Read ELECTRICAL WIRING POWERTRAIN CONTROL SYSTEM APPLICATION text version

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APPENDIX

ELECTRICAL WIRING POWERTRAIN CONTROL SYSTEM APPLICATION

PCM Powertrain Control Module: Location must be completely shielded from weather and case grounded to sheet metal. It should be oriented such that no moisture can accumulate in the 104-way connector. The ambient temperature at the PCM module shall not exceed 80° Centigrade (176° Fahrenheit). Exterior surface shall not exceed 140°F. NOTE: The powertrain control module requires battery power to be supplied at all times to maintain the keep-alive memory. Keep this in mind when installing load disconnect switches or solenoids. TP Throttle Position Sensor: Supplies a throttle position signal to the PCM-V processor. Do not tap into or splice any wire to the TP sensor. VSS Vehicle Speed Sensor for Trucks: The source of vehicle speed is model dependent. Possible sources are the Anti-Lock Brake System (ABS), a gear driven Vehicle Speed Sensor or the transmission Output Shaft Speed (OSS) Sensor. On 4x4 applications with a manual shifted transfer case, the Transfer Case Speed (TCSS) Sensor is the source of vehicle speed. The vehicle speed signal is either an A/C signal whose frequency changes with speed, or a SCP Data message depending on the source. Some applications have both. The vehicle speed signal is an input to the various sub-systems such as the PCM, instrument cluster (speedometer and odometer), speed control system, etc. The vehicle speed source must be operational to enter certain vehicle diagnostics. Do not tap into or splice any wire to the VSS input or sensors or engine and transmission damage may occur. If an additional vehicle speed signal is required, an additional sensor must be installed. gap is non-adjustable. All factory tone wheels have 120 teeth for every rear axle ratio offered. If the rear axle is changed, provisions for a tone wheel and the variable reluctance sensor have to be made. Calculations involving the circumference and output frequency would have to be made and are beyond the scope of this manual. It is necessary to configure the ABS, ZWAL, or CTM Module so that the correct number of tone wheel teeth are recorded in the module. The following table gives tire sizes and revolutions per mile values. If the tire make and size is not found in the table, the tire revolutions per mile must be calculated as outlined below. The tire manufacturer may be able to provide the revolutions per mile value. Once the tire revolutions per mile value is known, proceed to the Module Configuration section.

ELECTRICAL: Guidelines for Powertrain Control System Application SYSTEM:

All Powertrain Control Module wiring, in particular the 12A581 and 14401, must be a minimum of 2 inches from secondary ignition coil wires and at least 4 inches from the distributor, ignition coil tower, and starter motor (and its wiring) as well as 4 inches from the alternator output wiring. These clearances apply in particular to all PCM sensor and actuator pigtail wiring. PCM wires shall not be in the same bundle as other high-current non-PCM circuits (e.g., tachometer wire from coil to Thick Film Ignition Module (TFI), power seat/door lock/window, horn, alternator reg.) for a distance of more than 20 inches. Please refer to Electrical on page 282.

REQUIRED TOOLS

Rotunda New Generation Star (NGS) Tester. Ford Service Function (FSF) Program Card Version 1.1 or newer. The Rotunda New Generation Star (NGS) Tester and the Ford Service Function (FSF) Program Card can be obtained from Hickok Electrical Instrument Company by contacting (216) 541-8060 Extension 225. If your company has an account with Rotunda, contact Rotunda - OTC Division at 1-800-533-5338.

MODULE CONFIGURATION

Ensure that all harness connectors are connected to the module that requires configuration. Plug the NGS tester into the data link connector located below and to the right of the steering column. Actuate the ignition switch to the RUN position (engine off). Insert the Ford Service Function (FSF) Program Card into the Rotunda New Generation Star (NGS) Tester. Select SERVICE BAY FUNCTIONS using the trigger button. Scroll the highlight bar down to the module requiring configuration (see the Speedometer Calibration section). For the ZWAL Module, use the ABS option. Press the trigger button to select the module and select the TIRE SIZE/AXLE RATIO CONFIGURE using the trigger button. The current configuration cannot be read on this vehicle line. Press the trigger button to continue. Select TIRE SIZE by pressing the trigger button. Use the dial to select the custom revolutions/mile entry and press the trigger button. Enter two zero's using the number buttons and enter the 3-digit revolutions/mile value for the desired tire using the number buttons. Using the dial, select TONE RING SIZE and press the trigger button. Use the dial to select the rear axle ring gear size (10.25 in, 10.5 in or 11.25 in) and press the trigger button. If the preceding options are not present, use the dial to select the custom number of teeth and press the trigger button. Enter two zero's using the number buttons and enter the 3-digit tone wheel teeth value using the number buttons. Unless the axle has been changed, enter 120 as the number of tone wheel teeth. Using the dial, select OPTION and press the trigger button. Use the dial to select N/A and press the trigger button. Using the dial, select VEHICLE and press the trigger button. Use the dial to select F250/350 and press the trigger button. Press done (numeric 8 button) and the module will be programmed with the above data entered. To reprogram, repeat the above procedure.

