[CBR_GUY_IA]

SPECIAL SERVICE TOOLS
SS002-07

Title:
TECHSTREAM ECU FLASH
REPROGRAMMING PROCEDURE

Models:
'01 - '08 Applicable Toyota

April 26, 2007

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 the Technical Information System (TIS) 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 ECU's information.

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.


NOT all models are capable of flash reprogramming.







Parts Information







Warranty Information







Required Tools & Equipment

Process Overview

Techstream ECU flash reprogramming is a 4-step process:

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

^ Techstream ECU Reprogram Function

^ Techstream Health Check Function

NOTE :Techstream will automatically search TIS for the appropriate service bulletin using the current Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding service bulletin.

^ TIS Calibration Search

^ TIS TSB Search


NOTE :
TIS searches can be performed by picking Division/Model/Year, current calibration ID, or VDS code.

2. Connect the GR8 Battery Diagnostic Station.

The GR8 Battery Diagnostic Station includes a Power Supply Mode that maintains battery voltage at 13.5 volts during ECU reprogramming.

NOTE :ECU damage may occur if the correct battery charger and mode setting are NOT used.

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 (Figure 1).








c. Select available ECU(s) from the Calibration Update Check List (Figure 2).


Multiple ECUs can be selected.

d. Click the green arrow button (bottom right of screen) to retrieve current calibration ID(s) and check for available calibration updates.








e. Available calibration updates are indicated by a in the Calibration Update column (Figure 3). Click the link to access the appropriate service bulletin on TIS.

NOTE :^ Prior to flash reprogramming, check applicable Systems for DTCs and note any DTCs.

^ Clicking the link will automatically launch TIS and perform a calibration search.

f. Log in to TIS. (If already logged in, skip this step.)









g. To access the calibration file, click the service bulletin link in the Document Title column of the Calibration Search Result portlet (Figure 4).

NOTE :Only Toyota Certified Technicians and above may access calibration files.

B. Health Check Method.

a. Establish a vehicle connection.









b. Click the Health Check button on the System Select tab (Figure 5).

c. Choose desired ECU group(s) in the Health Check dialog box (Figure 6).

d. Click Next.








e. Click Continue to view Health Check results (Figure 7).








f. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to access the appropriate service bulletin on TIS (Figure 8).

NOTE :^ Note any DTCs stored in Systems that will be flash reprogrammed.

^ Clicking the link will automatically launch TIS and perform a calibration search.

g. Log in to TIS. (If already logged in, skip this step.)

h. To review the TSB and access the calibration file, click the service bulletin link in the Document Title column of the Calibration Search Result portlet.

NOTE :
Only Toyota Certified Technicians and above may access calibration files.

2. Connect the GR8 Battery Diagnostic Station.

A. Connect the GR8 Battery Diagnostic Station to the car and turn it on.









B. Select Power Supply Mode by following the screen flow below (Figure 10).

NOTE :^ ECU damage may occur if the correct battery charger and mode setting are NOT used.

^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle.

^ For details on how to use the GR8 Battery Diagnostic Station, please refer to the GR8 Instructions Manual, located on TIS, Diagnostics - Battery.








3. Click the appropriate calibration ID (Figure 11) and reprogram the vehicle's ECU with Techstream.

A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID link by matching the vehicle's current calibration ID to the Previous Calibration ID in the Calibration Identification Chart.


NOTE :^ Calibration files are embedded as live links in the service bulletin.

^ Some vehicles require special preparation - please review the selected TSB carefully.








B. Click Open to load calibration file information (Figure 12).

NOTE :Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT save calibrations locally on the hard drive or other media.

NOTE :^ Errors during the flash reprogramming process can permanently damage the vehicle ECU. Minimize the risk 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 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.

^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-V8150-KIT "Digital Battery Analyzer," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock Vehicles & Pre-Delivery".

^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery voltage at 13.5 volts while flash reprogramming the vehicle.
For details on how to use the GR8 Battery Diagnostic Station, please refer to the GR8 Instructions Manual, located on TIS, Diagnostics - Battery.








C. Click Next to start the calibration update process.








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

E. Confirm the following:

^ PC is connected to VIM.

^ VIM is connected to DLC3 connector.









^ Ignition is ON and engine is OFF or READY" OFF (hybrid vehicles).

F. 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.








^ Figure 16 shows an example of the update procedure for a two-processor ECU.








G. Turn ignition OFF.

H. Confirm the following:

^ Ignition is ON and engine is OFF or READY" OFF (hybrid vehicles).

^ Hood is open.

^ 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.

I. 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).

J. Cal 1 has completed the update process.









^ Turn ignition OFF for a minimum of 10 seconds. Confirm ignition is returned to the ON position.








K. Confirm ignition is ON.








L. Do NOT disturb the vehicle during flash reprogramming.








M. Turn ignition OFF for a minimum of 10 seconds. Then confirm ignition is returned to the ON position.








N. Confirm ignition is ON.








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

4. Affix Authorized Modification Label.








A. Using a permanent marker or ball point pen, complete the Authorized Modifications Label and attach to the vehicle (Figure 26). The Authorized Modifications Label is available through the MDC, P/N 00451-00001-LBL.

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.