Modifying 5th Bows Potentiometer - TSAS ECM
SUBJECT # 17:PROGRAMMING THE TSAS ECM AND MODIFYING THE 5TH BOW'S POTENTIOMETER
APPLICATION:
VIN SERIAL NOS. S700216-S7015157
Resistance Readings Table
(Make a copy before continuing repair)
Enter the new potentiometer resistance readings In the ECM. At the same time, modify the 5th bow's potentiometer on cars concerned.
Parts:
Bracket 45 59 407 (S7000215-S7014535)
Pop Rivet (5 mm) 79 72 516 (87000215-S7014535)
NOTE:
Make sure the top bag is not pinned up prior to starting programming.
Programming High and Low Limits
The programming procedure described below is specially adapted for this particular PSI, as the 5th bow's potentiometer has to be modified when programming a number at cars.
IMPORTANT
During the programming procedure, the top mechanism must be operated by means of ISAT Keep pressing the relevant button (F3 = UP, F4 = DOWN) for at least live seconds after the movements have stopped to be sure that the mechanism has reached the end positions.
The battery must be in good condition when programming is carried out.
The top should be fully raised, the first and 5th bows should be locked from the previous step.
1. Fold down the rear seat backrest.
IMPORTANT
If the backrest is not folded down, the rear window could be damaged by the head restraint while programming is in progress.
2. Open the header latches securing the top of the windshield frame.
3. Plug ISAT into the data link connector (DLC). The ignition switch should be in the OFF position.
4. Select "TSAS on SAT"
5. Turn the ignition switch to the ON position.
6. Press a window button to lower the window automatically and then immediately press ON/ENTER on SAT. Since the header latches are open. the ECM is prevented from returning to the rest or idle state.
7. Continue with point 8 or 9, depending upon the VIN Serial No.
8. Cars having a VIN Serial No. from S7000216 to S7014535 (inclusive):
These cars must have the 5th bow's potentiometer modified as follows:
a. Select "5Th BOW LATCH MOTOR, UP" in the "ACTIVATE" menu to open the fifth bow's latches.
b. Select "5TH BOW MOTOR, UP" In the "ACTIVATE" menu and run the 5th bow to the fully raised position.
c. Select "TONNEAU MOTOR, UP" in the "ACTIVATE" menu and run the Tonneau cover to the fully raised position.
d. Hold the 5th bow's potentiometer and steady and carefully cut it off as shown In Figure 24. Use a sharp pair of side cutters. See Figure 24.A.
e. Apply primer to the cut surface as corrosion protection.
Figures 25A, B, C
f. Place the potentiometer arm in the opening in the bracket See Figure 25.A.
g. Hold the bracket in position and fit the pop rivet through the top mechanism and bracket See Figure 25.B.
h. Rotate the bracket anticlockwise until it reaches Its end position and is edge-to-edge with the top mechanism. See Figure 25.C.
i. Fasten the bracket In this position from the inside by means of a pop rivet Make sure potentiometer arm is fully engaged in the slot in the bracket. Bend bracket slightly if necessary. DO NOT bend potentiometer arm.
j. Select "TONNEAU MOTOR, DOWN" In the "ACTIVATE" menu and when the Tonneau cover to the fully lowered position.
Keep pressing the F4 button for at least five seconds after the movement has stopped to be sure that the mechanism has reached the end position.
k. Select "5TH BOW MOTOR. DOWN" in the "ACTIVATE" menu.
Keep pressing the F4 button for at least five seconds after the movement has stopped to be sure that the mechanism has reached the end position.
l. Select "5TH BOW LATCH MOTOR, DOWN" In the "ACTIVATE" menu.
Keep pressing the F4 button for at least five seconds after the movement has stopped to be sure that the mechanism has reached the end position.
Continue with step 10.
Programming High and Low Limits continued:
9. Cars having a VIN Serial No. from S7014536-S7015157 Inclusive:
On these cars the 5th bow's potentiometer is not to be modified.
a. Select "TONNEAU MOTOR. DOWN" in the "ACTIVATE" menu and run the Tonneau cover to the fully lowered position.
