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Canada - Engine Controls - MIL ON/DTC's P0136/P0138 Set





Bulletin
TSB2042R

Issue Date
September 24, 2004

Title
M.I.L. "ON" DTC P0136 AND/OR P0138

Component
ENGINE ELECTRICAL

Models
'04 Prius

MARKET
Canada

TSB UPDATE NOTICE:
September 24, 2004: This TSB supercedes the previous TSB2042 date July 26, 2004 which is now obsolete and should be discarded.

Some customers may report a M.I.L. "ON" during certain engine operating conditions. The following diagnostic trouble codes may be found P0136, "Oxygen Sensor Circuit Malfunction," and/or P0138 "Oxygen Sensor Circuit High Voltage." Reprogram the Engine ECU to correct this condition.

APPLICABLE VEHICLES:
^ All 2004 model year Prius vehicles.





WARRANTY INFORMATION:





PARTS INFORMATION:





CALIBRATION ID INFORMATION:





REQUIRED SSTs:

REPAIR PROCEDURE A:

CAUTION:
USING ANY PREVIOUS VERSIONS OF VERSION 11.0a SOFTWARE FOR REPROGRAMMING MAY RESULT IN IRREPARABLE DAMAGE TO THE ENGINE ECU (you MUST use R160, dated 8/3/04 release, or newer)! Please refer to the verification procedure in step 6 below.

CONFIRMING THE CURRENT ENGINE ECU CALIBRATION:





1. Confirm that the vehicle has undergone Pre-Delivery Service (PDS).
2. Connect the Midtronics Tester and check the condition of the 12 volt auxiliary battery. Charge if necessary before proceeding.
3. Attach the 12 volt Prius Automatic Charger (P/N 00002--YA122-01 or CXC-2815).

NOTE:
If Prius Automatic Battery Charger P/N 00002-YA122 or CXC-2815 is used, ensure that the charger is set to the "HIGH" current setting.

4. Connect the Diagnostic Tester with the CAN vehicle interface module to the DLC3 connector.
5. Turn on the Diagnostic Tester.
6. Press the "YES" button on the Diagnostic Tester.





The number "160," or greater, should appear in the upper right-hand corner.

CAUTION:
Confirm that the correct version of the software (11.0a) and calibration update is loaded into the Diagnostic Tester, otherwise,
IRREPARABLE DAMAGE WILL OCCUR TO THE ENGINE ECU.
The date shown under "Version 11.0a" MUST be "8/3/04" or more recent.

IF NOT: STOP!!!
Update Diagnostic Tester with the newest version of software - 11.0a. The date shown must be "8/3/04" or newer.





7. Insert key into key slot.
8. Push the "POWER" switch twice without depressing the brake pedal and confirm that the hybrid system is "IG-ON."

NOTE:
- Do not the start the hybrid system.
- If the "READY" light is on, turn off and repeat step 7.
- Confirm that the "POWER" switch indicator is amber in colour.





9. Press the "ENTER" key on the Diagnostic Tester (after the screen is displayed and the newest version of software, 11.0a, is confirmed, as shown in step 6).





10. Select "3: ECU REPROGRAM" from the "APPLICATION SELECT" menu.






11. Select"1. ENGINE AND ECT" From the "ECU REPROGRAM SELECT SYSTEM TYPE" menu.





12. Select "2" CURRENT ECU CAL. from the "ECU REPROGRAM MAIN MENU."





13. Press the "YES" key.





14. The Diagnostic Tester is currently confirming that the CAN Interface Module has been updated. If not, the next three screens will be displayed. If the CAN Interface Module has been updated, proceed to Step 18.





15. Press the ENTER "key"





16. The CAN Interface Module update takes approximately 3 minutes.





17. Press the "EXIT" key.





18. Confirm that the Diagnostic Tester displays the following calibration ID:
^ 34702200, 34702100 or 34702000.

NOTE:
If the display shows a calibration ID of 34705000 or later, then the ENGINE ECU has already been reprogrammed. Press the "EXIT" key and turn off the Diagnostic Tester. Proceed to Recalibration Label Installation.

