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Generic Powertrain Control Module (Pcm) Procedure (18-033-03)

Publication date: 2004-09-13
Reference number: 18-033-03
Supersedes refnos: 18-009-04, 18-009-04 REV. A

GENERIC POWERTRAIN CONTROL MODULE (PCM) PROCEDURE

GENERIC POWERTRAIN CONTROL MODULE (PCM) PROCEDURE

TECHNICAL SERVICE BULLETIN

Reference Number(s): 18-009-04 REV. A, Date of Issue:  September 13, 2004
GROUP: Vehicle Performance
Superceded Bulletin(s): 18-009-04
NOTE: CHECK SOFTWARE AVAILABILITY ON DealerCONNECT USING THE StarSCAN AND THE INTERNET FLASH FILE DOWNLOAD PROCEDURE.
NOTE: THE StarSCAN SOFTWARE UPDATE CD CONTAINS ALL PREVIOUSLY RELEASED FLASH FILES PRIOR TO THE CD RELEASE DATE PRINTED ON THE CD LABEL.
NOTE: FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD NOVEMBER, 2004.
NOTE: THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-009-04 DATED MARCH 2, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.

SUBJECT

Generic Powertrain Control Module (PCM) Procedure

OVERVIEW

This bulletin involves programming a generic PCM with software using the StarSCAN.

MODELS

DISCUSSION

Replacement PCM's will require programming utilizing the StarSCAN. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed".

CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration.

PARTS REQUIRED

PARTS REQUIRED

Qty. Part No. Description Model Remarks
1 56029144AC Generic Powertrain Control Module HB 2004 Vehicles with a 3.7L Engine
1 56029078AC Generic Powertrain Control Module HB 2005 Vehicles with a 3.7L Engine
1 56028795AC Generic Powertrain Control Module HB 2004 Vehicles with a 4.7L Engine
1 56029080AC Generic Powertrain Control Module HB 2005 Vehicles with a 4.7L Engine
1 56029146AC Generic Powertrain Control Module HB 2004 Vehicles with a 5.7L Engine
1 56028983AC Generic Powertrain Control Module HB 2005 Vehicles with a 5.7L Engine
1 04896234AE Generic Powertrain Control Module LX Vehicles with a 2.7L/3.5L Engines Built on or before June 27, 2004
1 04606834AC Generic Powertrain Control Module LX Vehicles with a 2.7L/3.5L Engines Built on or after June 28, 2004
1 04606864AE Generic Powertrain Control Module LX 3.5L Engine and NAG1 Transmission Built on or after June 28, 2004
1 04896678AG Generic Powertrain Control Module LX Vehicles with a 5.7L Engine Built on or before June 27, 2004
1 04606837AE Generic Powertrain Control Module LX Vehicles with a 5.7L Engines Built on or after June 28, 2004
1 56029077AB Generic Powertrain Control Module ND Vehicles with a 3.7L Engine and Manual Transmission
1 56029078AC Generic Powertrain Control Module ND Vehicles with a 3.7L Engine and Automatic Transmission
1 56029079AD Generic Powertrain Control Module ND Vehicles with a 4.7L Engine and Manual Transmission
1 56029080AC Generic Powertrain Control Module ND Vehicles with a 4.7L Engine and Automatic Transmission
1 56044516AE Generic Powertrain Control Module WK Vehicles with a 3.7L Engine
1 56044515AE Generic Powertrain Control Module WK Vehicles with a 4.7L Engine
1 56044517AD Generic Powertrain Control Module WK Vehicles with a 5.7L Engine
1 04275086AB Label, Authorized Modification --- ---

SPECIAL TOOLS/EQUIPMENT REQUIRED

REPAIR PROCEDURE USING THE INTERNET TO RETRIEVE THE FLASH FILE

NOTE: The StarSCAN must be at version 4.07 or higher before the "Using The Internet To Retrieve The Flash File" repair procedure can be performed.
NOTE: The StarSCAN diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN for your dealership's network. For instruction on setting up your StarSCAN for the dealer's network; refer to the StarSCAN Quick Start Networking Guide available on the www.dcctools.com website under the "download center".
NOTE: Make sure the StarSCAN is configured to the dealership's network before proceeding.
NOTE: If this flash process is interrupted/aborted, the flash should be restarted.
  1. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle.
  2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop (optional).
  3. Retrieve the old PCM part number. Using the StarSCAN at the "Home" screen:
    1. Select "ECU View"
    2. Touch the screen to highlight the PCM in the list of modules.
    3. Select "More Options".
    4. Select "ECU Flash"
    5. Record the "Part Number", displayed on the "Flash PCM" screen, for later reference.
  4. If the StarSCAN is connected to the dealer's network drop and the vehicle, proceed to Step #5. If the StarSCAN is not connected to the dealer's network drop and the vehicle, proceed to Step #10
  5. Select "Browse for new file".
  6. Select the appropriate calibration.
  7. Select "Download to Scantool".
  8. Select "Close" after the download is complete. Proceed to Step #11.
  9. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop (if not already connected).
  10. Download the flash file from the Internet to the StarSCAN. Using the StarSCAN at the "Home" screen:
    1. Select "Flash Download".
    2. Select "Enter information manually". Press the "Next" button and follow the on screen instructions.
    3. Select the appropriate calibration.
    4. Select "Download to Scantool".
    5. Select "Close" after the download is complete.
  11. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle (if not already connected).
  12. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts.
  13. Download the file from StarSCAN to the vehicle. Using StarSCAN at the "Home" screen:
    1. Select "ECU View"
    2. Browse the list of controllers using the scroll arrows. Highlight the PCM.
    3. Select "More Options"
    4. Select "ECU Flash"
    5. Highlight the appropriate PCM "Calibration" from the list.
    6. Select "Update Controller".
    7. When update is completed, select "OK".
  14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN at the "Home" screen:
    1. Select "ECU View"
    2. Scroll through the list of controllers and highlight the WCM.
    3. Select "Misc. Function".
    4. Highlight "PCM Replaced".
    5. Select "Start"
    6. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step.
  15. Program the PCM mileage. Using the StarSCAN at the "Home" screen:
    1. Select "ECU View"
    2. Scroll through the list of controllers and highlight the PCM.
    3. Select "Misc. Function".
    4. Highlight "Check PCM Odometer".
    5. Select "Start"
    6. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step.
  16. If the vehicle is equipped with a 3.7L or 4.7L engine, proceed to Step #17. Using the StarSCAN at the "Home" screen:
    1. Select "ECU View"
    2. Scroll through the list of controllers and highlight the PCM.
    3. Select "Misc. Function".
    4. Highlight "Learn ETC".
    5. Select "Start"
    6. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step.
  17. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1 ).
    Fig 1: Authorized Modification Label
    G00183682

REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE

NOTE: Before flashing this module, make sure the StarSCAN is operating at the latest level and this is the latest flash file available from the StarSCAN update CD. To determine the latest StarSCAN software version level available refer to www.dcctools.com website under the "Latest News" link.
NOTE: If this flash process is interrupted/aborted, the flash should be restarted.
NOTE: For detailed information on the operation of the StarSCAN, refer to the Quick Reference documentation provided in the StarSCAN documentation kit. In addition, more recent information may also be available at the www.dcctools.com website. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help.
  1. Retrieve the old PCM part number. Using the StarSCAN at the "Home" screen:
    1. Select "ECU View"
    2. Touch the screen to highlight the PCM in the list of modules.
    3. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference.
  2. Insert the USB Key, into the USB port on the TechCONNECT or equivalent PC (Fig 2 ).
    Fig 2: USB Key and TechCONNECT PC
    G00381705
  3. Insert the StarSCAN Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN Software Update CD will start automatically.
    1. Select "Controller Flash".
    2. Follow the on screen instructions.
  4. At the "Select the type of information you wish to enter." screen:
    1. If the old "Part Number" was recorded in Step #1, proceed to Step #5.
    2. If the old "Part Number" is not known, proceed to Step #6.
  5. Select "Enter part number".
    1. Follow the on screen instructions. Enter the "Part Number" (use capital letters) recorded in Step #1 when prompted to do so. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step.
    2. Proceed to Step #7.
  6. Select "Enter YME Information".
    1. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step.
    2. Proceed to Step #7.
  7. Using the mouse highlight the appropriate "Calibration"
    1. Select "Save to USB"
    2. Follow the on screen instructions. Select "Next"#after each step . Select "Finish" after completing the last step.
  8. With the StarSCAN powered OFF, connect the USB Key and Gender Changer to the StarSCAN USB port (Fig 3 ).
    Fig 3: USB Key, Gender Changer, and StarSCAN
    G00381706
  9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts.
  10. Connect the StarSCAN to the vehicle.
  11. Power ON the StarSCAN.
  12. Download the file from the USB key to the StarSCAN. Using the StarSCAN at the "Home" screen:
    1. Select "Flash Download"
    2. Select "Use USB device"
    3. Follow the on screen instructions. Select "Next"# after each step. Select "Finish" after completing the last step.
    4. At the "Flash File List" screen, highlight the appropriate PCM "Calibration".
    5. Select "Download to Scantool"
    6. When the download is complete, select "Close".
  13. Download the file from the StarSCAN to the vehicle. Using the StarSCAN at the "Home" screen:
    1. Select "ECU View"
    2. Browse the list of controllers using the scroll arrows. Highlight the PCM.
    3. Select "More Options"
    4. Select "ECU Flash"
    5. Highlight the appropriate PCM "Calibration" from the list.
    6. Select "Update Controller"
    7. When update is completed, select "OK"
  14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN at the "Home" screen:
    1. Select "ECU View"
    2. Scroll through the list of controllers and highlight the WCM.
    3. Select "Misc. Function".
    4. Highlight "PCM Replaced".
    5. Select "Start"
    6. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step.
  15. Program the PCM mileage. Using the StarSCAN at the "Home" screen:
    1. Select "ECU View"
    2. Scroll through the list of controllers and highlight the PCM.
    3. Select "Misc. Function".
    4. Highlight "Check PCM Odometer".
    5. Select "Start"
    6. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step.
  16. If the vehicle is equipped with a 3.7L or 4.7L engine, proceed to Step #17. Using the StarSCAN at the "Home" screen:
    1. Select "ECU View"
    2. Scroll through the list of controllers and highlight the PCM.
    3. Select "Misc. Function".
    4. Highlight "Learn ETC".
    5. Select "Start"
    6. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step.
    NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased.
    NOTE: The following step is required by law.
  17. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1 ).

POLICY

Reimbursable within the provisions of the warranty.

TIME ALLOWANCE

Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual.

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