Flash Programming Failure Recovery (18-32-98)

SEQUENCE OF EVENTS OR WHAT OCCURS DURING REPROGRAMMING

The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures.

The process starts by selecting an update from the MDS2 or ISIS and then "loading" that update into the DRB III(R). Once the flash reprogramming update is loaded into the DRB III(R), and before the flash reprogramming begins, the DRB III(R) verifies that the update loaded from the MDS2 or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the MDS2 or ISIS) and has been selected for programming.

• The module is then placed into "Boot Strap" programming mode by the DRB III(R). This module mode gives the DRB III(R) permission and the ability to proceed with the flash reprogramming session.
• Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow.
• Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, will result in a non-responsive module (NR). A NR module is a module that is either partially erased or partially programmed.
• After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module.
• When reprogramming is completed, the flash memory is verified through an internal process in the DRB III(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming.
• Next, a DRB III(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off.
• After a slight pause, the DRB III(R) will prompt for the ignition switch to be turned ON. The DRB III(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully.

SOFTWARE VERSIONS MUST BE CURRENT

Before attempting a flash reprogramming session using MDS2, make sure you have the most current software installed. Update CDs are sent to dealers on a biweekly schedule, roughly 25 each year.

To verify whether your MDS2 software is current, check the upper right-hand corner of the MDS2 screen. The installed CD number and date are listed. In general, if the date is older than 3 weeks, a newer CD is available. (Often the TSB will state that MDS2, ISIS, or DRB III(R) must be at a certain release level or higher before attempting a specific flash reprogramming session.)

To verify whether your DRB III(R) software is current, check the upper right-hand corner of the MDS2 screen. The installed DRB III(R) available software is also listed along with the MDS2 information.

Two items: (1) If the MDS2 software is "out-of-date" it is possible that the DRB III(R) software is not current either. (2) Check the software on your DRB III(R) against the supported version on the MDS2.

Often, because of multiple DRB III(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6,2,5 from the DRB III(R) Main Menu and comparing it to what is available from a current MDS2 (See above).

If the MDS2 is current and the DRB III(R) is not, it may be due to the fact that the MDS2 does not force DRB III(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your MDS2 and DRB III(R) must have the LATEST software revisions installed.

DO NOT PASS on the option for updating to a "minor" revision!

Major updates require the DRB III(R) to be updated prior to allowing any flash programming.

DRB III(R) CABLES

Replace all suspect cables. 

An unserviceable DRB III(R) cable is an open invitation to a FAILED FLASH session! Inspect cables for loose connections, bad connectors, damaged pins and general wear and tear. When connecting the DRB III(R) cable, it is very important to insure that both the vehicle end and the DRB III(R) end of the cable are securely seated and that the locking devices at each end are working properly. If a latch or spring clip is not functioning, the cable could become partially or fully disconnected during the flash session.

Use the 8-foot cable part number CH7000 rather than the 12 foot CH7001 cable. A shorter cable has, at times, during validation testing, proved more successful than the long cable.

The 2-door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7010 cable (Pre-OBDII vehicles will use the CH7005 cable).

MDS2 CABLE (GPIB)

Replace any suspect GPIB cable. 

The GPIB cable provides the connection between MDS2 and the DRB III(R). This cable is used by the MDS2 for vehicle part number reads and to send update files to the DRB III(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the MDS2.

ISIS NULL MODEM CABLE

Replace any suspect null modem cables. 

International (ISIS), a PC-based CD program similar to MDS2 uses a null modem cable for vehicle part number reads and to send update files to the DRB III(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files.

GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS

Consider ALL cables to be wear items. 

Many successful dealers have dedicated cables devoted to "Flash ONLY".

Always have spare CH7000, CH7010 and GPIB or null modem cables available.

Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions.

ST22 SEBRING STRATUS 2-DOOR COUPES (2001-2003)

These vehicles use MMC based modules. The 8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from MDS2 to the SRT for flash reprogramming sessions on these vehicles.

PREPARING TO FLASH

It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming events at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRB III(R) or do something on the vehicle that could interrupt the flash process.

Before starting the flash session, read, record and erase all DTCs found on the vehicle.

Be sure to arrange the MDS2 and DRB III(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRB III(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRB III(R)s have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch).

Check User settings on the DRB III(R). From the DRB III(R) Main menu, press 6, 1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur.

VEHICLE BATTERY VOLTAGE

The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the flash reprogramming event. IF you are unsure of the vehicles capability to handle this load, connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming event. This will help to prevent unwanted resets by either the DRB III(R) and/or the vehicle module that are caused by voltage fluctuations.

Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed.

CONNECTED MODE FLASHING (USING MDS2)

In this mode, the DRB III(R) remains connected to the MDS2 and the vehicle throughout the flash session. The DRB III(R) is connected to the MDS2 using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000 for most vehicles).

