[quote]Cortana said she up date the firmware in his visor.[/quote]She never referred to his visor. [quote] How did she manage to make brand new armor without ever taking him out of the cryo-pod? More importantly, why wasn't the battle damage fixed when she "fixed it?"[/quote]It's a combination of two things. 1. His armor was changed via nanomachines 2. 343i has the artistic liscence to change how his armor looks.