Canada - Hybrid System - Hybrid ECU Update for Various Issues

Bulletin
1339

Issue Date
February 13, 2004

Market
Canada

Title:
HV ECU SOFTWARE UPDATE (REVISION)

Model
'04 Prius

The HV ECU calibration has been revised to prevent a number of potential conditions with the 2004 Prius HV system operation. The conditions that have been addressed include:

1. Vehicle will not "READY ON" after running out of gas, even after refueling. The HV ECU logic designed to protect the HV battery minimum State of Charge (SOC) has been revised to allow "READY ON" after refueling.
2. If certain inverter self--protection malfunctions occur continuously, the vehicle may remain "READY ON." The inverter fail safe logic has been changed.
3. A vehicle vibration can occur during a low State of Charge (SOC) condition just before the vehicle fully stops moving.
4. Certain open circuit conditions still permitted the vehicle to be driven in a fail safe mode.
5. Diagnostic codes may not be stored in the HV ECU when certain System Main Relay (SMR) open circuit conditions occur. The vehicle may stop without any diagnostic code.
6. Detection logic for inverter cooling system malfunctions has been improved.
7. Diagnostic codes may not be stored in the HV ECU, if DC/DC converter operation stops at higher temperatures. Detection logic was improved.
8. On vehicles equipped with the Smart Key System, it may be difficult to detect the smart key location due to interference in the cabin of the vehicle. This condition may not set a trouble code. Detection logic has been improved.
9. The "fail--safe" mode for communication malfunctions between the HV ECU and Battery ECU has been improved.
10. The voltage boosting system detection logic has been improved.
11. A high engine high idle condition occuring after more than 80% accelerator pedal depression during catalytic converter warm--up has been improved.

APPLICABLE VEHICLES:
- 2004 model year Prius vehicles produced BEFORE the Production Change Effective VINs shown below.







PRODUCTION CHANGE INFORMATION:







WARRANTY INFORMATION:







PARTS INFORMATION:







CALIBRATION ID INFORMATION:







REQUIRED SSTs:

REPAIR PROCEDURE A:

CAUTION:
USING ANY PREVIOUS VERSIONS OF VERSION 10.2a SOFTWARE FOR REPROGRAMMING MAY RESULT IN IRREPARABLE DAMAGE TO THE HV ECU (you MUST use 12/11/03 release, or newer)! Please refer to the verification procedure in Step 7.

Confirming the Current HV ECU Calculation







1. Confirm that the vehicle has undergone PDS.
2. Attach the 12 volt Prius Automatic Charger (P/N 00002--YA122--01).
3. Connect the Diagnostic Tester with the CAN vehicle interface module to the DLC3 connector.
4. Turn on the Diagnostic Tester.







5. Insert key into key slot.
6. 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 6. Confirm that the "POWER" switch indicator is amber in colour.

7. If you press the "YES" button immediately after turning the Diagnostic Tester on, the number "107" or greater should appear in the upper right--hand corner.

CAUTION:
Confirm that the correct version of the software (10.2a production) and calibration update is loaded into the Diagnostic Tester, otherwise, IRREPARABLE DAMAGE WILL OCCUR TO THE HV ECU. The date shown under "Version 10.2a" MUST be "12/11/03" or more recent.

IF NOT: STOP!!!
Update Diagnostic Tester with the newest version of software -- 10.2a. The date shown must be "12/11/03" or newer.

a) Press the "ENTER" key after the illustrated screen is displayed and the version is confirmed.







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







9. Select "2. HV ECU" from the "ECU REPROGRAM SELECT SYSTEM TYPE" menu.







10. Select "2. CURRENT ECU CAL" from the "ECU REPROGRAM" main menu.







11. Press the "Yes" key.







12. 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 16.







13. Press the "ENTER" key.







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







15. Press the "EXIT" key.







16. Confirm that the Diagnostic Tester displays the following calibration ID:
- 899834708401 or 899834708301 or earlier.

NOTE:
If the display shows a calibration ID of 899834708501 or later, then the HV ECU has already been reprogrammed.
Press the "EXIT" key and turn off the Diagnostic Tester.
Proceed to Recalibration Label Installation.

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

Reprogramming the HV ECU







1. Confirm that the battery voltage is above 11.3 volts. The Prius Automatic Charger MUST be connected.

CAUTION:
If battery voltage falls below 11.3 volts, irreparable damage to the HV 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.
7. Press the "ENTER" key.







8. Confirm that the Diagnostic Tester displays "899834708501" or later.


NOTE:
If the Diagnostic Tester displays "YES" instead of "NO," the HV 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 would cause 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 17 minutes to complete the reprogramming.
- During the reprogramming, do not touch the Diagnostic Tester and the cable in order to avoid reprogramming failures.
- If an error screen is displayed during this step, confirm the following:
- The battery voltage is above 11.3 volts. Connect the Prius Automatic Charger (P/N 00002--YA122--01) to the battery, if not completed in Repair Procedure A, step 2.
- Confirm that the power switch indicator is amber in colour.
- The Diagnostic Tester is firmly connected to the DLC connector.
- During this time, the cooling fan may come on.
- After reprogramming, warning lights may be displayed on the dash and multi--display. DTCs may be set in the memory of various ECU screens. This is normal and the codes must be cleared prior to release of the vehicle.







14. After approximately 17 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 "899834708501" (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:
899834708501 (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:
- ECU Part Number
89981--47082 (or newer part number)
- Calibration number
899834708501 (or newer calibration)
- 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.