22TC11-bZ4X-Deal

TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN 22TC11
SOFTWARE UPDATE – DC COLD WEATHER CHARGING
CERTAIN 2023 MODEL YEAR bZ4X
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians
performing this repair are required to successfully complete the most current version of the E-Learning
course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair
performed correctly; technicians performing this repair are required to currently hold at least one of the
following certification levels:
• Expert Technician (Hybrid)
Always check which technicians can perform the repair by logging on to
https://www.uotdealerreports.com. It is the dealership’s responsibility to select technicians with the
above certification level or greater to perform this repair. Carefully review your resources, the technician
skill level, and ability before assigning technicians to this repair. It is important to consider technician
days off and vacation schedules to ensure there are properly trained technicians available to perform this
repair at all times.
I.
OPERATION FLOW CHART
The flow chart is for reference only. DO NOT use it in place of the full technical instructions. Follow ALL
steps as outlined in the full technical instructions to confirm the campaign is completed correctly.
Verify Vehicle Eligibility
1. Confirm vehicle VIN matches RO
2. Check Vehicle Inquiry System for
campaign eligibility
Not Covered
No further action required
Covered
Perform Health Check and Verify the
Calibration ID’s of the 5 ECU’s (2WD)
or 6 ECU’s (AWD) listed in the TI
Old Calibration
Download both ECU reprogramming
package files
Reflash applicable ECU’s for package 1
2WD – EV, MG(FR), BAT
AWD – EV, MG(FR), MG(RR), BAT
Perform verification Health Check and
clear any DTC’s
New Calibration
Reflash applicable ECU’s for package 2
2WD – PWC, A/C
AWD – PWC, A/C
Perform verification Health Check and
clear any DTC’s
Campaign complete.
Return the vehicle to the customer.
II. IDENTIFICATION OF AFFECTED VEHICLES
1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY
a) Compare the vehicles VIN to the VIN listed on the Repair Order to ensure they match.
b) Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Limited Service Campaign, and
that it has not already been completed.
NOTICE:
TMNA warranty will not reimburse dealers for repairs completed on vehicles that are not affected or
were previously completed, even by another dealer.
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III. PREPARATION
A. TOOLS & EQUIPMENT
•
•
•
Standard Hand Tools
• DCA-8000 Battery Diagnostic Station
T-SB-0134-16
• T-SB-0107-20
Techstream ADVi / Techstream 2.0 / Techstream Lite
IV. BACKGROUND
A software update has been developed for certain 2023 model year bZ4X vehicles. Included in the update is an
improvement of DC fast charging performance during low temperatures.
The software update will require reprogramming each of the following ECUs using Techstream: EV, MG, BAT, PWC
and A/C.
*C
for AWD
-
-
*1
PWC ECU
(ELECTRIC CONVERTER UNIT ASSEMBLY)
*2
MG ECU
(FR E-AXLE ASSEMBLY)
*3
MG ECU
(RR E-AXLE ASSEMBLY)
*4
BAT ECU
(EV SUPPLY BATTERY ASSEMBLY)
*5
EV ECU
(EV CONTROL ECU)
*6
A/C ECU
(AIR CONDITIONING AMPLIFIER ASSEMBLY)
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V. SAFETY PRECAUTIONS
CRITICAL INFORMATION - READ THOROUGHLY
An ECU could be damaged if an error occurs in the communication while reprogramming the ECU. Confirm all work
is performed as described in these instructions.
1. CONFIRM TECHSTREAM IS THE LATEST VERSION
2. CONFIRM D/C CUT (30A) FUSE HAS BEEN INSTALLED
a) In order to perform ECU reprogramming the cut fuse must be in location *b. If Pre-Delivery Service (PDS) was
not performed on the vehicle, please remove cut fuse from location *a and install into location *b.
*1
*a
Relay Block
Remove D/C CUT FUSE (30A)
*b
Install D/C CUT FUSE (30A) (Original Location)
3. STABILIZE THE POWER TO THE PERSONAL COMPUTER SIDE
a) Be sure to connect the personal computer to an external AC power
supply.
