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Mahindra Maxximo Mini Van Vx 2012, Diagnostic Manual

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© 

2012 Mahindra & Mahindra Ltd

. All rights reserved. This book may not be reproduced or copied, in whole or in 

part, without the written permission of Mahindra & Mahindra Ltd. 

EMS DIAGNOSTIC MANUAL 

 

      

  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

 

    

MAN-00183

 

www.teknetmahindra.com 

ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP-TO-DATE AT THE TIME OF PUBLICATION. 
HOWEVER, SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE. THIS 
MANUAL IS STRICTLY MEANT FOR RESTRICTED INTERNAL CIRCULATION WITHIN M&M AUTHORIZED 
DEALER SERVICE CENTERS

. 

RELEASED BY – 

 

TECHNICAL PUBLICATION CELL 
MAHINDRA & MAHINDRA LTD. 

 

Rev1 – JUNE 2012

 

       

 

Summary of Contents for Maxximo Mini Van Vx 2012

Page 1: ...AL MAN 00183 www teknetmahindra com ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP TO DATE AT THE TIME OF PUBLICATION HOWEVER SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE TH...

Page 2: ...d use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 2 ABOUT THE EMS DIAGNOSTIC MANUAL The EMS Engine Management System diagnostic manual outlines the detailed procedures to tr...

Page 3: ...the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 3 CONTENTS 1 HOW...

Page 4: ...on the group under which the DTC appears The codes groups are hyperlinked to the respective trouble shooting chart pages The following is the structure of the Diagnostic Manual Brief description abou...

Page 5: ...Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 5 2 OVERVIEW OF THE IN VEHICLE NETWORK 3 RECOMMENDED TROUBLE SHOOTING PROCESS ENGINE EMS ECU...

Page 6: ...gine needs precise metering of fuel Due to manufacturing tolerances each injector deviates slightly from its idealized behavior Thus each injector has a correction factor which is engraved on top of i...

Page 7: ...ECU PROGRAMMING FLASHING The EMS ECU required to be flashed in the following conditions BLANK ECU 1 Procure blank EMS ECU from spare part dept ECU Part No 0315CAU00091N for C 55 Check for the correct...

Page 8: ...e Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 8 Notes 1 Ensure that the there is no communication breakdown o...

Page 9: ...ten consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use a...

Page 10: ...he prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unaut...

Page 11: ...Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty p...

Page 12: ...sor P0340 Camshaft failure due to no camshaft signal 39 P0341 Camshaft failure due to wrong camshaft signal Crankshaft speed sensor P0336 Crankshaft failure due to wrong crankshaft signal 49 P0335 Cra...

Page 13: ...excess temperature P0406 Exhaust Gas Recirculation Actuator power stage short circuit to battery P0405 Exhaust Gas Recirculation Actuator power stage short circuit to ground Fan control Relay P0480 F...

Page 14: ...it to battery P1655 System lamp short circuit to ground CAN U0073 CAN Bus OFF error No communication with smart tester 153 Injector 1 P126C No load on cylinder 1 reported 158 P0261 Cylinder1 Injector...

Page 15: ...901 Error during SOP test Uncertain cause P1902 Diagnostic fault check to report the ADC test error P1903 Diagnostic fault check to report the error in voltage ratio in ADC monitoring P1904 Diagnostic...

Page 16: ...ntity correction P1919 plausibility error in rail pressure monitoring P1670 Shut off request of injection cut off 192 P191A Diagnostic fault check to report the error due to torque comparison 193 P191...

Page 17: ...vehicle speed not valid Ignition key status P1658 Ignition key status wrong 231 Engine Over Heating P1503 Coolant temperature above critical limit Engine over heating 234 Fuel temperature high P1183...

Page 18: ...ument are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mah...

Page 19: ...rs These sensors are of variable resistance potentiometers type whose resistance changes according to the pedal position The ECU supplies a reference voltage to the APM sensor and measures the output...

Page 20: ...a Mahindra Ltd 20 DTC Detecting Condition Probable Causes An excessively low voltage 0 Volts from the APP1 sensor is sent to ECU An excessively high voltage 3 5 Volts for C04 ECU and 5 25 for C55 ECU...

