OS Swapping - How tusually o Please!

Morning all!
I apologize if I have chosen the wrong thread category.

Have acquired a couple of ECU/PCM's to experiment/learn with on the bench. (price was right: free) Oddly enough both are out of 2000 GMT800's and show to have the 9381344 operating system. The OS searches in the forums has found very little .xdf support and suggestions are usually made to switch to a more supported OS. GM TIS shows the 9381344 was replaced with the 12205612 OS at some point.


Having searched with multiple criteria, have yet to find out a explanation how to do such a OS swap. Probably using the wrong search criteria knowing my countyline brain.

I have a operational bench harness, as well as TunerPro, TunerProRT, and PCMHammer on the laptop. Used LSDroid to do the initial read with a OBDLink MX+

One of these may eventually end up in a 5.3 swap into a early '80's square body.

Thanks all, have learned allot on the forum and have a long way to go.

To swap the OS with PCM Hammer, go to Tools-Write Full Flash (Clone) and load a bin with the OS and calibration that you want to use

If it is a stock unmolested original GM OS BIN, there's a big list of things you will need to do with that BIN in Tuner Pro before it'll support your 5.3 liter motor. I use variations of the following OS BINS because they have XDF files that are richly developed:

12208322

12212156

12202088

12587603 - only for the 1 megabyte PCM devices

I also keep a long list of things to defeat in the OS prior to writing the BIN to my lab rat and in use PCM devices.

Rick

PC Hammer - check
.bin - check
OS System - there in lies the question.

Does having the correct .xdf and .bin constitute the complete operating system, or is there something else that is needed, such as cloning from a functional PcM.

Sorry, but I have not found what constitutes the complete operating system to do this.

Thank You for your time and putting up with us newbies

Bear with me, as I am digesting allot of information lately.
Both these came PCM's came from 2000 5.3/4L60E GMT800 vehicles, one a Tahoe the other a 1500
The 5.3 that will probably go in this unit was a 2002 and I will be using a non-computer controlled transmission so the .bin would be for a manual.

As far as I know, the PCM's were unmolested.

Thank You for the .bin suggestions.

Quote:

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Originally Posted by B52Bombardier1

If it is a stock unmolested original GM OS BIN, there's a big list of things you will need to do with that BIN in Tuner Pro before it'll support your 5.3 liter motor. I use variations of the following OS BINS because they have XDF files that are richly developed:

12208322

12212156

12202088

12587603 - only for the 1 megabyte PCM devices

I also keep a long list of things to defeat in the OS prior to writing the BIN to my lab rat and in use PCM devices.

Rick

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The XDF file is ONLY used to interpret and edit the BIN file and DOES NOT get written to the PCM. It DOES NOT become part of the OS. The XDF and the BIN MUST MATCH each other by OS name. For example, you will wind up with an unusable BIN if you attempt to edit a 12212156 OS BIN with an XDF for 12202088.

The BIN is the complete operating system. P01 PCM devices (red/blue connectors) all use OS files that are 512k bytes in size. The P59 PCM devices (green/blue connectors) all use OS files that are 1 megabyte in size.

Furthermore, you will be completely overwriting whatever BIN / OS is currently on your experimental junk yard PCM devices though for grins, I'd probably save a copy of the original OS. But really, its likely just taking up space on your hard drive and I've never found a useful reason to keep any BIN that I cannot find a matched XDF for.

Rick

Rick, Thank You! That is the answer I was looking for, and makes total sense now.

Yes, I have the existing .bin saved in a file. Time to play ( I mean experiment) now!

My 2004 has the P59 PCM and already exploring what may make my life easier on that one and has the more common operating system.

Thanks again,

Louis:rockon:

Quote:

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Originally Posted by B52Bombardier1

The XDF file is ONLY used to interpret and edit the BIN file and DOES NOT get written to the PCM. It DOES NOT become part of the OS. The XDF and the BIN MUST MATCH each other by OS name. For example, you will wind up with an unusable BIN if you attempt to edit a 12212156 OS BIN with an XDF for 12202088.

The BIN is the complete operating system. P01 PCM devices (red/blue connectors) all use OS files that are 512k bytes in size. The P59 PCM devices (green/blue connectors) all use OS files that are 1 megabyte in size.

Furthermore, you will be completely overwriting whatever BIN / OS is currently on your experimental junk yard PCM devices though for grins, I'd probably save a copy of the original OS. But really, its likely just taking up space on your hard drive and I've never found a useful reason to keep any BIN that I cannot find a matched XDF for.

Rick

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Not as to hijack the Op but this should be a sticky!
I stumbled upon this thread and it had he perfect answers that I had as well and I’m sure Most all newbies have..
great explanation. And good luck to the Op...

