SR-22-004 – Engine Stall From Control Unit Software Error – 2019-2022 Mitsubishi Outlander Sport

August 2, 2022 NHTSA CAMPAIGN NUMBER: 22V563000

Engine Stall From Control Unit Software Error

An engine stall can increase the risk of a crash.

 

NHTSA Campaign Number: 22V563

Manufacturer Mitsubishi Motors North America, Inc.

Components POWER TRAIN

Potential Number of Units Affected 76,508

 

Summary

Mitsubishi Motors North America, Inc. (MMNA) is recalling certain 2019-2022 Outlander Sport vehicles equipped with continuously variable transmissions and mechanical key ignition systems. A software error in the transmission control unit (CVT-ECU) may incorrectly reduce the transmission gear ratio at high speeds, which can result in an engine stall.

 

Remedy

Dealers will update the CVT-ECU software, free of charge. Owner notification letters were mailed August 24, 2022. Owners may contact MMNA customer service at 1-888-648-7820. MMNA’s number for this recall is SR-22-004.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

Check if your Mitsubishi has a Recall

 


SUBJECT:

INAPPROPRIATE CVT ECU SOFTWARE PROGRAMMING – SAFETY RECALL CAMPAIGN

No: SR-22-004
DATE: AUGUST 2022
MODEL:  SEE BELOW

 

PURPOSE

This Campaign Bulletin provides instructions to reprogram the CVT-ECU with updated software.

 

BACKGROUND

Improper software programming may cause the CVT-ECU to recognize a 0.1 second or greater temporary loss of signal from the Ignition Power Supply creating an erroneous gear ratio setting within the CVT.  Should this condition occur at speeds greater than 62 mph, an over-rev condition could result in engine damage due to the CVT dropping to the lowest gear ratio.

 

AFFECTED VEHICLES

Certain 2019-2022 Outlander Sport vehicles built between 7/31/2018 – 5/11/2022 equipped with CVT and mechanical key ignition system.

ATTENTION:  Dealers must check 2019-2022 Outlander Sport VINs on the  Warranty Superscreen to confirm if a vehicle is affected.

 

PROCEDURE

ATTENTION:

  • Cooling fan may turn on during reprogramming.
  • The battery charger must be connected to the 12V battery while updating to prevent battery discharge. A discharged battery may cause the reflash to fail, prevent the update, and the CVT-ECU may require replacement.
  • VERIFY THE LATEST VERSION OF SOFTWARE is installed when the update is complete.

 

IMPORTANT

Affected new or used inventory vehicles must be repaired before the vehicle is sold/delivered. Dealers must check their inventory vehicles’ VINs on the Warranty Superscreen to verify whether the vehicle is involved in this recall campaign. It is a violation of Federal law for a dealer to sell/deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by the notification under a sale or lease until the defect or noncompliance is remedied.

 

EQUIPMENT

  • The following equipment is needed to reprogram the ECU:
  • VCI (Vehicle Communication Interface) or VCI Lite – MB991824 or MB992744
  • MEDIC Laptop/Tablet with A/C power adapter – 520924, or FZG1MK2
  • MUT III Main Harness “A” (blue connector at the DLC end) – MB991910 or MB992745
  • USB 2.0 Cable – MB991827 or MB992747
  • MEDIC 3.5/4 update at # 749 or higher
  • For Standalone MUT III units, MUT-III SE Reprogramming Database N220701 or higher

 

ECU REPROGRAMMING CHART

Affected model MY CVT-ECU Part No. Software No. Software Version
New Old
GA2W 19-22 MY 8631B846 8631C054 11 18 04 11 18 03
GA5W 19-22 MY 8631B847 8631C055 11 19 04 11 19 03

 

REPAIR PROCEDURE

SOFTWARE/MEDIC VERSION VERIFICATION

1. Verify that the ECU has not already been updated to the latest S/W number in the table above. If the CVT ECU is at the latest level, reprogramming is not necessary.

NOTE:  Reprogramming the CVT ECU with the latest database (e.g., N220701 includes all past and current reprogramming for TSBs of affected vehicles.  It is not necessary to reprogram the ECU for each previous TSB.

