B. Engine ECM Reprogramming Procedure

B. ENGINE ECM REPROGRAMMING PROCEDURE

1. DOWNLOAD THE ENGINE ECM 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 Engine ECM.

(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 ECM 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."

WARNING

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

(h) Select "1. ENGINE AND ECT" 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, 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.

^ If the display shows 34705200, the Engine ECU does not need to be reprogrammed. Press the "EXIT" key, turn off the diagnostic tester, and proceed to "C. DIELECTRIC GREASE APPLICATION PROCEDURE".

^ If the display shows a calibration ID of 34702000, 34702100, 34702200, 34705000, or 34705100**, proceed to "4. REPROGRAM THE ENGINE ECU" below.

**Although the 34705100 calibration contains the correction to the current issue, since the customer is in the dealership please reflash the Engine ECM to the 34705200 calibration. THIS APPLIES ONLY TO VEHICLES THAT ARE INVOLVED IN SSC 50P, OTHER PRIUS VEHICLES NOT INVOLVED IN THE CAMPAIGN WITH THE 34705100 CALIBRATION DO NOT NEED TO BE REFLASHED!

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

4. REPROGRAM THE ENGINE ECU

(a) 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

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

(d) 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.

(e) Press the "YES" key.

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

(g) Press the "ENTER" key.

(h) Confirm that the diagnostic tester displays calibration ID 34705200 & "NO".

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

(i) Press the "ENTER" key.

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

(k) 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.

(l) After the following screen 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.

(m) 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

(n) After approximately 23 minutes, the diagnostic tester will display the illustrated screen.

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

(p) Press the "ENTER" key.

(q) Confirm that the diagnostic tester displays calibration ID 34705200 & "YES."

(r) Press the "EXIT" key.

5. CONFIRM THE UPDATED CALIBRATION ID WAS LOADED INTO THE ENGINE 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".

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

(e) Confirm that the diagnostic tester displays the calibration ID 34705200.

(f) Press the "ENTER" key.

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

(h) Turn off the diagnostic tester.

(i) 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

- 89661-47101

^ Calibration number

- 34705200

^ 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.