A. HV ECU Reprogramming Procedure

A. HV ECU REPROGRAMMING PROCEDURE

1. DOWNLOAD THE HV ECU CALIBRATION DATA FROM THE PC TO THE DIAGNOSTIC TESTER

2. CHECK BATTERY VOLTAGE

(a) Turn OFF all electrical accessories (i.e. audio systems, dome lamp, navigation system, air conditioner, etc.) to avoid battery fluctuations while reprogramming the HV ECU.

(b) Using the Midtronics Battery Tester, confirm that the battery voltage is greater than 11.5 volts.

^ If the voltage is less than 11.5 volts, charge and retest the battery as necessary.

^ The battery must be fully charged before proceeding to the next step.

(c) Connect the Prius Automatic Charger. This MUST be done on all vehicles even if the battery is fully charged.

(d) Set the Prius Automatic Charger to the "HIGH" current setting to
assure that the battery voltage stays consistently above 11.5 volts.





WARNING

3. CONFIRM THE CURRENT HV ECU CALIBRATION ID





(a) Confirm that the vehicle has undergone PDS.

(b) Connect the diagnostic tester with the CAN Module to the DLC3 connector.

(c) Turn ON the diagnostic tester.





(d) Insert key into key slot.

(e) 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.

^ Confirm that the "POWER" switch indicator is amber in color.





(f) Confirm that the diagnostic tester software is version "13.0a" or higher and press "ENTER."

^ If the software version is NOT "13.0a" or higher, load the correct version from TIS.





WARNING





(g) Select "3: ECU REPROGRAM" from the "APPLICATION SELECT" menu.





(h) Select "2: HV ECU" from the "ECU REPROGRAM SELECT SYSTEM TYPE" menu.





(i) Select "2: CURRENT ECU CAL" from the "ECU REPROGRAM MAIN MENU."





(j) Press the "YES" key when the "VERIFY CONNECTIONS" screen appears.





(k) The diagnostic tester will confirm if the CAN module has been updated.
^ If it has NOT been updated, the diagnostic tester will prompt you to perform a CAN module update, proceed to step "(l)."

^ If the CAN module has been updated, proceed to step "(o)."

USE STEPS "(l)", "(m)", & "(n)" WHEN PERFORMING THE CAN MODULE UPDATE





(l) Press the "ENTER" key to proceed with the CAN module update.

(m) The CAN module update will take approximately 3 minutes.

(n) When the "UPDATE COMPLETE" screen is displayed press the "EXIT" key, and proceed to step "(o)."





(o) Confirm the calibration ID.

2004 Prius:

^ If the display shows 899834717001, the HV ECU does not need to be reprogrammed. Press the "EXIT" key, turn off the diagnostic tester, and proceed to "B. ENGINE ECM REPROGRAMMING PROCEDURE."

^ If the display shows a calibration ID of 899834708201, 899834708301, 899834708401, 899834708501, 899834708601, 899834708701, or 899834715001, proceed to "4. REPROGRAM THE HV ECU" below.

2005 Prius:

^ If the display shows 899834712301, the HV ECU does not need to be reprogrammed. Press the "EXIT" key, turn off the diagnostic tester, and proceed to "B. ENGINE ECM REPROGRAMMING PROCEDURE".

^ If the display shows a calibration ID of 899834712001, 899834712101, or 899834712201, proceed to "4. REPROGRAM THE HV ECU" below.

(p) Press the "ENTER" key to return to the "ECU REPROGRAM MAIN MENU."

4. REPROGRAM THE HV ECU





(a) Remove the 15 amp EFI fuse located in the Engine Room Relay Box.

(b) Remove the ABS No. 2 Relay located in the Engine Room Relay Box.





(c) Remove the 7.5 amp ECU-IG fuse located in the driver's side Junction Block underneath the driver's side lower finish panel.





(d) Using the nylon pry tools, disengage the 6 claws (labeled A) and the 2 claws (labeled B).

(e) Using the nylon pry tools, disengage the two clips.

(f) Remove the driver's side scuff plate.





(g) Using the nylon pry tools, disengage the 2 claws, and remove the driver's side kick panel.

NOTE:
Certain production periods will have a plastic cap nut securing the kick panel. Remove it, if necessary.





(h) Disconnect the white 11-pin connector located in the driver's side kick panel.





