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Discussion Starter · #1 · (Edited)
I'm slowly working on a plan to upgrade my '99 van's "(black box) vehicle control module" to a 2002 safari van "(0411) powertrain control module". to do so involves swapping every wire on the van's 4-connector black box wiring harness over to the 2-connectors that terminate the harness into the 0411 PCM. the harness wire connector ends are the same for both controllers, so by removing the wires from the van's original connectors and plugging them into the newer connectors, the process basically becomes a plug-and-play exercise. it's an elaborate process however, involving about 80 wires. before I commit to the connector repinning, I want to make sure that I already know where every single wire goes. there may or may not be a complete spreadsheet of the correct connector repining floating round on the web; if there is, I don't have it.

the main reason I want to do this is because I am also in the process of converting to a twin electric fan setup, mounted behind an oversize radiator. the 0411 controller seems to be a "go-to" controller for retrofitting into vehicles of my vintage, where more than original capabilities are desired. for whatever reason, the stars aligned here - newer controllers are more difficult to use. in my case an installed, working 0411 should be just what I want because it has the capability to operate twin electric fans automatically, even though the astro/safari never had electric fans from the factory. as I understand it the black box controller does have the capability to operate one fan.

what I have done so far is scan and print the connector pages from the '99 & '02 astro/safari factory service manuals and tried to match up where the van wires would go on the newer connectors. then I rescanned the marked-up pages and will download them here.

the matchup is not complete yet, this is my first shot at it just sitting at a desk using the manual pages, without any hardware in front of me. there are also some matchups I got from a 2002 express van service manual. these scans I'm posting are still crude/unfinished but I wanted to start posting about this, with hopefully an end result that will give anyone else a working hardcopy of correctly repinned connectors. if anyone has already done this and wants to add their results here, by all means please do so.

here's the unfinished marked up pages.......:
scans of the '99 pages with handwritten location of wires on the 0411 connectors :
Handwriting Font Material property Rectangle Parallel


Font Parallel Rectangle Pattern Handwriting


Rectangle Font Material property Parallel Pattern


Font Rectangle Handwriting Material property Parallel


scans of the 2002 pages with handwritten locations of wires on the '99 connectors :
Font Material property Parallel Pattern Rectangle


Font Parallel Pattern Rectangle Monochrome


Font Rectangle Parallel Pattern Number


Font Rectangle Parallel Pattern Handwriting


chicken scratch/unfinished business :
Handwriting Font Material property Parallel Pattern


Handwriting Font Parallel Number Paper
 

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01 Astro RWD Cargo, 97 AWD Mark III
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Just how does this affect the engine/trans/ABS electronics?
 

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It will be running a different PCM, the 0411.

Basically it's just popping the wires out of the old connector, then popping them into the new connector at the proper places for the new PCM. Doesn't require cutting/soldering/anything, once you take the connector apart, you can just pull the tab back and the wire pulls through the back of the connector. Easy as pie.

Then you would flash the new operating system to support the 4.3, if not already for the 4.3.
It would make sense to move to the 12212156 OS if it's not on that one already, as there is excellent support for that OS.

Jeff- aka Lextech over at efilive forum has a bunch of spreadsheets for these swaps.

Faster computer than the earlier vans, better tuning options, etc.
 

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Discussion Starter · #4 ·
Just how does this affect the engine/trans/ABS electronics?
hi MI_Ghost,
as near as i can determine at this point, for my '99 van, unless i play with preset software parameters, the operating system that is preloaded into the 2002 safari PCM that i have should play nicely with the electronics in my van. for earlier years i don't know. a free to download, open source tuning program has come out that should allow you to turn things on/off & adjust parameters in the 0411 without spending a lot for a hardware/software/buy a license type package like EFIlive. i'll make up a post to describe that later.
i've been following along and posting in a thread about PCM control for electric fans : PCM Electronic Fan Control...
that thread has sort of entered limbo because before i can add much of anything new to that thread, i need to finish what i'm going to figure out in this new thread, and finish up the fan mounting design that you're waiting on for me to send your front panel. whew..
 

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Discussion Starter · #5 ·
It will be running a different PCM, the 0411.

Basically it's just popping the wires out of the old connector, then popping them into the new connector at the proper places for the new PCM. Doesn't require cutting/soldering/anything, once you take the connector apart, you can just pull the tab back and the wire pulls through the back of the connector. Easy as pie.

Then you would flash the new operating system to support the 4.3, if not already for the 4.3.
It would make sense to move to the 12212156 OS if it's not on that one already, as there is excellent support for that OS.

Jeff- aka Lextech over at efilive forum has a bunch of spreadsheets for these swaps.

Faster computer than the earlier vans, better tuning options, etc.

thanks Will!!!!!!!!!
 

