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1
Railbull Pressure sensorbull Pressure limiterSupply pump
bullSCV bullFuel temperature
Injector
Front Engine
Fuel pipe to
injector
Fuel pipe to Rail
Gambaran Umum Common Rail System
Lokasi Part
2
Diagram Konstruksi Supply Pump
Fuel System
3
Plunger
Drive shaft
Plunger
Filter
Regulating valve
Fuel temperature sensor
Feed pump
SCV
Pump body
Ring cam
Fuel System
Konstruksi Supply Pump
4
Fuel flow dalam supply pump
The fuel that is draw from the fuel tank passes through the route in the supply pump as illustrated and is fed into the rail
Fuel System
5
Fuel pump (DENSO type HP3)
Ring cam
Plunger B
Feed pump
Plunger A
Eccentric Cam Ring cam
camshaft
The eccentric camshaft is attached to the camshaft The eccentric cam is connected to the ring cam
The plunger and the suction valve are attached to the ring cam The feed pump is connected to the rear of the come shaft
Fuel System
6
Konstruksi
Eccentric Cam
Plunger
Ring cam
camshaft
Fuel System
Operation
Fuel System
Movie
8
Outer rotor
Inner rotor
Quantity increase
Quantity decrease
Intake port
Discharge port
Quantity increase (Fuel intake)
Quantity decrease (fuel discharge
The trochoid type feed pump which is integrated in the supply pump draws fuel from the fuel tank and feeds it to the driven by the drive shaft
Konstruksi Feed Pump
Fuel System
9
Suction Control Valve
Fuel System
10
Plunger
Feed pump
Short time ON duty
Large valve opening
Large valve open
In case of short time ON duty
Fuel System
Maximum intake quantity
Movie
11
Plunger
Feed pump
Long time ON duty
Small valve opening
Small valve opening
In case of long time ON duty
Fuel System
Minimum intake quantity
12
Injector Structure and System
An injector consists of a nozzle command piston
command chamber and solenoid valve that controls
the ONOFF of the outflow orifice The command
piston moves vertically in accordance with the fuel
pressure in the command chamber As the nozzle is
integrated with the command piston the orifice of the
injector opens and closes with the vertical movement
of the command piston
Fuel System
Movie
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
2
Diagram Konstruksi Supply Pump
Fuel System
3
Plunger
Drive shaft
Plunger
Filter
Regulating valve
Fuel temperature sensor
Feed pump
SCV
Pump body
Ring cam
Fuel System
Konstruksi Supply Pump
4
Fuel flow dalam supply pump
The fuel that is draw from the fuel tank passes through the route in the supply pump as illustrated and is fed into the rail
Fuel System
5
Fuel pump (DENSO type HP3)
Ring cam
Plunger B
Feed pump
Plunger A
Eccentric Cam Ring cam
camshaft
The eccentric camshaft is attached to the camshaft The eccentric cam is connected to the ring cam
The plunger and the suction valve are attached to the ring cam The feed pump is connected to the rear of the come shaft
Fuel System
6
Konstruksi
Eccentric Cam
Plunger
Ring cam
camshaft
Fuel System
Operation
Fuel System
Movie
8
Outer rotor
Inner rotor
Quantity increase
Quantity decrease
Intake port
Discharge port
Quantity increase (Fuel intake)
Quantity decrease (fuel discharge
The trochoid type feed pump which is integrated in the supply pump draws fuel from the fuel tank and feeds it to the driven by the drive shaft
Konstruksi Feed Pump
Fuel System
9
Suction Control Valve
Fuel System
10
Plunger
Feed pump
Short time ON duty
Large valve opening
Large valve open
In case of short time ON duty
Fuel System
Maximum intake quantity
Movie
11
Plunger
Feed pump
Long time ON duty
Small valve opening
Small valve opening
In case of long time ON duty
Fuel System
Minimum intake quantity
12
Injector Structure and System
An injector consists of a nozzle command piston
command chamber and solenoid valve that controls
the ONOFF of the outflow orifice The command
piston moves vertically in accordance with the fuel
pressure in the command chamber As the nozzle is
integrated with the command piston the orifice of the
injector opens and closes with the vertical movement
of the command piston
Fuel System
Movie
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
3
Plunger
Drive shaft
Plunger
Filter
Regulating valve
Fuel temperature sensor
Feed pump
SCV
Pump body
Ring cam
Fuel System
Konstruksi Supply Pump
4
Fuel flow dalam supply pump
The fuel that is draw from the fuel tank passes through the route in the supply pump as illustrated and is fed into the rail
Fuel System
5
Fuel pump (DENSO type HP3)
Ring cam
Plunger B
Feed pump
Plunger A
Eccentric Cam Ring cam
camshaft
The eccentric camshaft is attached to the camshaft The eccentric cam is connected to the ring cam
The plunger and the suction valve are attached to the ring cam The feed pump is connected to the rear of the come shaft
Fuel System
6
Konstruksi
Eccentric Cam
Plunger
Ring cam
camshaft
Fuel System
Operation
Fuel System
Movie
8
Outer rotor
Inner rotor
Quantity increase
Quantity decrease
