Operation Procedure
LOCATE CALIBRATION FILEThe 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.
^ Within the TSB, click on the link for the calibration file.
B. Search by model under the ECU Flash Reprogramming Section.
^ Under the ECU Flash Reprogramming section on TIS, a drop-down 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.
DOWNLOAD FILE TO TESTER
2. Download the calibration file to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration files from TIS onto the Diagnostic Tester Program Card.
NOTE:
Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or later. Only a 12 MB program card (P/N 01002593-005) may be used for this process.
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 shown (Figure 4).
NOTE:
^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card.
^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram ECU with Tester shown).
^ 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.
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 shown (Figure 5).
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 on-screen prompts to install or reinstall CUW.
D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below. The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester Program Card. Click NEXT on the first screen (Figure 7).
NOTE:
If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0) are located under Diagnostics ECU Flash Reprogramming (Figure 6).
E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that was downloaded.
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.
F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are correct.
* 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.
^ Type I calibration files are only compatible with software version 10.1a and older versions.
^ Type II calibration files are only compatible with software version 10.2a and newer versions.
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.
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.
I. The CUW will now delete the calibration file(s) selected (see Figure 12).
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.
K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click SEND.
L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process takes approximately 2-6 minutes (see Figure 15).
M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the CUW (Figure 16).
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.
REPROGRAM ECU WITH TESTER
3. Reprogram the vehicle ECU with the Diagnostic Tester.
NOTICE:
Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risks by following the steps below.
^ 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 electrical 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 temperatures do not exceed 158°F.
^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference TSB No. SS004-01, "ECU Flash Reprogramming Error Message.")
^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming.
^ Set the parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T, "Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery."
To ensure stable battery voltage, a battery charger may be connected during reprogramming if:
^ Voltage does not fall below 11.4 volts.
^ Voltage does not rise above 16.0 volts.
^ 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 vehicle's current ECU calibration. (See Figure 17.)
NOTE:
The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the vehicle ECU contains only 2 calibration IDs.
B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for selected screens are shown in Figure 19.
NOTE:
^ Each flash calibration update will take approximately 15 to 45 minutes.
^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update (calibration ID number).
^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU.
^ Failure to complete all updates may result in PERMANENT ECU DAMAGE!
CONFIRM UPDATE
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.
B. Using a permanent marker or ball point pen, enter the required information on the Authorized Modifications Label (Figures 21 and 22).
C. Affix this 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.