EMISSIONS RECALL
AA2N0 PM SENSOR & ENGINE ECU SOFTWARE ENHANCEMENT
Subject:

PM Sensor & Engine ECU Software Enhancement

Date:

7-12-2016

Bulletin No.:

RCB-004-16

Recall No.:

AA2N0

Affected Models:

Certain 17MYCOE Trucks equipped with a J05 engine

IMPORTANT:
Verify the vehicle requires the work to be performed by referencing the vehicle by
VIN within the Hino Warranty System (DCS).
OVERVIEW:
The PM sensor of the subject vehicle population does not include the following necessary
monitors.
PM sensor tip clogged
PM sensor not in exhaust stream
PM sensor fixed resistance
PM sensor module performance (gain too high)
The following procedure provides direction for reprogramming the PM sensor and ECU
software to include the necessary monitors.

SUBJECT VEHICLES:
Certain 2017MY Hino COE trucks (155, 155h, 195 or 195h) equipped with a J05 engine.

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BEFORE YOU BEGIN
- Read and understand all instructions and procedures before you begin the work.
- Read and follow all NOTICES and WARNINGS set forth in this publication. These alerts help
to avoid damage to components, serious personal injury, or both.
- Park the vehicle on a level and solid surface and apply the parking brake.
- Confirm the engine is stopped, the starter switch is in the off (LOCK) position, and the key is
removed.
- Wear safety glasses to prevent eye injuries.
- Place wheel chocks in front of and behind all wheels.
- A battery charger is installed on the vehicle to ensure battery power does not go low during
reprogramming.
-The laptop battery state is fully charged or a remote AC power supply is hooked to the laptop
to ensure the battery power does not go low during reprogramming.

PARTS
PART NUMBER

89663-E3R42A
89663-E3R52A
COE PMS

DESCRIPTION

J05ETP Engine Control Unit (ECU)
Software
J05EUG Engine Control Unit (ECU)
Software
PM Sensor Software

VEHICLE PREPARATION
1. Park the vehicle on a level and solid surface.

QUANTITY

As Required By VIN
As Required By VIN
As Required By VIN

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2. Confirm the engine is stopped, the starter switch is in the off (LOCK) position, and the key is
removed.

3. Apply the parking brake.

4. Chock all of the wheels.

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PM SENSOR UPDATE WIZARD (PMSUW) PREPARATION
Overview
A special reprogramming application (PMSUW) is required to reprogram the PM sensor. It is
necessary to download the reprogramming application, as well as the new software files which
are required to update the PM sensor to the latest calibration. The PMSUW reprogramming
application needs to be installed on your computer. This may require IT support if access is
restricted regarding installation of programs on your computer’s hard drive.
PMSUW Installation
If using the PMSUW for the first time, download the “ReproTool.exe” file, the
“Conventional_PMS” software file, and the “COE_PMS” software file from the
http://www.Hinonet.net website. Save the files to the hard drive of your computer.

1. Right click on the desktop and select “New”, “Folder”.

2. Name the folder “Hino PM Sensor Software”.

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3. Log into Hinonet, go to the “Service” tab, “Tech Assist” then the “Recall Downloads” tab.

4. Double click the “File name PMReproV2.Zip” Select “Save As” and save it to the “Hino PM
Sensor Software” folder on the desktop.

5. Right click on the “File name PMRepro.ZIP” and select “Extract All”.

6. Save the files in the “Hino PM Sensor Software” folder. The PMSUW installation is
complete.

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PC PREPARATION

PC Power Management
WARNING: Disable the computer features listed below. Failure to disable these features may
severely damage the vehicle’s PM sensor.
1. Screen saver
2. Energy saving features
a. Monitor
b. Hard disks
c. System standby
NOTICE: The illustrations depict what you will see on your computer screen with regard to the
features which should be disabled. The location on the screen of the features to be disabled
will vary, however, based upon the operating software. Consult your IT department as required.
Interface
It is acceptable to use the DST-I (Software Version 2.0 or later) or the NEXIQ USB-Link™ 2
as an interface to perform this reprogramming procedure. If using a DST-i or NEXIQ interface
for the first time, a driver needs to be installed in order to use DST-i or NEXIQ USB-Link™ 2 on
your computer. The driver for DST-i can be downloaded from the DENSO website and the
driver for NEXIQ USB-Link™ 2 from the NEXIQ website. See below.
DENSO home page: http://www.ds3.denso.co.jp/gnrl/setup/
NEXIQ home page: http://nexiq.com/USBLink2Drivers

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PM SENSOR REPROGRAM REPAIR PROCEDURE

1. It is acceptable to use the DST-i (Software Version 2.0 or later) or the NEXIQ USB-Link™ 2
as an interface to perform this reprogramming procedure. To assemble the interface cable,
perform the following steps.
(1) Connect the DLC (Diagnostic Link Connector) cable to the interface.
(2) Connect the USB Cable to the interface.
(3) Connect the USB connector to the USB port on your computer.
NOTICE: DST-i with a software version below 2.0 will not work for this reprogramming
procedure. Also, the original “NEXIQ USB-Link” interface will not work for this reprogramming
procedure.