 

For MEDIC 3.5/4 users only:  (MUT-III SEV users go to step 5)

2. Verify the MEDIC 3.5/4 is at version 3.5 and update # is 749 or higher.

If your MEDIC 3.5/4 update is at least 749, continue with the Reprogramming Procedure. If your MEDIC 3.5/4 update is below 749, update your MEDIC as follows:

3. Select the MEDIC 3.5/4 Admin tab and click on “Updates”.

4. If the MEDIC update screen advises updates are available, click the “Begin” button. After all updates are complete, GO TO THE REPROGRAMMING PROCEDURE.

5. STANDALONE MUT-III SE SCAN TOOL VIEWER (STV) ONLY: (MEDIC 3.5 USERS – GO TO THE REPROGRAMMING PROCEDURE).  Verify that your MUT-III SE has the most current version of the reprogramming database from the MUT-III SE Main Page.

a. Press the MUT-III SE STV icon.

b. Press the ECU Reprogramming button.

c. Press SDB Data List, select the reprogramming data system and press the OK button.

d. Confirm that the database number displayed in the upper right above the chart is N220701 or higher.

i. If the database number displayed on your MUT-III SE is N220701 or greater, continue to the next section.

ii. If the reprogramming database number displayed on your MUT-III SE is lower than N220701, then the MUT-III SE database needs to be updated.

iii. Once the database number is confirmed, hit the Home button to go back to the System Select screen.

 

REPROGRAMMING PROCEDURE

CAUTION

To ensure that the vehicle battery maintains 12V during the procedure, hook- up a battery charger to the vehicle during the procedure.

NOTE: VCI Stand−alone reprogramming is not available for this procedure.  The laptop/tablet and the VCI must remain connected for the entire procedure.

1. Connect the equipment as follows:

NOTE: VCI Lite and MEDIC 4.0 Toughpad shown for illustration purposes only.

  • Turn the MEDIC PC/tablet on. If the battery indicator in the lower right hand corner of the screen does not show a full charge, it is recommended that either the battery be charged prior to beginning or be used with the A/C power adaptor connected.
  • Connect the USB cable to the VCI/VCI Lite. When the laptop/tablet displays the MUT-III SE main screen, connect the USB cable to the device.
  • Connect the MUT-III SE main harness with the blue DLC connection to the VCI/VCI Lite. Connect the blue connection of the MUT-III SE main harness to the vehicle’s data link connector.
  • For VCI only (p/n MB991824): Turn the VCI power switch ON. Verify that the indicator lamp in the upper right corner of the screen is green.

 

CAUTION

DO NOT DISTURB THE HARNESS CABLES OR CONNECTIONS DURING THE REPROGRAMMING PROCESS AS IT COULD CAUSE THE CONTROL UNIT TO LOSE DATA. IF THE USB CABLE IS DISCONNECTED DURING THIS PROCEDURE, A WARNING MESSAGE WILL DISPLAY.

NOTE:  Due to limited space it may be easiest to connect the battery charger cable onto ground point.

 

2. Turn the ignition switch to the “ON” position.

 

3. Using MEDIC, from the main page, click the“MUT-III SE STV” icon at the top center of the screen to open MUT-III SE.

 

4. Press the Model Information Displaybutton (car icon) and verify that all of the vehicle information is correct.

 

5. Press the Reprogramming icon.

 

6. Press on ECU Reprogramming (SDB).

 

7. Press ELC-AT/CVT/TC-SST from the System list and then the IMMO & Keyless & TPMS from the Loading Option Setup.

 

8. The Automatic ECU Reprogramming (SDB) database screen will display.

  • Verify that the NEW ECU Software (2019-2022 Outlander Sport/RVR 4B11 F/W1CJC. Change target ratio from lowest to actual ratio when CVT-ECU wake up.)  Refer to the Software Chart on page 1 if necessary.)
  • Press the OK button.

 

9. Press the OK button to start reprogramming.

 

10. Once the reprogramming is initiated, the screen will indicate the reprogramming progress. It may take 4-5 minutes to complete.

NOTE:  Do not disturb the cables or turn off the ignition during reprogramming to prevent damage to the ECU.

 

11. Once reprogramming is completed, turn the ignition switch to OFF and then press the OK button to confirm the reprogramming results.

 

12. Software Verification Procedure: Turn the ignition switch back into the ON position and press the Special Function under the ELC-AT/CVT/TC-SST.

 

13. Press ECU information found under Special Function.

 

14. Verify that the Software Version has been updated from 111803 or 111903 to 111804 or 111904.

 

15. Press the ALL DTC button.

 

16. Press the Erase and Read all DTCs button to initiate DTC confirmation.

 

17. Press the OK button to erase all DTCs.

 

18. Using a ball-point pen, enter the appropriate ECU part number, Software Part Number (ROM ID#), this Technical Service Bulletin number, your dealer code, and the current date on the Engine Compartment/Control Module Label (p/n MSSF024G00). The Vendor Code is not applicable. The label is available from your facing PDC.

