TECHNICAL INSTRUCTIONS SAFETY RECALL 21TA04 – Potential Increased Braking Distance – 2020-2021 Toyota Supra

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© 2021 Toyota Motor Sales, USA ◄ IMPORTANT UPDATE ► The attached Technical Instructions have been updated. Refer to the details below. DATE TOPIC September 10, 2021 • A warning about not disturbing the vehicle while it is reprogramming has been added. The most recent update in the attached Technical Instructions will be highlighted with a red box. Please review this notification with your staff to assure that all relevant personnel have been briefed regarding this subject. Thank you for your cooperation. TECHNICAL INSTRUCTIONS SAFETY RECALL 21TA04 POTENTIAL INCREASED BRAKING DISTANCE CERTAIN 2020 – 2021 MODEL YEAR SUPRA VEHICLES The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this recall 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 recall repair are required to currently have completed all of the following courses: • TIN519B – GR Supra New Model Technical Introduction 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. 2 I. OPERATION FLOW CHART Install Latest version of Toyota ISTA Less than ISTA version 4.30.20.23876 Did Verify Vehicle Eligibility Check TIS Vehicle Inquiry System to verify vehicle eligibility Covered Not Covered No further action required Check Toyota ISTA Version At least ISTA version 4.30.20.23876 or higher Check Current I-Level Reprogram vehicle Lower than I-Level S18T-21-07-519 Check Current I-Level Campaign Completed Return Vehicle to Customer At least I-Level S18T-21-07-519 or higher At least version S18T-21-07-519 (or higher) Less than I-Level S18T-21-07-519 II. IDENTIFICATION OF AFFECTED VEHICLES • Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Campaign, and that it has not already been completed prior to dealer shipment or by another dealer. • TMS warranty will not reimburse dealers for repairs completed on vehicles that are not affected or were completed by another dealer. III. BACKGROUND The subject vehicles are manufactured by BMW. According to BMW, the subject vehicles have been equipped with an engine management software that, under certain specific engine start conditions, could damage a component that provides braking power assistance. In this condition, there could be a loss in the brake assist and an increase in stopping distance. This can lead to an increased risk of a crash. IV. PREPERATION A. TOOLS & EQUIPMENT • Techstream ADVi (TSADVUNIT) • Battery Diagnostic Tool (DCA-8000P) • Toyota Supra Diagnostic Cable (01018-00118) 3 V. OVERVIEW OF WORK PROCEDURE (REPROGRAMMING USING ISTA) Software inside the vehicle’s computers are reprogrammed using Toyota ISTA. Reprogramming of ECUs via Toyota ISTA requires that the software version of all the vehicle ECUs to be unified; therefore, reprogramming is always carried out for all ECUs. It is not possible to select a target ECU and then reprogram it individually. Always follow the directions of this document when carrying out reprogramming work in order to prevent any potential damage to the ECUs due to by communication errors, voltage drops, or other problems. VI. WORK PROCEDURE TABLE OF CONTENTS COMPONENTS ·································································································································································································· SECTION VII INSTALL THE LATEST VERSION OF TOYOTA ISTA ······························································································ SECTION VlII CHECK ISTA LANGUAGE SETTINGS ···································································································································· SECTION IX CHECK ISTA VERSION OF TECHSTREAM ADVi ······································································································ SECTION X ENSURE THAT VEHICLE HAS COMPLETED PRE-DELIVERY SERVICE ······································ SECTION XI PREPARE THE TECHSTREAM AVDi ········································································································································ SECTION XII PREPARE THE VEHICLE ······································································································································································ SECTION XIII CONNECT THE BATTERY CHARGER ···································································································································· SECTION XIV CONNECT THE TECHSTREAM ADVi TO THE VEHICLE ·················································································· SECTION XV CHECK THE I-LEVEL ················································································································································································ SECTION XVI PERFORM THE REPROGRAMMING (UPDATE I-LEVEL) ················································································ SECTION XIII DISCONNECT TOYOTA ISTA ···························································································································································· SECTION XVII PLACE VEHICLE IN SLEEP MODE FOR 15 MINUTES ························································································ SECTION XIX VII. COMPONENTS ENGINE CONTROL COMPUTER UPDATE THE I-LEVEL TO: S18T-21-07-519 (OR GREATER) 4 VIII. INSTALL THE LATEST VERSION OF TOYOTA ISTA A. INSTALL THE LATEST VERSION OF TOYOTA ISTA 1. It is CRITICAL to install the latest version of Toyota ISTA on the Techstream ADVi. Your current ISTA version may not be sufficient for this campaign. Minimum* ISTA Version Required for this Campaign: 4.30.20.23876 *Versions of ISTA higher than 4.30.20.23876 are also acceptable. As a best practice you should always download the latest version of ISTA before performing this campaign. 2. Access this URL for instructions on how to download the latest version of ISTA: Toyota ISTA Installation Instructions IX. CHECK ISTA LANGUAGE SETTINGS A. CHECK ISTA LANGUAGE SETTINGS 1. The screenshots in this document were developed using ISTA software configured for “American English”. 2. It is recommended that you ensure your ISTA is configured for “American English” (rather than “British English”) so that the screenshots match your screen. 3. Double-click the icon to start Toyota ISTA. Note: After double-clicking, it takes about 15 seconds for Toyota ISTA to start. Please wait without double-clicking again. 4. The following screen appears. Click “Accept”. 5 5. Click on the Configuration Button as indicated in the illustration. 6. Click on the Client settings tab as indicated in the illustration. 7. Select “American English” 8. Click “OK” 9. ISTA may require a restart for the language change to take effect. 1 2 3 4 6 X. CHECK ISTA VERSION OF TECHSTREAM ADVi A. CHECK ISTA VERSION OF TECHSTREAM ADVi 1. Its CRITICAL to confirm that the ISTA version installed on your Techstream ADVi meets or exceeds version 4.30.20.23876 before proceeding. Your current ISTA version may not be sufficient for this campaign. 2. Double-click the icon to start Toyota ISTA. Note: After double-clicking, it takes about 15 seconds for Toyota ISTA to start. Please wait without double-clicking again. 3. The following screen appears. Click “Accept”. 7 4. Click on the Configuration Button as indicated in the illustration. 5. Click on the Version status tab as indicated in the illustration. 6. Compare the installed verison to the minium reuqired version: 4.30.20.23876. If the version is less than version 4.30.20.23876, install the latest version. XI. ENSURE THAT VEHICLE HAS COMPLETED PRE-DELIVERY SERVICE Make sure that Pre-delivery Service has been completed before this reprogramming. If Predelivery service has not been completed before this reprograming, the reprogramming may not be completed correctly. Refer to T-SB-0083-19 (2020 model year Supra) or T-SB-0038-20 (2021 model year Supra) for Pre-delivery technical instructions. XII. PREPARE THE TECHSTREAM AVDi 1. Ensure the Techsteam software is installed, registered, and up to date 2. Complete all pending Windows updates. 3. Disable any automatic Windows updates and configure antivirus software so that it doesn’t automatically run. 4. Disable all automatic screen savers. 5. Disable “sleep mode” within windows power settings. 6. Close all other applications. 7. Attach the Techstream ADVi directly to an AC Power Supply. 8. DO NOT perform any other functions while Toyota ISTA is reprogramming. 8 XIII. PREPARE THE VEHICLE A. PREPARE THE VEHICLE During reprogramming, each system (lights, mirrors, seats, windows, etc.) will be operated automatically for initialization. If operation is obstructed, a fault code is recorded, and the initialization may not finish normally. To prevent this, follow each instruction displayed on the screen while carrying out work. 1. Before working, make sure the vehicle is parked in a flat location that is not subject to direct sunlight. 2. The ambient temperature has to be higher than 59° F. 3. Allow the temperatures of the engine, transmission, and brake system to fall to the ambient temperature. 4. Set the steering wheel and tires straight ahead position. 5. DO NOT place anything on the windshield so that the wiper can work normally, because the wiper may move automatically during reprogramming for initialization. 9 6. Remove all the inserted and connected data carriers from the vehicle and disconnect the data connections (e.g. Bluetooth paired mobile phones), so they DO NOT interrupt programming by communication or connection. 7. DO NOT place anything on, in front of, or behind the front seats because the front seats move automatically during reprogramming for initialization. 8. DO NOT cover the headlights with protective covers, because temperatures may rise, and the headlights may be deformed or damaged. 9. Set the shift lever to “P”, and then engage the parking brake. 10. Turn off the engine, and set all of the switches of the electrical components to off. 11. Close all doors and the back door, the hood must remain open as the battery charger will need to be connected to the charging terminals during the reprogramming process. 