Repair Procedure - Attachment ll

2001-2002 MIATA PCM REPLACEMENT

A. VEHICLE INSPECTION PROCEDURE

NOTE: This recall is to correct a Non Methane Organic Gas (NMOG) Emission that may exceed the standard due to insufficient emission control logic and calibration of the Powertrain Control Module (PCM) during the engine warm-up period after cold start.

1. Verify that the vehicle is within the following ranges:

2001 Miata VIN Range: JM1NB353*10200018 - 219554 (built between 7-10-2000 and 6-29-2001)

- If the vehicle is within the above range, proceed to step 2.
- If the vehicle is not within the above range, return the vehicle to the customer or inventory.


2002 Miata VIN Range: JM1NB353*20219555 - 234924 (built between 7-02-2001 and 7-19-2002)

- If the vehicle is within the above range, proceed to step 2.
- If the vehicle is not within the above range, return the vehicle to the customer or inventory.




2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for a Campaign Label Recall 3505H attached to the vehicle's hood or bulkhead. Refer to eMDCS System - Warranty Vehicle Inquiry Results table.







NOTE: Verify recall number as the vehicle may have multiple recalls.

B. REPAIR PROCEDURE

Before starting procedure:

- OBTAIN ALL KEYS FROM CUSTOMER.

NOTE: If this procedure is performed and customer has additional keys that are not at the dealer, those keys will no longer start the engine.

1. Replace PCM:

a. Disconnect the negative battery cable.

b. Disconnect the connectors from the PCM installed on the upper part of the brake pedal.




c. Push the harness (PCM harness) installed to the brake pedal bracket toward the rear of the vehicle to expose the PCM bracket nut.

d. While moving the harness toward rear of vehicle, push the stay until it comes apart from the stud with the PCM installation nut.




e. Remove the PCM installation nut at the brake pedal bracket.




f. Remove the nut attaching the PCM bracket to the firewall.

g. Install in the reverse order of removal.

Tightening torque

Bolt, nut: 7.9 to 10.7 N�m (80 to 110 kgf�cm, 70 to 95.4 in�lbf)

2. Select repair procedures below according to how many valid keys were provided:

- Customer has 2 or more valid keys: REPAIR PROCEDURE I
- Customer has only 1 valid key: REPAIR PROCEDURE I


REPAIR PROCEDURE I - Customer has 2 or more valid keys

NOTE:
- Up to Eight (8) keys can be programmed to one vehicle.

NOTE:
If no specific time interval is given, each step should be performed within 30 seconds of the previous step.




1. Physically label all valid keys numerically (Key 1, Key 2, Key 3 etc...).

2. Using key 1, turn ignition switch to ON position, and observe that security light illuminates (for 12 seconds) in instrument cluster.

3. Turn key 1 to LOCK position.

4. Cycle key 1 from LOCK to ON position six times with last cycle finishing with key in ON position. During key cycling sequence, the key should not remain in ON position or LOCK position for more than 1 second. It is particularly important to ensure that the 6th turn is done within 1 second. The security light should remain illuminated for longer than 5 seconds at the end of the 6th cycle (in ON position).

- If security light remains on for longer than 5 seconds, remove key 1 and go to STEP 5.

- If the security light does not remain on for longer than 5 seconds, remove key 1 and repeat STEPS 2-4 with key 1.

5. Using key 2, turn ignition switch to ON position. Observe that security light illuminates (for 12 seconds).

- Turn key 2 to LOCK position and remove from steering lock.

6. Using key 1, start engine. Observe that security light illuminates (for 12 seconds) and engine continues to run for more than 15 seconds.

- Turn key 1 to LOCK position and remove from steering lock.

7. Repeat STEP 6 using each valid key.

8. Wait for 30 seconds to quit reprogram mode.

9. After reprogramming, clear DTCs of PCM with WDS or equivalent.

REPAIR PROCEDURE II - Customer has only 1-valid key

NOTE:
- You must have at least one valid key and a minimum of two keys to perform this procedure.

- Up to 8 keys can be programmed to the vehicle.

- Obtain the Immobilizer code word (8-digits) by logging on to MS3.




1. Locate the immobilizer control unit (under the driver side of dash).

2. Write down the 10-digit serial number found on the control unit.

3. Log on to MS3 at and access the immobilizer page.

4. Follow on-screen instructions to obtain the code word using the 10-digit serial number from the immobilizer control unit.