(i) Confirm the Prius Automatic Charger is still connected and set on the "HIGH" current setting to assure that the battery voltage stays consistently above 11.5 volts during reprogramming.





WARNING

(j) Select "3: UPDATE ECU CAL" from the "ECU REPROGRAM MAIN MENU."





(k) Select "1: IN-SERVICE ECU" from "UPDATE ECU CAL SELECT ECU TYPE" menu.





(l) Confirm the following before proceeding:

^ IG is "OFF." Push the "POWER" switch without depressing brake pedal until the indicator lamp is not lit.

^ 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.

(m) Press the "YES" key.





(n) Confirm that the diagnostic tester displays the appropriate vehicle type for the car that you are working on.

(o) Select the correct vehicle type for the car that you are working on and press the "ENTER" key.





(p) Confirm that the diagnostic tester displays the appropriate calibration ID.

2004 Prius: 899834717001 & "NO"
2005 Prius: 899834712301 & "NO"

NOTE:
If the diagnostic tester displays "YES", the HV ECU has been reprogrammed already. Press the "EXIT" key and turn off the diagnostic tester.

(q) Press the "ENTER" key.





(r) Select the matching calibration ID that is currently on the vehicle.

(s) Press the "ENTER" key.

NOTE:
After the matching calibration ID is selected, the diagnostic tester will momentarily display a "VERIFYING PROGRAM CARD INFO" screen.





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





(t) After the screen above is displayed, 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.

^ Confirm that the power switch indicator is amber in color.

(u) Press the "YES" key.

NOTE:
^ Do not do anything that would cause an electrical load to the vehicle after pressing the "YES" key.

^ After pressing the "YES" key, the diagnostic tester will momentarily display an "INITIALIZING CAN INTERFACE" screen.





WARNING








(v) When the reprogramming has been completed, the diagnostic tester will display the illustrated screen.

(w) Push the "POWER" switch without depressing the brake pedal until the indicator lamp is not lit, to turn the "IG-OFF."

(x) Press the "ENTER" key.





(y) Confirm that the diagnostic tester displays the appropriate calibration ID and "YES."

2004 Prius: 899834717001 & "YES"
2005 Prius: 899834712301 & "YES"

(z) Press the "EXIT" key.

5. CONFIRM THE UPDATED CALIBRATION ID WAS LOADED INTO THE HV ECU





(a) 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.

^ Confirm that the power switch indicator is amber in color.





(b) Select "2: CURRENT ECU CAL" from the "ECU REPROGRAM MAIN MENU."





(c) Press the "YES" key when the "VERIFY CONNECTIONS" screen appears.





(d) The diagnostic tester is currently confirming that the CAN interface module has been updated.





(e) Confirm that the diagnostic tester displays the correct calibration ID.

2004 Prius: 899834717001
2005 Prius: 899834712301

(f) Press the "ENTER" key.





(g) Reconnect the white 11-pin connector located in the driver's side kick panel.





(h) Reinstall the driver's side kick panel, and reattach the 2 claws.

NOTE:
Certain production periods will have a plastic cap nut securing the kick panel. Reinstall it if necessary.





(i) Reinstall the driver's side scuff plate.

(j) Reattach the 2 clips.

(k) Reattached the 6 claws (labeled A) and the 2 claws (labeled B).





(l) Reinstall the 7.5 amp ECU-IG fuse to the driver's side Junction Block underneath the driver's side lower finish panel.





(m) Reinstall the ABS No. 2 Relay to the Engine Room Relay Box.

(n) Reinstall the 15 amp EFI fuse to the Engine Room Relay Box.

(o) Clear any DTC codes that have been set.

(p) Turn off the diagnostic tester.

(q) Push the "POWER" switch once without depressing the brake pedal until the indicator lamp in not lit to turn the ignition OFF.

6. RECALIBRATION LABEL INSTALLATION

(a) Using a permanent marker, write the following information on the recalibration label:

^ ECU Part Number

- 2004 Prius: 89981-47170
- 2005 Prius: 89981-47123

^ Calibration number

- 2004 Prius: 899834717001
- 2005 Prius: 899834712301

^ Dealer Code

^ Repair Date

^ Change Authority

- Service Campaign No.





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

NOTE:
Additional recalibration labels (in packages of 25) can be ordered through the Material Distribution Center (MDC). The Material Number is 00451-00001-LBL.