TIRE SIZE AND REVOLUTIONS PER MILE

TIRE SIZE

LT215/85R16 LT235/85R16 LT235/85R16 LT235/85R16 LT235/85R16 LT265/75R16 LT265/75R16 225/70R19.5 225/70R19.5 7.50X17 7.50X17

COMPONENTS:

BPP Brake Pedal Position Switch: Supplies the processor a signal for converter clutch operation. A connection here may have an adverse effect on transmission operation. Refer to the ELECTRICAL WIRING SECTION "ADDING LIGHTS OR ELECTRICAL DEVICES'' (page 249) for guidelines. CAUTION: Any connection to the PCM V system (i.e., wiring, components) or alterations to the system may adversely affect vehicle operation (transmission and/or engine). BARO/ Barometer Pressure Sensor/Manifold Absolute MAP Pressure Sensor: Must be physically in a higher location than the intake manifold and angled with the vacuum nipple at least 4 degrees downwards. MAP vacuum line must have a downward slope to the manifold without any potential kinking or twisting. BARO has no vacuum line. DTR Digital Transmission Range Sensor: Located on the outside of the transmission at the manual lever. The DTR sensor completes the Start circuit in Park and Neutral, the Back-Up Lamp circuit in Reverse and the Neutral Sense circuit (4x4 ONLY) in Neutral. The DTR Sensor also opens/closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P,R,N,D,2,1). Do not tap into or splice any wire to the DTR circuits or engine and transmission damage may occur and affect its operation. HO2 Heated Oxygen Sensor: Pigtail wire must be at least 4 inches from the exhaust pipe and exhaust manifold. If necessary, a clip should be used to secure its location.

MAKE/ APPLICATION

FIRESTONE/ ALL SEASON GOODYEAR/ ALL SEASON GENERAL/ ALL SEASON GOODYEAR/ ALL TERRAIN GENERAL/ ALL TERRAIN FIRESTONE/ ALL SEASON FIRESTONE/ ALL TERRAIN GENERAL/ ALL SEASON GENERAL/ ALL TERRAIN FIRESTONE GOODYEAR

REVOLUTIONS/ MILE

682 655 657 653 654 655 649 653 654 605 620

SPEEDOMETER CALIBRATION

The vehicle speedometer receives the calibrated speed signal (sine wave) from the ABS Module or the Rear only ABS (ZWAL) Module through Circuit 679 (GY/BK) [except Mexico where the signal is received from the Central Timing Module (CTM) Module]. The input to the ABS, ZWAL, or CTM Module is provided by the DSS (Differential Speed Sensor) in the rear axle through Circuits 523 (R/PK) and 519 (LG/BK). If a tire change is performed, it is necessary to configure the ABS, ZWAL, or CTM Module so that the correct vehicle speed is indicated on the speedometer. The square tooth tone wheel in the rear axle is attached to the ring gear. A variable reluctance sensor is mounted to the front section of the rear axle housing with a precise air gap with respect to the tone wheel. These two components make up the DSS (Differential Speed Sensor). The rear axle case has a fixed mounting boss for the variable reluctance sensor and therefore the air

CALCULATING TIRE REVOLUTIONS PER MILE

Position the vehicle on level ground, load with the standard weight for the specific application, and inflate the tires to the recommended pressure (ensure that the tires are cold). Measure the tire height from the ground to the top of the tire in inches. Ensure an accurate reading to the nearest 1/8 inch. Divide 20,168 by the tire height in inches to get the tire revolutions per mile. EXAMPLE: Measured tire height - 33 inches REVOLUTIONS/MILE = 20168/33 = 611 Revolutions/Mile

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ELECTRICAL WIRING POWERTRAIN CONTROL SYSTEM APPLICATION

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