Ecu Flash Reprogramming Process T-ss002-01
Ecu Flash Reprogramming Process T-ss002-01
Ecu Flash Reprogramming Process T-ss002-01
BULLETIN
Applicable Models
March 9, 2001
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized
devices responsible for managing the operation of a system or subsystem. For the
purposes of this bulletin, the term ECU is used as a generic label for the following SAE
J1930 standard references:
S Powertrain Control Module (PCM)
S Engine Control Module (ECM)
S Transmission Control Module (TCM)
S or any other Toyota specific control unit
Flash reprogramming allows the ECU software to be updated for changes in vehicle
calibrations without removing the ECU from the vehicle. Flash calibration updates for
specific vehicle models/ECUs will be released as field fix procedures described in
individual service bulletins. This bulletin details the ECU flash reprogramming process
and the applications within the Technical Information System (TIS) and the Toyota
Diagnostic Tester used for reprogramming.
Flash calibration updates can only be applied to the vehicle/ECU combination for which
they are intended. ECUs have internal security that will not allow them to be
programmed with another ECUs information.
Applicable
Vehicles
Warranty
Information
S 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia
and Tundra vehicles.
S 2002 (and later) model year Camry, Solara and Tacoma vehicles.
S 2003 (and later) model year Corolla and Matrix vehicles.
S All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder,
Avalon, and Tacoma (3RZFE engine).
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
N/A
Page 1 of 19
SS002-01
Title:
March 9, 2001
PART NAME
N/A
0045100001LBL
NOTE:
Authorized Modifications Labels may be ordered in packages of 25 from the Materials
Distribution Center (MDC) through the TDN Dealer Support Materials System, or by
calling the MDC at 1-800-622-2033.
Required
SSTs
PART NUMBER
QUANTITY
01001271
01002744
01002593-005
00002MP815T
Essential SSTs.
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may
be ordered by calling SPX/OTC at 1-800-933-8335.
Process
Overview
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March 9, 2001
NOTE:
The calibration file contains the Calibration ID number(s) for a specific vehicle ECU
(see Figure 1).
FIGURE 1. SAMPLE CALIBRATION FILE
Calibration
File
CAL ON TESTER
CAL ON TESTER
01 RAV4
AT
ENG:1AZ-FE
VEHICLE:
01 RAV4
AT
ENG:1AZ-FE
[ENTER] TO SELECT
[EXIT] TO RETURN
CALIBRATION ID
45001100
65001100
Calibration ID
Numbers
(1 to 3 ID numbers
may be displayed)
[EXIT] TO RETURN
NOTE:
The total number of Calibration ID numbers corresponds to the number of
reprogrammable processors in the ECU (see Figure 2).
FIGURE 2. ECU FLASH REPROGRAMMING PROCESS
Scan Tool Side
Vehicle Side
Cal. ID No. 3
Cal. ID No. 2
Processor 3
Cal. ID No. 1
Processor 2
Processor 1
Calibration File
(CAL ON TESTER)
ECU
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March 9, 2001
The following steps in this bulletin describe how to properly flash reprogram an ECU.
1. Locate calibration file on TIS.
Calibration files may be found in two areas (see Figure 3):
A. Search by model and year for a Technical Service Bulletin addressing a specific
Product issue.
S Within the TSB, click on the link for the calibration file.
B. Search by model under the ECU Flash Reprogramming Section.
S Under the ECU Flash Reprogramming section on TIS, a dropdown list of the
latest calibration files will be displayed.
C. Proceed to step 2 for instructions on how to download the calibration file from TIS
to the Diagnostic Tester Program Card.
FIGURE 3. LOCATING CALIBRATION FILE
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March 9, 2001
A. Before downloading a new calibration file from TIS, check the current calibration
files stored on the Diagnostic Tester Program Card by following the screen flow
below (Figure 4).
FIGURE 4. CHECKING CALIBRATION FILES ON DIAGNOSTIC TESTER PROGRAM CARD
B*
*APPLICATION SELECT*
ECU REPROGRAM
MENU
ECU REPROGRAM
MAIN MENU
1: DIAGNOSIS
2: CUSTOMIZE
3: ECU REPROGRAM
D **
CAL ON TESTER
01 RAV4
AT
ENG:1AZ-FE
01 RAV4
MT
ENG:1AZFE
[ENTER] TO SELECT
[EXIT] TO RETURN
1:
2:
3:
4:
5:
E
CAL ON TESTER
VEHICLE:
01 RAV4
AT
ENG:1AZ-FE
CALIBRATION ID
45001100
65001100
[EXIT] TO RETURN
** 01 = 2001 MY
AT = Automatic Transmission
MT = Manual Transmission
ENG = Engine Type
NOTE:
S Screen D may be blank if no calibrations are stored on the Diagnostic Tester
Program Card.
S If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3
(page 16 of this bulletin).
S A maximum of two calibration files may be loaded on the tester at one time with
Diagnostic Tester software version 10.2a and later. Prior versions may store up to
four calibration files.
