Ecu Flash Reprogramming Process (SS001-01)

Publication date: 2003-09-22
Reference number: SS001-01

ECU FLASH REPROGRAMMING PROCESS

TECHNICAL SERVICE BULLETIN

Reference Number(s): SS001-01, Date of Issue: September 22, 2003

LEXUS:	All Models
SECTION:	Special Service Tools
COPYRIGHT:	© 2018 Lexus, a division of Toyota Motor Sales, USA License Agreement TMS1002

Superceded Bulletin(s): SS001-01, Date of Issue: March 9, 2001

NOTE:

September 22, 2003: 2003 (and later) models added; Operation Procedures updated for CAN Interface Module with the latest Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v. 6.0), and calibration files.
The previous TSIB should be discarded.

Introduction

Electronic Control Unit (ECU) is a Lexus term used to describe integrated computerized devices responsible for managing the operation of a system or sub-system. 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 Lexus specific control unit

Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations without removing the ECU from the vehicle. Flash calibration updates for specific vehicle models/ECU's will be released as field fix procedures described in individual service bulletins. This bulletin details the ECU flash reprogramming process and the applications within the Technical Information System (TIS) and the Lexus Diagnostic Tester used for reprogramming.

Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECU's have internal security that will not allow them to be programmed with another ECU's information.

Applicable Vehicles

2001 (and later) model year GS 430/300, IS 300, LS 430 & LX 470 vehicles.
2002 (and later) model year SC 430 vehicles.
All 2003 (and later) model year Lexus vehicles.

Parts Information

PARTS INFORMATION

PREVIOUS PART NUMBER	CURRENT PART NUMBER	PART NAME
N/A	00451-00001-LBL	Authorized Modifications Label

NOTE: Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution Center (MDC) through the TDN Dealer Support Materials System, or by calling the MDC.

Warranty Information

WARRANTY INFORMATION

OP CODE	DESCRIPTION	TIME	OFP	T1	T2
N/A	Not Applicable to Warranty	---	---	---	---

Required SST's

Fig 1: Special Service Tools

NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SST's may be ordered by calling SPX/OTC.

Process Overview

ECU Flash Reprogramming is a 4-step process:

Locate the desired calibration file on TIS (Technical Information System).
Calibration files may be found in two areas:
1. Search by model and year for a Technical Service Information Bulletin addressing a specific product issue.
2. Search by model under the ECU Flash Reprogramming section.
Download the calibration file from TIS to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file is not currently stored on the Diagnostic Tester Program Card.
Reprogram the vehicle ECU with the Diagnostic Tester.
Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration through flash reprogramming.
Confirm successful flash update and affix calibration update sticker.
Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using the calibration update sticker.

NOTE: The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Fig 2).

Fig 2: Sample Calibration File
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: The total number of Calibration ID numbers corresponds to the number of reprogrammable processors in the ECU (see Fig 3).

Fig 3: ECU Flash Reprogramming Process
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Operation Procedure

The following steps in this bulletin describe how to properly flash reprogram an ECU.

LOCATE CALIBRATION FILE
Locate calibration file on TIS.
Calibration files may be found in two areas (see Fig 4):
1. Search by model and year for a Technical Service Information Bulletin addressing a specific Product issue.
  - Within the TSIB, click on the link for the calibration file.
2. 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.
3. Proceed to step 2 for instructions on how to download the calibration file from TIS to the Diagnostic Tester Program Card.
Fig 4: Locating Calibration File
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

DOWNLOAD FILE TO TESTER
Download the calibration file to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is an 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.
1. 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 below (see Fig 5).
  
  Fig 5: Checking Calibration Files On Diagnostic Tester Program Card
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
  - 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.
2. 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 below (see Fig 6).
  
  Fig 6: Deleting Calibrations From Diagnostic Tester Program Card
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. 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 Fig 7.
  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.
  
  Fig 7: Installing Calibration Update Wizard (CUW)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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 (see Fig 8).
  
  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 (see Fig 7).
  
  Fig 8: Launching Calibration Update Wizard
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that was downloaded.
  
  Fig 9: Confirming Calibration Software Version
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
6. Confirm the Diagnostic Tester software version and connections to the TIS workstation are correct.
  
  Fig 10: Confirming Diagnostic Tester Connections
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
7. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file (see Fig 11).
  Click NEXT on the TIS workstation. Once communications begin between the PC and the Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED .
  
  Fig 11: Placing Diagnostic Tester In "Get Cal From PC" Mode
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. 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 Fig 12. Click DELETE .
  
  NOTE: If there is adequate memory to store the calibration file, skip to step J.
  
  Fig 12: Deleting Selected Calibration Files
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. The CUW will now delete the calibration file(s) selected (see Fig 13.
  
  Fig 13: Deletion Of Calibration Files In Process
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. 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 Fig 14). Click NEXT to continue the process.
  
  Fig 14: Display Calibration Files On Diagnostic Tester Program Card
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (see Fig 15). Click SEND .
  
  Fig 15: Sending New Calibration File To Diagnostic Tester Program Card
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process takes approximately 2-6 minutes (see Fig 16).
  
  Fig 16: Downloading Of Calibration File In Process
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the CUW (see Fig 17).
  
  Fig 17: Download Of Calibration File Completed
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 VEHICLE ECU WITH TESTER
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 TSIB No. SS003-01 , "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-L, "Midtronics Battery Tester," and follow TSIB No. PG009-02 , "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 .
1. 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 Fig 18.)
  NOTE: The vehicle may contain up to 3 separate calibration ID numbers. In the example shown below, the vehicle ECU contains only 2 calibration ID's.
  
  Fig 18: Determining Current ECU Calibration
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Continue to update the ECU calibration file following the screen flow below (see Fig 19). Details for selected screens are shown in Fig 20.
  
  Fig 19: ECU Programming Overview
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Each flash calibration update will take approximately 15 to 45 minutes.
  - Screens E through J (see Fig 19) 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!
  Fig 20: ECU Reprogramming Detail
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

CONFIRM UPDATE
Confirm successful flash calibration update and affix calibration update sticker.
Follow these steps to confirm the calibration was reprogrammed to the ECU.
1. The new calibration file should be displayed as the current ECU calibration file.
  
  Fig 21: Confirmation Of ECU Reprogramming
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a permanent marker or ball point pen, enter the required information on the Authorized Modifications Label (see Fig 22 and Fig 23).
  
  Fig 22: Authorized Modifications Label
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 23: Sample Completed Authorized Modifications Label
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Affix this label under the hood in the location determined by the specific vehicle TSIB or Campaign.
NOTE: Wait 60-90 seconds for ink to set before handling.