Re-work Information - PTC Service

Re-work Information - PTC Service
Important information:
1. Disconnect 12V Battery before starting retro fit procedure.
2. Firmware must be loaded into controllers “in order” specified, failure
to follow instructions damages controllers and are no longer usable.
(VCU’s and CDCM’s are expensive)
4. Do not connect PTC HV – High Voltage Connection to PCU or LV – Low
Voltage Connection until programming is complete.
(VCU’s and CDCM’s are expensive)
3. Make sure Anti-freeze is completely evacuated from heater core prior
to removal, big mess to clean up in drivers side foot well.
PTC Retro-fit Instructions 10-15-2012
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Re-work Information - PTC Service
PTC Service Design, HV Layout:
PTC Service
Design!
PTC
Cabin
Compartment
Motor
Compartment
PTC Retro-fit Instructions 10-15-2012
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• PTC Heater Kit
– PTC Heater Assembly
– Jumper wire, replaces relay
– Plastic connector to replace
“T” in cooling system
– Yellow control wire
– Coolant recovery device, this
is a cheap plastic 5 gallon
bucket and shop vacuum.
PTC Retro-fit Instructions 10-15-2012
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• Tools Suggested
– Curved Awl, to remove
heater hoses from heater
core
– Long nose pliers, to remove
clamps from heater core
– Torx bit set
– Bosch 12V 12 Volt Cordless
Lithium Ion Reciprocating
Hand Saw PS60 saw to modify
front of dash
– Coolant recovery device, this
is a cheap plastic 5 gallon
bucket and shop vacuum.
PTC Retro-fit Instructions 10-15-2012
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• Tools required
– 5 Gallon Coolant Recovery
bucket.
– Note: need to make sure all
coolant is removed from
heater core prior to removing
from vehicle. If all coolant is
not removed coolant will
require clean up in driver side
compartment.
– 17.5” – 2 x 4 brake pedal
holding device. Required to
remove heater core and
install PTC Unit.
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• Remove hood, latch and
windshield wiper assembly.
• Pinch off hose on left side
and right side of tee
connection and remove tee.
• Install strait connector and
reinstall clamps.
• Connect hose to recovery
bucket and fluid heater
connection and evacuate
balance of coolant from
heater and core.
• Remove hoses from fluid
heater and connection to
PCU.
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Re-work Information - PTC Service
Remove tee from upper hose
And install strait hose connector.
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• Remove Fluid heater
assembly.
• Reinstall fastener to support
A/C Lines
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• Remove ignition key from
ignition switch. Make sure
column is locked in place.
 (This is to avoid damage to
clock spring for Air Bag)
 Tape added for safety
• Disconnect u-joint from
steering gear.
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 Two man operation – Man 1
place foot on brake pedal.
Man 2 open brake bleed
screw left or right rear brake
cylinder assy and close. Man
1 install 2x4 to hold down
brake pedal for heater core
removal.
• Remove fasteners that
retain aluminum inlet and
outlet from heater core.
Remove attaching 2
retaining screws from
heater core to air box to
remove core.
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• Remove fastener from
between inlet and outlet to
remove retaining plate and
gasket
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• Remove fastener from
between inlet and outlet to
remove retaining plate and
gasket and plastic support
brackets from heater core
assy.
• Modify front of dash to
allow the Tyco HV and LV
connectors to pass from the
passenger compartment to
the under hood.
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Install PTC Heater Assy in
heater box and reuse two
fasteners from heater core
to retain.
PTC in place now thread HV
and LV connectors through
front of dash.
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• Make sure oval grommet is
fully seated in front of dash.
• Tie wrap HV and LV wires to
existing wire looms across
front of dash under hood.
 Reminder do not connect HV
and LV wires at this time
 Install blind plug in HV PCU
Connection
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Plug yellow wire into
VCU A180.A Connector
Pin # 24/26 pin connector.
This connector will need to
be unplugged from VCU. Use a
Small screwdriver to lift the
unlock Tab on the connector.
Insert the square pin into the
Connector body.
Make sure the Pin is fully seated
in the connector Body.
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• Relay to be removed,
located in relay center
under fuse panel on
passenger side of vehicle.