5. Record the code.

NOTE:
- If no specific time interval is given, each step should be performed within 30 seconds of the previous step.

6. Using valid key 1, turn ignition switch to ON position. Observe that security light illuminates (for 1 - 2 seconds) in instrument cluster then turns off.

7. Turn valid key 1 to LOCK position and remove from steering lock.

8. Using NEW key 2, cycle key 2 from LOCK to ON position six times with last cycle finishing with key in ON position. The key should not remain in ON position or LOCK position for more than 1 second. It is particularly important to ensure that the 6th turn is done within 1 second.

NOTE:
If security light illuminates at any time during STEP 8, remove key and restart from STEP 6.

9. Observe flashing of security light (300 ms ON, 300 ms OFF) in instrument cluster.

NOTE:

- If security light does not begin flashing quickly, remove key and restart from STEP 6.

10. Wait for 5 minutes until security light decreases in flashing frequency to 1.2 seconds.

11. Perform Code Word Input Procedure:

NOTE:
- A code word is composed of eight digits from 19 and is part of the immobilizer unit from the manufacturer. Each unit has its own code word. To obtain the code word, you need to have the immobilizer serial number, to input into MS3.

- To input the code word into the PCM, turn the ignition key and count the number of flashes of the security light. The calculation of the number of flashes of the security light comes with the timing of the turning of the key.

EXAMPLE:
- To input the number 3 as the first digit of the code word, wait for the security light to turn off, and then turn the ignition switch to the ON position and count three flashes. After the third flash, when the security light turns off, turn the ignition switch back to the LOCK position. Enter the remainder of the digits using this method.

a. Read the first digit of the code word.

b. Turn the ignition from LOCK to ON when the security light IS NOT ILLUMINATED.

c. Count the number of flashes for the first digit.

d. When the security light turns off, turn the ignition to LOCK.

e. Repeat STEPS 11a-11d for each code word digit (do not wait more than 30 seconds between entering code word digits or programming mode will automatically be terminated).

12.When code word is registered correctly in the PCM, the security light stops flashing and illuminates steady.

- If the security light turns OFF, the code word was not entered correctly. Return to STEP 6 and restart procedure.

13. Turn key 2 to ON position. Observe that security light illuminates (for 1 - 2 seconds).

14. Turn key 2 to LOCK position.

15. Using key 2, start engine. Observe that security light illuminates (for 1 - 2 seconds) and engine continues to run for more than 15 seconds.

NOTE:
- Cranking time may be longer than normal.

6. Turn key 2 to LOCK position and remove from steering lock.

17. Repeat STEPS 15-16 using key 1.

CAUTION:
Do not allow 30 seconds to pass between the programming of each key. After 30 seconds without a key turning in the ignition, programming mode will automatically terminate.

18.Wait for 30 seconds and vehicle will automatically exit reprogram mode.

19. After reprogramming is complete, clear any DTCs from PCM using WDS or equivalent.

C. CAMPAIGN LABEL INSTALLATION
Complete a "Campaign Label" with the recall number written on the sticker and affix it to the vehicle's hood or bulkhead. Refer back to the illustration under 'A. VEHICLE INSPECTION PROCEDURE'.


Attention: Mazda Service Managers

On 2001-2002 MY Miata vehicles, the Non Methane Organic Gases (NMOG) value may exceed the regulation value. Therefore, the PCM software has been modified to improve the emission performance. However, with this modification, the idle speed in cold condition will be higher than the current speed, after installing the modified PCM.

Therefore, please be sure to explain the following to your customers.

Change of Idling Speed in Cold Condition

1) The initial idle speed just after starting the vehicle: Increase by 200 - 300 rpm.

Before PCM replacement: Approx. 2,000 rpm

After PCM replacement: 2,200 2,300 rpm

2) The idle speed 5 seconds after starting the vehicle: Increase by 200 - 300 rpm.

Before PCM replacement: Approx. 1,400 rpm

After PCM replacement: 1,600 1,700 rpm

Note 1) The idle speed in warm condition will remain the same.

Note 2) The idle speed in cold condition with the modified PCM will be the same as that for 2003-2005 MY Miata vehicles.