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Engine Control Module: Service and Repair

Engine Control Module (ECM) Replacement/Fuel Injector Flow Rate Programming & Option Programming

Engine Control Module (ECM) Replacement Procedure
The following A-G steps provide an overview procedure to replace and reprogram an ECM. Each A-G step is explained further in this section.
- A) Record the Fuel Injector Flow Rates manually from the old ECM. The fuel injector flow rates can be obtained using the scan tool Special Function Option Reprogramming - Injector Flow Rates.
- B) Capture the Option Content from the old ECM using the scan tool Special Function Capture and Restore Option Content.
- C) Replace the old ECM with the new ECM.
- D) Program the latest software and calibrations into the new ECM using the Service Programming System Remote Programming procedure (Select Diagnostic Tool - Tech2).
- E) Program the recorded Fuel Injector Flow Rates into the ECM using the Service Programming System Pass-Thru procedure (Select Diagnostic Tool - Pass Thru).
- F) Restore the original Option Content into the new ECM by using the scan tool Special Function Capture and Restore Option Content.
- G) Perform the fuel supply pump relearn procedure by allowing the engine to idle in Park or Neutral until normal operating temperature is achieved.

A. Recording Fuel Injector Flow Rates
Each fuel injector is designated with 30 hexadecimal characters (0-9 or A-F) that MUST be programmed into the ECM for correct engine fueling for each specific cylinder. These characters can be located in one of three places:
- Fuel Injector ID plate located on the top of each fuel injector. (Preferred Method) The correct order for the fuel injector flow rates for the following illustration are as follows:

5564 7D9A 9EAA 8E8F A090 8300 0000 BD







- Scan Tool Special Function Option Reprogramming - Injector Flow Rates
- Cylinder Head Cover Label







Important:
When entering the injector flow rates into the Service Programming System (SPS), 30 characters are needed. However, only 24 characters will show up on the scan tool AND 24 characters on the cylinder head cover label. This is because characters 23-28 are always 0. These 0's must be entered into the SPS in the correct location.

Important:
They only way to be assured that the injector flow rates on the scan tool or on the cylinder head cover label are correct is to check them against each fuel injector ID plate.

B.Capturing Option Content
The scan tool has the ability to capture all of the option content from the old ECM so it can be transferred to the new ECM. This is located under the Special Function Capture and Restore Option Content. The following is a list of the supported option content that will be stored in the scan tool:
- Power Take Off (PTO) Options
- Cruise Control Options
- Exhaust Brake Options
- Vehicle Speed Limit

If communications cannot be established with the old ECM, the technician will need to ask the customer which of the above option content was previously being used.

C. Removal and Installation
Removal Procedure
- ECM (1) is attached in the left rear side of transmission (2).







1. Turn OFF the ignition.
2. Disconnect the negative battery cable.
3. Remove the ECM cover nuts (5) and bolt (4).
4. Remove the ECM cover (3).
5. Disconnect the ECM connectors.
6. Remove the ECM fixing bolts (6).
7. Remove the ECM (1).







Installation Procedure
1. Install the ECM (1).
2. Tighten the ECM fixing bolts (6).

ECM fixing bolts
Tightening Torque: 8 N-m (69 lb-in)

3. Connect the ECM connectors.
4. Install the ECM cover (3).
5. Tighten the ECM cover nuts (5) and bolt (4).

ECM cover nuts
Tightening Torque: 7 N-m (61 lb-in)

ECM cover bolt
Tightening Torque: 8 N-m (69 lb-in)

6. Connect the negative battery cable.

D. Programming Software and Calibrations
1. Make sure the hardware lock is installed on the TIS2000 terminal printer (LPT) port unless you are using a satellite-connected server.
2. Launch TIS2000 and click on Service Programming System.
3. Select the following from the Select Diagnostic Tool and Programming Process screen:
- Select Diagnostic Tool - Tech 2
- Select Programming Process - Reprogram ECU
- Select ECU Location - Vehicle

4. Click Next.
5. Follow the instructions on the Preparing for Communication screen, which will Request Info, from the ECM.
6. Turn On the ignition with the engine OFF.
7. Use the scan tool to Request Info, from the new ECM located under the Service Programming System option from the scan tool Main Menu. Follow the On-Screen instructions.
8. Turn OFF the ignition.
9. Take the scan tool to the TIS2000 terminal, connect the 110 volt power supply to the scan tool then turn it ON.

Important:
The ribbon cable cannot exceed 25 feet or programming errors may occur.

10. Connect the ribbon cable between the TIS2000 terminal RS-232 port and the scan tool side port.
11. Continue to follow the SPS On-Screen instructions to download the correct software and calibrations to the scan tool.
12. Bring the scan tool to the vehicle then connect it to the data link connector (DLC) ensuring a robust connection.
13. Disconnect the ABS module harness connector (walk the connector out as to not damage the lock tab). The ECM will not program unless the ABS module Class 2 communications are disabled.
14. Turn ON the ignition with the engine OFF.
15. Before ECM programming, ensure the following are met:
- Vehicle batteries are fully charged and there is no charging system concern. All charging system concerns must be repaired before programming the ECM.
- Ensure NO battery charger is connected.
- Turn OFF all accessories that may put a load on the batteries.
- Do not change the ignition position unless instructed to do so.
- Program only when the ECM is exposed to temperatures in the 32-122 °F (0-50 °C) range.