Page 21: ...sent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shal...

Page 22: ...tten consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use...

Page 23: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 24: ...r pedal sensor connector DISCONNECTED ECU connector CONNECTED Turn ignition ON Measure the voltage between pin D of the accelerator pedal connector and battery negative Step 1 Connect the smart tester...

Page 25: ...penalty prosecution 2012 Mahindra Mahindra Ltd 25 Ignition OFF Examine the short circuit of reference line to ground line Repair replace the wiring harness Clear the error codes and verify Step 3 Go t...

Page 26: ...Accelerator pedal sensor connector DISCONNECTED ECU connector CONNECTED Check the continuity between pin D and pin F of the accelerator pedal sensor connector Step 6 Does continuity exist YES Ignition...

Page 27: ...edal sensor connector DISCONNECTED ECU Connector DISCONNECTED Check the continuity between pin E of the accelerator pedal sensor connector and pin 83 of ECU connector Step 7 Does continuity exist Igni...

Page 28: ...le for penalty prosecution 2012 Mahindra Mahindra Ltd 28 Step 10 Ignition OFF Accelerator pedal sensor connector DISCONNECTED Check and confirm the accelerator pedal sensor pins are free of any oxidat...

Page 29: ...sors These sensors are variable resistance potentiometers whose resistance changes according to the pedal position The ECU applies a reference voltage to the APM sensor and then measures the voltage t...

Page 30: ...30 DTC Detecting Condition Probable Causes An excessively low voltage 0 Volts from the APP2 sensor is sent to ECU An excessively high voltage 1 65 V for C04 ECU and 2 5 V for C55 ECU from the APP2 se...

Page 31: ...sent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shal...

Page 32: ...tten consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use...

Page 33: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 34: ...to Step 3 Ignition OFF Accelerator pedal sensor connector DISCONNECTED ECU connector CONNECTED Check the continuity between pin A and pin B of the accelerator pedal sensor connector Step 2 NO Is volt...

Page 35: ...penalty prosecution 2012 Mahindra Mahindra Ltd 35 Step 4 Go to Step 5 Ignition OFF Accelerator pedal sensor connector DISCONNECTED ECU Connector DISCONNECTED Check the continuity between pin A of acce...

Page 36: ...ty exist YES Ignition OFF Accelerator pedal sensor connector DISCONNECTED ECU connector CONNECTED Check the continuity between pin A and pin C of the accelerator pedal sensor connector Step 6 Does con...

Page 37: ...edal sensor connector DISCONNECTED ECU Connector DISCONNECTED Check the continuity between pin B of the accelerator pedal sensor connector and pin 82 of ECU connector Step 7 Does continuity exist Igni...

Page 38: ...le for penalty prosecution 2012 Mahindra Mahindra Ltd 38 Step 9 Step 10 Ignition OFF Accelerator pedal sensor connector DISCONNECTED Check and confirm the accelerator pedal sensor pins are free of any...

Page 39: ...nt document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahind...

Page 40: ...for reference and senses the Top dead center TDC of the No 1 cylinder in the compression stroke and allows the ECU to determine when to start the injection Sl No DTC Description 1 P0340 Camshaft failu...

Page 41: ...prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unautho...

Page 42: ...ent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall...

Page 43: ...tten consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use...

Page 44: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 45: ...Go to Step 4 Go to Step 3 Is voltage 4 7 to 5 25V NO Ignition OFF Cam phase sensor connector DISCONNECTED ECU connector CONNECTED Check the continuity between pin 3 and pin 1 of the cam phase sensor...

Page 46: ...r penalty prosecution 2012 Mahindra Mahindra Ltd 46 Does continuity exist Go to Step 5 Ignition OFF Cam phase sensor connector DISCONNECTED ECU Connector DISCONNECTED Check the continuity between pin...

Page 47: ...nition OFF Cam phase sensor connector DISCONNECTED ECU connector CONNECTED Check the continuity between pin 3 and pin 2 of the cam phase sensor connector Step 6 Does continuity exist YES Ignition OFF...