Keep pressing the F4 button for at least five seconds after the movement has stopped to be sure that the mechanism has reached the end position.
b. Select "5TH BOW MOTOR. DOWN" in the "ACTIVATE" menu.
Keep pressing the F4 button for at least five seconds after the movement has stopped to be sure that the mechanism has reached the end position.
c. Select "5TH BOW LATCH MOTOR. DOWN" in the "ACTIVATE" menu.
Keep pressing the F4 button for at least five seconds after the movement has stopped to be sure that the mechanism has reached the end position.
Then continue with step 10.
10. Select "POT POS 5TH BOW" in the "READ VALUES" menu to read the 5th bow's low limit. Make a note of the reading .
11. Select "5TH BOW LATCH MOTOR. UP" in the "ACTIVATE" menu to open the 5th bow's latches.
12. Select "5TH BOW MOTOR. UP" in the "ACTIVATE" menu and run the 5th bow to the fully raised position. Keep pressing the F3 button for at least five seconds after the movement has stopped to be sure that the mechanism has reached the end position.
13. Select "POT POS 5TH BOW" in the "READ VALUES" menu to read the 5th bow's high limit. Make a note of the reading on Line I in the table above.
14. Select "TONNEAU MOTOR. DOWN" in the "ACTIVATE" menu and run the Tonneau cover to the fully lowered position.
Keep pressing the F4 button for at least five seconds after the movement has stopped to be sure that the mechanism has reached the end position.
15. Select "POT POS TONNEAU" in the "READ VALUES" menu to read the Tonneau cover's low limit. Make a note of the reading on line H in the table above.
16. Select "TONNEAU MOTOR. UP" in the "ACTIVATE" menu and run the Tonneau cover to the fully raised position.
Keep pressing the F3 button for at least five seconds after the movement has stopped to be sure that the mechanism has reached the end position.
17. Select "POT POS TONNEAU" in the "READ VALUES" menu to read the Tonneau cover's high limit. Make a note of the reading on line E in the table above.
18. Select "MAIN MOTOR. UP" in the "ACTIVATE" menu and run the top to the fully raised position.
Keep pressing the F3 button for at least five seconds after the movement has stopped to be sure that the mechanism has reached the end position.
19. Select "POT POST MAIN MOTOR" in the "READ VALUES" menu to read the top's high limit. Make a note of the reading on line A in the table above.
20. Select "MAIN MOTOR, DOWN" in the "ACTIVATE" menu and run the top to the fully lowered position.
Keep pressing the F4 button for at least five seconds after the movement has stopped to be sure that the mechanism has reached the end position.
21. Select "POT POS MAIN MOTOR" in the "READ VALUES" menu to read the top's low limit. Make a note of the reading on line D in the table above.
NOTE:
The trunk carpet needs to be re--Installed under the lip.
Programming High and Low Limits continued:
22. Using the table above, calculate the new potentiometer resistance readings for the high and low limits of the end positions.
23. Use ISAT to enter the new potentiometer resistance readings in the TSAS control module by selecting the following commands in the "PROGRAMMING" menu.
The overlapping positions on lines B, C, F, G, J and K in the table will be programmed later. Skip past these by pressing "OK" on ISAT.
^ A "MAIN MOTOR, HIGH LIMIT"
^ D "MAIN MOTOR, LOW LIMIT"
^ E "TONNEAU MOTOR, HIGH LIMIT"
^ H "TONNEAU MOTOR, LOW LIMIT"
^ I "5TH BOW MOTOR, HIGH LIMIT"
^ L "5TH BOW MOTOR, LOW LIMIT"
^ End by pressing ESC once on ISAT then use the "END" command to store the programmed resistance readings.
IMPORTANT
Unless programming is ended by pressing ESC once from the PROGRAMMING menu, then using the END command. the new readings will not be stored in the TSAS ECM.
Do not unplug ISAT from the data link connector (DLC). Continue programming of the overlapping positions as described on the next several pages.