2. Locate the PM sensor on the passenger side frame rail, above the tailpipe.

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3. Disconnect the electrical connector to the PM sensor by pulling the yellow locking tab up
then pulling the connector out.
NOTICE: To prevent damage to the PM sensor, make certain the key is removed from the
ignition switch prior to disconnecting the PM sensor.

4. Connect the male end of the PM sensor reprogramming harness to the vehicle harness
connector. Ensure the yellow locking tab is engaged. Connect the female end of the PM sensor
reprogramming harness to the PM sensor. Ensure the yellow locking tab is engaged.

5. Connect the PM sensor reprogramming harness to the interface (NEXIQ USB Link 2 or
DST-i).

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6. Ensure that the power switch on the PM sensor reprogramming harness is set to the “OFF”
position.

7. Insert the ignition key into the starter switch and turn the key to the “ON” position.

8. Open the “ReproTool.exe” application that was saved to the Hino PM Software Folder on
your desktop.

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9. Select the “Configuration” icon.

10. Select the “Load Programming File” icon.

11. From the “Hino PM Sensor Software” folder previously saved to your desktop, select the
“COE_PMS_R1.s19” file and then select the “Open” icon.

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12. Under “Used Device”, select either DST-i, or USB-Link2 depending on the interface you are
using.

13. Select the “Set” icon.

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14. Select the “PC Check” icon.

15. Select the “Check” icon.
NOTICE: Ensure that the driver of the connected interface device (DST-i or NEXIQ USBLink™ 2) is installed and that the interface device is properly connected.

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16. The PM sensor can be reprogrammed if “[OK]” is displayed on both top and bottom rows as
shown on the left, below. If OK, select the “Return” icon.
“[NG]” will be displayed on the top row if the driver of the interface device is not installed.
Install the driver as per the manual for the interface and then perform the “PC Check” again.
“[NG]” will be displayed on the bottom row if the interface device is not properly connected.
Ensure that the cables are connected and the interface device is turned on (DST-i has an
ON/OFF switch). Ensure that the correct device is selected for “Used device” under
“Configuration” (step 7, above). Select the “Return” icon to go back to the main menu.

17. Select the “Reprogram” icon.

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18. Select the “Connect” icon.

NOTICE: If a connection error is displayed, repeat steps 1-18 and ensure all steps were
performed correctly.

19. Once prompted, turn the power switch on the PM sensor reprogramming harness to the
“ON” position within 10 seconds after clicking the “Connect” icon. Select the “Boot Mode” icon
once it is selectable. Repeat steps 15 through 19 if the “Boot Mode” icon does not become
selectable.
NOTICE: The “Please Wait!” warning will remain flashing throughout this procedure.
NOTICE: The “Turn on Power supply switch on to sensor within 10 seconds” message will be
displayed throughout this procedure. The power switch is to remain “ON” until step 24, below.

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20. Select the “Erase” icon once it becomes selectable.

21. Select the “Blank” icon once it becomes selectable.

22. Select the “Program” icon once it becomes selectable.

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23. Monitor the programming progress bar. If the progress bar reaches 100% and no errors
are shown, select the “Return” icon and proceed to step 24, below.
”Writing error [Time out]” will be displayed if the programming fails. Close the window and
proceed to step 23a, below.

NOTICE: Skip steps 23a through 23d if programming was successful on step 23, above.
23a. Repeat steps 15 through 17, above. Ensure the PM sensor reprogramming sensor
harness switch is set to the “OFF” position before selecting the “Connect” icon. Select the
“Connect” icon.

23b. Turn the power switch on the PM sensor reprogramming harness to the “ON” position
within 10 seconds after selecting the “Connect” icon as per the instruction on the screen.

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23c. Select the “Forced Connect” icon once it is selectable.

23d. Repeat steps 19 through 23, above.
If programming is now successful, proceed to step 24, below.
If programming fails again, repeat steps 23a through 23d once more. If you receive a “Writing
Error, [time out]” after three failed reprogramming attempts, the PM sensor is faulty and will
require replacement. After replacing the PM sensor, validate it has the latest software by
performing steps 25 through 28, below. If the new sensor is not at the latest software level,
repeat this procedure from the beginning to update the software on the replacement PM
sensor.

24. Turn the power switch on the PM sensor reprogramming harness to the “OFF” position.

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25. Select the “Sensor Version” icon.

26. Turn the power switch on the PM sensor reprogramming harness to the “ON” position and
select the “Version Check” icon.
NOTICE: If a communication failure message is displayed after selecting the “Version Check”
icon, repeat steps 24 through 26, to validate the sensor version.

