A. Reprogram PCM and Inspect Catalytic Converter

The DealerCONNECT System, DRB III(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable.

NOTE:
Whenever a module is programmed, the software in the DRB III must be programmed with the revision level 63.10 or later. If this flash process is interrupted or aborted, the flash process must be repeated.

1. Using a CH7025 cable, connect the DRBIII to the external power supply.

2. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII memory. To clear the memory:

a. Start at the "MAIN MENU" screen and simultaneously press the "More" and "Yes" keys.

b. A screen will appear requesting a "Cold Boot".

c. Follow the on screen instructions by selecting the "F4" key.

d. When the DRBIII reboots to the MAIN MENU, proceed to Step # 3.

3. Using a CH7035B cable, connect the DRBIII to TechCONNECT.

4. Open "TechTOOLS" and verify that the "DRBIII Status: Connected" message is in the upper right corner of the TechTOOLS screen.

5. In the criteria box on the TechCONNECT screen, enter the last 9 digits of the Vehicle Identification Number (VIN), or use the Y.M.E. session function.

6. Click on the "Show Updates" button at the bottom of the TechCONNECT screen.

7. Download the flash files by depressing the control key on the TechCONNECT keyboard and then selecting the appropriate flash file. Note the file availability dates in the table below.

8. Click on the "Download/Update" button on the bottom of the TechCONNECT screen.

9. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, continue to Step 10.

10. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process.

NOTE:
Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash.

11. Connect the DRBIII to the vehicle.

12. Turn the ignition key to the "RUN" position.

13. Download the flashes from the DRBIII to the vehicle.

Using the DRBIII:

a. Select "Vehicle Flash".

b. Follow the directions on the DRBIII screen.

NOTE:
Due to the PCM programming procedure, a Diagnostic Trouble Code (DTC) may be set. Disconnect the battery cable and wait at least 30 seconds. Reconnect the battery cable. This will clear all DTCs stored. To enhance customer satisfaction, remember to set the clock.

14. Shut the engine off and remove the DRBIII.

15. Raise the vehicle on a suitable hoist.

16. Using a rubber mallet (about 1 lb in weight), strike the underside of the catalytic converter starting about one foot away. Listen to the sound.

> If no rattling sound is heard, continue with Section D Install the Authorized Modification Label.

> If a rattling sound is heard, continue with Section B - Catalytic Converter Replacement (XJ, ZJ and AN) or Section C - Catalytic Converter Replacement (TJ).

NOTE:
Step 16 will only determine if the catalyst has mechanically deteriorated. This step cannot determine that a no-catalyst condition exists (the catalyst housing is empty). Subsequent driving of the vehicle will enable the new software to detect a no-catalyst condition. If detected, the MIL will illuminate and set Diagnostic Trouble Code "P0420". Therefore, if a vehicle returns (during the original or the extended catalytic converter warranty period) after this recall has been performed with the MIL illuminated and DTC code P0420 set, the catalytic converter must be replaced.