CAUTION: An interruption of the tool harness connection during programming may cause ECM damage.

16. Use the scan tool to reprogram the ECM by choosing to Reprogram ECU under the Service Programming System option from the scan tool Main Menu.
17. Turn OFF the ignition and the scan tool.
18. Reconnect the ABS module harness connector.
19. Turn ON the ignition with the engine OFF.
20. Clear DTCs in the transmission control module (TCM) as a CAN communication DTC may have set during the programming event.

E. Programming Fuel Injector Flow Rates
1. Connect the scan tool to the data link connector (DLC).

Important:
The ribbon cable cannot exceed 25 feet or programming errors may occur.

2. Connect the ribbon cable between the TIS2000 terminal RS-232 port and the scan tool side port.
3. Make sure the hardware lock is installed on the TIS2000 terminal printer port (LPT) unless you are using a satellite-connected server.
4. Turn ON the ignition with the engine OFF.
5. Turn ON the scan tool.
6. Launch TIS2000 and click on Service Programming System.
7. Select the following from the Select Diagnostic Tool and Programming Process screen:
- Select Diagnostic Tool - Pass Thru
- Select Programming Process - Reprogram ECU
- Select ECU Location - Vehicle

8. Follow the SPS On-Screen instructions to program the Injector Flow Rates.
9. Turn OFF the ignition for 30 seconds.
10. Turn ON the ignition with the engine OFF.
11. Use the scan tool to verify each programmed fuel injector flow rate was entered correctly. See "Recording Fuel Injector Flow Rates" for their location on scan tool.

F. Restoring Option Content
Use the scan tool to restore the previously captured option content under Special Functions Capture and Restore Option Content. If the information was not captured or could not be captured from the old ECM, each option content parameter must be re-entered using the scan tool Special Function Option Reprogramming. The technician will need to ask the customer which of the supported option content was previously being used.

G. Fuel Supply Pump Relearn Procedure
The ECM goes through a fuel supply learn procedure to fine tune the current supplied to the fuel rail pressure (FRP) regulator. This learning process is only performed when the engine is idling.

1. Install the scan tool.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine and let idle until engine coolant temperature (ECT) reads 149 °F (65 °C) or higher while observing the Supply Pump Status parameter with the scan tool. The scan tool changes status Not Learn > Tentative > Leaning > Learned.
4. If the ECM has correctly learned the fuel supply pump current adjustment, the Supply Pump Status parameter on the scan tool will indicate Learned.

Fuel Injector Flow Rate Programming
Follow Step A: Recording Fuel Injector Flow Rates then Step E: Programming Fuel Injector Flow Rates above to program the fuel injector flow rates into the ECM.

Option Programming
All Option Content programming is performed using either the scan tool under Special Function Option Reprogramming or the TIS 2000 system. The following options are available for reprogramming:
- Power Take Off (PTO) Options
- Cruise Control Options
- Exhaust Brake Options
- Vehicle Speed Limit

Power Take Off (PTO) Options
The PTO Option Programming must be done when any of the following procedures are performed:
- When the upfitter installed a PTO.
- When the ECM is replaced.
- When a change of the PTO settings are needed.


Cruise Control Options
The Cruise Control Option Programming must be done when any of the following procedures are performed:
- When the ECM is replaced.
- When a change of the minimum cruise control speed is needed.
- When a change of the maximum cruise control speed is needed.

The operational speed range of the cruise control system can change by user request within the following allowable range.
- Minimum: 25 MPH (40 km/h)
- Maximum: 75 MPH (120 km/h)

Exhaust Brake Options
The Exhaust Brake Option Programming must be done when any of the following procedures are performed:
- When the ECM is replaced.
- When a change of the exhaust brake assist in cruise control is needed.

It is set up during the cruise control so that the exhaust brake may be effective when the actual vehicle speed is higher than set speed. It can change by user request. This exhaust brake assist in cruise control is enabled when the following conditions are met:
- Exhaust brake in cruise mode is programmed.
- Exhaust brake request switch is ON.
- In cruise control.
- Accelerator pedal is not pressed.
- Actual vehicle speed is higher than 4 MPH (6.4 km/h) from set speed.
- Fuel injection quantity is 0 cu.mm/stk.

This exhaust brake assist in cruise is disabled when the one of the following conditions is met.
- Exhaust brake in cruise mode is not programmed.
- Exhaust brake request switch is OFF.
- Not being the cruise control.
- Accelerator pedal is pressed.
- Actual vehicle speed is less than 1.5 MPH (2.4 km/h) of set speed.
- Fuel injection quantity more than 1 cu.mm/stk.

Vehicle Speed Limit
The Vehicle Speed Limit Option Programming must be done when any of the following procedures are performed:
- When the ECM is replaced.
- When a change of the maximum vehicle speed is needed.

The maximum vehicle speed can change by user request within the following allowable range.
- Minimum: 20 MPH (32 km/h)
- Maximum: 75 MPH (118 km/h)
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