10 XIV. CONNECT THE BATTERY CHARGER A. CONNECT A BATTERY CHARGER 1. Connect the specified battery charger at the locations in the illustration. Battery Charger Mode Voltage Battery Type DCA-8000 Power Supply Mode 13.5-14.6 AGM Before starting the reprogramming procedure, please make sure you have connected the DCA-8000 battery charger. The usage of a charger during the ECU Software update process is mandatory. During this reprogramming the headlights will turn on, and the seats and other electrical components will function. To prevent damage to the ECU’s, due to flat battery or voltage drop, ALWAYS connect the specified battery charger. • Unlike other Toyota vehicles, the Toyota Supra is capable of drawing high amperage (a peak of 70 Amps flows at maximum) during diagnosis and repair. The Toyota Supra is equipped with an AGM type battery, discharges will affect the life span of the battery. AGM batteries must not have a charging voltage that exceeds 14.6 volts. • Always connect the power supply of the battery charger to an outlet directly. If a power strip or other device is used, and multiple electrical components are connected, the battery charger may detect a power supply error due to insufficient current, and it may not be possible to charge the battery. • Make sure that the battery charger is off before connecting it. • Make sure you respect the correct polarity when connecting the battery charger cables like displayed in the illustration below. • DO NOT disconnect the battery charger during reprogramming work. • Observe the instructions of the battery charger manual, and check the dealership electrical system to ensure the circuit of the outlet to be used can operate the battery charger. 11 XV. CONNECT THE TECHSTREAM ADVi TO THE VEHICLE NOTICE: It is an absolute necessity that the vehicle is connected to the Techstream ADVi via the Toyota Supra Diagnostic Cable which has a LAN ethernet connection. In order to maintain successful communication between the Techstream ADVi and the vehicle, the Toyota Supra Diagnostic cable must be used. Other interfaces that connect to the Techstream ADVi via USB are not allowed. Attempting to use such other devices may cause permanent ECU damage due to the slower communication speed. A. CONNECT THE CABLE (connection sequence): 1. Always connect the Supra diagnostic cable first to your PC LAN port (1) and only after that to the OBD port of the vehicle (2). If this order of operations is not respected, possible vehicle communication issues may occur when using Toyota ISTA software. B. POSITION THE CABLE 1. Position the SUPRA diagnostic cable out of the vehicle as shown in the illustration. Otherwise the SUPRA diagnostic cable may be pinched, communication disconnected, and ECU’s permanently damaged. 2. The Toyota Supra Diagnostic cable should always be passed through the position shown in the figure below. If it passes through any other position it is possible that the cable will be damaged. 3. Using the gap between the rear fender and the side garnish, pull the Supra Diagnostic cable to the outside of the vehicle. Please use protective tape for fixation and protection of the cable. 12 Note:  DO NOT attempt to pass the ISTA diagnostic cable though the window opening. The window glass may move during reprogramming or initialization.  Ensure the cable is out of the path of the front Driver’s seat. During initialization the driver’s seat moves and could damage cable or disconnect the OBDII connector during movement.  Additionally, DO NOT attempt to pass the ISTA diagnostic cable through any other position of the door opening as it may cause damage to the cable. 13 XVI. CHECK THE I-LEVEL A. START TOYOTA ISTA 1. Double-click the icon to start Toyota ISTA. Note: After double-clicking, it takes about 15 seconds for Toyota ISTA to start. Please wait without double-clicking again. 2. The following screen appears. Click “Accept”. 14 3. Double-click the operations bar to maximize screen and make the toolbar visible. B. ACTIVATE PAD MODE 1. PAD mode can be activated by pressing the start button 3 times in under 0.8 seconds (very fast, foot off the brake pedal) or by directly connecting the Toyota ISTA software and initiating the vehicle connection. Note: Ensure the pre-delivery service has already been completed on the vehicle. Part of pre-delivery service involves switching of “transportation mode”, which is required before proceeding with this remedy procedure. While the vehicle is in PAD mode all energy monitoring logic will be disabled. The technician must utilize a battery charger to maintain sufficient current during all diagnosis and programming activities. If the battery charger is not connected battery life will be affected and ECU damage could occur. DO NOT open or close the driver’s door during the programming routine. Perform only the vehicle operations indicated on the Toyota ISTA screen. 