PCM has already been reprogrammed with this database, this message displays
and reprogramming will not continue.

It is possible that the MUT-III main harness is not properly connected to the VCI unit.

9. Verify that the harness is connected properly, then press ENTER. The VCI will retry
reprogramming.
10. A monitor indicates that reprogramming is in progress.

There are five phases in the reprogramming process. The VCI will continue with the
process automatically. Do not press any key.

Step 1: Saves data to the back-up memory.

Step 2: Erases data in the ECU.
Step 3: Writes new data in the ECU.
Step 4: Verifies the new data is transferred.
Step 5: Erases diagnosis and back-up memory.
11. The new ECU part number and ROM-ID display.

You must turn the ignition switch to OFF to complete the reprogramming process.

12. Start the engine and disconnect the MUT-III.

III. Error List

Vehicle battery voltage is low

If the battery voltage is below 9.8 V, this error will display for five seconds.

Recharge or replace the battery. Press ENTER to continue.

Download Error
This message displays if:

- the MUT-III harness is disconnected during

reprogramming
- the ignition switch is turned off during
reprogramming
- a communication problem occurs during
reprogramming
- battery voltage is low

No response from vehicle ECU

This message displays if:

- the vehicle ECU does not require reprogramming

- the MUT-III harness is disconnected during reprogramming
- the ignition switch is off

Checking ECU download error

This message displays if there is a communication problem. Turn the ignition switch to
OFF and retry.

ECU check error

This message displays if the memory card data does not match the ECU data. Press
ENTER to update the ECU with the memory card data.

D/B incorrect, reinstall D/B

This message displays if the data in the memory card is not appropriate for the PCM.
Press ENTER to return to the main menu. Remove the memory card from the VCI and
install in the MUT-III PC, then retry data transfer.

CK VNxxxxxx; No Data
This message displays if there is no reprogramming data in the memory card. Press
ENTER to return to the main menu. Remove the memory card from the VCI and install
in the MUT-III PC, then retry data transfer.

IV. Warranty Information

PCM reprogramming based on customer complaint or recall only. Use the appropriate
PCM reprogramming labor operation listed in the applicable TSB.

Labor time for updating ROM packs is no longer applicable.

Attachment A

ATTACHMENT A - RN to VN Database Numbers

If you are using reprogramming information in a TSB that was issued before MUT-III
reprogramming capability became available, use the tables to determine the appropriate
MUT-III database number.