Page 48: ...DISCONNECTED ECU Connector DISCONNECTED Check the continuity between pin 1 of the cam phase sensor connector and pin 44 of ECU connector Step 7 Does continuity exist Ignition OFF Examine the open circ...

Page 49: ...ocument are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra M...

Page 50: ...SHAFT SPEED SENSOR COMPONENT LOCATION SL NO DTC DESCRIPTION 1 P0336 Crankshaft failure due to wrong crankshaft signal 2 P0335 Crankshaft failure due to no crankshaft signal NORMAL OPEARTION When engin...

Page 51: ...use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 51 DTC Detecting Condition Probable Causes The crankshaft speed sensor signal is not detected by the ECU in the first few se...

Page 52: ...n consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and...

Page 53: ...prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unautho...

Page 54: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 55: ...cution 2012 Mahindra Mahindra Ltd 55 YES Turn ignition OFF Crankshaft speed sensor connector DISCONNECTED Check the continuity between pin 1 and pin 2 of the crankshaft speed sensor connector Step 1 I...

Page 56: ...NO Does continuity exist Ignition OFF Examine the open circuit Repair Replace the wiring harness Clear the error codes and verify Step 5 Ignition OFF Crankshaft speed sensor connector DISCONNECTED ECU...

Page 57: ...liable for penalty prosecution 2012 Mahindra Mahindra Ltd 57 Ignition OFF Crankshaft speed sensor connector DISCONNECTED ECU connector CONNECTED Check the resistance between pin 1 and pin 2 of the cra...

Page 58: ...ocument are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra M...

Page 59: ...a Ltd 59 FUEL TEMPERATURE SENSOR COMPONENT LOCATION Sl No DTC DESCRIPTION 1 P0183 Fuel Temperature sensor voltage above upper limit 2 P0182 Fuel Temperature sensor failure voltage below lower limit NO...

Page 60: ...er than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 60 DTC De...

Page 61: ...consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and s...

Page 62: ...rior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthori...

Page 63: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 64: ...U connector CONNECTED Check the continuity between pin 2 and pin 1 of the fuel temperature sensor Turn ignition OFF Fuel temperature sensor connector DISCONNECTED ECU connector CONNECTED Turn ignition...

Page 65: ...Fuel temperature sensor connector DISCONNECTED ECU connector DISCONNECTED Check the continuity between pin 1 of the fuel temperature sensor connector and pin 12 of the ECU connector Does continuity ex...

Page 66: ...2 Mahindra Mahindra Ltd 66 RESISTANCE OF THE FTS AT VARIOUS TEMPERATURES OF THE FUEL Temperature Min Resistance Max Resistance 20 C 2 351 K 2 649 K 40 C 1 118 K 1 231 K Ignition OFF Check for poor ter...

Page 67: ...document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra...

Page 68: ...ahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 68 RAIL PRESSURE SENSOR COMPONENT LOCATION Sl No DTC Description 1 P0193 Rai...

Page 69: ...penalty prosecution 2012 Mahindra Mahindra Ltd 69 NORMAL OPERATION The ECU supplies a reference voltage to the rail pressure sensor The rail pressure sensor output voltage varies with variation in ra...

Page 70: ...en consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use an...

Page 71: ...en consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use an...

Page 72: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 73: ...ity exist YES Go to Step 4 Go to Step 3 Is voltage 4 7 to 5 25V NO Ignition OFF Rail pressure sensor connector DISCONNECTED ECU connector CONNECTED Check the continuity between pin 3 and pin 1 of the...

Page 74: ...nalty prosecution 2012 Mahindra Mahindra Ltd 74 Go to Step 5 NO Go to Step 5 Ignition OFF Rail pressure sensor connector DISCONNECTED ECU Connector DISCONNECTED Check the continuity between pin 3 of r...

Page 75: ...FF Rail pressure sensor connector DISCONNECTED ECU connector CONNECTED Check the continuity between pin 3 and pin 2 of the rail pressure sensor connector Step 6 Does continuity exist YES Ignition OFF...

Page 76: ...pressure sensor connector DISCONNECTED ECU Connector DISCONNECTED Check the continuity between pin 1 of the rail pressure sensor connector and pin 76 of ECU connector Step 7 Does continuity exist Igni...