Intake port
Discharge port
Quantity increase (Fuel intake)
Quantity decrease (fuel discharge
The trochoid type feed pump which is integrated in the supply pump draws fuel from the fuel tank and feeds it to the driven by the drive shaft
Konstruksi Feed Pump
Fuel System
9
Suction Control Valve
Fuel System
10
Plunger
Feed pump
Short time ON duty
Large valve opening
Large valve open
In case of short time ON duty
Fuel System
Maximum intake quantity
Movie
11
Plunger
Feed pump
Long time ON duty
Small valve opening
Small valve opening
In case of long time ON duty
Fuel System
Minimum intake quantity
12
Injector Structure and System
An injector consists of a nozzle command piston
command chamber and solenoid valve that controls
the ONOFF of the outflow orifice The command
piston moves vertically in accordance with the fuel
pressure in the command chamber As the nozzle is
integrated with the command piston the orifice of the
injector opens and closes with the vertical movement
of the command piston
Fuel System
Movie
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
4
Fuel flow dalam supply pump
The fuel that is draw from the fuel tank passes through the route in the supply pump as illustrated and is fed into the rail
Fuel System
5
Fuel pump (DENSO type HP3)
Ring cam
Plunger B
Feed pump
Plunger A
Eccentric Cam Ring cam
camshaft
The eccentric camshaft is attached to the camshaft The eccentric cam is connected to the ring cam
The plunger and the suction valve are attached to the ring cam The feed pump is connected to the rear of the come shaft
Fuel System
6
Konstruksi
Eccentric Cam
Plunger
Ring cam
camshaft
Fuel System
Operation
Fuel System
Movie
8
Outer rotor
Inner rotor
Quantity increase
Quantity decrease
Intake port
Discharge port
Quantity increase (Fuel intake)
Quantity decrease (fuel discharge
The trochoid type feed pump which is integrated in the supply pump draws fuel from the fuel tank and feeds it to the driven by the drive shaft
Konstruksi Feed Pump
Fuel System
9
Suction Control Valve
Fuel System
10
Plunger
Feed pump
Short time ON duty
Large valve opening
Large valve open
In case of short time ON duty
Fuel System
Maximum intake quantity
Movie
11
Plunger
Feed pump
Long time ON duty
Small valve opening
Small valve opening
In case of long time ON duty
Fuel System
Minimum intake quantity
12
Injector Structure and System
An injector consists of a nozzle command piston
command chamber and solenoid valve that controls
the ONOFF of the outflow orifice The command
piston moves vertically in accordance with the fuel
pressure in the command chamber As the nozzle is
integrated with the command piston the orifice of the
injector opens and closes with the vertical movement
of the command piston
Fuel System
Movie
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
5
Fuel pump (DENSO type HP3)
Ring cam
Plunger B
Feed pump
Plunger A
Eccentric Cam Ring cam
camshaft
The eccentric camshaft is attached to the camshaft The eccentric cam is connected to the ring cam
The plunger and the suction valve are attached to the ring cam The feed pump is connected to the rear of the come shaft
Fuel System
6
Konstruksi
Eccentric Cam
Plunger
Ring cam
camshaft
Fuel System
Operation
Fuel System
Movie
8
Outer rotor
Inner rotor
Quantity increase
Quantity decrease
Intake port
Discharge port
Quantity increase (Fuel intake)
Quantity decrease (fuel discharge
The trochoid type feed pump which is integrated in the supply pump draws fuel from the fuel tank and feeds it to the driven by the drive shaft
Konstruksi Feed Pump
Fuel System
9
Suction Control Valve
Fuel System
10
Plunger
Feed pump
Short time ON duty
Large valve opening
Large valve open
In case of short time ON duty
Fuel System
Maximum intake quantity
Movie
11
Plunger
Feed pump
Long time ON duty
Small valve opening
Small valve opening
In case of long time ON duty
Fuel System
Minimum intake quantity
12
Injector Structure and System
An injector consists of a nozzle command piston
command chamber and solenoid valve that controls
the ONOFF of the outflow orifice The command
piston moves vertically in accordance with the fuel
pressure in the command chamber As the nozzle is
integrated with the command piston the orifice of the
injector opens and closes with the vertical movement
of the command piston
Fuel System
Movie
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
6
Konstruksi
Eccentric Cam
Plunger
Ring cam
camshaft
Fuel System
Operation
Fuel System
Movie
8
Outer rotor
Inner rotor
Quantity increase
Quantity decrease
Intake port
Discharge port
Quantity increase (Fuel intake)
Quantity decrease (fuel discharge
The trochoid type feed pump which is integrated in the supply pump draws fuel from the fuel tank and feeds it to the driven by the drive shaft
Konstruksi Feed Pump
Fuel System
9
Suction Control Valve
Fuel System
10
Plunger
Feed pump
Short time ON duty