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March 9, 2001
B. You have the option to delete calibrations off the tester before downloading a new
calibration. The CUW also provides this option if there is not enough memory for
the new calibration. To delete one or all of the calibrations, follow the screen flow
below (Figure 5).
FIGURE 5. DELETING CALIBRATIONS FROM DIAGNOSTIC TESTER PROGRAM CARD
*APPLICATION SELECT*
ECU REPROGRAM
MENU
ECU REPROGRAM
MAIN MENU
1: DIAGNOSIS
2: CUSTOMIZE
3: ECU REPROGRAM
CAL ON TESTER
01 RAV4
AT
ENG:1AZ-FE
01 RAV4
MT
ENG:1AZFE
[ENTER] TO SELECT
[EXIT] TO RETURN
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1:
2:
3:
4:
5:
March 9, 2001
C. If this is the first time you have downloaded a calibration file from TIS to the
Diagnostic Tester Program Card, you MUST first install the latest version of the
Calibration Update Wizard (CUW) onto your TIS workstation PC, as shown in
Figure 6.
This step is also required if you are using a version of CUW earlier than
version 6.0. CUW 6.0 is the only version compatible with Diagnostic Tester
software version 10.2a and later. If necessary, select the link to the TIS
Diagnostic Applications Installer and follow the onscreen prompts to install or
reinstall CUW.
FIGURE 6. INSTALLING CALIBRATION UPDATE WIZARD (CUW)
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March 9, 2001
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March 9, 2001
E. Confirm the Diagnostic Tester has the appropriate software for the type of
calibration file that was downloaded.
FIGURE 8. CONFIRMING CALIBRATION SOFTWARE VERSION
OR
NOTE:
The calibration type is specific to the software version loaded on your Diagnostic
Tester. If you selected the wrong version when downloading the calibration file, you
will receive an error when attempting to install the file on the Diagnostic Tester.
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March 9, 2001
F. Confirm the Diagnostic Tester software version and connections to the TIS
workstation are correct.
FIGURE 9. CONFIRMING DIAGNOSTIC TESTER CONNECTIONS
* NOTE:
This screen displays the required version of Diagnostic Tester software that is
compatible with the selected calibration file, and the other required steps to
properly connect the Diagnostic Tester to your PC.
S Type I calibration files are only compatible with software version 10.1a and
older versions.
S Type II calibration files are only compatible with software version 10.2a and
newer versions.
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March 9, 2001
G. Place the Diagnostic Tester in the GET CAL FROM PC mode to receive the
calibration file (Figure 10).
Click NEXT on the TIS workstation. Once communications begin between the PC
and the Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED.
FIGURE 10. PLACING DIAGNOSTIC TESTER IN GET CAL FROM PC MODE
A
*APPLICATION SELECT*
1: DIAGNOSIS
2: CUSTOMIZE
3: ECU REPROGRAM
B
ECU REPROGRAM
MENU
1: ENGINE & ECT ECU
2: HV ECU
3: ECT ECU
PC COMMUNICATION
C
ECU REPROGRAM
MAIN MENU
1:
2:
3:
4:
5:
PC COMMUNICATION
DISCONNECTED
CONNECTED
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March 9, 2001
H. The CUW determines if there is enough memory to store the calibration file on the
Diagnostic Tester Program Card. If there is insufficient memory, the CUW will ask
you to select the calibration file(s) to delete from the Diagnostic Tester Program
Card to make room for the new calibration file.
If necessary, check the calibration file(s) to delete, as shown in Figure 11.
Click DELETE.
NOTE:
If there is adequate memory to store the calibration file, skip to Step J, page 13.
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I.
March 9, 2001
The CUW will now delete the calibration file(s) selected (see Figure 12).
DOWNLOAD
FILE TO TESTER
J. The top half of the CUW screen displays the calibrations currently stored on the
Diagnostic Tester Program Card. The bottom half of the screen displays the new
calibration to be loaded onto the Diagnostic Tester Program Card (see Figure 13).
Click NEXT to continue the process.
FIGURE 13. DISPLAY OF CALIBRATION FILES ON DIAGNOSTIC TESTER PROGRAM CARD
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March 9, 2001
K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card
(Figure 14). Click SEND.
FIGURE 14. SENDING NEW CALIBRATION FILE TO DIAGNOSTIC TESTER PROGRAM CARD
L. The calibration file will now be downloaded to the Diagnostic Tester Program
Card. This process takes approximately 2-6 minutes (see Figure 15).
FIGURE 15. DOWNLOADING OF CALIBRATION FILE IN PROCESS
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March 9, 2001
M. The CUW will prompt when the calibration file is completely downloaded. Click
OK to close the CUW (Figure 16).
FIGURE 16. DOWNLOAD OF CALIBRATION FILE COMPLETED
NOTE:
With the calibration file loaded on the Diagnostic Tester Program Card, it is not
necessary to repeat the above steps to reprogram a different vehicle needing the same
calibration file. The steps above are only required when a new calibration file must be
loaded onto the Diagnostic Tester Program Card.