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Here is a write-up that has some great pictures of taking the connectors apart, re-pinning, etc. 12200411 PCM swap - GM Truck Central
Basically the same. Except now we have PCMhammer GitHub - LegacyNsfw/PcmHacks: PCM Hammer & PCM Logger, tools for General Motors Powertrain Control Modules (PCMs). to be able to read/write the PCM using cheap hardware. If you are using a supported OS you can use the free TunerPro TunerPro and TunerPro RT - Professional Automobile Tuning Software with the proper XDF to copy/change tables/options/etc.

For changing the PCM pins, you look up your current application pinout, and then the one from the donor PCM/OS and make a spreadsheet like the one attached below, filling out what is needed(remove .txt from attachment), you can use LibreOffice if you don't have MSO https://www.libreoffice.org/
Note: Don't just take this spreadsheet and run with it, compare it to YOUR specific circumstances. :)
 

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Discussion Starter · #7 · (Edited)
here's pics of my JY 0411 and it's red & blue connectors that i plan to use. i snipped off the wired connectors with some good length left on the wires in case i need some pigtails. i'm going to look at these still wired connectors to see what wires my JY PCM was actually using. i'll mark these wires on the scans i posted above when i get a chance.

Wood Circuit component Tints and shades Art Electric blue


Rectangle Serveware Gas Metal Natural material


Light Automotive lighting Rectangle Wood Bumper


Office supplies Electric blue Fashion accessory Art Craft


i don't have the "feel" for getting the gray plastic caps off of the back of the connectors - i broke both of these......
Wood Automotive exterior Auto part Metal Rectangle


Bag Electrical wiring Cable Electronic device Wood


Wood Natural material Plant Rectangle Animal product


Electrical wiring Rope Electrical supply Wire Wood


Collar Wood Luggage and bags Bag Rectangle


Wood Art Paint Fashion accessory Electrical supply


have to upload the pics here..........
 

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i don't have the "feel" for getting the gray plastic caps off of the back of the connectors - i broke both of these......
They break pretty easy, nothing to worry about though.
 

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and finish up the fan mounting design that you're waiting on for me to send your front panel. whew..
:) I am waiting patiently :)

I will add you as my 2nd goto source (behind Will) for electronics.
I can make things work mecanically. Electronically I am a smoke maker (I know enough to know that I am dangerous).
 

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Discussion Starter · #10 ·
Here is a write-up that has some great pictures of taking the connectors apart, re-pinning, etc. 12200411 PCM swap - GM Truck Central
Basically the same. Except now we have PCMhammer GitHub - LegacyNsfw/PcmHacks: PCM Hammer & PCM Logger, tools for General Motors Powertrain Control Modules (PCMs). to be able to read/write the PCM using cheap hardware. If you are using a supported OS you can use the free TunerPro TunerPro and TunerPro RT - Professional Automobile Tuning Software with the proper XDF to copy/change tables/options/etc.

For changing the PCM pins, you look up your current application pinout, and then the one from the donor PCM/OS and make a spreadsheet like the one attached below, filling out what is needed(remove .txt from attachment), you can use LibreOffice if you don't have MSO https://www.libreoffice.org/
Note: Don't just take this spreadsheet and run with it, compare it to YOUR specific circumstances. :)

hi will,
i downloaded your attachment and got the blue & red connector pages - what exactly am i looking at?????????
 

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Just an example spreadsheet.
You can create one that also has your 99 pinouts listed as well, if you are into that kinda thing ;)
Makes it easy to post/share/download/print a copy when it's all said and done.
 

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Discussion Starter · #12 ·
i've got a few more pics i'll add here.........
very fancy gm splice on the tan/white wires - i haven't looked at the connector numbers yet, but i think this might be where the multiple "circuit 551" tan/white wires i noted might come together
Wood Electrical wiring Electrical supply Art Wire


Circuit component Electrical wiring Electricity Cable Gas


Wood Electrical wiring Electrical supply Circuit component Wire


Branch Twig Wood Terrestrial plant Plant


Circuit component Wood Electrical wiring Gas Cable


a 2-in-to-1
Green Electrical wiring Line Electrical supply Wire


another 2-in-to-1
Amber Electrical wiring Wood Cable Electrical supply


that's it for now...........
 

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Discussion Starter · #13 ·
Just an example spreadsheet.
You can create one that also has your 99 pinouts listed as well, if you are into that kinda thing ;)
Makes it easy to post/share/download/print a copy when it's all said and done.

thanks will, i like that !!!!
an easy to view final post available to anyone is what i am hoping to be able to post if/when i get a correctly running 0411 installed. i've seen a lot of threads talking about this but don't see clear usable final results posted. i know about lextech but his thread at efilive seems to be purposely poisoned with blather about resumes.........
 