 

19. Test drive the vehicle to confirm proper operation.

 

PARTS INFORMATION

PART PART NUMBER
Engine Compartment/Control Module

Label

MSSF024G00

 


Chronology of Defect / Noncompliance Determination – SR-22-004 Submitted 8/2/2022

Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision:

 

In May 2019, Mitsubishi Motors Corporation (MMC) received 3 field reports from the US indicating the engine did not start or stalled while driving. MMC began an investigation.

 

From July 2019 through April 2020, MMC received 1 additional field report from the US. MMC continued its investigation and began analysis of engines that were returned to MMC after being replaced due to alleged occurrences of this condition. The analysis indicated there was piston to exhaust valve contact, but no root cause was identified, and the investigation continued.

 

From May 2020 through Apr 2021, MMC received 5 additional field reports and continued its analysis of additional returned engines. These engines appeared to have the same piston to exhaust valve contact.

 

From May 2021 through Dec 2021, MMC continued investigating returned engines based on a Fault Tree Analysis and performed a bench test to duplicate the phenomenon of the exhaust valve hitting the piston.

Additionally, Mitsubishi Motors R&D of America, Inc. (MRDA) performed on-site investigations on vehicles exhibiting a similar condition and determined the control logic of the CVT-ECU may have affected the condition. MMC started focusing its attention on the CVT.

 

From Jan 2022 through June 2022, MMC conducted further in-depth analysis, investigation and simulations and determined that when the CVT-ECU resets, it will respond by setting the CVT target gear ratio to the lowest gear ratio. During this time, MMC also worked to identify the range of vehicles potentially affected by this condition.

 

On July 26, 2022, MMC concluded that 2019 – 2022 model year vehicles equipped with a CVT and mechanical key may have an unreasonable safety risk, determined that a field action was necessary in the US, and together with Mitsubishi Motors North America, Inc. (MMNA), decided to conduct a safety recall. Although the 2011-2018 models equipped with a CVT and mechanical key are substantially similar to the 2019-2022 models, MMC is not aware of similar incidents in the 2011-2018 models. While a CVT-ECU software change was made beginning with the 2019 model year, MMC is unable to determine at this time those software changes have contributed to this issue. MMC will continue to monitor the earlier model years and take appropriate action as necessary.

 

MMC has received 21 field reports and 29 potential warranty claims (19 of which were also field reports) from the US between May 2019 and May 2022. However, MMC and MMNA are not aware of any reports of fire, accident or injury related to this condition.

 


4 Affected Products

Vehicle

MAKE MODEL YEAR
MITSUBISHI OUTLANDER SPORT 2019-2022

 


7 Associated Documents

Recall Acknowledgement

RCAK-22V563-2137.pdf 693.75KB

RCAK-22V563-2137

 


Chronology Report

RMISC-22V563-7082.pdf 72.904KB

RMISC-22V563-7082

 


Defect Notice 573 Report

RCLRPT-22V563-8250.PDF 215.113KB

RCLRPT-22V563-8250

 


Remedy Instructions and TSB

RCRIT-22V563-4075.pdf 992.159KB

RCRIT-22V563-4075

 


Manufacturer Notices(to Dealers,etc)

RCMN-22V563-5000.pdf 218.074KB

RCMN-22V563-5000

 


Manufacturer Notices(to Dealers,etc)

RCMN-22V563-4732.pdf 325.547KB

RCMN-22V563-4732

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22V563-7621.pdf 154.023KB

RCONL-22V563-7621

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V563&docType=RCL

 


 

J2534 Reprogramming – Mitsubishi

J2534 Reprogramming – Mitsubishi

 

Introduction

Mitsubishi Motors North America, Inc. offers J2534-1 Powertrain Control Module (PCM) re-flash capability in accordance with CARB & EPA regulations. Mitsubishi Motors vehicles use re-flashable PCMs starting with the 1998 model year. Before attempting a re-flash of a Mitsubishi PCM, you must obtain a validated J2534-1 pass-thru device. In addition, you must only re-flash a Mitsubishi PCM when a specific Mitsubishi Motors Technical Service Bulletin (TSB) calls for it. All TSBs are available in the Service Information portion of this website. In some cases, re-flash procedures are accompanied by replacement of parts or other related procedures. Failure to follow these guidelines may result in an unsatisfactory repair.