• Plug in red wire and jumper
wire as illustrated
 Reminder do not connect
HV and LV wires at this time
 Install blind plug in HV PCU
Connection
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Re-work Information - PTC Service
PTC Service Design, HV & LV Layout:
To Fluid heater connector
Additional Jumper
Red wire and yellow wire
Need to be threaded from
Driver side of vehicle to
Passenger side to make connections
D
PTC Retro-fit Instructions 10-15-2012
Relay Box,
Position 24
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Re-work Information - PTC Service
Circuit Changes (red) to ABS Gen-2: Climate Wake up
VCU Unit
CLIMATE WAKE UP
Dash Harness
HVAC Harness
Connect yellow wire from VCU
To pin 14/27 pin connector.
Cut wire going into connector
Tape off wire in connector and
Use splice on yellow wire to
Make connection from HVAC Harness.
From CDCM
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Re-work Information - PTC Service
Circuit changes (red) to ABS Gen-2: PTC Introduction (this change is common for ESP Vehicles)
1-. Remove cabin Water Pump Relay
Hot Always
Heat Request
Fault Output
Ground
1/4
2/4
3/4
PTC
4/4
2-. New connector: mating face of the
current FH connector
3-. Remove ’Cabin Water Pump Connector’ and attach branch to main branch harness
4-. Remove ’Cabin Water Pump’ from vehicle
PTC Retro-fit Instructions 10-15-2012
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PTC Heater Programming
Programming is done with two cables. PCAN and SIADIS.
PCAN is the white cable that connects to the OBD2 connector in the fuse box
SIADIS is the black cable that connects to the flat connector under the passenger
side of the dash.
PCAN is used for BMS,CDCM and VCU programming and SIADIS for PCU programming.
Programming must be done in a specific order and with the PTC heater electrically
disconnected from the vehicle!!!
Deviation from this order will result in control unit failure!!!!!
BMS
Turn the ignition key to the ON position
Open the Programming Tool
Select the Use CAN box located at the left center of the programming tool
Click Browse located in the right upper corner
From the pop up window, double click the file named MLec_A306_427.s19
Click Start located at the right center of the programming tool
At this point you will hear the battery contactors open
Once finished click Exit and turn the ignition key off
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PTC Heater Programming
CDCM
Turn the ignition key to the ON position
Open the CCP_Tool
Select File in the left upper corner then select Open File
Click CCP in the center top of the pop up window
Double click CDCM Firmware, then double click cdcm_0_9_1.hex
In the left upper corner select CDCM from the ECU drop down tab
Click Initialize CAN interface ,just below the ECU drop down tab
Click FLASH located in the right lower of the CCP Tool.
At this point you will hear the condenser fan start running
Once the condenser fan stops the programming is complete, Click Release CAN interface
and shut the ignition key off.
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PTC Heater Programming
PCU
At this point switch to the SIADIS cable
With the ignition key off open the C167_Loader
In the left upper corner click the SELECT tab
From the pop up window double click 590_2024_A_GEN2_069_001_00P_ABS_PTC
Turn the Ignition to the ON position, This will auto start to program
At this point the contactors will not close
Once finished click OK on the Download Complete pop up window
Switch OFF ignition key
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PTC Heater Programming
VCU
At this point switch back to the PCAN cable
Turn the ignition key ON for 3 seconds, OFF for 3 seconds then back ON
Open the CCP_Tool
In the right upper corner change the Program block end address from 7FFF to 78FF
Select File in the left upper corner then select Open File
Click CCP in the center top of the pop up window
Double click VCU Firmware, then double click vcu_2_2_reworkedcluster_withPTC.hex
In the left upper corner select VCU from the ECU drop down tab
Click Initialize CAN interface ,just below the ECU drop down tab
Click FLASH located in the right lower of the CCP_Tool
At this point the “P R N D E” display will go dark; this is how you know the
programming is loading properly.
If this does not happen click the Release CAN interface button; close the CCP_Tool;
Switch the Ignition OFF then back ON; reopen the CCP_Tool and restart the process
Once programming is complete the “P R N D E” display will light back up and the car
will chime. Turn ignition key to the OFF position
If the “P R N D E” display does not light back up the VCU will need to be replaced
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PTC Heater Programming
Heater Connections
Heater connections must be made in the correct order!!!! Deviation from this order
will result in control unit failure!!!!!
All connections must be made with the ignition key OFF and the key Removed from
the ignition switch
Remove the High Voltage blank plug from the PCU and install the High Voltage cable
from the new PTC heater
Connect the Low Voltage 3 pin connector previously on the fluid heater to the 3 pin
connector from the new PTC heater.
Start the vehicle and check for proper operation.
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