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Ford, Powerstroke, Pre-1999
A. Removing the Computer:
1. The first step in removing the computer is to disconnect the wiring harness from the computer. The harness is accessed from under the hood near the firewall and the driver's side fender (Figure 1). There will be a 10mm bolt in the middle of the harness. Loosen bolt to disconnect harness (Figure 2).
Figure 1
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Figure 2 |
2. Remove the two 10mm nuts holding the bracket to the computer box (Figure 3). Next, remove the bracket from the computer box (Figure 4).
Figure 3 |
Figure 4 |
3. The computer is ready to slide out. Now you will need to remove the 6.5mm bolt from the upper right side of the inner fender well (Figure 5). You will need a long screwdriver or a pry bar to pry the inner fender well down to make enough room for the computer to slide out (Figure 6). The inner fender well is made of a light weight sheet metal which will bend easily and return its normal position without being damaged.
Figure 5 |
Figure 6 |
4. After prying the inner fender well down, pull the computer straight out from its location. (Figure 7) Note which way the computer comes out so you can replace the computer the same way it comes out.
Figure 7 |
B. Connector Preparation:
1.Once you have the computer removed, locate the end opposite of the wiring harness connector. This end usually has either a small black plastic cover or a thin metal cover. Pry the cover out gently. A double-sided electrical edge will now be exposed (Figure 4).
2. Use a sharp knife or a flat screwdriver to remove the connector cover (Figure 8) and expose the printed circuit board connector (Figure 9) for the required preparation and cleaning.
NOTE:
Most electrical edge connectors have a thin coating of protective grease on them. Remove this using a Q-tip, cloth, or paper towel. Make sure you clean both sides of the connector thoroughly, you can use a small amount of alcohol if necessary.
Most electrical edge connectors also have a thin lacquer coating over the electrical contacts. This is from the factory and is normal. To clean this, use a sharp knife or a flat screwdriver. Be careful to apply gentle pressure and clean only this coating off, do not remove or damage the electrical contacts.
Figure 8 |
Figure 9 |
We recommend cleaning one contact at a time, to minimize problems or damage. Clean the area in between the contacts also. (Remember to clean both sides of the electrical connector.) Watch closely! If you see the silver contacts give off fine metal shavings as you scrape lightly, you are finished with this step. STOP!
3. Control Device installation. Your control device may be in the form of either a "chip" or a small "printed circuit board". Use the appropriate instructions below, in other words, either 3.A or 3.B below.
3A. Chip Installation. You can now plug the chip into the connector. The chip will fit flush with the computer box (Figure 10). We recommend securing the chip with electrical tape or duct tape to the computer box (Figure 11).
Figure 10 |
Figure 11 |
3B. P.C. Board Installation. Bend the flat cable (between the board's connector and the board) in a "U" shape. The board will slip into the computer box so that it is not exposed to dust and dirt. You can now carefully press the female board connector onto the computer's exposed male connector. We recommend covering the opening with the original cover or electrical tape or duct tape (Figure 12).
Figure 12 |
C. Re-installing The Computer:
1. Pry the inner wheel well down and push the computer through mounting hole in the firewall. Replace the computer the same way it came out. The computer will rest in the mounting hole.
2. Replace the bracket around the computer and tighten the two 10mm nuts. Re-connect the wire harness and tighten the 10mm bolt in the center of the wiring harness. Test the vehicle by starting the vehicle and checking for a "check engine soon" light. If the engine starts ok and the "check engine soon" indicator flashes on but does not remain lit... STOP, YOU ARE DONE!
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