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Powertrain Control Module (PCM) - Vehicles Built From: 06-2003 > < Electronic Engine Controls

Streetka 2003.5 (01.2003-07.2005)

Electronic Engine Controls - 1.3L Duratec-8V (Rocam)/1.6L Duratec-8V (Rocam) - Powertrain Control Module (PCM)—Vehicles Built Up To: 06/2003 Streetka 2003.5 (01/2003-07/2005)
Removal and Installation

Special Tool(s)

Drill Bush, Powertrain Control Module

418-537 (29-016)
General Equipment
Grips

Removal

NOTE:
NOTE:: If a new PCM is being installed, connect WDS. Upload the PCM configuration information using the programmable modules installation routine prior to commencing the removal of the PCM.
NOTE:
NOTE:Make sure that the windshield wiper motor is in the park position.
  1. Remove the steering column.
    For additional information, refer to: Steering Column (211-04 Steering Column, Removal and Installation).
  1. Remove the audio unit.
    For additional information, refer to: Audio Unit (415-01 Audio Unit, Removal and Installation).

  1. Detach the door opening weatherstrips.

  1. Remove the A-pillar trim panels.
    1. Starting from the top of the A-pillar pull off the trim panel (three clips).
    1. Unhook from the instrument panel (two hooks).

  1. Prise off the side blanking covers (two each side).

  1. Detach the front floor covering.

  1. Disconnect the air distribution flap actuation cable.

  1. Detach the ashtray.

  1. Disconnect the cigar lighter and lamp electrical connectors.

  1. Remove the instrument panel retaining bolts.
  1. Close the hood.

  1. Remove the windshield wiper arms.

  1. Remove the left and right-hand side upper cowl panel retaining screw covers and screws (right-hand side shown).

  1. Remove the left and right-hand side upper cowl panel retaining screws (right-hand side shown).
  1. Open the hood.

  1. Remove the cowl panel.

  1. Remove the water drain panel.

  1. Remove the instrument panel fixing nuts.
  1. With the aid of another technician detach and support the instrument panel.

  1. While supporting the instrument panel with the aid of another technician, cut the wiring harness cable ties.

  1. While supporting the instrument panel with the aid of another technician, detach the PCM from the bracket.
  1. Reposition the instrument panel and secure.

  1. Position the PCM on the floor.

  1. Insert the special tool into the PCM electrical connector.
  1. CAUTION:
    CAUTION:Make sure the special tool is used to guide the drill bit. Failure to follow this instruction may result in damage to the PCM electrical connector.
    Using the special tool as a guide, drill into the shear bolt using a 6 mm drill bit, until the head is removed.
  1. . Remove the special tool from the PCM electrical connector and clean all foreign material from the PCM electrical connector.

  1. . Disconnect the PCM electrical connector and remove the PCM.

  1. Remove the remains of the shear bolt from the PCM using grips.

Installation
  1. Install a new shear bolt and securing clip, using the special tool to push the clip onto the shank of the bolt.

  1. Install the PCM electrical connector to the PCM.
    • Tighten the bolt until the head shears off.

  1. With the aid of another technician install the PCM into the bracket.

  1. NOTE:
    NOTE:Install new cable ties.
    Attach the wiring harness.
  1. Locate the instrument panel into position.

  1. Install the instrument panel retaining nuts.

  1. Install the water drain panel.

  1. Install the cowl panel.
  1. Close the hood.

  1. CAUTION:
    CAUTION:Do not overtighten the upper cowl panel retaining screws. Failure to follow this instruction may result in damage to the windshield.
    Install the left and right-hand side upper cowl panel retaining screws (right-hand side shown).

  1. Install the left and right-hand side upper cowl panel retaining screw covers (right-hand side shown).

  1. Install the windshield wiper arms.

  1. Install the instrument panel retaining bolts.

  1. Connect the air distribution flap actuation cable.

  1. Connect the cigar lighter and lamp electrical connector.

  1. Install the ashtray.

  1. Attach the front floor covering.

  1. Attach the side blanking covers (two each side).

  1. Install the A-pillar trim panels.
    1. Hook into the instrument panel (two hooks).
    1. Starting from the bottom of the A-pillar push on the trim panel (three clips).

  1. Attach the door opening weatherstrips.
  1. Install the audio unit.
    For additional information, refer to: Audio Unit (415-01 Audio Unit, Removal and Installation).
  1. Install the steering column.
    For additional information, refer to: Steering Column (211-04 Steering Column, Removal and Installation).
  1. NOTE:
    NOTE:If a new PCM is being installed, connect WDS. Upload the PCM configuration information using the programmable modules installation routine prior to commencing the removal of the PCM.
    Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect.

Powertrain Control Module (PCM) - Vehicles Built From: 06-2003 > < Electronic Engine Controls