NOTICE:
The ECU could be damaged if the battery voltage of the personal
computer drops while reprogramming.
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b) Turn off the screen saver and power saving mode of the personal
computer so that the power to the hard disk is kept supplied.
NOTICE:
If the screen saver or power saving mode launches while
reprogramming, the communication may be disconnected,
resulting in the damage of the ECU.
c) DO NOT block the ventilation opening for the cooling fan of the
personal computer.
NOTICE:
If the ventilation opening for the cooling fan is blocked with a
sheet cover or the like, the personal computer may be heated
excessively, causing the operation of the personal computer to
stop.
Due to the stop of the operation, the communication for
reprogramming signals could be stopped, resulting in the damage
of the ECU.
VI. CALIBRATION ID VERIFICATION
1. CHECK FOR DTC’S
a) Using a Techstream, perform a Health Check to check for any
Diagnostic Trouble Codes.
NOTICE:
This Campaign covers only the software update to the ECUs
detailed in these instructions. It does not cover the diagnosis or
replacement of any other systems on the vehicle.
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2. CHECK CURRENT CALIBRATION
a) Locate the calibration ID of the ECU’s that require reprogramming to determine if an update is available.
b) Determine the status of an available update; indicated by a YES or NO.
HINT:
If the CID’s indicate ‘Yes’, proceed with the update procedure.
The ECUs that require reprogramming
(●: Require, -: Do not require)
Drive Type
EV ECU
(EV)
MG ECU
(Motor
Generator)
MG ECU
(Rear Motor
Generator)
BAT ECU
(EV Battery)
PWC ECU
(Plug-in
Control)
A/C ECU
(Air
Conditioner)
2WD
AWD
●
●
●
●
●
●
●
●
●
●
●
*1
EV ECU
*2
MG ECU
*3
MG ECU (Only for 4WD models)
*4
BAT ECU
*5
*6
PWC ECU
A/C ECU
Notice: You will need to scroll the ECU menu to find all ECU cals.
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Drive
Type
2WD
AWD
Calibrations
System
Current
Calibration ID
EV
8A2524237000
8A2524224200
Motor Generator
8A2814201200
898844236000
EV Battery
8989F4204100
8989F4601100
Plug-in Control
892634212000
892634218000
Air Conditioner
8865F4213002
8865F4213100
EV
8A2524238000
8A2524225200
Motor Generator
8A2814202200
898844237000
Rear Motor
Generator
8A2914201200
898844238000
EV Battery
8989F4210100
8989F4210200
Plug-in Control
892634212000
892634218000
Air Conditioner
8865F4213002
8865F4213100
NEW
Calibration ID
Reprogramming Package File
8A2524224200 / 898844236000 /
8989F4601100
892634218000 / 8865F4213100
8A2524225200 / 898844237000 /
898844238000 / 8989F4210200
892634218000 / 8865F4213100
VII. DOWNLOAD ECU REPROGRAMING PACKAGE FILES
1. Download and save the two
reprogramming package files (.cuw)
applicable to the vehicle.
o
o
2WD Package 1 (EV, MGFR, BAT)
2WD Package 2 (PWC, A/C))
o
AWD Package 1 (EV, MGFR, MGRR,
BAT)
AWD Package 2 (PWC, A/C).
o
*a
Image of the Package (CUW) File
Configuration
*b
Package (CUW) File #1
*c
Package (CUW) File #2
a) The CUW file is a package file that contains
several programs that reprogram ECUs, and
one CUW package is capable of
reprogramming multiple ECUs successively
NOTICE:
All the ECUs must be reprogrammed.
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◄ CRITICAL MESSAGE ►
It is critical that T-SB-0134-16 and T-SB-0107-20 in addition to the Technical Instructions for this LSC are followed.
This TSB outlines all steps necessary to prevent reprogramming failure. Toyota will not provide reimbursement coverage
for reprogramming failures if this TSB is not followed. If you have a reprogramming failure that requires ECU
replacement and the Technical Instructions and TSB were followed correctly, please create a case with the Technical
Assistance Hotline documenting all information related to the failure. If sufficient reporting is received related to re-flash
failure, there will be consideration for reimbursement.
