MergedFile

6. ON-VEHICLE INSPECTION AND SERVICE


1. REQUIRED SERVICE OPERATION
When the Engine-ECU, ETACS-ECU, Injector, Suction control valve or supply pump assembly
of the common rail system are replaced, the technician has to carry out the required service opera-
tions summarized in the tables below.

(1) When the Engine-ECU is replaced

Required Service MUT-III operational steps Referred section in this
Operation chapter
IMMOBILIZER→Special Function→ENG/EV
Engine Key Code Registra-
1 Key Code & Chassis No./VIN Reg. "2. Chassis No. writing"
tion & Chassis No. Writing
Injector ID Code Registra- MPI/GDI/DIESEL→Special Function→INJ. ID
2 tion* Writing (Exchanging ECU) "5. Injector ID code registra-
tion"
Small Injection Quantity MPI/GDI/DIESEL→Special Function→Learning
3 Learning Procedure →Small Injection qt. Learning "6. Small injection quantity
learning"

*Note: If the old ECU can communicate with MUT-III, you may copy the injector ID codes stored in
the old ECU and save it into MUT-III before installing the new ECU. Then you can paste the stored
injector codes to the new ECU.




(2) When the ETACS-ECU is replaced
Required Service MUT-III operational steps Referred section in this
Operation chapter
IMMOBILIZER→Coding→Chassis No./VIN
1 Chassis No. writing "2. Chassis No. writing"
Writing
Ignition Key ID Registration IMMOBILIZER→Special Function→Key Regis-
2 "3. Ignition key ID registration"
tration
Keyless Entry Secret Code ETACS→Special Function→Keyless ID Regis- "4. Keyless entry secret code
3
Registration tration registration"


(3) When the Injector is replaced
Required Service MUT-III operational steps Referred section in this
Operation chapter
Injector ID Code Registration MPI/GDI/DIESEL→Special Function→INJ ID "5. Injector ID code registra-
1 Writing (Exchanging INJ.)
tion"

Small Injection Quantity MPI/GDI/DIESEL→Special Function→Learning "6. Small injection quantity
2
Learning Procedure →Small Injection qt. Learning learning"


(4) When the Suction Control Valve or the Supply Pump Assembly is replaced

Required Service MUT-III operational steps Referred section in this
Operation chapter
Supply Pump Correction MPI/GDI/DIESEL→Special Function→ "7. Supply Pump Correction
1 Learning Procedure Initialization→Supply Pump Exchange Service learning"














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6. ON-VEHICLE INSPECTION AND SERVICE


2. CHASSIS NUMBER WRITING
The Chassis No. is stored in the Engine-ECU or ETACS
-ECU by the vehicle manufacturer. If the Chassis No. in
the Engine-ECU or ETACS-ECU is eliminated fraudu-
lently, the engine warning lamp illuminates and DTC
(Diagnostic Trouble Code) No.P0630 (Chassis No. mal-
function) appears. When the Engine-ECU or the ETACS
-ECU is replaced, the registration of the Chassis No. is
required, otherwise diagnosis code No. P0630 (Chassis
No. malfunction) will be stored. Enter the Chassis No. in
accordance with the following procedure:
Fig. 6-1








<When Engine-ECU is replaced> <When ETACS-ECU is replaced>




































Fig. 6-2

◇ Check that diagnosis code No.P0603 (EEPROM malfunction) is not set. If diagnosis
code No.P0603 (EEPROM malfunction) is set, entered Chassis No. cannot be
stored. Therefore, carry out troubleshooting and repair the malfunction first when
Caution
this code is set.
◇ Before connecting or disconnecting the MUT-III, turn the ignition switch to the
"LOCK" (OFF) position.














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6. ON-VEHICLE INSPECTION AND SERVICE


(1) When the Engine-ECU is Replaced
1. Connect the MUT-III to the 16-pin diagnosis connect-
or, and start up the MUT-III program.
2. Select "IMMOBILIZER".
3. Select "Special Function".
4. Select "ENG/EV Key Code Reg. & Chassis No. Writ-
ing".





Fig. 6-3



5. Push the OK button after "Completed, and the screen
is moved to “Chassis No. writing function".















Fig. 6-4


6. Enter the Chassis No. of registering vehicle and push
the OK button.














Fig. 6-5



7. Chassis No. writing result is displayed.















Fig. 6-6







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6. ON-VEHICLE INSPECTION AND SERVICE


(2) When the ETACS-ECU is Replaced
1. Connect the MUT-III to the 16-pin diagnosis connect-
or, and start up the MUT-III program.
2. Select "IMMOBILIZER".
3. Select "Coding".
4. Select "Chassis No./VIN Writing".







