Powertrain Control Module Replacement/Programming EFI

Important: Switching a PCM from vehicle to vehicle will cause the memory data (Glow Plug System Type, and TDC Offset) to follow the PCM. If the PCM remains in the vehicle, all the memory data must be relearned, treat the PCM as a Reprogrammed PCM except for TDC Offset (manual TDC Offset learn procedure must be performed).

If the diagnostic procedures call for the PCM to be reprogrammed or replaced then programming the EEPROM (memory data) in the PCM will be necessary. Use the procedures listed at the bottom of this section.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cables.



2. Disconnect the connectors from the PCM.
3. Remove the PCM from under the IP cluster.

Important: To prevent possible electrostatic discharge to the PCM, do not touch the component leads, and do not remove the integrated circuit from the carrier.

4. Remove the PCM mounting hardware.

1. Install the PCM mounting hardware.
2. Connect the connectors to the PCM.
3. Install the PCM under the IP cluster.
4. Connect the negative battery cables.

The MIL, the antilock and the brake lamps will continue to be enabled until the PCM is programmed. Once the programming is complete, the lamps will be turned OFF and the normal operation will occur.

5. Go to PCM Programming.

Follow all of the procedures that are listed in the specific category listed below that best describes the repair performed.

PCM Replaced (New)

1. Program "Flash" the PCM.
2. Operate vehicle to 170°F (77°C). TDC Offset auto lean being performed.

Reprogrammed PCM (Flash)

1. Operate vehicle to 170°F (77°C). TDC Offset auto lean being performed.
2. Learn Glow Plug System Type.

Disconnected PCM/Reuse
Memory OK.

1. Perform the following set up:

•	The battery is charged.

•	The ignition is ON.

•	The data link connector is attached.

2. Perform the programming. Refer to an up to date Techline terminal/equipment for user instructions.
3. If the PCM fails to reprogram, do the following:

•	Check all of the PCM connections.

•	Check the Techline terminal/equipment for the latest software version.

•	Try again to reprogram the PCM. If the reprogramming fails again, replace the PCM. Refer to PCM replacement.

Important: Vehicle must be in operating condition before performing this procedure.

1. Using the scan tool, select Special Functions, Engine Output Functions and Glow Plug System Learn.
2. Activate the Glow Plug System Learn by selecting ON. After the learn function has been preformed Not Learned will be displayed on the scan tool (in this step, the scan tool is clearing the system type).
3. Go back to the Special Functions menu and select Glow Plug.
4. Activate the Glow Plug system by selecting ON (in this step, the glow plug relay is now sending the identifying (signature) voltage to the PCM).
5. The PCM will now be able to indentify the coorect glow plug system type. For visiual verifaction of the glow plug system, refer to Component Views.
6. Clear the DTC P0380.
7. Allow the PCM to power down for at least 45 seconds.
8. Turn the ignition on leaving the engine off. Using the scan tool verify that DTC P0380 has not reset.
9. If DTC P0380 reset, perform the following:

•	Check the connections at the glow plug relay.

•	Try again to relearn the glow plug system. If the relearn fails again, refer to P0380.

Important: The PCM will only perform an auto learn when a TDC Offset is not present (new/reflashed PCM).

The PCM will automatically activate the TDC Offset program when the engine coolant is greater than 77°C (170°F) and engine rpm is less than 900 (a momentary engine stumble will occur once the engine has reached the desired temperature and rpm, this is an indication that PCM auto learn function has been activated). It is possible that a 0.00 TDC Offset can be achieved. If the TDC Offset is programed out of range, a DTC P1214 will set.