01-004/03 2001-2003 Protege, 2002-2003 Protege5 - RATTLING NOISE AT 1000-3000 RPM COLD ENGINE

Note: This bulletin contains revised sections. Please update your records accordingly.

UPDATE NOTE

• This bulletin supersedes 01-004/03, issued 4/14/03. The step 14 of 2003 Protege & Protege5 Reprogramming Instructions has been updated.

APPLICABLE MODEL(S)/VINS

2001-2003 Protege (2.0L FS only)

2002-2003 Protege5

DESCRIPTION

Some customers may experience an engine rattle noise under light to moderate acceleration with engine coolant temperatures below 65 C (149 F) and engine RPMs between 1000 and 2900 RPM.

The noise is the result of the intentional swirl effect that is generated when the Variable Tumble Control System (VTCS) plates in the intake manifold are closed. Swirl accelerates the burn of the air/fuel mixture which reduces emissions when the engine is cold. The noise does not have a negative effect on the engine, and disappears as soon as coolant temperature reaches 65 C (149 F). There is a counter-measure to help reduce the noise in order to improve customer satisfaction.

Customers having this concern should have their vehicle repaired using one of the following procedures:

REPAIR PROCEDURE

1. Verify customer concern.

2. Check vehicle VIN range:

   01-02 Protege

   • From VIN JM1BJ22**1*400001 to JM1BJ22**2*551281, go to STEP 3

   • From VIN JM1BJ22**2*551282 to JM1BJ22**2*641000, go to STEP 4

   02 Protege5

   • From VIN JM1BJ24**2*440775 to JM1BJ24**2*551281, go to STEP 3

   • From VIN JM1BJ24**2*551282 to JM1BJ24**2*641000, go to STEP 4

   03 Protege / 03 Protege5

   • From VIN JM1BJ2***3*100001 to JM1BJ2***3*143365, go to STEP 4

3. Replace the VTCS delay valve, then proceed to step 4.

4. Program the PCM using WDS (Version B22 or later), verify the correct calibration from the table below:

   SPECIAL PROGRAMMING INSTRUCTIONS FOR:

   02 Protege & Protege5

   Due to current WDS B24.* software issues, to reprogram 2002 model year vehicles to the required calibration, you will need to select 2001 MY in the WDS "Select Vehicle Specification" screen.

   NOTE: If a 2002 vehicle was reprogrammed with the 2002 MY selected in the "Select Vehicle Specification" screen, it will not have the correct calibration and will need to be reprogrammed again using the special programming instructions noted above.

   03 Protege & Protege5

   For 2003 Protege & Protege5 with VIN RANGE: JM1BJ2***3*100001 to JM1BJ2***3*143365, proceed to 2003 Protege & Protege5 Reprogramming Instructions on the following pages.

   Year/Tranmssion	File Name	Tear Tag	New Calibration P/N
   2001 MTX	DXAGBT0	TUN1	1L2U-AA
   2001 ATX	DXAGAS0	AVO1	1L2U-BA
   2001-2002 MTX	QKMABB0	XMU1	2ALU-EA
   2002 MTX	QKMABB0	XMU2	2ALU-EA
   2001-2002 ATX	QKAABA0	UID1	2ALU-FA
   2002 ATX	QKAABA0	UID2	2ALU-FA
   2002 ATX	QKBA7A0	5MAB	2ALU-GA
   2003 MTX	QOAMFB0	5MGA	3ALU-JC
   2003 ATX	QOAAGA0	5MHA	3ALU-KC
   2003 ATX	QOABBC0	5MIA	3ALU-LC

5. Install revised PCM calibration sticker (9999-95-AMDC 97 available through MStore) in appropriate position (next to vehicle emissions label) with the calibration P/N provided in the table above.

6. Verify repair.

PART(S) INFORMATION

Part Number	Description	Qty.	Notes
N23613980A	Delay Valve	1	Application: All 2001 Model Year & 2002 model year built on and before November 5, 2001

WARRANTY INFORMATION

NOTE: This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warranty term information.