Large valve opening
Large valve open
In case of short time ON duty
Fuel System
Maximum intake quantity
Movie
11
Plunger
Feed pump
Long time ON duty
Small valve opening
Small valve opening
In case of long time ON duty
Fuel System
Minimum intake quantity
12
Injector Structure and System
An injector consists of a nozzle command piston
command chamber and solenoid valve that controls
the ONOFF of the outflow orifice The command
piston moves vertically in accordance with the fuel
pressure in the command chamber As the nozzle is
integrated with the command piston the orifice of the
injector opens and closes with the vertical movement
of the command piston
Fuel System
Movie
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
Operation
Fuel System
Movie
8
Outer rotor
Inner rotor
Quantity increase
Quantity decrease
Intake port
Discharge port
Quantity increase (Fuel intake)
Quantity decrease (fuel discharge
The trochoid type feed pump which is integrated in the supply pump draws fuel from the fuel tank and feeds it to the driven by the drive shaft
Konstruksi Feed Pump
Fuel System
9
Suction Control Valve
Fuel System
10
Plunger
Feed pump
Short time ON duty
Large valve opening
Large valve open
In case of short time ON duty
Fuel System
Maximum intake quantity
Movie
11
Plunger
Feed pump
Long time ON duty
Small valve opening
Small valve opening
In case of long time ON duty
Fuel System
Minimum intake quantity
12
Injector Structure and System
An injector consists of a nozzle command piston
command chamber and solenoid valve that controls
the ONOFF of the outflow orifice The command
piston moves vertically in accordance with the fuel
pressure in the command chamber As the nozzle is
integrated with the command piston the orifice of the
injector opens and closes with the vertical movement
of the command piston
Fuel System
Movie
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
8
Outer rotor
Inner rotor
Quantity increase
Quantity decrease
Intake port
Discharge port
Quantity increase (Fuel intake)
Quantity decrease (fuel discharge
The trochoid type feed pump which is integrated in the supply pump draws fuel from the fuel tank and feeds it to the driven by the drive shaft
Konstruksi Feed Pump
Fuel System
9
Suction Control Valve
Fuel System
10
Plunger
Feed pump
Short time ON duty
Large valve opening
Large valve open
In case of short time ON duty
Fuel System
Maximum intake quantity
Movie
11
Plunger
Feed pump
Long time ON duty
Small valve opening
Small valve opening
In case of long time ON duty
Fuel System
Minimum intake quantity
12
Injector Structure and System
An injector consists of a nozzle command piston
command chamber and solenoid valve that controls
the ONOFF of the outflow orifice The command
piston moves vertically in accordance with the fuel
pressure in the command chamber As the nozzle is
integrated with the command piston the orifice of the
injector opens and closes with the vertical movement
of the command piston
Fuel System
Movie
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
9
Suction Control Valve
Fuel System
10
Plunger
Feed pump
Short time ON duty
Large valve opening
Large valve open
In case of short time ON duty
Fuel System
Maximum intake quantity
Movie
11
Plunger
Feed pump
Long time ON duty
Small valve opening
Small valve opening
In case of long time ON duty
Fuel System
Minimum intake quantity
12
Injector Structure and System
An injector consists of a nozzle command piston
command chamber and solenoid valve that controls
the ONOFF of the outflow orifice The command
piston moves vertically in accordance with the fuel
pressure in the command chamber As the nozzle is
integrated with the command piston the orifice of the
injector opens and closes with the vertical movement
of the command piston
Fuel System
Movie
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
10
Plunger
Feed pump
Short time ON duty
Large valve opening
Large valve open
In case of short time ON duty
Fuel System
Maximum intake quantity
Movie
11
Plunger
Feed pump
Long time ON duty
Small valve opening
Small valve opening
In case of long time ON duty
Fuel System
Minimum intake quantity
12
Injector Structure and System
An injector consists of a nozzle command piston
command chamber and solenoid valve that controls
the ONOFF of the outflow orifice The command
piston moves vertically in accordance with the fuel
pressure in the command chamber As the nozzle is
integrated with the command piston the orifice of the
injector opens and closes with the vertical movement
of the command piston
Fuel System
Movie
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
11
Plunger
Feed pump
Long time ON duty
Small valve opening
Small valve opening
In case of long time ON duty
Fuel System
Minimum intake quantity
12
Injector Structure and System
An injector consists of a nozzle command piston
command chamber and solenoid valve that controls