Fig. 6-7


5. Enter the Chassis No. of registering vehicle and push
the OK button.














Fig. 6-8



6. Chassis No. writing result is displayed.
7. Resister the ignition key ID code for the vehicle
equipped with the Immobilizer system. (Refer to Key ID
Registration Criteria Table)











Fig. 6-9




























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6. ON-VEHICLE INSPECTION AND SERVICE


3. IGNITION KEY ID REGISTRATION
(1) Criteria Table
The ignition key contains a transponder (small transmitter), which retains an unique key ID. Under
any of the conditions described in the table below, the Chassis No. and key ID should be registered
in the ETACS-ECU (immobilizer-ECU) or Engine-ECU again. In addition, the keyless entry secret
code should be registered in the ignition key (with transmitter)
Item Operation contents and procedure
When the Engine-ECU is replaced Write the Chassis No.
When the ETACS-ECU (immobilizer-ECU) is Write the Chassis No.
replaced Register all ignition key ID again.
When the key ring antenna is replaced Operation is not needed.
When the ignition key is added separately.* Register all ignition key ID again.
Register all ignition key keyless entry secret code again (with
transmitter only).
When the ignition key is lost separately. Register all ignition keys other than the lost ignition key again.
Register all ignition key keyless entry secret codes other than the
lost ignition key again.
When the ignition key is replaced by the full Register all ignition keys again <Barcode No. input>.
service key set or the handle lock service Register all ignition key keyless entry secret codes again (set sup-
key set is replaced by the piece. ply only).
When the ignition key is replaced separately Register the replaced ignition key keyless entry secret code.
by the door service key set, the glove box
service key set or the filler cap service key
set is replaced by the piece.

Do not replace the Engine-ECU and ETACS-ECU (immobilizer-ECU) simultaneously.
Always replace the ECUs one at a time when multiple ECUs are replaced, and then re-
Caution
place the next ECU after registering the necessary IDs.
Do not register the ignition key registered for other vehicles.
You may register up to eight different ignition key ID in the memory of the ETACS-ECU
Note
(immobilizer-ECU).
<Registration flow chart>




































Fig. 6-10

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6. ON-VEHICLE INSPECTION AND SERVICE


(2) Key ID Registration Method (One Code Per Key)









For Engine-ECU










Fig. 6-11


1. Connect the MUT-III to the 16-pin diagnosis connect-
or, and start up the MUT-III program.
2. Select "IMMOBILIZER".
3. Select "Special Function".
4. Select "Key Registration.








Fig. 6-12


5. Enter the password and press the OK button. Then,
"Executing!" is displayed and the registration process
starts.

If the wrong password is entered consecutively 5
times, the password entry will be disabled for 16
Note minutes.
The key registration cannot be cancelled during
the operation.




Fig. 6-13


6. When the key registration is completed, "Completed"
is displayed. To register the next key, follow the mes-
sage on the screen and press the OK button. Then,
"Executing!" is displayed again and the registration pro-
cess for the next key starts. To finish the key registra-
tion, press the cancel button.
In order to register another key consecutively after
registering the first key, the ignition switch must be
turned to the ON position with the second key
Note
within 30 seconds after turning it to the
Fig. 6-14 "LOCK" (OFF) position with the first key.
Up to 8 keys can be registered.


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6. ON-VEHICLE INSPECTION AND SERVICE


4. KEYLESS ENTRY SECRET CODE REGISTRATION
Each individual encrypted code is registered inside the transmitter, and so it is necessary to resister
these codes with the EEPROM inside the receiver in the following cases:
◇ When the transmitter or ETACS-ECU is replaced.
◇ If more transmitters are to be used.
◇ If it appears that a problem is occurring because of faulty registration of a code.
◇ If customer loses a key (need to register all the remaining keys in order to delete keyless ID of
lost key).
◇ If customer changes or adds spare key.
A maximum of four different codes can be stored in the EEPROM memory (four different transmitters
can be used). When the code for the first transmitter is registered, the previously registered codes for
all transmitters are cleared. Therefore, if you are using four transmitters or are adding more transmit-
ters, the codes for all transmitters must be registered at the same time.
<Registration Procedure>
1. Check that the doors lock normally when the key is used.
2. Insert the ignition key.
3. Connect the MUT-III to the diagnosis connector.
4. Start up the MUT-III.
5. Select "System Select" from "Menu".
6. Select "ETACS" from "System Select".
7. Select "Special Function" from "ETACS".
8. Select "Keyless ID Registration" from "Special Function".
9. Press the OK button.
10. Press the OK button to clear the secret codes for all the current registered transmitters.
11. Press the OK button.
Note The secret code registration mode is entered.

12. Within 1 minute after the registration mode is entered, push the button of the transmitter to be
registered once, and push the button of the transmitter consecutively twice within 10 seconds. The
secret code registration is complete.
13. When two or more transmitters are registered, push the button of the transmitter to be registered
once within 1 minute after the registration of the previous secret code is complete. Then, push the
button of the transmitter consecutively twice within 10 seconds.