Page 77: ...osecution 2012 Mahindra Mahindra Ltd 77 Ignition ON Rail pressure sensor connector CONNECTED ECU connector CONNECTED Start the Engine Using Smart tester check the output of RPS Step 9 Is it 600 to 850...

Page 78: ...positive deviation of rail pressure exceeded concerning set value PCV NORMAL OPERATION The ECU compares the rail pressure monitored by the rail pressure sensor against the expected pressure generated...

Page 79: ...Ltd 79 NO Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the error codes and clear Turn ignition OFF Turn ignition ON Verify if P1492 or P1493 is present Is P1492...

Page 80: ...and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 80 Check for any loose connections in the pre supply fuel pump Check and confirm the pre supply pump functions properly Clear th...

Page 81: ...ndra Ltd 81 RAIL PRESSURE DEVIATION Sl No DTC Description 1 P1494 maximum negative rail pressure deviation with closed pressure control valve exceeded NORMAL OPERATION The negative rail pressure devia...

Page 82: ...IATION Sl No DTC Description 1 P1495 minimum rail pressure exceeded NORMAL OPERATION The rail pressure is within the limit based on the engine speed DTC Detecting Condition Probable Causes The rail pr...

Page 83: ...be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 83 RAIL PRESSURE DEVIATION Sl No DTC Description 1 P1496 maximum rail pressure exceeded NORMAL OPERATION The rail pressure is within the li...

Page 84: ...DTC Description 1 P1190 Rail pressure sensor raw value is above maximum offset NORMAL OPERATION The ECU monitors the rail pressure in the system has been reduced to the level of the atmospheric press...

Page 85: ...o DTC Description 1 P1191 Rail pressure sensor raw value is below minimum offset NORMAL OPERATION The ECU monitors the rail pressure in the system has been reduced to the level of the atmospheric pres...

Page 86: ...ument are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mah...

Page 87: ...the cylinder head The sensor uses a thermistor which is sensitive to the change in temperature The thermistor resistance changes as the temperature of the engine coolant flowing past the sensor change...

Page 88: ...to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 88 DTC Detecting Condition Probable Causes An excessively low voltage from the sensor is sent to ECU An exces...

Page 89: ...ent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall...

Page 90: ...rior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthori...

Page 91: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 92: ...CONNECTED ECU connector CONNECTED Check the continuity between pin 2 and pin 1 of the coolant temperature sensor YES Does continuity exist Ignition OFF Examine the short to ground Repair replace the w...

Page 93: ...F Coolant temperature sensor connector DISCONNECTED ECU connector DISCONNECTED Check the continuity between pin 1 of the coolant temperature sensor connector and pin 33 of the ECU connector Does conti...

Page 94: ...indra Ltd 94 RESISTANCE OF THE CTS AT VARIOUS TEMPERATURES OF THE FUEL Temperature Min Resistance Max Resistance 20 C 2 351 K 2 649 K 40 C 1 118 K 1 231 K 80 C 0 313 K 0 332 K Step 6 Ignition OFF Cool...

Page 95: ...esent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mah...

Page 96: ...VALVE MODULATOR COMPONENT DESCRIPTION A pulse width modulated signal is output for the Exhaust Gas Recirculation actuator control The ECU derives the duty cycle based on the engine speed and injector...

Page 97: ...and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 97 NORMAL OPERATION The engine runs based on the EGR mapping ECU supplies PWM signal as ground to the EGR modulator DTC Detectin...

Page 98: ...r written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized...

Page 99: ...t the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to un...

Page 100: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 101: ...ndra Ltd 101 NO Is the voltage is 12Volts Ignition OFF Check and verify the 15 amps EGR fuse is Okay Step 2 Go to Step 4 Turn ignition ON EGR actuator connector DISCONNECTED ECU connector CONNECTED Tu...

Page 102: ...2 of the EGR actuator connector and terminal 87 of the ECU relay Step 3 Does continuity exist Ignition OFF Repair the open circuit Clear the error codes and verify Ignition OFF Check for proper funct...

