T-SB-0043-13 Rev

T-SB-0043-13
Rev1
March 18, 2013
RAV4 EV ECU Flash Reprogramming Procedure
Service
Category
Engine/Hybrid System
Section
Hybrid/Battery Control System
Market
USA
Applicability
YEAR(S)
MODEL(S)
2012 – 2014
RAV4 EV
ADDITIONAL INFORMATION
REVISION NOTICE
February 11, 2014 Rev1:
• Applicability has been updated to include 2014 model year RAV4 EV vehicles.
Any previous printed versions of this bulletin should be discarded.
Introduction
Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash
calibration updates for the RAV4 EV are released as field-fix procedures described in individual
Service Bulletins. This bulletin details the ECU flash reprogramming process and outlines use of the
Techstream Health Check Function and the Tesla Powertrain Service Diagnostics program.
NOTE
Flash reprogramming of the RAV4 EV ECU can only be performed with the Tesla Powertrain Service
Diagnostics program.
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
N/A
Not Applicable to Warranty
–
–
–
–
Parts Information
PART NUMBER
PART NAME
QTY
00451-00001-LBL
Authorized Modification Labels
1
NOTE
Authorized Modification Labels may be ordered in packages of 25 from the Materials Distribution
Center (MDC) through Dealer Daily – Dealer Support Materials Orders.
© 2014 Toyota Motor Sales, USA
Page 1 of 16
Rev1
T-SB-0043-13
March 18, 2013
Page 2 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
PART NUMBER
QTY
Techstream 2.0*
ADE
TS2UNIT
1
NOTE
• Only Techstream 2.0 should be used for this update.
• Techstream Software version 9.00.025 or later is required.
• Tesla Powertrain Service Diagnostic Software version 0.5.23 or later is required.
• Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at
1-800-368-6787.
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
GR8 Battery Diagnostic Station*
00002-MCGR8
1
EV HV Powertrain Diagnostic Cable Kit**
82824-36150-01
1
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
* Essential SST.
** Special order.
© 2014 Toyota Motor Sales, USA
T-SB-0043-13
Rev1
March 18, 2013
Page 3 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Techstream Preparation
Selecting the Correct VIM.
Techstream software requires a VIM selection before it can be used for reprogramming.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
Figure 1.
© 2014 Toyota Motor Sales, USA
T-SB-0043-13
Rev1
March 18, 2013
Page 4 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Techstream Preparation (Continued)
3. Select the correct Interface Setup from the drop down list.
For Techstream 2.0, select MongoosePro MFC.
NOTE
Mongoose Driver MUST be installed before Mongoose selections will be available.
Refer to the Technical Information System (TIS), Diagnostics – Scantool page for additional
information.
4. Click OK.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle’s applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate Service Bulletin using the
current Calibration ID from the vehicle. Calibration file links can be found embedded in the
corresponding Service Bulletin.
2. Connect the GR8 Battery Diagnostic Station using “Power Supply Mode” only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
NOTICE
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Perform the RAV4 EV ECU software update using the Tesla Powertrain Service
Diagnostics program.
Launch the Tesla Powertrain Service Diagnostics program and initiate the update process to
complete the reprogramming.
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
© 2014 Toyota Motor Sales, USA
T-SB-0043-13
Rev1
March 18, 2013
RAV4 EV ECU Flash Reprogramming Procedure
Operation Procedure
1. Verify the vehicle’s applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Figure 2.
© 2014 Toyota Motor Sales, USA
Page 5 of 16
T-SB-0043-13
Rev1
March 18, 2013
RAV4 EV ECU Flash Reprogramming Procedure
Operation Procedure (Continued)
C. Choose desired ECU group(s) in the Health Check dialog box.
Figure 3.
D. Click Next.
E. Click Continue to view Health Check results.
Figure 4.
© 2014 Toyota Motor Sales, USA
Page 6 of 16
T-SB-0043-13
Rev1
March 18, 2013
Page 7 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Operation Procedure (Continued)
F. Available calibration updates are indicated by a Yes link in the Update column.
Click the Yes link to access the appropriate Service Bulletin on TIS.
NOTE
• Note any DTCs stored in systems that will be flash reprogrammed.
• Clicking the Yes link will automatically launch TIS and perform a calibration search.
Figure 5.
G. Log into TIS. (If already logged in, skip this step.)
© 2014 Toyota Motor Sales, USA
T-SB-0043-13
Rev1
March 18, 2013
Page 8 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Operation Procedure (Continued)
H. To review the Service Bulletin and access the calibration file, click the Service Bulletin link in
the Document Title column of the Calibration Search Result portlet.
NOTE
Only Toyota Certified Technicians and above may access calibration files.
Figure 6.