You are correct. The "chip" itself could not care less what is inside. The OS of the "chip" only directs the actions. All of this can seem incredibly hard but GM has made it easy for you... If you are in to learn, learn the ability and inability of each and you will be fine. GM wasn't stupid with what they did :)

Quote:

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Originally Posted by crazy4chevs

Not as to hijack the Op but this should be a sticky!
I stumbled upon this thread and it had he perfect answers that I had as well and I’m sure Most all newbies have..
great explanation. And good luck to the Op...

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crazy4chevs - agreed on the sticky with a definition! searched and searched this forum and others for a basic description of what constituted the operations system, when it is the .bin itself. B52Bombadier1 explained it perfectly.
While my current spare test units are just for experimenting, I still did not want to kill them.
Have enjoyed this journey thus far.
Now if I can just find the spot to turn off the downstream O2 sensors, LOL!

I have an extensive list of things to kill within the operating system but alas, the list is on a different computer. This list is what works for me and might be different for your vehicle, as equipped. But it'll at least get you started. I also have screen shots within Tuner Pro RT of where some of these things are stashed.

I will try to post the list later today and as with so many things in this skill set / hobby, its a compilation of the work of so many other people.

Rick

That would be very much appreciated.
This forum has been a wealth of knowledge and your assistance has been outstanding.

Hope to pay it forward in the future teaching some of the younger generation that have a interest in such projects. My 15 year old son keeps looking over my shoulder trying to figure out what I am studying so hard. LOL!
He just purchased a 2003 1500 with a V6. All this will help him along also.

Thanks again!

Louis

Quote:

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Originally Posted by B52Bombardier1

I have an extensive list of things to kill within the operating system but alas, the list is on a different computer. This list is what works for me and might be different for your vehicle, as equipped. But it'll at least get you started. I also have screen shots within Tuner Pro RT of where some of these things are stashed.

I will try to post the list later today and as with so many things in this skill set / hobby, its a compilation of the work of so many other people.

Rick

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Here you go . . . . .

DTC Codes For Deletion In Tunes

For O2 Sensors:
P0137 P0157

P0138 P0158

P0140 P0160

P0141 P0161

The EVAP codes:

P0440 Evaporative Emission System

P0442 Evaporative Emission System Leak Detected (small leak)

P0443 Evaporative Emission System Purge Control Valve Circuit

P0446 Evaporative Emission System Vent Control Circuit

P0449 Evaporative Emission System Vent Control Circuit Intermittent

P0452 Evaporative Emission System Pressure Sensor/Switch Low

P0453 Evaporative Emission System Pressure Sensor/Switch High

P1441 Evaporative Emission (EVAP) System Flow During Non-Purge

P1665 EVAP Vent Solenoid Control Circuit

The seven EGR codes:

P0401 Exhaust Gas Recirculation Flow

P0402 Exhaust Gas Recirculation Flow Insufficient Detected

P0404 Exhaust Gas Recirculation Flow Excessive Detection

P0405 Exhaust Gas Recirculation Control Circuit Range/Performance

P1404 Exhaust Gas Recirculation (EGR) Closed Position Performance

P1406 EGR Valve Pintle Position Circuit

P1409 EGR Vacuum System Leak

On some donor PCM’s there are five Secondary Air Injection codes, your PCM may be a little bit different:

P0410 Secondary Air Injection System

P0412 Secondary Air Injection Switching Vavle A Circuit

P0418 Secondary Air Injection System Control A Circuit

P1415 Secondary Air Injection (AIR) System Bank 1

P1416 Secondary Air Injection (AIR) System Bank 2

On some donor PCM’s there were six Fuel Level Sensor codes, your PCM may be a little bit different:

P0461 Fuel Level Sensor A Circuit Range/Performance

P0462 Fuel Level Sensor A Circuit Low

P0463 Fuel Level Sensor A Circuit High

P1431 Fuel Level Sensor 2 Circuit Performance

P1432 Fuel Level Sensor 2 Circuit Low Voltage

P1433 Fuel Level Sensor 2 Circuit High Voltage

On some donor PCM’ there are two Catalyst System codes, your PCM may be a little bit different:

P0420 Catalyst System Efficiency Below Threshold (Bank 1)

P0430 Catalyst System Efficiency Below Threshold (Bank 2)

For misfire sensitivity
C5621 and C5622 and other for RPM and temperature, etc.

Rick, you awesome! Thanks for the assist.
If ever we get to where we can travel again and we get up to see my kinfolk that are spread between Shreveport and Vivian I will buy you slice of IceBox Pie at Strawn's!

Sure, absolutely. I love the coconut cream pie at Strawn's.

Rick