Engine Controls - Error When Reprogramming ECU

SPECIAL SERVICE TOOLS
SS004-01
REVISED

May 25, 2001

Title:
ECU FLASH REPROGRAMMING ERROR MESSAGE

Models:
Applicable Models

TSB REVISION NOTICE:
September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix, and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB should be discarded.

Introduction

During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to determine the cause for the error message.

Applicable Vehicles
^ 2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra vehicles.

^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.

^ 2003 (and later) model year Corolla and Matrix vehicles.

^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma (3RZ-FE engine)





Required SSTs

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.





Warranty Information

Test Procedure





During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic Tester for one of the following reasons:

1. Immobilizer key not properly registered or auto-registration mode left open.

2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure.

3. The Diagnostic Tester cable is damaged, causing an open communication circuit.

NOTE:
The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a damaged cable.

To eliminate the possibility of the first 2 reasons causing the error message, do the following:





1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99, "Scan tool Immobilizer key Code Utility

2. Conduct the ECU flash reprogramming process explicitly following key operation instructions. Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details.

To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test procedures, the resistance values must be below 6.0 ohms to pass.

Test CABLE TEST 1.





A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962 OBDII together (P/N 01002744).

B. Test for continuity.

^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash reprogramming process.

^ If there is no continuity, proceed to CABLE TEST 2.

CABLE TEST 2.





A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962 OBDII (P/N 01002744).

B. Test DLC cable (P/N 02001637) for continuity.

^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3.

^ If there is no continuity, the cable needs to be replaced.

CABLE TEST 3.





A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity.

^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2, and 3 while wiggling and flexing the cables.

^ If there is no continuity, proceed to CABLE TEST 4.

CABLE TEST 4.





A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a Phillips screwdriver.

B. Test J1962 OBDII cable (P/N 02003180) for continuity.

^ If there is no continuity, the cable needs to be replaced.

^ If there is continuity, proceed to CAN Interface Module Test 5.

CAN INTERFACE MODULE TEST 5.





A. Test the CAN Interface Module (P/N 01002744) for continuity.

^ If there is no continuity, the CAN Interface Module needs to be replaced.

^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while wiggling and flexing the cables.