the ONOFF of the outflow orifice The command
piston moves vertically in accordance with the fuel
pressure in the command chamber As the nozzle is
integrated with the command piston the orifice of the
injector opens and closes with the vertical movement
of the command piston
Fuel System
Movie
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
12
Injector Structure and System
An injector consists of a nozzle command piston
command chamber and solenoid valve that controls
the ONOFF of the outflow orifice The command
piston moves vertically in accordance with the fuel
pressure in the command chamber As the nozzle is
integrated with the command piston the orifice of the
injector opens and closes with the vertical movement
of the command piston
Fuel System
Movie
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
13
Injector Structure and System
Fuel System
Movie
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
14
OFF ON
Electro magnetic valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic pressure
Hydraulic pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector Operation
Fuel System
Movie
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
15
Basically the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed
1 Fuel injection amount control
Fuel injection control
Fuel System
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
16
2 Fuel injection timing controlFuel injection control
Basically the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount
Fuel System
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
17
2 Fuel injection timing control
Multiple stage injection control
Fuel injection control
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions The injection
that takes place before the main
injection is called pre-injection
which is provided primarily for
reducing combustion noise and NOx
The injection that takes place after
the main injection is called
after-injection which is provided
primarily for activating the catalyst
Fuel System
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
18
2 Fuel injection timing control
EX) Multiple stage injection control for 4M41 DID
Fuel injection control
Time
Pilot Injection
Pre InjectionMain
InjectionPost
InjectionAfter
Injection
Op
enin
g o
f In
ject
ion
fa
ce
Fuel System
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
19
3 Fuel pressure controlFuel injection control
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure in accordance with the signals input from various sensors Accordingly the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter
Fuel System
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
20
4 Idle speed controlFuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed and controls the fuel injection amount so that the actual idle speed will attain the target idle speed (feedback control) Furthermore the following compensations are added to control the engine at a stable idle speed
Fuel System
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
21
5 Throttle valve controlFuel injection control
System Configuration Diagram
When engine is running
Engine-ECU actuates the throttle valve control servo to fully open the throttle valve In a driving range in which the exhaust gas recirculation control is being effected the throttle valve closes to create a vacuum in the inlet manifold
When engine is stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds This cuts off the flow of intake air and prevents the engine from run on (dieseling)
When a problem develops
If the engine-ECU detects a serious problem it immediately closes the throttle valve fully to stop the engine
Fuel System
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
23
Fuel filter
High cleaning efficiency filter
Fuel System
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
24
1048698 Mounted on the front of the rear axle to reduce the shock during impact1048698 Materials without lead and hexavalent chromium have been employed for the fuel tank with attention to environmental issues1048698 A fuel cut valve which prevents fuel leakage when the vehicle banks or rolls over has been located inside the fuel tank for fewer openings and hose bonding points on the fuel tank top surface
Fuel tank
Fuel System
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (SQL) at the end of line (EOL) check SQL start and SGL end by MIL status as follow
Procedure for Small quantity learning
Idling
When injector is changed
After IG Off to ON
Precondition1 Vehicle speed 0kmh
2 Accelerator pedal Fully close
3 Power steering not operated
4 Electric load Off
5 Water temp 80 deg or higher
6 AT oil temp 60 degor higher
7 Oil temperature 30 deg or higher
8 Shift position N or P
9 AC Off
10 Idle condition stable
SQL startSQL complete
SQL NG
MIL Blink MIL Off
When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode
Fuel System