This mode is useful when the MDS2 is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button and then selecting "Show Updates".

Again, it is important that other users do not attempt to reboot or move the MDS2 while a flash is in-progress.

The reprogramming procedure of this mode is initiated by selecting the "Update Controller Software" button on the MDS2.

DISCONNECTED FLASH MODE

This mode allows a user to flash a vehicle without being connected to the MDS2. This is a popular mode for flashing in a remote area of the service garage or in a back lot.

Before you attempt to use this mode, you must configure the DRB III(R) for the desired update(s). To do this, you must connect the DRB III(R) to the MDS2 using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the MDS2 (for update file downloading) while the CH7025 cable is used to provide power to the DRB III(R).

After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download Software to DRB" button on the MDS2. Obviously, the DRB III(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the MDS2 screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again.

When the updates have finished downloading, you may disconnect from the MDS2 and take the DRB III(R) to wherever the vehicle is located. The updates will remain in DRB III(R) memory for 8 hours while the DRB III(R) is without power. If the DRB III(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRB III(R) for another 8 hours without power.

To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7" from the Main Menu on the DRB III(R). Step by step instruction will follow on the DRB III(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRB III(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box".

PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES

Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on MDS2, this can be of great assistance when trying to flash a module. If the files selected don't download on the first try, try again.

The technician should NOT leave the vehicle when flash reprogramming a module. 

Again, check to make sure that all cable connections are secure and that the DRB III(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened.

Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed.

Pay special attention to DRB III(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRB III(R) instructions.

Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred. If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position then back ON). Reset the DRB III(R) (power down for 3 seconds and then power up) before attempting to restart the flash process.

Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRB III(R) instructions were followed, perform the following:

• "Cold boot" the DRB III(R). This removes the problem flash file from the DRB III(R). (Push MORE and YES buttons at the same time, then press F4)
• Reload the flash update file from the MDS2.
• If it fails to complete in the connected mode, first reboot the MDS2 before re-attempting the flash download to the DRB III(R).
• Proceed to reflash the module.

On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one.

After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed.

Verify the update by reading the new part number using the DRB III(R). A good double check is to read the part number using DRB III(R) stand alone.

ERROR MESSAGES

Block Echo/Compare Errors 

Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7000, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Review the sections on Vehicle Battery Voltage and Cable recommendations.

Checksum Errors 

Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRB III(R) memory problems. If the DRB III(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRB III(R). (To "Cold Boot", press the MORE and YES buttons on the DRB III(R), at the same time. Then press "F4"). Reload the flash update file(s) from the MDS2. If it fails to complete in the connected mode, first reboot the MDS2 before re-attempting the flash download to the DRB III(R). Then re-attempt the flash reprogramming process.

ABORT RECOVERY

Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process, after the erase phase has started, will render the control module to a non-functional state.

Generally, but not always, NR modules may be recovered successfully.

Briefly abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar the other sections in this document and follow all DRBIII(R) user prompts carefully.

Because a NR module is not able to provide the DRBIII(R) with ID information, the technician must do this when prompted by the DRBIII(R). Be patient when performing this process. Because the module does not respond to standard diagnostic request, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with the actual controller list (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine"). Because of module variations, it is important to correctly identify the PCM/TCM so the correct flash procedure will be used. Failure to do this will cause further problems and may damage the module. A table is provided below to help identify the proper module to select. This table correctly identifies the modules that were on the vehicles when they were built. However, some modules will have supersedence from parts. Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming.

One more note about key cycling. When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process.

General Steps for Abort Recovery 

1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section.
2. Cycle the Vehicle's ignition key to the LOCKED position and back to the RUN position.
3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable.
4. Depending of where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table as a guide.
5. After selecting the proper control module type, follow the prompts that are displayed on the DRBIII(R).
   NOTE: IF AN ERROR MESSAGE IS DISPLAYED AT THIS POINT, AN INCORRECT MODULE TYPE WAS MOST LIKELY SELECTED. IF THIS OCCURS, START THE PROCESS OVER.
6. If the recovery process is unsuccessful perform the following:
   1. Review all Tips and Techniques in this document.
   2. Reboot/Restart the MDS2.
   3. "Cold Boot" the DRB III(R). (Press the MORE and YES buttons on the DRB III(R) at the same time, then press F4).
   4. Start this process over from item #1. If using Disconnected Mode, the flash update will have to be reloaded from the MDS2 or ISIS.

The TCM Configuration Tables apply to vehicles that use an EATX/NGC/AW4 controller. Applications using the PCM module (JTEC/SBEC) for assisting transmission shifting or TCC operation are not listed since the transmissions are not fully electronic.

PROGRAMMABLE MODULES

Below are listed the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable.

POWERTRAIN MODULES - ENGINE AND TRANSMISSION

NON-POWERTRAIN CONTROL MODULES