19. Press the "ENTER" key to return the main menu.

REPAIR PROCEDURE B:

Reprogramming the Engine ECU





1. Confirm that the auxiliary battery is fully charged using the Midtonics tester before proceeding. The Prius Automatic Charger MUST be connected during reprogramming.

CAUTION:
Do not use a jumper battery in place of the Midtonics tester or IRREPARABLE DAMAGE TO THE ENGINE ECU MAY RESULT.

2. Select "3" UPDATE ECU CAL" from the .ECU REPROGRAM MAIN MENU."





3. Select "1: IN-SERVICE ECU" from "UPDATE ECU CAL SELECT ECU TYPE" menu.





4. Confirm the following before proceeding:
^ IG is "OFF." Push the "POWER" switch once without depressing brake pedal until the indicator lamp turns off.
^ Engine hood is opened.
^ All electrical accessories are OFF (i.e., audio systems, dome lamp, navigation system, air conditioner, etc.).
^ The parking brake is applied.

5. Press the "YES" key.





6. Confirm that the Diagnostic Tester displays the appropriate vehicle type. If it is not the correct vehicle, please refer to TSB No. 0941 "ECU Flash Reprogramming Process" to update the Diagnostic Tester.
7. Press the "ENTER" key.





8. Confirm that the Diagnostic Tester displays "34705000" or later.

NOTE:
If the Diagnostic Tester displays "YES" instead of "NO," the Engine ECU has been reprogrammed already. Press the "EXIT" key and turn off the Diagnostic Tester. Proceed to Recalibration Label Installation.

9. Press the "ENTER' key.





10. Select the current matching calibration ID that is currently on the vehicle.
11. Press the "ENTER" key.





NOTE:
If you select the wrong calibration ID, the Diagnostic Tester will display the screen shown to the right. Please select the correct calibration ID again after pressing the "ENTER" key.





12. Push the "POWER" switch twice without depressing the brake pedal and confirm that the hybrid system is "IG--ON."

NOTE:
^ Do not start the hybrid system, if the "READY" light is on. You will need to turn the vehicle OFF and repeat step 12.
- Confirm that the power switch indicator is amber in colour.





13. Press the "YES" key.

NOTE:
Do not do anything that will increase an electrical load to the vehicle after pressing the "YES" key.





CAUTION:
- The progress bar will display after approximately one minute.
- It will take approximately 24 minutes to complete the reprogramming.
- During the reprogramming, do not touch the Diagnostic Tester and the cable in order to avoid reprogramming failures.
- After reprogramming, warning lights may be displayed on the dash and multi-display. DTCs may be set in the memory of various ECUs. This is normal and the codes must be cleared prior to release of the vehicle.





14. After approximately 24 minutes, the Diagnostic Tester will display the screen shown at right.
15. Push the "POWER" switch until the indicator lamp turns off without depressing the brake pedal.
16. Press the "ENTER" key.





17. Confirm that the Diagnostic Tester displays both "34705000" (or a newer calibration) and "YES."
18. Press the "EXIT" key.





19. Push the "POWER" switch twice without the brake pedal depressed and confirm that the hybrid system is "IG--ON."

NOTE:
- Do not start the hybrid system in "READY" mode.
- Power switch indicator must be amber in colour.





20. Press the "YES" key.





21. The Diagnostic Tester is currently confirming that the CAN Interface Module has been updated.





22. Select .2. CURRENT ECU CAL. from the .ECU REPROGRAM MAIN MENU.





23. Confirm that the Diagnostic Tester displays the correct calibration ID: 34705000 (or a newer calibration).
24. Press the "ENTER" key.
25. Turn off the Diagnostic Tester.
26. Push the "POWER" switch once without depressing the brake pedal to turn ignition off.
27. Clear any DTC codes that have been set.

RECALIBRATION LABEL INSTALLATION:

1. Install the Recalibration (Authorization Modifications) Label.
a. Using a permanent marker, write the following information on the recalibration label:
- ECM part number 89661-47070 (or newer part number).
- Calibration number 34705000 (or newer calibration).
- Your dealer code.
- Repair date.





b. Install the Recalibration Label on the underside of the hood in front of the driver (see illustration).

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.
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