 

What is J2534-1?

J2534-1 is a Society of Automotive Engineers (SAE) standard that enables the use of a J2534-1 pass-thru device (available through Special Tool Manufacturers) and a personal computer to re-program a PCM with updated instructions, as well as perform other procedures on some PCMs. Mitsubishi Motors vehicles use re-flashable PCMs starting with the 1998 model year. Before attempting a re-flash of a Mitsubishi PCM, you must obtain a validated J2534-1 pass-thru device. In addition, you must only re-flash a Mitsubishi PCM when a specific Mitsubishi Motors Technical Service Bulletin (TSB) calls for it. All TSBs are available in the Service Information portion of this website. In some cases, re-flash procedures are accompanied by replacement of parts or other related procedures. Failure to follow these guidelines may result in an unsatisfactory repair.

There are two distinct families of PCMs, based on the communication protocol used for re-flashing. Each family of PCMs requires a specific software solution available on this website as follows:

  • Legacy PCMs Refer to (Reprogramming System Identification Chart) for details (ISO9141) protocol for re-flash communication. A software application, Update Manager, is required to re-flash this type of PCM. Update Manager consists of 2 parts, Update Manager A & Update Manager B. Use Update Manager A to determine the current PCM instruction level (current flash level), known as ROM-ID. Then use Update Manager B to re-flash the PCM with re-flash files and other support files downloaded from this website. If installed for the first time, some K-Line PCM’s require additional initialization procedures – for example, Immobilizer Key Code Transfer. To perform these initialization procedures, a MUT-III Special tool must be used. Please refer to the “Special Tool” section of this webpage for details.
  • The latest technology PCMs Refer to (Reprogramming System Identification Chart) use CAN protocol for re-flash communication. In addition, some CAN-based PCMs require additional initialization procedures if installed in a vehicle for the first time, such as VIN writing, Variant Coding (programming specific vehicle attributes) and Immobilizer Key Code Transfer. All procedures are done using the MUT3-SE CAN Passthru application available for download from this website. Use MUT3-SE CAN Passthru to obtain the PCM Part number, VIN stored in the PCM (necessary before any other procedures). Then download additional software components and support files through MCDS Server to enable the MUT3-SE CAN Pass-Thru application to perform other procedures as needed.

 


 

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https://mitsubishitechinfo.com

https://mitsubishitechinfo.com/epacarb/

 


 