Page 103: ...shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 103 Radiator Cooling Fan COMPONENT DESCRIPTION The fan is located behind the Radiator It is an electrical motor run by a 12V supply...

Page 104: ...ble for penalty prosecution 2012 Mahindra Mahindra Ltd 104 NORMAL OPERATION When the engine coolant temperature rises above 97 deg Celsius ECU actuates the radiator fan relay and the Fan motor gets th...

Page 105: ...esent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mah...

Page 106: ...out the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to...

Page 107: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 108: ...ty prosecution 2012 Mahindra Mahindra Ltd 108 Clear the error codes and verify Turn ignition OFF Ensure that the fan relay is inserted properly in the connector Remove the relay Give 12 volts to termi...

Page 109: ...the fan relay in its position Turn ignition ON Check voltage between terminal 86 of fan relay connector and battery ground Is the voltage 12 Volts YES NO Step 3 Turn ignition OFF Fan relay REMOVED EC...

Page 110: ...Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 110 Check fan relay terminals for oxidation da...

Page 111: ...t document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindr...

Page 112: ...PRESUPPLY PUMP COMPONENT DESCRIPTION The pre supply pump is located inside the fuel tank It is an electrical pump run by a 12V supply from battery and controlled by ECU It creates a positive suction...

Page 113: ...other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 113 D...

Page 114: ...rror codes and verify Check the 15Amps fuse of the pre supply pump Ignition OFF Replace the fuse Clear error codes and verify NO YES Go to Step 3 Is the fuse Okay Is the voltage 12Volts Go to Step 8 C...

Page 115: ...circuit Clear the error codes and verify YES NO Is the voltage is 12V Ignition OFF Check the continuity between pin 30of the pre supply pump relay connector and pin 87 of the ECU main relay connector...

Page 116: ...Check the continuity between pin 68 of ECU connector and pin 85 of the pre supply pump relay connector Does continuity exist Ignition OFF Repair the open circuit Clear the error codes and verify Ignit...

Page 117: ...e Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 117 BRAKE SWITCH COMPONENT DESCRIPTION The b...

Page 118: ...NENT LOCATION Sl No DTC Description 1 P1792 Brake signal not plausible 2 P1791 Brake signal received is defective NORMAL OPERATION The brake main switch sends the output of 12V to ECU if the pedal is...

Page 119: ...hout the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to...

Page 120: ...consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and s...

Page 121: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 122: ...battery negative Step 1 Clear the error codes and verify Go to Step 5 YES Is the voltage 12Volts NO Go to Step 4 Is the voltage 12 Volts Step 2 Turn ignition ON ECU connector DISCONNECTED Brake switc...

Page 123: ...ED Brake switch connector CONNECTED Check the voltage between pin 24 of the ECU connector and battery negative in brake pedal released condition Go to Step 6 Is the voltage 12Volts NO Go to Step 7 YES...

Page 124: ...amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 124 CLUTCH SWITCH Turn ignition OFF Check for any loose connections or pin oxidation Rectify if found...

Page 125: ...nt document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahind...

Page 126: ...ra Ltd 126 CLUTCH SWITCH COMPONENT DESCRIPTION The clutch switch is located on the clutch pedal assembly The signal is checked for plausibility using gear information For C04 Clutch switch is a normal...

Page 127: ...be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 127 DTC Detecting Condition Probable Causes The switch output voltage remains in 12 V even after pressing the clutch pedal For C04 The sens...

Page 128: ...t the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to un...

Page 129: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 130: ...to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 130 Procedure Clear the error codes and verify Connect the smart tester Turn the ignition ON Initialize the d...

Page 131: ...ra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 131 Does continuity exist NO Ignition OFF Repair replace the open circuit in the...

Page 132: ...32 Ignition OFF ECU connector DISCONNECTED Clutch switch connecter CONNECTED Clutch pedal in pressed condition and check the continuity between ECU connector pin 23 and battery negative Step 3 Ignitio...

Page 133: ...amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 133 ECU MAIN RELAY Sl No DTC Description 1 P121B Main relay opens too early 2 P121A Main relay sticky...

Page 134: ...nt document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahind...