15 B. NAVIGATE TO I-LEVEL CHECK SCREEN 1. From Toyota ISTA home screen, click “Cases”-> “New” -> “Read out vehicle data”. 2. At the bottom right of the screen, click “Full identification”. 16 3. At the “Connection manager” screen, select the vehicle identification number, and then click “Establish connection”. 17 4. “Background process is being carried out” is started automatically. Note: If the following “Information” dialog box is displayed, click “OK” to continue. 18 5. After clicking “OK”, “Background process is being carried out” continues. 6. “Reading vehicle data” may be displayed 19 7. After “Background process is being carried out” has ended, the “Control unit tree” screen appears. Note: When Fault memory “Present” or “Existing” is displayed at the bottom left of the screen, check for DTCs. Note that this campaign does not cover the diagnostic fees and/or repairs for any DTC’s. 20 Note: If the dialog box in the image appears when the screen changes to “Control unit tree” screen, click “OK” to close the dialog box, and then continue work. Toyota ISTA will attempt to establish a data exchange with the central server. In the absence of an available connection route (because of no Internet connection is available or the PC connection isn’t setup), Please verify your connection and click “OK”. 21 C. CHECK I-LEVEL 1. Select “Vehicle details”. 2. The “Vehicle details” screen appears. Check the displayed “Current I level:”, and then refer to the table below to determine if the vehicle requires reprogramming. 3. Confirm if the vehicle requires reprogramming based upon the “Current I-Level” of the vehicle. Use the decoder below. Result “Current I-Level” of Vehicle Required Action NG Lower than S18T-21-07-519 REPROGRAMMING REQUIRED. Continue with this procedure. OK Equal to or Greater than S18T-21-07-519 WORK IS COMPLETE. Reprogramming is not required. Refer to page 34 for instructions on closing out of ISTA and disconnecting the diagnostic cable. How to Decode I-Level Superiority 1: Series (vehicle model) 2: Year Released 3: Month Released 4: Serial Number EXAMPLE: Lower: S18T-19-03-585 Higher: S18T-19-07-555 In the example, S18T-19-07-555 is higher than S18T-19-03-585 because it was released in a later month (July compared to March). I-Level: 22 XVII. PERFORM THE REPROGRAMMING (UPDATING I-LEVEL) A. PERFORM THE REPROGRAMMING 1. Perform the reprogramming if the vehicle’s current I-Level is lower than S18T-21-07-519. 2. Select “Service plan” – > “Programming plan”. 3. The screen changes to the “Action plan” screen and “Please wait” message appears. 4. After the “please wait” message closes and the screen changes, click “Perform action plan”. Note: After clicking “Perform action plan”, carry out the on-screen instructions of Toyota ISTA reliably. 23 If you see the following screen during reprogramming: DO NOT SWITCH OFF THE IGNITION DO NOT DEACTIVATE PAD MODE DO NOT DISCONNECT THE BATTERY CHARGER DO NOT OPEN ANY DOORS OR INSERT ANY SEAT BELTS DO NOT DISCONNECT THE DIAGNOSTIC CABLE Leave the car as is, and call TAS (Technical Assistance). If for any reason during the reprogramming, you believe the update is “frozen” or has otherwise failed: DO NOT TURN THE IGNITION OFF DO NOT DISCONNECT THE BATTERY CHARGER DO NOT OPEN ANY DOORS DO NOT DISCONNECT THE DIAGNOSTIC CABLE Leave the vehicle as is and call TAS for assistance. TAS will likely be able to help you recover the vehicle. Ignore these instructions from ISTA if they happen to appear. Follow the instructions above instead and CALL TAS. 24 5. “Executing measures plan” appears the top middle of the screen (header line). Check the content that is displayed in the “Information” dialog box, and then click “OK”. 6. “Warning!” and “Notice!” will be displayed in the “Attention!” dialog box. Check the content in the dialog box, and then click “Continue” to continue the “Action plan”. 25 7. Please check carefully the content displayed in the “Preparation for the vehicle programming” dialog box, and then click “Continue”. 26 The programming could take a long time. DO NOT disturb the vehicle until it’s finished reprogramming. Refer to the progress bar at the top of the screen to confirm the status. if you truly believe there is some problem with the vehicle reprogramming, DO NOT DISTURB THE VEHICLE, call TAS for assistance. The combination meter will turn off during reprogramming and the vehicle may look like it has been powered off. DO NOT press the Start/Stop button. Refer to ISTA for programming status. DO NOT put your head or hand in the window of the vehicle you are reprogramming. Since the window may close automatically at the time of initialization, there is the risk of being be pinched and injured. DO NOT open or close the driver’s door during the programming routine. The programming could take a long time. Ensure that the vehicle is not accidentally disturbed by other team members during the reprogramming. 27 8. The top middle of the screen (header line) switches to “Saving individual data”. “Save individual data HU-H” is executed first. If it completes normally, a checkmark (✓) is displayed in the “Status” column. Note: The icons in the diagram indicate the status. 