VIII.
VEHICLE PREPERATION
1. PLACE VEHICLE IN “POWER ON”, “READY OFF”
a) Press the power button until “POWER ON” and “Not Ready to Drive” is displayed on the dash
2.
CONFIRM ALL ELECTRICAL LOADS ARE OFF
• Vehicle in the IG position
•
(READY OFF).
•
• Transaxle in Park.
• Parking brake engaged.
•
Turn off all electrical accessories (i.e. climate control,
audio system, etc.)
Headlight switch in the DRL OFF position. (w/ DRL
OFF position)
Windshield wiper switch in the OFF position.
a) When the vehicle has no “OFF position” in the light control switch:
1) Turn the IG ON.
2) Set the light control switch to the AUTO position and make sure
that the exterior lights are turned on.
3) Light up the automatic light control sensor with work light to
keep the exterior lights turned off.
3. CONNECT THE 12V BATTERY TO A POWER SUPPLY
a) Connect the DCA-8000 or other type of a power supply (not a battery charger) to the 12 V battery.
b) Tap the Reflash icon from the Main Menu screen of the DCA-8000.
A power supply MUST be used during reprogramming. ECU damage will occur if the battery
voltage is not properly maintained during this re-flash procedure. This procedure takes 2 hours
with the vehicle on and battery power supply is crucial.
NOTICE:
A power supply must be connected directly to the 12V battery terminals and NOT the remote jump posts
under the hood (if equipped).
4. VERIFY TECHSTREAM SETUP
a) Verify that the Techstream meets the following conditions:
• The latest version of software is loaded.
• The Techstream battery is fully charged. If not, connect the Techstream to a 120 V source.
• The DLCIII cable is in good condition.
7
The Techstream’s battery voltage must also be maintained during the re-flash procedure. Plug
the Techstream into a 120 v outlet during this procedure. This procedure takes 2 hours with the
Techstream on and the battery power supply is crucial.
NOTICE:
If the Techstream communication with the vehicle fails during the re-flash procedure, the ECU will be
damaged.
IX. UPDATE CALIBRATION
NOTICE:
While reprogramming, keep IG ON. Never turn the IG off or ENGINE-START.
As reprogramming completes in approximately a maximum of five minutes per ECU, stay near the vehicle and
DO NOT allow anyone to operate the vehicle or Techstream in order to prevent troubles from occurring.
Pressing the “Cancel” button or the “X” button on the top right means to cancel reprogramming and could
damage the ECU while reprogramming. Be sure to press “Retry” to continue reprogramming.
1. DOUBLE-CLICK THE DOWNLOADED PROGRAM PACKAGE
a) Start reprogramming with package 1
b) When all reprogramming steps are completed for package 1 you
will restart the process with package 2
2. IF THE SCREEN ON THE LEFT IS DISPLAYED, CLICK “CURRENT
CUW”
3. LAUNCH CALIBRATION WIZARD
a) Select Next
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5. SELECT A DEVICE TOOL
a) Select “Next”
6.
CONFIRM THAT EACH “NEW CAL ID” IS CORRECT, AND
THEN CLICK ON “NEXT”
a) Refer to calibration and reprogramming ID list in section VI step 2
7.
FOLLOW THE ON-SCREEN INSTRUCTIONS
8.
FOLLOW THE ON-SCREEN INSTRUCTIONS
NOTICE: DO NOT turn the IG ON with the brake pedal depressed.
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9.
PERFORM SECURITY SIGNATURE TO THE SERVER
a) Follow the instructions on screen
Hint: The reprogramming will not begin without the security
signature
10. LOG IN TO TIS
a) Input TIS login credentials and select “Login”
Note: This step requires internet.
