TECHSTREAM Ecu Flash Reprogramming Procedure (SS002-07)

TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE

TECHNICAL SERVICE BULLETIN

TECHSTREAM ECU FLASH REPROGRAMMING PROCEDURE

Model(s): 2001 - 2008 Applicable Lexus

Section: SPECIAL SERVICE TOOLS

Bulletin No.: SS002-07

Date: March 5, 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.

Applicable Vehicles

• 2001 - 2008  model year applicable Lexus  vehicles.

Parts Information

PREVIOUS PART NUMBER	CURRENT PART NUMBER	PART NAME	QTY
N/A	00451-00001-LBL	Authorized Modification Label	1

Warranty Information

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

Required Tools & Equipment

REQUIRED EQUIPMENT		SUPPLIER	PART NUMBER	QTY
TIS Techstream*  NOTE: Software version 2.00.008, or later, is required.	Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.	ADE	TSPKG1	1

REQUIRED SPECIAL SERVICE TOOLS (SSTs)		SUPPLIER	PART NUMBER	QTY	DRW(2)
Digital Battery System Analyzer (1)	Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.	SPX/OTC	00002-V8150-KIT	1	24
GR8 Battery Diagnostic Station (1)	Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.	SPX/OTC	00002-MCGR8	1	-
(1) Essential SSTs. (2) Drawer number in SST Storage System.

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 TSIB Search
   NOTE: TIS searches can be performed by picking Division/Model/Year, current calibration ID, or VDS code.
2. Connect the GR8 battery charger.

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

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.

1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
   1. ECU Reprogram Method:
      1. Establish a vehicle connection.
      2. Click the ECU Reprogramming  button on the System Select tab (Fig 1).
         Fig 1: Display Screen - ECU Reprogramming Button

         Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
      3. Select available ECU(s) from the Calibration Update Check List (Fig 2).
         NOTE: Multiple ECUs can be selected.
      4. Click the green arrow button (bottom right of screen) to retrieve current calibration ID(s) and check for available calibration updates.
         Fig 2: Display Screen - Calibration Update Check List

         Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
      5. Available calibration updates are indicated by a Yes  in the Calibration Update  column (Fig 3). Click the Yes  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 Yes  link will automatically launch TIS and perform a calibration search.
           Fig 3: Display Screen - Calibration Update

           Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
      6. Log in to TIS. (If already logged in, skip this step.)
      7. To access the calibration file, click the service bulletin link in the Document Title column of the Calibration Search Result  portlet (Fig 4).
         NOTE: Only Lexus Senior, Master, and DS Technicians may access calibration files.
         Fig 4: Display Screen - Document Title

         Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   2. Health Check Method.
      1. Establish a vehicle connection.
      2. Click the Health Check  button on the System Select  tab (Fig 5).
         Fig 5: Display Screen - Health Check

         Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
      3. Choose desired ECU group(s) in the Health Check  dialog box (Fig 6).
      4. Click Next  .
         Fig 6: Display Screen - Health Check Dialog Box

         Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
      5. Click Continue  to view Health Check results (Fig 7).
         Fig 7: Display Screen - Health Check Results

         Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
      6. Available calibration updates are indicated by a Yes  link in the Cal Update?  column. Click the Yes  link to access the appropriate service bulletin on TIS (Fig 8).
         NOTE:

         • Note any DTCs stored in systems that will be flash reprogrammed.
         • Clicking the Yes  link will automatically launch TIS and perform a calibration search.
           Fig 8: Display Screen - Service Bulletin On TIS

           Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
      7. Log in to TIS. (If already logged in, skip this step.)
      8. To review the TSIB and access the calibration file, click the service bulletin link in the Document Title  column of the Calibration Search Result  portlet.
         NOTE: Only Lexus Senior, Master, and DS Technicians may access calibration files.
         Fig 9: Display Screen - Calibration Search Result

         Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2. Connect the GR8 battery charger.
   1. Connect the battery charger to the car and turn it on.
   2. Select Power Supply Mode  by following the screen flow below (Fig 10).
      NOTE:

      • 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 charger, please refer to the GR8 Instructions Manual, located on TIS, Diagnostics - Battery  .
        Fig 10: Flow Chart - Power Supply Mode

        Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. Click the appropriate calibration ID (Fig 11) and reprogram the vehicle's ECU with Techstream.
   1. After reviewing the procedures outlined in the selected TSIB, 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 TSIB carefully.
        Fig 11: Calibration Identification Chart

        Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   2. Click Open to load calibration file information (Fig 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.
      Fig 12: Calibration File Information Screen Display

      Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
      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 TSIB No. PG001-06 , "Battery Maintenance for In-Stock Vehicles & Pre-Delivery"  .

      
      To ensure stable battery voltage, a battery charger MUST be connected so:

      • Voltage does NOT fall below 11.4 volts.
      • Voltage does NOT exceed 16.0 volts.
   3. Click Next to start the calibration update process.
      Fig 13: Calibration Update Process Screen Display

      Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   4. Select Techstream VIM  as the desired programming device. Then click Next.
      Fig 14: Display Screen - Techstream VIM

      Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   5. 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).
        Fig 15: Display Screen - VIM Connections

        Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   6. 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.
      • Fig 16 shows an example of the update procedure for a two processor ECU.
        Fig 16: Display Screen - Calibration Selection Confirmation

        Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   7. Turn ignition OFF.
      Fig 17: Screen Display - Vehicle Preparation

      Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   8. 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.
      Fig 18: Screen Display - Prepare For Reprogramming

      Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   9. 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).
        Fig 19: Screen Display - Flash Calibration Update In Process

        Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
      NOTE:

      • If vehicle requires only ONE calibration update, then proceed to step  N in this bulletin.
      • If vehicle requires a SECOND calibration update, then continue as follows:
        • For serial communication vehicles, go to step J.
        • For CAN communication vehicles, go to step  L.
   10. Cal 1 has completed the update process.
       • Turn ignition OFF for a minimum of 10 seconds.
       • Confirm ignition is returned to the ON position.
         Fig 20: Screen Display - Flash Calibration Update Successful

         Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   11. Confirm ignition is ON.
       Fig 21: Screen Display - Prepare For Reprogramming

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   12. Do NOT disturb the vehicle during flash reprogramming.
       Fig 22: Screen Display - Flash Calibration Update In Process

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   13. Turn ignition OFF for a minimum of 10 seconds. Then confirm ignition is returned to the ON position.
       Fig 23: Screen Display - Flash Calibration Update Successful

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   14. Confirm ignition is ON.
       Fig 24: Screen Display - Prepare For Verifying Vehicle

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   15. Confirm all calibrations were updated as specified in the service bulletin.
       Fig 25: Screen Display - Calibrations Updated Specified Service Bulletin

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
       NOTE: Some DTCs may have been set during the reprogramming process. Clear all DTCs after restoring vehicle.
4. Affix Authorized Modification Label.
   1. Using a permanent marker or ball point pen, complete the Authorized Modifications Label and attach to the vehicle (Fig 26). The Authorized Modifications Label is available through the MDC, P/N 00451-00001-LBL.
      Fig 26: Identifying Authorized Modification Label

      Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   2. Attach the 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.