Note MUT-III displays the number of the registered transmitters.

Registration mode will be cancelled under the following conditions:
◇ When the encrypted codes for four transmitters have been registered
◇ When no encrypted code has been registered for one minute or more after the registra-
Note tion mode started
◇ When one minute has passed after the registration of the previous transmitter
◇ When the MUT-III and the diagnosis connector are disconnected
◇ When the encrypted code registration is terminated by the MUT-III


14. Press the OK button.
15. Check the number of the registered transmitters.
16. Return to the previous step.
17. Select "Keyless Reception Check" from "Special Function".
18. Depress the transmitter button. If the transmitter can receive signal normally, the MUT-III will
show variation of the received signals and whether the transmitter button has been registered or not.
19. Return to the main menu and complete.
20. Remove the MUT-III.
21. Check that the keyless entry system works normally with the registered keys.








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6. ON-VEHICLE INSPECTION AND SERVICE

5. INJECTOR ID CODE REGISTRATION
(1) Purpose
Because individual injectors have different injection
characteristics, the Engine-ECU corrects injection time
for each cylinder to improve injection accuracy.
For this reason, when the injector or Engine-ECU is re-
placed, injector correction data must be registered after-
wards in the Engine-ECU using the MUT-III.
Correction data is converted into an identification code
consisting of 30 alphanumeric characters and printed on
the injector connector.
Fig. 6-15
When the Engine-ECU is replaced, collect in advance the injector identification code
Note
from the current Engine-ECU. Doing it makes registration easy.

If the injector identification code is not registered, the engine warning lamp goes on and
diagnosis code No. P1626 is logged.
Caution
Failure to register the injector identification code correctly will cause rough idling, abnor-
mal noise, and emission deterioration.



(2) Registration Procedure
1. When replacing the Engine-ECU, connect the current Engine-ECU to the body harness.

This operation is purposed to read the injector identification code stored in the Engine-
Note ECU. Reading the identification code in this way before replacement can eliminate man-
ual input of the identification code after replacement.
2. After the ignition switch is in "LOCK" (OFF) position, connect the MUT-III to the diagnosis connect-
or.
3. Turn the ignition switch to "ON" position.
4. Select SPECIAL FUNCTION from the function menu.
5. When the current Engine-ECU is still mounted, read and register the injector identification code as
follows:
(1) Select Read Injector ID Code (for Engine-ECU replacement) from the SPECIAL FUNCTION
menu.
(2) Select Write and Save Injector ID Code from the menu to read data from the current Engine-
ECU and save the data if it could be read normally.
(3) Mount the new Engine-ECU on the vehicle.
(4) Select SPECIAL FUNCTION from the function menu.
(5) Select Write Injector ID Code (for Engine-ECU replacement) from the SPECIAL FUNCTION
menu.
(6) Select SAVED INJECTOR ID WRITING from the Write Injector ID Code menu to write the da-
ta, which was saved previously, to the Engine-ECU.

6. If the injector has been replaced or data has not been
read from the current Engine-ECU, register the injec-
tor identification code as follows:
(1) Select “Write Injector ID Code” from the SPECIAL
FUNCTION menu.
(2) If the injector was replaced, specify whether to
write to every cylinder or a specific cylinder.
(3) Select the write mode from the menu, enter the
identification code printed on the injector, and execute
writing.
Fig. 6-16
Even if the number of the cylinder to be registered does not match the actual injector
Caution
mounting location, registration ends normally. Specify the cylinder number correctly.

Pub. No. PTAE1228 6 - 8

6. ON-VEHICLE INSPECTION AND SERVICE


Note The identification code is displayed in order of the frame numbers when it is read.


7. Make sure that the engine warning lamp that is on changes to blinking, indicating the registration is
complete.
When the injector is replaced, executing the write operation also clears the values of
Note
small injection quantity learning.

8. Execute small injection quantity learning.
(Refer to the Small Injection Quantity Learning Procedure).
9. Confirm that the engine warning lamp is off, and also make sure that the diagnosis code is not
stored.










































































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6. ON-VEHICLE INSPECTION AND SERVICE


6. SMALL INJECTION QUANTITY LEARNING

If small injection quantity learning has not been executed, the engine warning lamp
blinks.
When the requirements for learning are satisfied by operation after replacement of the
Caution
Engine-ECU, learning is automatically executed even if no instruction is given from the
MUT-III. Accordingly, the malfunction indicator lamp goes off. However, the learning
thus executed is tentative and limited. Be sure to complete leaning using the MUT-III.