Overlapping positions - MAIN MOTOR
1. Select "POT POS MAIN MOTOR" in the "READ VALUES" menu.
2. Operate the top using the ROOF switch until the distance between the edge of the first bow and the middle of the trunk lid's forward edge is 110cm (42.9").
Ask someone to help you and make sure that the top does not move.
3. Select "POT POS MAIN MOTOR" and make a note of the reading on line B on page 35.
The reading obtained is the main motor's high overlap limit ("MAIN MOTOR, OVERLAP HIGH LIMIT).
4. The main motor's low overlap limit is calculated by deducting six units from the high overlap limit ("OVERLAP HIGH LIMIT" - 6 = "OVERLAP LOW LIMIT"). See line C in the table.
Overlapping positions - TONNEAU MOTOR
5. Move forward to read "POT POS TONNEAU" under the "READ VALUES" menu in ISAT
6. Continue to raise the top mechanism with the ROOF button so that the distance between the front edge of the Tonneau cover and the rear edge of the cross member behind the rear seat backrest is 26cm (approx. 10 1/4").
7. Read "POT POS TONNEAU" and note the reading in row F in the table on page 35. This reading is the same as the Tonneau cover high overlap value ("TONNEAU MOTOR OVERLAP HIGH LIMIT").
8. Operate the Tonneau cover with the ROOF button so that the distance between the front edge of the Tonneau cover and the rear edge of the cross member behind the rear seat backrest is 20cm (approx. 7 3/4").
9. Read "POT POS TONNEAU" and note the reading in row G in the table on page 35. This reading is the same as the Tonneau cover low overlap value ("TONNEAU MOTOR. OVERLAP LOW LIMIT").
Overlapping positions - 5TH BOW MOTOR
10. Select "POT POS 5TH BOW" in the READ VALUES" menu.
11. Raise the top fully using the ROOF switch. Continue to operate the top mechanism with the ROOF switch until the Tonneau cover is closed and the distance between the edge of the 5th bow's cloth lip and the middle of the trunk lid's forward edge is 30cm (11.7").
12. Select "POT POST 5TH BOW" and make a note of the reading on line K in the table on page 35. The reading obtained is the 5th bow's low overlap limit ("5TH BOW MOTOR, OVERLAP LOW LIMIT").
13. The 5th bow's high overlap limit is calculated by adding eight units to the low overlap limit ("OVERLAP LOW LIMIT" + 8 = "OVERLAP HIGH LIMIT"). See line J in the table.
14. Enter the new potentiometer resistance readings for the high and low overlap limits in the TSAS ECM. Use ISAT and select the following commands in the "PROGRAMMING" menu.
The end positions on lines A, D, E, H, I and L in the table should have been programmed earlier. Skip past these by pressing "01<" on ISAT
^ B "MAIN MOTOR, OVERLAP HIGH LIMIT"
^ C "MAIN MOTOR, OVERLAP LOW Limit"
^ F "TONNEAU MOTOR, OVERLAP HIGH LIMIT"
^ G "TONNEAU MOTOR, OVERLAP LOW LIMIT"
^ J "5Th BOW,MOTOR, OVERLAP HIGH Limit"
^ K "5Th BOW MOTOR, OVERLAP LOW LIMIT"
IMPORTANT
Unless programming is ended by pressing ESC once from the PROGRAMMING menu, then using the END command, the new readings will not be stored in the TSAS ECM.
Checking
1. Clear any DTC's.
2. Terminate communication between ISAT and the TSAS ECM via the "END" menu.
3. Operate the top mechanism through a complete up and down cycle by means of the ROOF switch.
4. Connect ISAT and check all potentiometer readings by selecting "PROGRAMMING" menu and comparing the readings programmed in the ECM with those calculated in the table above.
5. If all readings coincide, terminate communications via the "END" menu.
6. If one or more of the readings do not coincide, the correct reading as shown in the table must be entered in the ECM. Then go back to step 2 above and continue from there.
Calculating the potentiometer resistance readings
Make a copy of this table and use the copy to calculate the new potentiometer resistance readings. File in service record for vehicle for future reference.