11. PERFORM SECURITY SIGNATURE TO THE SERVER
a) Input TIS login credentials and select “Login”
12. PERFORM SECURITY SIGNATURE TO THE SERVER
a) Select “Send”
13. COPY SIGNATURE FROM TIS
a) Select “Copy to Clipboard”
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14. PASTE SIGNATURE INTO TECHSTREAM
a) Select “Next”
15. DUE TO COMMUNICATION BETWEEN ECUs BEING LOST
DURING REPRGORAMMING THE HEADLIGHTS MAY
TURN ON AS A FAIL-SAFE.
a) Do not cover the headlights
b) If the headlights turn on they cannot be turned off
16. RECALIBRATION WILL NOW BEGIN
Notice: Only one ECU in the package will be reprogramed at a
time.
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17. CALIBRATION UPDAED
a) The following Screens will appear at the end of each reflash.
b) Press a key or operate the mouse to close the window.
18. REPEAT PROGRAMMING STEPS FOR EACH CAL ID IN THE PROGRAM PACKAGE
a) The IG OFF and ON operation and the security signature verification need to be conducted whenever the
Calibration process finishes. Follow the instructions shown on the screen.
19. AFTER REPROGRAMMING, MAKE SURE THAT THE
“CURRENT CAL ID” IS CORRECT
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20. USE THE CHECKSHEET TO TRACK UPDATES AND
CONFIRM ALL CAL IDs HAVE BEEN UPDATED
a) Check the corresponding box off on the check sheet as the
reprogramming has finished. (Make a copy of the applicable
check sheet located in the appendix and use it)
*a
DO NOT skip reprogramming.
X. SEND VEHCILE INFORMATION
1. PERFORM VERIFICATION HEALTH CHECK
a) Using a Techstream, perform a Health Check.
b) Clear DTC’s that may have set during the re-flash procedure.
c) Re-run the Health Check to confirm that no DTC’s reappear.
THIS VERIFICATION HEALTH CHECK IS
NECESSARY to update the results and CID’s
to the National database.
2. COMPLETE ECU UPDATE AUTHENTICATION
a) Input TIS Credentials
HINT: Health check will complete once TIS credentials have been entered
Repeat the programming steps for the remaining ECUs (systems) using the downloaded
reprogramming package 2 (.cuw) files.
Performed Task
Next Action and Reference
Reprogram the remaining ECUs with the package 2
Reprogramming the ECUs
(.cuw) files.
with the package 1 (.cuw) files Go to “IX. UPDATE CALIBRATION”.
Completed reprograming with
both CUW packages. (.cuw)
file
ECU reprogramming is complete.
Go to “XI. COMPLETE REPAIR”.
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XI. COMPLETE REPAIR
1.
a.
COMPLETE HEALTH CHECK AND CONFIRM CID UPDATE
On the Stored Data tab, confirm the following for each of the ECUs systems:
• The Calibration number has the “New CID” number.
• Refer to calibration and reprograming ID list in section VI. for new CID numbers
• The Update column lists “No”
Example of a Calibration ID that does not have an update available.
Confirm the CID's have been updated successfully to the NEW CID's by someone other than the
individual who performed the repair.
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17. PRINT CUSTOMER HEALTH CHECK REPORT
a. From the Stored Data tab, select the Customer Health Check Report button (TIS will launch when button is
pressed).
a)
b)
c)
d)
Log in to TIS.
Input Vehicle Mileage and Repair Order number.
Check the “Performed” campaign button for campaign 22TD05.
Select the Report button.
e) Confirm Customer Health Check Report information is correct.
f) Print Customer Health Check Report from TIS.
g) Sign and provide to the customer.
18. Disconnect DCA-8000
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−
−
−
◄ VERIFY REPAIR QUALITY ►
Confirm the ALL Calibrations have been updated successfully to the NEW CID.
− EV ECU
− A/C ECU
− PWC ECU
− BATT ECU
− MGFR ECU
− MGRR ECU (AWD ONLY)
Confirm there are no DTC’s after the Calibration update.
If you have any questions regarding this Campaign, please contact your regional representative
XII. APPENDIX
A. CAMPAIGN DESIGNATION DECODER
Examples:
19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019
20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020
21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021
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[Check Sheet] _2WD Models
17
[Check Sheet] _AWD Models
18