(1) Purpose
◇ To keep emission and noise level at adequate levels, the Engine-ECU must learn injector param-
eters for fuel injection in idle mode.
◇ During the learning, the Engine-ECU calculates actual injection from each cylinder based on
changes in engine speeds and corrects pilot injection control. It then keeps records of this
amount of correction as a learned value.
◇ For this reason, after the Engine-ECU or injector is replaced, learning must be executed using
the MUT-III.

Engine friction changes or injector deterioration over time may cause fluctuation in pilot
injection. After use over time, it may prevent injection of an accurate amount of fuel ac-
cording to the indication by the Engine-ECU. This is why learning must be executed
Note again periodically.
For this reason, the Engine-ECU periodically leans injection according to the cumulative
mileage.
Note that making the MUT-III learn again resets the cumulative mileage.

The engine sound may change or idling engine speeds may increase during injection
Note
learning. These are not abnormalities.

(2) Learning Procedure
1. After the ignition switch is in "LOCK" (OFF) position, connect the MUT-III to the diagnosis connect-
or.
2. Put the vehicle in the following idling stable conditions:
◇ Engine coolant temperature: 80 - 90°C
◇ Automatic transmission fluid temperature: 60°C or higher
◇ Lamps, A/C condenser fan and all accessories: OFF
◇ Transmission: Neutral <M/T>, "P" range <A/T>
◇ Power steering: Static state
3. Select SPECIAL FUNCTION from the function menu.
4. Select SMALL INJECTION QUANTITY LEARNING from the SPECIAL FUNCTION menu to exe-
cute learning.

If the vehicle conditions go out of the learning conditions during idling, learning is inter-
Caution rupted.
To re-execute learning, the ignition switch must once be turned off.

5. Continue idling for about 3 minutes before learning is completed.

6. Confirm that the engine warning lamp is off. If it still blinks, re-execute learning.














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6. ON-VEHICLE INSPECTION AND SERVICE


7. SUPPLY PUMP CORRECTION LEARNING
(1) Purpose
◇ The Engine-ECU learns the relation between the suction control valve (linear solenoid valve) of
the supply pump drive current and the fuel injection volume.
◇ The learning value is calculated from the suction control valve drive current and the rail pressure
sensor output voltage.
◇ When the supply pump is replaced, therefore, this learning must be executed.
◇ Re-learning is executed when the engine is idling after the learning value in the Engine-ECU has
been reset by the MUT-III.

(2) Learning Procedure
1. After the ignition switch is in "LOCK" (OFF) position, connect the MUT-III to the diagnosis connect-
or.
2. Turn the ignition switch to "ON" position. (Do not start the engine)
3. Select SPECIAL FUNCTION from the function menu.
4. Select SUPPLY PUMP CORRECTION LEARNING from the SPECIAL FUNCTION menu and exe-
cute the initializing of the learning value.
5. After initializing, run the engine at idle in the following conditions.
◇ Accelerator pedal: OFF
◇ Engine coolant temperature: 60°C or higher
◇ Fuel temperature: 30°C or higher
6. Confirm that the item No. 65 High pressure pump learned status on MUT-III Service Data is "2".
Note "2" indicates that the learning has completed.





















































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6. ON-VEHICLE INSPECTION AND SERVICE


8. GLOW SYSTEM
< << <SERVICE SPECIFICATIONS>

Item Standard value
Resistance between glow plug plate and glow plug body (parallel 0.12 - 0.38
resistance for 4 glow plugs at 20°C (ohms)
Glow plug relay resistance at 20°C (ohms) 18 - 22
Glow plug resistance at 20°C (ohms) 0.5 - 1.5


Self-Regulating Glow System Check
1. Check that the battery voltage is 11 - 13 V.
2. Check that the engine coolant temperature is 40°C or
less.

If the engine coolant temperature is too high, dis-

Note connect the engine coolant temperature sensor
connector.
3. Measure the resistance between the glow plug plate
and the glow plug body (earth).
Standard value: 0.12 - 0.38 ohms (at 20°C)

The resistance value is the parallel resistance val-
Note

ue for the four glow plugs.

4. Connect a voltmeter between the glow plug plate and
the glow plug body (earth).
5. Measure the voltage immediately after the ignition
switch is turned to ON (without starting the engine).
Standard value: 9 - 11 V (Drops to 0 V after 4 - 8 sec-
Fig. 6-17 onds have passed)
In addition, check to be sure that the glow indicator lamp
(red) illuminates immediately after the ignition switch is
turned to ON.
6. Measure the voltage while the engine is cranking.
Standard value: 6 V or more
7.Start the engine and measure the voltage while the
engine is warming up.
However, if the engine coolant temperature rises above
60°C or when 180 seconds have passed since the en-
gine was started, the voltage will always return to 0 V.
(Refer to the Glow Plug Energization Timing Chart.)
Standard value: 12 - 15 V
The time during which the voltage appears
Note (energizing time) will depend on the engine coolant
temperature.


















Pub. No. PTAE1228 6 - 12