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Discussion Starter · #14 ·
:) I am waiting patiently :)

I will add you as my 2nd goto source (behind Will) for electronics.
I can make things work mecanically. Electronically I am a smoke maker (I know enough to know that I am dangerous).
thanks for the kind words MI_Ghost !!
AstroWIll is light years ahead of me ... he is DEeMAN!!
 

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I will throw these here as well and then I think I'm done cluttering up your thread. :)

Have to remove the .txt file extension.


Edit: added a spreadsheet as well and an 02 Astro bin that doesn't have egr :)
 

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Discussion Starter · #17 · (Edited)
these pictures pertain to 2 wires i will be adding to my 0411 to control the electric fans when i get them installed. this was discussed in the thread i linked to above so i'll just hit the highlights here....... a prewired, add-on, e-fan control relay box for 2 fans was factory installed on 2005-06 chevy/GMC full size trucks. this assembly on later models was part of the main fuse panel and not separate.

i took this relay box & wiring off of a JY '05 tahoe......
Electrical wiring Cable Circuit component Wire Electrical supply



i need to figure out a place to mount this somewhere under the hood..........
Circuit component Passive circuit component Computer data storage Data storage device Font


sticker tag inside the relay box cover...
Rectangle Font Technology Parallel Gas



the green and blue wires come out of the JY tahoe PCM connectors and plugged in to the relay box harness........
Circuit component Passive circuit component Hardware programmer Electrical wiring Gas


Circuit component Electrical wiring Hardware programmer Electronic engineering Cable



i'll take these 2 wires out of the JY tahoe connectors. the green wire will go in my 0411's C1 (blue) connector in the #42 position; the blue wire will go in the C2 (red) connector in the #33 position. note that these 2 wire positions are not used on the 2002 astro pin charts i posted above.
Circuit component Hardware programmer Electronic engineering Computer hardware Electricity


the relay box now only needs power & ground - the 2 oval connectors in the top picture plug in to the fan motors. when it's all mounted, this physical part of the puzzle will be complete.

BUT THERE'S MORE (of course there is)..........
a sensor still needs to be added to the AC refrigerant high pressure line to automatically cycle the fans to satisfy the wants and needs of the AC system.
 

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Discussion Starter · #18 · (Edited)
since e-fans never came in the astro/safari, there was no need for this sensor, and adding it is a little more involved than the relay box. 1999-2002 camaro/firebirds did use a sensor compatible with the 0411, so off to the JY for this, from a 2000 camaro :
Gas Electrical wiring Wire Cable Fashion accessory

the sensor on the tubing must be replicated on the astro/safari AC refrigerant high pressure line. the wires on the sensor connector will plug in to the 0411 connector.

the low pressure switch shown below is already installed :
Camera accessory Auto part Font Cameras & optics Engineering



the camaro sensor needs to go somewhere on this line in the astro :
Motor vehicle Automotive tire Hood Automotive design Steering wheel


parts needed to add the sensor that i bought new :


a new line to replace the one installed right now :
Food Packing materials Fluid Gas Liquid


Metal Art Rock Glass Transparent material


a new sensor, and a braze on bung designed specifically for this mod :
Plastic Plastic wrap Electric blue Packing materials Ingredient


i got a shop in town to attach the bung to the new line :
Bicycle part Wood Bicycle handlebar Rim Gas



in this position :
Amber Automotive lighting Wood Cable Automotive exterior


the refrigerant will have to be evacuated to install the new line, which i have not done yet. with the wires connected and the 0411 made aware of it's new responsibility, this will be a nice high quality e-fan mod that is all GM.

this is the point at which i can't add anything else to the PCM fan control thread until i have a working 0411, so on with the repining quest!!
 

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If you have any problems running in closed loop, take a look at the o2 sensors. Don't know if they were different between the 99 and 02, grey vs black plugs.
 

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Discussion Starter · #20 · (Edited)
If you have any problems running in closed loop, take a look at the o2 sensors. Don't know if they were different between the 99 and 02, grey vs black plugs.
it's important to have an adult in the room here - thank you for keeping an eye on things!!!!!!!!!!!!

1999 black plug (4-wire, square connector) O2 sensor :
Automotive lighting Bicycle part Automotive tire Cable Electric blue


acdelco : 213-360
GM OEM : 12558143
fits all positions upstream or downstream of cat converter on 1998 & 1999 astro/safari


2002 gray plug (4-wire, square connector) O2 sensor :
Automotive lighting Audio equipment Cable Electric blue Auto part



fits upstream right (pre converter) and downstream/post converter on 2000 - 2002 astro/safari :
acdelco 213-817
GM OEM 12561776

fits upstream left (pre converter) on 2000-2002 astro/safari :
acdelco 213-818
GM OEM 12561777
 
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