Engine Controls - Pinging/knocking on Light Acceleration
ENGINEEG056-06
REVISED
Title:
ENGINE "PINGING" OR
"KNOCKING" NOISE
Models:
'04 - '06 Sienna
September 7, 2006
TSB REVISION NOTICE:
^ August 22, 2007: The Note below the Introduction has been modified. The OFP has been updated in the Warranty Information table. The Note below the Parts Information table has been updated. Steps 7 and 8 in the Repair Procedure have been updated.
^ November 28, 2006: A note has been added to the Introduction. 2 OFPs have been deleted. Information has been added or updated for vehicles with laser cruise control - Brake Actuator Assembly has been added to Warranty Information and Parts Information, the note in Parts Information has been updated, and the Repair Procedure has been expanded starting with step 6, "Reset the ECM (PCM)...". PLEASE READ ENTIRE TSB.
Previous versions of this TSB should be discarded.
Introduction
Some 2004 - 2006 model year Sienna vehicles may exhibit an intermittent "pinging" or "knocking" noise under light throttle cruise or acceleration between 1400 - 1800 rpm when the engine is at operating temperatures in warm ambient conditions. The Engine Control Module (ECM) (SAE term: Powertrain Control Module/PCM) knock sensor logic has been improved to eliminate this condition.
NOTE:
^ Before proceeding, verify the ECM (PCM) calibration has NOT been updated by checking for the Authorized Modifications Label (shown in step 1 of the Repair Procedure).
^ Harsh ATM shifting may result if any Repair Procedure steps are omitted (specifically steps 6 and 11).
^ Failure to perform this TSB in the order indicated in the Repair Procedure will render the brake actuator inoperative and set M.I.L. "ON" lights that CANNOT be cleared.
Applicable Vehicles
^ 2004 - 2006 model year Sienna vehicles.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Federal Emissions Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific complaint.
Parts Information
Required SSTs
Calibration Identification Chart
Repair Procedure
1. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in Figure 1. Confirm if the ECM (PC M) calibration has been updated. If NOT the latest ECM (PCM) calibration go to step 2.
2. 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 2).
- The sample screen prints seen below are the 13.4a software version and may differ from subseciuent software versions.
NOTE:
^ If the Calibration ID matches the "Previous Calibration ID" as shown in the Calibration Identification Chart in this TSB, proceed with flash reprogramming.
^ If the Calibration ID matches the "New Calibration ID" as shown in the Calibration Identification Chart, this vehicle has already been programmed. Refer to the Technical Information System (TIS) for diagnostic procedures applicable to any stored DTCs.
3. If the ECU calibration ID is NOT the same as the "New Calibration ID" listed previously, proceed to Flash Reprogram ECM (PCM).
4. Flash Reprogram ECM (PCM)
NOTE:
A battery charger should be connected to the battery during the Flash Reprogram in order to maintain proper battery voltage and prevent damage to the ECM (PCM).
A. Follow the procedures outlined in TSB No. SS002-01, "ECU Flash Reprogramming Process, " and flash the ECM (PCM) with the NEW calibration file update.
NOTE:
If the "Check Engine" light is ON when the ignition is turned back on to begin the reprogramming process, a scan tool cable problem exists. Refer to TSB No. SS004-O1, "ECU Flash Reprogramming Error Message."
B. Enter the required information on the Authorized Modifications Label and affix it to the vehicle at the location shown in Figure 1. The Authorized Modifications Label is available through the MDC, P/N 00451-00001-LBL.
5. Follow the procedures outlined in TSB No. EG045-04, "Entering VIN During ECM (PCM) Replacement and/or DTC P0630," and write the VIN to the ECM (PCM).
6. Reset the ECM (PCM) learned values using the Diagnostic Tester. Refer to the procedures below.
- The sample screen prints seen below are the 13.4a software version and may differ from subsequent software versions.
NOTE:
Failure to reset the ECM (PCM) memory will result in continued ATM shifting complaints.
7. For vehicles NOT equipped with laser cruise control, proceed to step 10.
8. For 2004 model year vehicles equipped with laser cruise control, a NEW Brake Actuator Assembly (with VSC ECU) MUST be installed at the time of recalibration if the ECM (PCM) has never been updated.
Refer to the table to confirm if the main ECM (PCM) calibration files and Brake Actuator Assembly (with VSC ECU) have already been updated.
If the vehicle is equipped with laser cruise control and the Brake Actuator Assembly has NOT been replaced, use the Parts Information table in this TSB to order the correct part (2WD or 4WD) and follow the instructions listed on TIS:
2004 model year Sienna Repair Manual, Brake - Brake Control/Dynamic Control System - "Brake Actuator Assy (w/VSC): Replacement" to replace the Brake Actuator Assembly (with VSC ECU).
9. Follow the procedures outlined in TSB No. BR001-04, "Zero Point Calibration," to calibrate the sensors affected by the Brake Actuator Assembly replacement.
10. Start the engine and warm it up to normal operating temperature before test-driving.
11. Test-drive the vehicle to confirm proper vehicle operation (and proper laser cruise control operation, if so equipped).
12. Calibration update is complete.
^ Select premium unleaded gasoline with an Octane Rating of 91 or higher for optimum engine performance.
^ The effect of the new calibration may become more apparent after several days of driving as the ECM (PCM) "learned values" are re-established from the customer's driving.