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).

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

4. Connect the Diagnostic Tester with the CAN 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 color.





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 one of the following calibration IDs:

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.