Electronic Control Modules: Removal & Installation Dodge Pickup R2500

REMOVAL

1. Remove the negative battery cable from the battery.
2. Pull up on the CAB harness connector release and remove connector.
3. Remove the CAB mounting bolts.
4. Remove the pump connector from the CAB.
5. Remove the CAB from the HCU.

INSTALLATION

Note. If the CAB is being replaced with a new CAB, it must be reprogrammed with the use of a DRBIII(R).

1. Install CAB to the HCU.
2. Install the pump connector to the CAB.
3. Install mounting bolts. Tighten to 2 N.m (16 in. lbs.).
4. Install the wiring harness connector to the CAB, and push down on the release to secure the connector.
5. Install negative battery cable to the battery.

The Engine Control Module (ECM) is bolted to a support bracket near the fuel filter. The support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block.

1. Record any Diagnostic Trouble Codes (DTCs) found in the ECM.
2. To avoid possible voltage spike damage to the ECM, ignition key must be off, and negative battery cables must be disconnected before unplugging ECM connectors.
3. Disconnect both negative battery cables at both batteries.
4. Remove the 50-way and 60-way connector bolts at the ECM. NOTE: The connector bolt is a female Allen head. As bolt is being removed, very carefully remove connectors from the ECM.
5. Remove five ECM mounting bolts, and remove ECM from the vehicle (Схема №2)

Do not apply paint to ECM. Poor ground will result.

1. Position ECM to ECM support bracket, and install five mounting bolts. Tighten bolts to 24 N.m (18 ft. lbs.).
2. Check pin connectors in ECM and the 50-way and 60-way connectors for corrosion or damage. Repair as necessary.
3. Clean pins in the 50-way and 60-way electrical connectors with a quick-dry electrical contact cleaner.
4. Very carefully install the 50-way and 60-way connectors to ECM. Tighten connector Allen bolts.
5. Install both negative battery cables.
6. Turn key to ON position. Without starting engine, slowly press throttle pedal to floor and then slowly release. This step must be done (one time) to ensure accelerator pedal position sensor calibration has been learned by ECM. If not done, possible DTCs may be set. .
7. Use DRBIII(R) scan tool to erase any stored companion DTCs from ECM.

1. Disconnect the positive and negative battery cables from the battery.
2. Partially remove the integrated power module from the engine compartment. Refer to INTEGRATED POWER MODULE .
3. Remove the front control module retaining screws.
4. Using both hands, pull the front control module straight from the integrated power module assembly to disconnect the 49-way electrical connector. Remove the front control module from the vehicle.

1. Install the front control module on the integrated power module assembly by pushing the 49-way electrical connector straight in.
2. Install the front control module retaining screws. Torque the screws to 7 in. lbs.
3. Install the integrated power module. Refer to INTEGRATED POWER MODULE .
4. Connect the positive and negative battery cables.

1. Position the driver seat to the full rearward and inclined position.
2. Working under the driver's front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws.
3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart.
4. Remove the heated seat module from under the front seat.

1. Position the heated seat module under the front seat.
2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module.
3. Working under the driver's front seat, install the heated seat module retaining screws.
4. Re-position the driver seat.

Use the DRBIII(R) scan tool to reprogram the new Powertrain Control Module (PCM) with the vehicle's original identification number (VIN) and the vehicle's original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set.

The PCM is located in the engine compartment attached to the dash panel (Схема №5)

To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors.

1. Disconnect negative battery cable at battery.
2. Remove cover over electrical connectors. Cover snaps onto PCM.
3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (Схема №6)
4. Remove three PCM mounting bolts (Схема №6), and remove PCM from vehicle.

Use the DRBIII(R) scan tool to reprogram the new Powertrain Control Module (PCM) with the vehicle's original identification number (VIN) and the vehicle's original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set.

1. Install PCM and 3 mounting bolts to vehicle.
2. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be the same. Repair as necessary before installing connectors.
3. Install three 32-way connectors (four 38-way connectors if equipped with NGC).
4. Install cover over electrical connectors. Cover snaps onto PCM.
5. Install negative battery cable.
6. Use the DRBIII(R) scan tool to reprogram new PCM with vehicle's original Vehicle Identification Number (VIN) and original vehicle mileage.

1. Disconnect and isolate the battery negative cable.
2. Remove the steering column upper and lower shrouds. Refer to COLUMN.
3. Disconnect the steering column wire harness connector from the Sentry Key Immobilizer Module (SKIM).
4. Remove the screw securing the SKIM module to the steering column (Схема №7)
5. Release the SKIM antenna ring retaining clips from around the ignition switch lock cylinder housing, and remove the SKIM.

Note. If the SKIM is replaced with a new unit, a DRBIII(R) scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders. Refer to TRANSPONDER PROGRAMMING .

1. Slide the SKIM antenna ring around the ignition switch lock cylinder housing, and clip in place (Схема №7)
2. Install the retaining screw.
3. Connect the steering column wire harness connector to the Sentry Key Immobilizer Module (SKIM).
4. Install the steering column upper and lower shrouds. Refer to COLUMN.
5. Connect the battery negative cable.