28 9. The top middle of the screen (header line) switches to “Executing Software actions”. When “Warning” dialog box appears, click “OK”. 29 10. The reprogramming progress status of each ECU is displayed in the “Status” column. The overall progress status of reprogramming is indicated by “Executing software actions” at the top center of the screen (header line), which shows the reprogramming progress status and approximate “Remaining time”. • Even when the “Status” column is filled with checkmarks (✓), always check the display at the top center of the screen (header line) for the progress status, because initialization and other work is being carried out in addition to reprogramming. • Wait until the reprogramming in finished before manipulating the ISTA software to avoid interfering with the reprogramming. 30 11. “Executing follow-up operations” is displayed in the center of the screen (header line). Note: If the following “Information” dialog box is displayed during “Executing follow-up operation”, click “OK” to continue the follow-up operation. After reprogramming is complete, follow the on-screen instructions and carry out initialization and other work. 31 Note: If the following dialog box appears, click “OK”. 12. “Calculating final context” appears at the center of the screen (header line). At the same time, a “Please wait….” message appears to allow for the completion of the action plan. 32 13. After the “Status of action plan implementation” dialog box appears, click “OK”. 33 14. NOTICE: After reprogramming has completed Toyota-ISTA may request additional functions to complete. These additional functions may include initialization of seats, windows, mirrors or headlights. Toyota-ISTA may provide instructions such as ensuring there are no obstructions of the object that requires initialization. Please follow all necessary on-screen prompts and ensure that the vehicle is parked in a safe manner to complete each initialization. If these directions are not followed properly, the vehicle could produce additional DTCs. In the example shown below, the “ride height sensors: start-up” service function” needs to be performed. If ride height is required, you will need to insert the ride height for both the front and rear wheels. This will require you to measure this height in millimeters. The repair manual procedure can be found in this location: Vehicle Exterior > LIGHTING (EXT) > HEIGHT CONTROL SENSOR > INSTALLATION 5. ADJUST HEIGHT CONTROL SENSOR (DOC ID: RM100000001JCL5) 34 15. Click on “Action plan” 16. Check the I-Level. Make sure that the “(current)” and “(target)” I-Levels are equal. 35 17. Ensure the current I-Level meets or exceeds S18T-21-07-519. 18. If the I-Level does not meet or exceed S18T-21-07-519, go to Section X to confirm that you are using the proper version of Toyota ISTA. XVIII. DISCONNECT TOYOTA ISTA A. CLOSE OUT OF TOYOTA ISTA 1. Select “Cases” -> “Active” to display the “Case list”. 2. Confirm the vehicle information is correct, and then click “Close case”. Ensure the current I-Level meets or exceeds S18T-21-07-519 36 3. When the “Open actions in action plan” dialog box appears, click “Yes”. 37 4. Make sure that the frame of the icon at the left end of the toolbar at the top left of the screen has turned gray, and then click “×”. 5. You may have to click the frame icon in the left end of the tool bar in order to close the case. 6. Click “OK” when the “Close program” dialog box appears. 38 7. Open the driver-side door, press the Start/Stop button once, and then close the door. Note: PAD mode is turned off, and the headlights are turned off by opening the driver-side door, pressing the Start/Stop button once, and then closing the door. 8. Disconnect the ISTA diagnostic cable and battery charger. XIX. PLACE VEHICLE IN SLEEP MODE FOR 15 MINUTES A. Place vehicle in sleep mode for 15 minutes 1. It is necessary to place the vehicle in sleep mode for 15 minutes to allow the KOMBI and fuel tank ECU to establish the correct size of fuel tank. 2. Sleep mode can be activated by shutting all the doors, hood, trunk and parking the vehicle for 15 minutes with keys away from the vehicle. XX. CAMPAIGN DESIGNATION DECODER 19 19 = 2019 20 = 2020 21 = 2021 22 = 2022 23 = 2023 Etc… Year Campaign is Launched 19TA01 T T = Toyota L = Lexus Vehicle Make A A = Safety Recall Remedy B = Safety Recall Interim C = Special Service Campaign D = Limited Service Campaign E = Customer Support Program (May use other characters in unique cases) Field Action Category and Phase 01 01 = 1st Field Action of the year 02 = 2nd Field Action of the year 03 = 3rd Field Action of the year (The sequence is unique for each Field Action category) Field Action Sequence 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 ◄ VERIFY REPAIR QUALITY ► • Confirm the I-Level meets or exceeds S18T-21-07-519. This Safety Recall is not considered compelted untli the I-Level of the vehicle is S18T-21-07-519 or greater.

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