DIY Network

Mopar Turbo-Upgrade: Performance-Control Module From "Tricked Out" episode DTRK-110

According to guest expert Gary Howell, the Neon's ram-air intake brings cold air into the turbo, the exhaust upgrade provides improved flow out of the turbo and the ignition upgrade provides hotter spark. The weakest link is fuel-delivery. The Mopar upgrade bridges that link with high-flow injectors and computer-controlled performance.

In this episode of Tricked Out, host Andrew Totolos installs a turbo performance upgrade -- including new high-flow fuel injectors and performance control module -- on a 2003 Dodge Neon. In this second segment, Andrew Totolos and guest expert Gary Howell continue the Neon's fuel-system upgrade by installing the new power-train control module.

Materials used in this episode:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this episode include:

Mopar Stage-1 kit, including:

• Set of four 527-cc/minute fuel injectors
  
• Mopar performance power-trained control module
  

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

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Figure A

Performance Control Module

• After the air box is removed, the next step is to remove the existing power-train control module is to disconnect the electrical connections. To make more room for the plugs to come out, unplug the air temperature sensor and remove it from the charge air pipe first (figure A). Keep it in a safe place and be sure to return it after installing the new control module.
  

• Then, slide the safety lock back, push the retaining tab, and pull each of the three plugs out of the control unit. The module comes out with the mounting bracket attached (figure B).

• First remove the nut that holds the side of the bracket to the sub-frame. Then, there are two lower bolts that can be reached from either above or below, depending on your reach and how dirty you want to get. Remove them both (figure C), and with a little work, the module and bracket assembly will come out.

  Figure B

  Figure C

  
  

• The new module is a direct replacement for the original unit. The size and the securing hardware are the same. The only difference is the programming inside the unit.

• There are three screws that hold the power-train control module to the bracket. Just remove the screws (figure D), transfer over the bracket, and screw the new unit into place (figure E).

  Figure D

  Figure E

  
  

  	Figure F
  	Figure G
  	Figure H

• Since the new unit is exactly the same on the outside, it goes on the same way it came off (figure F). There's some play in the bracket, so the easiest way to line up the mounting hardware is to loosely install the mounting nut. Then start the bolts at the bottom of the bracket. Once everything's in line, the bolts and nuts can all be tightened down.

• Reconnect the harness plugs to the new power-train module (figure G), and slide the safeties closed to lock the connectors in place.

• Replace the air temperature sensor in the charge air pipe and plug it back in (figure H).

• With all of the power-train module connections made, just do everything in reverse.

• An extra set of hands will make the job easier.

• Don't forget to replace the air temperature sensor and the retaining nut in the back corner.
  

  Previous mods under the hood include upgraded coil and plug-wire set for hotter spark. The new PCM and fuel injection will be a good match for the prior upgrades.

Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

Special Resources for Tricked Out, episode 110

Howell Automotive
Website: www.howellautomotive.com