Off-Board Powertrain Control Module Repalacement
Reprograming:IMPORTANT:
This procedure must only be used if the ON BOARD POWERTRAIN CONTROL MODULE REPLACEMENT procedure cannot be performed.
1. Verify that the service stall system (SSS) version number, shown on the Main Menu screen in the upper left corner is, S26.00, or greater. If not, the SSS must be updated to version S26.00, or greater. (Call 1-800-7SATURN for assistance.)
2. With the new powertrain control module (PCM) on a bench, connect PCM to Programmer (SA 9153Z) and connect PCM Programmer to SSS.
3. Turn PCM Programmer switch to ON.
4. Select Identify Vehicle.
5. Select Enter VIN Manually.
6. Select F3.
7. Enter VIN, press enter.
8. Select Options.
9. Select Steering (EVO) for all vehicles, and Handwheel Sensor if vehicle is a coupe.
NOTE: All 1991 16V (DOHC) engines were equipped with power steering (EVO) systems and all 1991 Coupes were equipped with hand wheel sensors.
10. Select Air Conditioning and/or ABS depending on vehicle's optional equipment.
NOTE: If vehicle was sold by another Retailer, contact the Saturn Retailer Support Center at 1-800-828-2112 to find out what optional equipment is on the vehicle.
11. After entering all applicable options, press enter.
12. Select System Utilities.
13. Select EEPROM Reprogramming, then press enter and follow the instructions displayed until the EEPROM Reprogramming Menu appears.
14. Select Change VIN and enter the same VIN as in Step 7.
15. Select Change Options and select the same ooptions entered in steps 9 and.
16. Select Change Calibrations and follow displayed steps until select PCM/TC is displayed.
17. Select PCM/EC.
18. Select the calibration shown on the following chart for the vehicle being worked on, then press enter.
19. On automatic transaxle equipped vehicles, you will be prompted to select a valid PCM/TC calibration. Highlight the appropriate calibration, then press enter. If valid PCM/TC calibration is already in box, this screen will not be displayed.
20. When the download is complete, select F3 to continue.
21. Select F1O to return to the Main Menu.
22. Verify new vehicle software has been loaded:
a. Select Dynamic Display.
b. Select View Serial Data.
c. Select PCM/EC.
d. Select Vehicle ID. Verify the following information is correct:
NOTE: VIN must match vehicle heing serviced.
23. Turn Off PCM Reprogrammer and unplug PCM.
Replacement:
1. Turn PCM retaining screw with a screwdriver 1/4 turn counterclockwise and remove the PCM from the electronic brake control module and PCM bracket assembly.
2. Disconnect the connections from the PCM and remove the PCM from the vehicle.
3. Make sure the anti-rattle foam is secure in the electronic brake control module and PCM bracket assembly before installation of the new PCM. If the foam is present, proceed to step 4. If the foam is not present, proceed to steps 3a through 3c and install an adhesive-back foam shim stock.
a. Cut five, 2-3/4" inch pieces of Kent Industries, 1-1/4" x 1/8" Adhesive-Back Shim Stock (P/N 451) or equivalent.
b. Install two pieces of the adhesive-back shim stock to the front-side (vertical side as viewed in vehicle) of the electronic brake control module and PCM bracket assembly, starting 1/2 inch in from the outer edge. The second piece should be spaced 1/2 inch in from the first piece before installing. (Refer to illustration.)
c. Install three pieces of the adhesive-back shim stock to the top-side (horizontal side as viewed in the vehicle) of the electronic brake control module and PCM bracket assembly, starting one inch in from the outer edge. The second and third pieces should be spaced one inch away from the other pieces before installing. (Refer to illustration.)
NOTICE: To prevent PCM pin damage, make sure connectors are aligned with PCM connector housings before installing the connectors.
4. Plug the connectors into the new PCM and push the new PCM up into the bracket assembly until two clicks are heard.
IMPORTANT: To help prevent PCM pin damage, a Mylar strip may be over the connector pins on the PCM. Do not remove this Mylar strip. When the connector is installed it will push the Mylar strip to the base of the connector.
5. Affix the Campaign Completion Label, as described under Campaign Procedures "Campaign Completion Label."
6. If the vehicle is registered in California, fill out a "Vehicle Emission Recall Proof of Correction" certificate, as described under Campaign Procedures "California Registered Vehicles."
7. If the vehicle is equipped with an automatic transaxle, proceed to the following "TRANSAXLE ADAPTIVE LEARN IN PROCEDURE."
TRANSAXLE ADAPTIVE LEARN IN PROCEDURE
1. Place shift mode switch in the normal mode position.
2. Warm up the transaxle until oil temperature exceeds 45°C (113°F)
3. Perform 10 sets of upshifts (1-2, 2-3, 3-4) at thirty percent throtle.
4. While coasting at 56k/h (35 mph), slowly accelerate to half throttle to achieve a 4-3 downshift.
5. With gear shift selector in D3 and while coasting at 32 km/h (20 mph), slowly accelerate to seventy-five percent throttle to achieve a 3-2 downshift.