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27. Verify that the PM sensor software version was updated to the correct level. Refer to the
image below for the proper CAL_ID and CVN of the updated PM sensor software. If the
CAL_ID and CVN match the image shown below, reprogramming was successful. Select the
“Return” icon to go back to the main menu and exit the program.
CAL_ID= 3037H
CVN=0a52H

28. Turn the power switch on the PM sensor reprogramming harness to the “OFF” position,
and turn the ignition key switch to the “OFF/Lock” position and remove the key from the starter
switch.

29. Disconnect the PM sensor reprogramming harness from the vehicle harness connector by
releasing the yellow locking tab. Disconnect the PM sensor reprogramming harness from the
PM sensor by releasing the yellow locking tab.
NOTICE: To prevent damage to the PM sensor, make certain the key is removed from the
ignition switch prior to disconnecting the PM sensor.

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30. Connect the electrical connector to the PM sensor. Ensure the yellow locking tab is pushed
down to lock the connector in place.

31. The preferred method to show the recall has been performed is to install a white paint mark
on the PM sensor housing as shown in the photograph below.

32. The PM sensor reprogram repair procedure is complete. Proceed to the engine ECU
reprogramming procedure.

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ENGINE ECU REPROGRAM REPAIR PROCEDURE:

1. It is acceptable to use the DST-i or the NEXIQ USB-Link™ 2 as an interface to perform this
reprogramming procedure. To assemble the interface cable, perform the following steps.
(1) Connect the DLC (Diagnostic Link Connector) to the interface.
(2) Connect the USB Cable to the interface.
(3) Connect the USB connector to the USB port on your computer.

2. Connect the DLC cable to the vehicle’s DLC connector. The DLC connector is found under
the dash on the left side of the steering column.

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WARNING: Disable the computer features listed below. Failure to disable these features may
severely damage the vehicle’s ECU.
1. Screen saver
2. Energy saving features
a. Monitor
b. Hard disks
c. System standby
NOTICE: The illustrations above depict what you will see on your computer screen with regard
to the features which must be disabled. The location on the screen of the features to be
disabled will vary based upon the operating software. Consult your IT department as required.
3. On your computer, locate the “Hino DX2” icon and open it.

4. Hino DX2 will prompt you for a “User ID” and “Password”. Enter your User ID, password
and then select the “Login” icon.

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5. Insert the ignition key into the starter switch and turn the key to the “ON” position.

6. Select the “Reprogramming” icon.

7. Select “300 Series” under the “Vehicle Classification” drop down menu.

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8. Select “Engine J-Series” under the “System Classification” drop down menu and then select
the “OK” icon.

9. Inspect the current ECU software level based on the following table:
J05ETP Engine Control Unit (ECU) Software

89663-E3R42A

J05ETP Engine Control Unit (ECU) Software

89663-E3R52A

Does the current ECU software level match one of the software part numbers above?
Yes - ECU software reprogramming is NOT required, proceed to step 22.
No - ECU software reprogramming is required, proceed to step 10.

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10. Select the “Click” button.

11. Select the “Browse” icon and locate the appropriate ECU software part number based on
the following table:
J05ETP Engine Control Unit (ECU) Software

89663-E3R42A

J05ETP Engine Control Unit (ECU) Software

89663-E3R52A

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12. Select “ECU Program Update” under the “Contents of Work” drop down menu.

13. Select the “Write To ECU” icon.
Note: The “Judgment” should be the color green or the color yellow. If the color red is shown,
reconfirm your software versions and battery status for the vehicle and laptop.

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14. Once the ECU programming is complete, the “Finish” icon will be made available to select.
Select the “Finish” icon.

15. Turn the starter switch to the “LOCK” position and remove the key.

16. Insert the ignition key into the starter switch and turn the key to the “ON” position.

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17. During ECU software reprogramming, other DTC’s may have been set. These DTC’s will
need to be cleared prior to completing this Emissions Recall. Select the “Diagnosis” icon.

18. Check mark the “Device Classification”. This should automatically check mark the
remaining devices. Select the “Read Out” icon.

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19. Select the “Delete All” icon.

20. Select the “Delete” icon.

21. ECU reprogramming is complete. Select the “OK” icon.

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22. Select the “New Diagnosis” icon.

23. Select the “OK” icon.

24. Turn the starter switch to the “LOCK” position and remove the key.

25. Proceed to the final inspection section to complete this recall procedure.

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FINAL INSPECTION

1. To complete this recall procedure, review the recall and confirm the following:
The PM sensor software reprogramming recall has been completed prior to performing this
procedure.
When reprogramming the PM sensor and engine ECU, DTC’s may have inadvertently been set
in the engine ECU. Make certain that all codes logged as a result of the ECU reprogramming
have been cleared from the Engine ECU, Transmission ECU, ABS ECU, DCU and VCS prior to
releasing the truck back to the customer.

CLAIM APPLICATION
PM Sensor and Engine ECU Reprogramming:
a) Recall No: AA2N0
b) Labor charge: 1.3hr
c) Warranty code: 86311
d) Trouble code: 98
e) Operation code: 86350AOT
f) Original failed part: 9999999999