Canada - Engine Controls - Techstream(R) ECU Re-Flash Procedure

Bulletin
TSB2758

Issue Date
May 10, 2007

Market
Canada

Title
TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE

Component
SPECIAL SERVICE TOOLS

Models
'01 - '08 APPLICABLE TOYOTA

INTRODUCTION:

Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of E-TAS and the Calibration Update Wizard (CUW).

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.

NOTE:
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:
- Powertrain Control Module (PCM)
- Engine Control Module (ECM)
- Transmission Control Module (TCM)
- Or any other Toyota specific control unit

APPLICABLE VEHICLES:
- 2001 - 2008 model year applicable Toyota vehicles.

NOTE:
NOT all models are capable of flash reprogramming.






PARTS INFORMATION:

NOTE:
Authorized Modification Labels may be ordered in packages of 25 from your PDC.






WARRANTY INFORMATION:







NOTE:
- Please contact your zone Area Parts & Service Managers to order additional Techstream units.
- The Toyota Diagnostic Tester (TDT) and CAN Interface Module may also be used to perform the service procedures listed in this bulletin.

NOTE: The TDT is not used for some calibrations beginning 2007MY, ECU damage is possible.
Please check your appropriate TSB before proceeding.

NOTE*:
- Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards, or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
- The Midtronics Battery charger MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash programming the vehicle.

PROCESS OVERVIEW:

Calibration updates are released as field-fix procedures to repair MIL on conditions, drivability concerns, Campaigns and customer satisfaction. Ensure that TSB's/TIP's are followed accurately before any calibrations are performed. After reviewing the procedures outlined in the selected TSB/TIP, click the appropriate calibration ID located in E-TAS.

Techstream ECU flash reprogramming is a 4-step process:

1. Verify the vehicle's applicability for recalibration and locate desired calibration file. Vehicle applicability/calibration ID #'s can be determined by the following methods:







- Techstream ECU Reprogram Function (figure 1)







- Techstream Health Check Function (figure 2)

NOTE:
Calibration file information can be found in the corresponding service information.
- E-TAS TSB Search (problem, symptom, condition DTC, CAMP)
- E-TAS Calibration Search (E-TAS > Tools > Diagnostic Tester > Calibration Updates)

2. Connect the Midtronics battery charger.
The Midtronics battery charger includes a Power Supply Mode that maintains battery voltage at 13.5 volts during ECU reprogramming.

3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream. Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and facilitate the ECU flash reprogramming process.

4. Affix the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using the Authorized Modification Label.

OPERATION PROCEDURE:

The following steps describe how to properly flash reprogram an ECU using the Techstream diagnostic application.

NOTE:
Ensure Techstream has been updated with the latest version of software.

1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. ECU Reprogram Method:
a. Establish a vehicle connection.







b. Click the ECU Reprogramming button on the System Select tab.
c. Select available ECU(s) from the Calibration Update Check List.

NOTE:
Multiple ECUs can be selected.












d. Click the green arrow button (bottom right of screen) to retrieve current calibration ID(s)
e. Available Calibration Update Information can be found in E-TAS > Tools > Diagnostic Tester > Calibration Updates.

NOTE:
- Prior to flash reprogramming, check applicable systems for DTCs and note any DTCs.

f. Log in to E-TAS. (If already logged in, skip this step.)







g. To access the calibration file, click the icon to the left of the Calibration Update Information located in E-TAS.

2. Connect the Midtronics battery charger.
A. Connect the battery charger to the car and turn it on.

NOTE:
Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk by following the steps below.
- ECU damage may occur if the correct battery charger is NOT used.
- Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle.
- Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during reprogramming.
- Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add to or significantly change the vehicle's electrical load while reprogramming.
- Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
- Confirm cable connections between the vehicle and Techstream are secure.
- Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
- Set parking brake.

Complete ALL flash calibration updates provided for each ECU.

3. Locate the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.







A. Click Open to load calibration file information







B. Click Next to start the calibration update process.







C. Select Techstream VIM as the desired programming device. Then click Next.







D. Confirm the following:
- Tablet PC is connected to Backpack.
- DLC3 cable is connected to the vehicle.
- Ignition is ON and engine is OFF or Ready Off (hybrid vehicles).
- Click Next.







E. Verify correct current calibration and new calibration information.

NOTE:
- The total number of calibration IDs in the calibration file corresponds to the number of reprogrammable processors in the ECU.
- Each calibration file may contain up to three separate calibrations.







F. Turn ignition OFF.







G. Confirm the following:
- Ignition is ON and engine is OFF or Ready Off (hybrid vehicles).
- Hood is open.
- Emergency brake is applied.
- All accessories are OFF.
- Battery voltage is above 11.4 volts.

NOTE:
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below 11.4 volts, ECU damage may occur.







H. Do NOT disturb the vehicle during flash reprogramming.

NOTE:
- ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
- Reprogramming time will vary depending on model and ECU communication protocol. Vehicles using CAN communication protocol will reprogram much faster (2 - 7 minutes).







I. Calibration update has been completed.
- Turn ignition OFF for a minimum of 10 seconds.
- Confirm ignition is returned to the ON position.

NOTE:
- If vehicle requires only ONE calibration update, then proceed to Step J in this bulletin.
- If vehicle requires a SECOND calibration update then continue from Step H again.







J. Confirm ignition is ON.







K. Confirm all calibrations were updated as specified in the service bulletin.

NOTE:
Some DTCs may have been set during the reprogramming process. Clear all DTCs after restoring vehicle.

4. Affix Authorized Modification Label.







A. Using a permanent marker or ball point pen, complete the Authorized Modifications Label and attach to the vehicle. The Authorized Modifications Label is available through your facing PDC, P/N 00451-00001-25.
B. Attach the label under the hood in the location determined by the specific vehicle TSB or Campaign #.

NOTE:
Wait 60 - 90 seconds for ink to set before handling.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.