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Mongoose-Plus J2534 OEM Vehicle Interface Cable - Ford / Lincoln / Mercury OEM Reprogramming and Diagnostics
  • Industry-leading J2534 Pass-Thru Technology: Enabling diagnostics, reprogramming and security functions for dealerships and the independent repair facility. Economical and compact pass-thru devices provides an easy-to-use interface that allows you to repair complex vehicles with OE applications in your shop. Each type (see single branded types above) Mongoose-Plus is engineered to work with one of the following OEM's J2534 applications for Chrysler, Ford, GM, Nissan, Toyota, & VW/Audi.
  • Supports Current & Earlier Vehicles: Enables diagnostics, programming and other “dealer” functions through OEM applications
  • NEW Bluetooth Wireless Options Available: Providing wireless connectivity between your laptop and the Mongoose-Plus
  • Expert Product Support: Staffed by technicians who understand vehicle repair and J2534 Pass‑Thru applications to help you with any technical setup questions
  • Key Registration and Immobilizer Support: Using NASTF Vehicle Security Professional credentials
Bestseller No. 8
RAP2 OEM J2534 Remote Reprogramming Tool for GM / Ford / Chrysler / Toyota / Honda / Nissan / Hyundai / Kia / BMW / Mercedes
  • All in one kit. Everything you need to reprogram vehicles in your shop. Includes OEM software and we do the programming for you.
  • Stop sending vehicles to the dealer or calling a mobile technician. We do the programming for you.
  • Includes hardware, OEM software, voltage maintainer and access to our team of remote experts so vehicles can be reprogrammed in your shop hassle‑free.
  • Call to schedule your programming session, plug it in, and we do the rest!
  • Currently covers BMW, Chrysler, Ford, GM, Toyota, Honda, Hyundai / Kia, Mercedes and Nissan.
Bestseller No. 9
LAUNCH X431 PRO5 with Free J2534 ECU Reprogramming Tool for OEM Reprogramming and Diagnostics, 50+ Reset,OE-Level All Systems Bi-Directional Scanner for CANFD/DOIP/Heavy Duty Truck,Key IMMO Scan Tool
  • Featured with a brand-new upgrade system, X-431 PRO5 is newly designed for All Makes, All Models, and Full system diagnosis and assists the technician to make the vehicle diagnosis and repair easier at all skill levels.
  • [J2534 ECU Reprogramming Tool, No IP Limitation]: LAUNCH X431 PRO5 scan tool Upgrade all functions of X431 V+, PROS V1.0, PAD3. With the SmartBox3.0 can download the OEM software from the manufacturer’s server for free.
  • [3 IN-1 FREE J2534 ECU Programming Device: LAUNCH X431 PRO5 support all new J2534/DOIP/CANFD protocols to access data and OE programming downloads for most Car; Support DC9-36V for HD Vehicle ( No NEED buy HD Module, SAVING $900+.)
  • [ One-stop Intelligent Tools]: Workshop level scan tool X431 PRO5 with the repair fix solutions database, Code Assist, Repair Tips,Component Measurement, TSB, Relevant Cases,DTC Analysis to simplify complex diagnostic and achieve the trouble-free repair.
  • [50+ Reset, Continuously Updated Reset Functions]: 50 resets reaching into the smallest parts to root out the problems. Extra 300+ repair functions ( in-vehicle catalog) for specific models extend the capability to regeneration, initiation, matching, etc.
Bestseller No. 10
LAUNCH X431 PRO5 Diagnostic Scanner, J2534 Reprogramming Tool with ECU Coding, Upgrade of X431 PRO3/V+, 50+ Service, Intelligent Diagnostics, Guided Functions, CAN FD/DoIP, 2-Year Free Update
  • 👍[New & Outstanding X431 PRO5 Scanner] LAUNCH X431 PRO5 scan tool, upgrade of LAUNCH X431 PRO3 & X431 V+ PRO, configures a SmartBox 3.0 VCI (J2534/DoIP/CAN FD compliant) that performs online programming for BMW & Benz models as OEM level. More powerful features: Online Coding for Porsche/Audi, Heavy-duty Truck Diagnostics, VAG Guided Functions, 50+ Services, etc., bring ease & efficiency. Powerful software even covers online diagnostics for FCA cars & newer model data.
  • [J2534 Programming with Smartbox3.0] If you’re seeking all-in-one solutions for car ECU tuning needs, LAUNCH X431 PRO5 programming tool is ready to work for you. Support online programming for BMW&Benz and hold exclusive programming backup/restoration. Come with a Smartbox 3.0 device of J2534 standard and pair with a PC to download OEM software to upgrade the ECU software, which maximizes the vehicle performance and minimizes diagnostic problems.
  • [ECU Coding Customizes All You Want] With top of the tech instruction and vehicle data, LAUNCH X431 PRO5 diagnostic scanner performs well in ECU Coding and makes everything easier 1) recode adaptive data after ECU replacement 2) personalization/retrofit to improve car comfort: deactivate auto start-stop or change interior lights 3) coding data backup/reserve 4) online coding for BMW/Benz/Porsche/VW/Skoda/Seat 5) online matching/calibration for VW/for Audi, etc.
  • [Huge Vehicle Software Database] LAUNCH scanner PRO5 can be nominated as a powerful troubleshooter for 99% of post 1996-automobiles. Provide abundant exclusive functions for effortless diagnostics: Benz/BMW Data Backup/Restoration; Benz/BMW Manual Mode Programming; Benz SCN Coding/Variant Coding; BMW Coding (with newer data to 2022.03); AutoAuth for FCA SGW(2018 later); Various Online Coding Data for VW/for Audi, etc. 2-Year free updating will keep renewing the data for more vehicles.
  • [AutoAuth Access & 50+ Services] Partnered AutoAuth FCA US, LAUNCH scanner can directly login to the AutoAuth account and secure check (reading DTC, active test, reset functions, etc.) for FCA vehicles. 50+ services that are needed for repair shops have been packed in X431 PRO5 auto scanner, such as Hot functions (Oil Reset, EPB Reset, SAS Reset, ABS Bleeding, etc.) and Comprehensive functions (High Voltage Battery Diagnostics, Transport Mode),

Last update on 2023-02-27 / Affiliate links / Images from Amazon Product Advertising API

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