Delay Valve Replacement and PCM Reprogram

Warranty Type	A
Symptom Code	82
Damage Code	9W
Part Number Main Cause	N236 13 980A
Quantity	1
Operation Number / Labor Hours:	XX444XR1 / 0.8

PCM Reprogram

Warranty Type	A
Symptom Code	82
Damage Code	9W
Part Number Main Cause	****18881
Quantity	0
Operation Number / Labor Hours:	XX444XR2 / 0.8

2003 Protege & Protege5 Reprogramming Instructions

VIN RANGE: JM1BJ2***3*100001 to JM1BJ2***3*143365

NOTE:

• It is not necessary to remove any fuses or relays during PCM reprogramming when the WDS screen prompts you to do so. You may accidentally stop power to one of the PCM terminals and cause the PCM to be blanked or you may receive error messages during the WDS reprogramming procedure.
• WDS shows the calibration part number after programming the PCM.
• Please be aware that PCM calibration part numbers and file names listed in any Service Bulletin may change due to future releases of WDS software and additional revisions made to those calibrations for service related concerns. When reprogramming a PCM, WDS will always display the "latest" calibration P/N available for that vehicle. If any calibration has been revised/updated to contain new information for a new service concern/issue, it will also contain all previously released calibrations.
• When performing this procedure, if the WDS PTU is not docked and connected to 115V-120V, we recommend that a battery charger be installed on the vehicle battery and turned ON to a maximum charge of no more than 20 AMPS to keep the vehicle battery up to capacity. If you exceed 20 AMPS it will damage the WDS PTU.

1. Confirm that the vehicle is within the VIN range as noted above.

   NOTE: DO NOT Perform this procedure on vehicles out of this range.

2. Connect WDS DLC cable to vehicle's DLC connector (lower portion of dash in front of driver).

3. Press "16 PIN", "All except those below", and then press tick.

4. Screen shows cable hookup. Turn ignition switch to ON. Press tick.

5. When the progress bar begins to move in establishing communication to PCM screen, Disconnect the data link cable from the DLC connector.

6. When screen shows "NO communication can be established with the PCM screen, would you like to retry", Select "NO ".

7. Reconnect the data link cable to the DLC connector.

8. Follow screen prompts when asked to turn ignition OFF and ON.

9. Screen shows the WDS is unable to communicate, press tick.

10. Select "ALL OTHERS" at the bottom of the select vehicle screen. Press tick.

11. Screen shows to enable the WDS to identify the PCM. Press tick.

12. Enter the current calibration number in the PCM part number section of the screen (see list below).

    Example: 3ALU - 12A650* - JA

    *: These digits are embedded in WDS screen.

    NOTE: You need to highlight the second box to enter the remaining two suffix digits.

    Vehicle	Current Calibration Number*
    2003 MTX	3ALU-JA
    2003 ATX (Without Sport shift)	3ALU-KA
    2003 ATX (With Sport shift)	3ALU-LA

    *: These are the only 2003 model year calibration numbers that require an updated calibration for this issue.

13. Press tick.

14. When vehicle specification screen appears, If the data shown is correct for the vehicle you're working on, press YES. If this data is incorrect, abort this process and recheck the entered calibration number.

15. When the run engine management diagnostic screen appears, press tick.

16. When screen shows VIN and R.O., press tick.

17. Select "TOOL BOX", "Module Reprogramming ", then press tick.

18. PLEASE WAIT screen appears.

19. Select "Module Reprogramming", "PCM ", then press tick.

20. When the "another calibration is available" screen appears confirm that the file name and new part number are correct by using the list below.

    Vehicle	File Name	Calibration Part Number
    2003 MTX	Q0AMFB0	3ALU-JC
    2003 ATX (Without Sport shift)	Q0AAGA0	3ALU-KC
    2003 ATX (With Sport shift)	Q0ABBC0	3ALU-LC

21. If the above is correct, press YES.

22. After reading PCM Reprogramming screen NOTE, press tick.

23. When the TSB screen appears, press tick.

24. Turn ignition OFF as indicated in the operator action screen appears, press tick.

25. After PCM Reprogramming screen note appears NOTE: These actions are not necessary on the Protegé. Press tick.

26. Select NO when the PAT screen appears.

27. Turn ignition ON as indicated in the operator action screen.

28. At this point the DOWN LOADING DATA screen appears and the reprogramming begins.

    CAUTION: The reprogramming process takes approximately 20 -25 minutes, during this time take actions to assure that the vehicle ignition system or WDS cables are not disturbed.

29. Turn the ignition switch OFF when the operator action appears. Press tick.

30. Turn the ignition switch ON when the operator action appears. Press tick.

31. When operator action screen appears, press tick.

32. Fill out the PCM reprogramming Label with data on this screen and place near the emission label on hood.

33. Press tic and start the engine.