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
26
Registration and learning item Operation type
Injector replacement
Supply pump replacement
Engine-ECU replacement
1 Injector identification Applicable --- Applicable
2 Small injection quantity learning (SQL)
Applicable --- Applicable
3 Supply pump correction learning
--- Applicable ---
After fuel-related parts are replaced the common rail engine must register their
identification codes with the engine-ECU and execute learning
Note When the engine-ECU is replaced collect in advance the injector
identification code from the current engine-ECU Doing it makes registration easy
Common rail engine learning function
Fuel System
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
27
1 Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail Assrsquoy
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail assrsquoy when changing parts
---------------------
Supply pump Assrsquoy
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump assrsquoy when changing parts
Initialize learned value by MUT-III
Injector
---------------------
Pay attention to the discharge because of injector drive voltage 85V
Register after erasing correction value by MUT-III
Engine-ECU
----------------------
---------------------
Register the injector correction value supply pump learned value by MUT-III
Fuel System
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
28
2 Caution and method of Injector correction(12)
1) There are correction value QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU
Fuel System
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
29
2 Caution and method of Injector correction(22)
2) Make sure the replace injector cylinder No
(because it can not detect cylinder No mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is nopartial value registered in ECU)
Fuel System
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
30
3 Diagnosis function
Increase diagnosis items (CDI Approx100 items IDIApprox30items)
Ex) New diagnosis items
Diagnosis items Diagnosis code
Failure parts Remarks
Abnormal of intake valve seized
P0638 ETV Failure of ETV motor (judge of valve seized)
Abnormal of DC motor excessive current flow
P2118 ETV Failure of ETV motor (excessive current)
Failure of NEG phase unmatched
P0016 Crank angle sensor
Cam position sensor
Cam position sensor and crank angle sensor output waveform unmatched
Injector function (non injection)
P0301 to P0304
ECU Poor increasing angular speed by combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount too big against requirement
Fuel System
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
31
1 Injector identification code registration procedure
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 replaced injector
correction data must be registered afterwards 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
Common rail engine learning function
Fuel System
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
32
1 Injector identification code registration procedure
Select the write mode from the menu enter the identification
Code printed on the injector and execute writing
Common rail engine learning function
Fuel System
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
33
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
1) Before replace the current engine-ECU
connect the MUT-III
2) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
3) Select ldquoINJ ID Writing (Exchanging ECU)rdquo
menu
4) Select ldquoInjector ID Read amp Saverdquo menu
Caution
If the injector ID code is not registered the
engine warning lamp goes on and diagnosis
code No P1626 is logged
Common rail engine learning function
Fuel System
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
34
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
5) The injector ID code from the current engine
-ECU is displayed
6) Click the Check from task bar
7) The injector ID code is saved to MUT-III from
the current engine-ECU
8) Replace the new engine-ECU
Common rail engine learning function
Fuel System
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
35
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
9) Select ldquoSaved Injector ID Writingrdquo menu
10) Select the injector ID code from the current
engine-ECU click the Check from task bar
11) The injector ID code from the current engine
-ECU is written to the new engine-ECU
Common rail engine learning function
Fuel System
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
36
12) For other way select ldquoAll Injector ID Writingrdquo menu
13) Input the each injection ID code by keyboard
14) Make sure that the engine warning lamp that
is on changes to blinking indicating the
registration is complete
15) Execute small injection quantity learning
Small Injection Quantity Learning Procedure
1 Injector identification code registration procedure
A Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
37
1 Injector identification code registration procedure
B Injector ID code writing (Exchanging injector)
1) Select ldquoSpecial Functionrdquo from the function
menu of MUT-III
2) Select ldquoINJ ID Writing (Exchanging INJ)rdquo
menu
3) Select number of replaced Injector ID writing
menu or ldquoAll Injector ID Writingrdquo menu
4) Input the each injection ID code by keyboard
Common rail engine learning function
Fuel System
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
38
2 Small Injection Quantity Learning procedure
Purpose To keep emission and noise level at adequate levels the engine-ECU must learn Injector fuel injection in idle mode
During 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
Caution
If small injection quantity learning has not been executed
the engine warning lamp blinks
Common rail engine learning function
Fuel System
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
39
2 Small injector quantity learning procedure
1) Put the vehicle in the left-hand idling stable
condition
2) Select ldquoSpecial Functionrdquo from the function
menu
3) Select ldquoLearningrdquo menu
- Engine coolant temperature 80 ndash 90ordmC
- AT temperature 60ordmC or higher
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering Static state
Common rail engine learning function
Fuel System
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
40
2 Small injector quantity learning procedure
4) Select ldquoSmall Injection qt Learningrdquo item
5) Click the Check from task bar
Caution
If the vehicle conditions go out of the learning
conditions during idling learning is interrupted
To re-execute learning the ignition switch must
Once be turned off
6) Continue idling for about 3 minutes before
learning is completed
7) Confirm that the engine warning lamp is
off If it still blinks re-execute learning
Common rail engine learning function
Fuel System
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
41
3 Supply Pump Correction Learning procedure
Purpose To 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
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
42
1) Select ldquoInitializationrdquo from the function
menu
2) Select item No 21 ldquoSupply pump exchange
servicerdquo
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal OFF
- Engine coolant temperature 60ordmC or higher
- Fuel temperature 30ordmC or higher
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
43
3) Click the Check
4) After initializing run the engine at idle in the
left-hand conditions
5) Confirm that the item No65 High pressure
pump learned status on MUT-III Service Data
is ldquo2rdquo
ldquoFFrdquo Initial Condition
ldquo0rdquo Non-learning statue
ldquo1rdquo Temporary learning completed statue
ldquo2rdquo Learning Completed statue
3 Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
44
Initialization setting value for Supply pump
Replace
Initialization setting
value New data of Supply
PumpNew data of Supply
Pump
EEPROMsupply pump discharge
characteristic data
supply pump discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
45
Bagaimana mengganti Common Rail Common Rail tidak dapat dibongkar menjadi komponen yang terpisah ( harus diganti secara assy )
Pressure Sensor
Pressure
Limiter
Tidak dapat
dibongkar
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
46
Bagaimana cara memasukan QR code untuk injector baruSaat mengganti Injector atau ECU harus memasukan kembali QR Code dari Injector
New data
Re - Input
ganti Injector
ganti ECU
semua 4 Injectors
QR code baru
Engine ECU
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
47
Bagaimana memasukan QR code pada Injector
Saat mengganti InjectorSaat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT ndash3 Tester
Save data to MUT ndash3 Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input QR
code
Setting
Delete Code DTC P0604
Delete Code DTC P0604
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
48
Small injection Quantity Learning Procedure
PRASYARAT
- Engine coolant temperature 80ordmC atau lebih tinggi
- AT temperature 60ordmC atau lebih tinggi
- Lamps AC condenser fan and accessories OFF
- Transmission Neutral
- Power steering tidak dioperasikan
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
49
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
50
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
51
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
52
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
53
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
54
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
55
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
56
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
57
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
58
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
59