© 2014 Toyota Motor Sales, USA
T-SB-0043-13
Rev1
March 18, 2013
Page 9 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Operation Procedure (Continued)
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
• ECU damage may occur if the correct battery charger and mode setting are NOT used.
• Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash
reprogramming the vehicle.
• For details on how to use the GR8 Battery Diagnostic Station, refer to the
GR8 Instruction Manual located on TIS, Diagnostics – Tools & Equipment –
Battery Diagnostics.
Figure 7.
1
1
Confirm “Power Supply Mode” Is Selected
© 2014 Toyota Motor Sales, USA
T-SB-0043-13
Rev1
March 18, 2013
Page 10 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Operation Procedure (Continued)
3. Perform the RAV4 EV ECU software update using the Tesla Powertrain Service
Diagnostics program.
After reviewing the procedures outlined in the selected Service Bulletin, launch the Tesla
Powertrain Service Diagnostics program.
NOTE
The vehicle may require special preparation — please review the selected Service Bulletin
carefully.
A. Click Start.
B. Click All Programs.
C. Click Tesla Powertrain Service Diagnostics
RAV4.
© 2014 Toyota Motor Sales, USA
Figure 8.
T-SB-0043-13
Rev1
March 18, 2013
Page 11 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Operation Procedure (Continued)
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
• Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm
battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE
16.0 volts during reprogramming.
• Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do
NOT add to or significantly change the vehicle’s electrical load while reprogramming.
• Confirm cable connections between the vehicle and Techstream PC are secure.
• Do NOT disconnect or turn off Techstream PC or vehicle ignition, and do NOT close Tesla
Powertrain Diagnostic program during reprogramming.
• Set parking brake.
• If the battery’s state of charge or capacity are in question, test with SST. No.
00002-V8150-KIT “Digital Battery Analyzer,” and follow Service Bulletin No. PG001-06,
“Battery Maintenance for In-Stock Vehicles & Pre-Delivery,” or the appropriate
“Maintenance for HV & Auxiliary Batteries” Service Bulletin.
• The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain
battery voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to
use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual located on
TIS, Diagnostics – Tools & Equipment – Battery Diagnostics.
D. Disconnect the Techstream DLC3 connector.
© 2014 Toyota Motor Sales, USA
Rev1
T-SB-0043-13
March 18, 2013
Page 12 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Operation Procedure (Continued)
E. Connect the RAV4 EV Diagnostic Cable (DLC3 No. 2 is located in the rear cargo area).
Figure 9.
Figure 10. Diagnostic Cable Connected
3
1
2
4
5
1
To Vehicle
2
DLC3 No. 2
3
CAT 5 Ethernet Cable
4
USB Ethernet Adapter
5
To PC
F. Confirm the communication light is green.
Figure 11.
© 2014 Toyota Motor Sales, USA
T-SB-0043-13
Rev1
March 18, 2013
Page 13 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Operation Procedure (Continued)
G. Click on the Firmware Download tab.
H. Click the Play button.
HINT
File will automatically download and be displayed on this screen. Please ensure PC is
connected to dealership wireless network.
Figure 12.
I. Verify the information displayed on the warning
message before proceeding.
Figure 13.
© 2014 Toyota Motor Sales, USA
T-SB-0043-13
Rev1
March 18, 2013
Page 14 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Operation Procedure (Continued)
J. The ECU Software Update will begin and take approximately 10 – 20 minutes to complete.
NOTE
Do NOT turn ignition OFF or disconnect the battery charger during this process.
Figure 14.
K. Click OK.
© 2014 Toyota Motor Sales, USA
T-SB-0043-13
Rev1
March 18, 2013
Page 15 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Operation Procedure (Continued)
L. Disconnect the Tesla Powertrain Diagnostic Cable and close the program.
M. Connect the Techstream DLC3 cable to the OBDII connector under the dash.
N. Perform a Health Check to confirm the firmware was installed correctly and to check for DTCs.
Figure 15.
© 2014 Toyota Motor Sales, USA
T-SB-0043-13
Rev1
March 18, 2013
Page 16 of 16
RAV4 EV ECU Flash Reprogramming Procedure
Operation Procedure (Continued)
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen, complete the Authorized Modifications Label
and attach to the vehicle. The Authorized Modifications Label is available through the MDC,
P/N 00451-00001-LBL.
Figure 16.
1
2
89690-42014
1.3.57
31301
3
3/1/13
4
T-SB-####-13
5
1
Replacement ECU Part Number
4
Date Completed
2
New Calibration ID(s)
5
Service Bulletin or Campaign Number
3
Dealer Code
B. Attach the label under the hood in the location determined by the specific Service Bulletin
or Campaign.
NOTE
Wait 60 – 90 seconds for ink to set before handling.
C. Test drive the vehicle to confirm proper operation.
© 2014 Toyota Motor Sales, USA