The Diagnostic Tester now has the calibration file stored and you may proceed to the
next step to reprogram the vehicle ECU.
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March 9, 2001
NOTICE:
Errors during the flash reprogramming process can permanently damage the vehicle
ECU. Minimize the risks by following the steps below.
S Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming.
S Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT
RISE ABOVE 16.0 volts during reprogramming.
S Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.).
S Do not add to or significantly change the vehicles electrical load while reprogramming.
S Confirm the hood is open and ensure under hood temperatures do not exceed 158F.
S Confirm cable connections between the vehicle and Diagnostic Tester are secure.
(Reference TSB No. SS00401, ECU Flash Reprogramming Error Message.)
S Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition
during reprogramming.
S Set the parking brake.
S Complete ALL flash calibration updates provided for each ECU.
If the batterys state of charge or capacity are in question, test with SST No.
00002MP815T, Midtronics Battery Tester, and follow TSB No. PG01702,
Battery Maintenance for InStock Vehicles & PreDelivery.
To ensure stable battery voltage, a battery charger may be connected during
reprogramming if:
S Voltage does not fall below 11.4 volts.
S Voltage does not rise above 16.0 volts.
S Setting is on SLOW charge and not BOOST.
A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL
from the ECU REPROGRAM MAIN MENU. Determine the vehicles current ECU
calibration. (See Figure 17.)
NOTE:
The vehicle may contain up to 3 separate calibration ID numbers. In the example
shown below, the vehicle ECU contains only 2 calibration IDs.
FIGURE 17. DETERMINING CURRENT ECU CALIBRATION
ECU REPROGRAM
MAIN MENU
CALIBRATION ID
45001000
65001000
PRESS [ENTER]
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March 9, 2001
B. Continue to update the ECU calibration file following the screen flow below
(Figure 18). Details for selected screens are shown in Figure 19.
FIGURE 18. ECU REPROGRAMMING OVERVIEW
ECU REPROGRAM
MAIN MENU
1:
2:
3:
4:
5:
1: IN-SERVICE ECU
2: NEW ECU
C (NEW ECU)*
UPDATE ECU CAL
BEFORE PROCEEDING
1) REGISTER
IMMOBILIZER KEYS
2) ENSURE AUTO
REGISTRATION MODE
IS CLOSED
PRESS [ENTER] /[EXIT]
SELECT CAL TO
UPDATE ECU
PRESS [ENTER] /[EXIT]
F*
DONE
NO
NO
H*
G
UPDATE ECU CAL
TURN IG ON
CAUTION!
DO NOT DO ANYTHING
THAT WOULD CAUSE AN
ELECTRICAL LOAD TO THE
VEHICLE.
UPDATE NOW?
PRESS [YES] OR [NO]
J*
REPROGRAMMING
REPROGRAM COMPLETE
TIME: 00:09:18
DONE
YES
NO
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March 9, 2001
NOTE:
S Each flash calibration update will take approximately 15 to 45 minutes.
S Screens E through J (Figure 18) will need to be repeated for each flash calibration
update (calibration ID number).
S All updates must display YES to complete the entire calibration file update for the
vehicle ECU.
S Failure to complete all updates may result in PERMANENT ECU DAMAGE!
FIGURE 19. ECU REPROGRAMMING DETAIL
C (NEW ECU)
UPDATE ECU CAL
BEFORE PROCEEDING
1) REGISTER
IMMOBILIZER KEYS
2) ENSURE AUTO
REGISTRATION MODE
IS CLOSED
PRESS [ENTER] /[EXIT]
F
UPDATE ECU CAL
CURRENT CAL
45001000
65001000
SELECT MATCHING ID
45001000
42473000
56700300
PRESS [YES] OR [NO]
H
UPDATE ECU CAL
REPROGRAMMING
TIME: 00:09:18
J
UPDATE ECU CAL
NEW CAL
45001100
65001100
DONE
YES
NO
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March 9, 2001
4. Confirm successful flash calibration update and affix calibration update sticker.
Follow these steps to confirm the calibration was reprogrammed to the ECU.
A. The new calibration file should be displayed as the current ECU calibration file.
FIGURE 20. CONFIRMATION OF ECU REPROGRAMMING
ECU REPROGRAM
MAIN MENU
CALIBRATION ID
45001100
65001100
PRESS [ENTER]
B. Using a permanent marker or ball point pen, enter the required information on the
Authorized Modifications Label (Figures 21 and 22).
FIGURE 21. AUTHORIZED MODIFICATIONS LABEL
DATE:
Replacement
ECU Part Number
Calibration ID(s)
8966148241
45001100, 65001100
THESE MODIFICATIONS HAVE BEEN APPROVED
AS APPROPRIATE BY EPA AND CARB
Dealer Code
DEALER CODE:
31301
CHANGE AUTHORITY:
DATE:
6/2/03
Date Completed
TSB EG###03
TSB or Campaign Number
C. Affix this label under the hood in the location determined by the specific vehicle
TSB or Campaign.
NOTE:
Wait 6090 seconds for ink to set before handling.
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