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
60
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
61
Injector ID Procedure
Penggantian Injector
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
62
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
63
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
64
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
65
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
66
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
67
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
68
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
69
Injector ID Procedure
Penggantian ECU
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
70
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
71
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
72
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
73
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
74
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
75
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
76
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
77
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
78
Supply Pump Initialization Procedure
PRASYARAT
- Engine coolant temperature 60ordmC atau lebih tinggi
- Fuel temperature 30ordmC atau lebih tinggi
- Accelerator pedal OFF
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
79
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
80
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
81
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
82
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
83
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector Seal
Gasket
Washer
O-Ring
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
85
Mengganti Rail baruMengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part yang diganti
Mengganti pipa baru
Injector
bullRailDischarge
pipe
bullSupply pump
bullRailInlet pipe
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
86
COMMON RAIL SYSTEMS
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
87
Procedure for fuel line replacement should be operated with attention to the cautionary statement
The contents of ldquoCAUTIONrdquo is the same as L200 4D56rsquos (see below)
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
88
Memeriksa kebocoran (Fuel System)1 IG switch OFF
No leakage
2 Engine Start
3 Ganti pipa pengembalian dan start Engine (tidak bisa hidup)
No leakage
4 Gunakan MUT-III memeriksa kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High voltage
Active TestbullInjector Cut 1bullInjector Cut 2bullInjector Cut 3bullInjector Cut 4
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
90
Penggantian Fuel Filter
From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter Warning switch
Water level warning switch
Fuel filter case (Aluminum)
Service Detail
Filter
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
91
Fuel Filter Structure
Filter
Fuel filter Warning switch
From Fuel Tank To Supply pump
Hand pump
Water level warning switch
Fuel filter case
(Aluminum)
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
92
Tersumbatnya Fuel filter akan dideteksi dengan Fuel filter warning switch
Combination meter
Fuel filter warning switch
Fuel Filter
warning lamp
Fuel FilterSaat Fuel filter terdapat beberapa masalah maka Fuel warning lamp akan menyala
tersumbat
Fuel Filter Warning Lamp
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
93
Combination meter
Fuel filter warning switch ECU
Combination meter
Filter
Fuel Filter warning
lamp
To Supply pump
Engine Speed sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
94
Warning Status Step
Water level warning
Flashing1
Fuel Filter warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter Water level warning lamp
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
95
Ketika Fuel filter warning lamp menyala berarti perlu untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka Fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
96
Melepas Filter
lepas Connector
lepas Inlet hose
Drain water
Fuel level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
97
Memasang kembali Fuel filter
Install Inlet and Outlet
hose
Install the fuel tank cap
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
98
Install fuel filter Reset warning lamp
Reset warning lamp
Within 3 ndash 60 sec
Connect the connector
IG ON
3 sec
OFF
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
99
Install fuel filter Reset warning lamp
Keluarkan udara dari Fuel systemHand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail
![Fuel System - SmartCockpit · Airbus A319-320-321 [Fuel System] Page 1. Airbus A319-320-321 [Fuel System] Page 2. Airbus A319-320-321 [Fuel System] Page 3](https://img.pdfslide.net/doc/110x75/5e92c30e78777b5f2b4e604d/fuel-system-airbus-a319-320-321-fuel-system-page-1-airbus-a319-320-321-fuel.jpg)