Page 135: ...ignition ON Clear the error codes and verify Turn ignition OFF Ensure that the main relay is inserted properly in the connector Remove the relay Give 12 volts to terminal 86 and ground the terminal 8...

Page 136: ...the voltage 12 Volts YES NO Step 3 Turn ignition OFF Main relay connector DISCONNECTED ECU connector DICONNECTED Check continuity between terminal 87 of main relay connector and terminal 4 of ECU con...

Page 137: ...012 Mahindra Mahindra Ltd 137 Turn Ignition OFF Main relay connector DISCONNECTED ECU connector DICONNECTED Check continuity between terminal 85 of Main relay connector and terminal 50 of ECU connecto...

Page 138: ...ge has to guarantee to perform diagnosis functions The Electronic Control Unit ECU monitors battery voltage COMPONENT LOCATION Sl No DTC Description 1 P563 Battery voltage above upper limit 2 P562 Bat...

Page 139: ...uthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 139 BATTERY TESTING PROCEDURE Check charging system including battery for proper operation Refer the charging syste...

Page 140: ...ocument are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra M...

Page 141: ...NET DESCRIPTION The PCV is located on the common rail assembly Pressure is built up in common rail by the high pressure pump As name signifies PCV controls the pressure in common rail as per the comma...

Page 142: ...he Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 142 DTC Detecting Condition Probable Causes...

Page 143: ...the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unau...

Page 144: ...ithout the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount...

Page 145: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 146: ...12 Mahindra Mahindra Ltd 146 Ignition OFF Check and verify the 15 amps fuse of PCV EGR is Okay Is the voltage 12Volts Step 2 Go to Step 4 Turn ignition ON PCV connector DISCONNECTED ECU connector CONN...

Page 147: ...nuity between pin 2 of the PCV connector and terminal 87 of the main relay Step 3 Does continuity exist Ignition OFF Repair the open circuit Clear the error codes and verify Ignition OFF Check for pro...

Page 148: ...document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra...

Page 149: ...dra Mahindra Ltd 149 SYSTEM CHECK LAMP POWER STAGE FAULT STATUS NORMAL OPERATION When the ignition is switched ON the system check lamp will glow ON for 02 seconds and will get switched OFF if no erro...

Page 150: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 151: ...all be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 151 Connect the smart tester Turn the ignition ON Initialize the diagnostic tool Record the DTC and clear Turn ignition OFF Turn igniti...

Page 152: ...he system check lamp glows YES NO Ignition OFF Lamp failed Replace the instrument cluster Clear the error codes and verify Ignition OFF Check for damage oxidation in instrument cluster and ECU connect...

Page 153: ...Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for p...

Page 154: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 155: ...rized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 155 Step 2 Turn ignition OFF Check voltage at terminal 16 of the Diagnostic connector and battery negative Step 1 Is th...

Page 156: ...ra Mahindra Ltd 156 Step 4 Turn ignition OFF Diagnostic connector DISCONNECTED Check continuity between terminals 4 5 and battery negative terminal Does continuity exist YES NO Turn ignition OFF ECU c...

Page 157: ...ONNECTED Diagnostic hardware is faulty Step 5 Turn ignition OFF ECU connector DICONNECTED Check continuity between terminal 14 of Diagnostic connector and terminal 65 of ECU connector Does continuity...

Page 158: ...e and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 158 FUEL INJECTOR 1 COMPONENT DESCRIPTION The ECU controls the injection quantity and injection timing based on the system pres...

Page 159: ...consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and s...

Page 160: ...ritten consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized us...

Page 161: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 162: ...se and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 162 Is continuity exits YES Ignition OFF Repair the short circuit Clear the error codes and verify Go to Step 2 Turn ignition...

Page 163: ...alty prosecution 2012 Mahindra Mahindra Ltd 163 Ignition OFF Injector 1 connector DISCONNECTED ECU connector DISCONNECTED Check the continuity between pin 2 of the injector connector and pin 73 of the...

Page 164: ...e of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 164 Ignition OFF Check the resistance between pin 1 and pin 2 of the i...

Page 165: ...ed use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 165 FUEL INJECTOR 2 COMPONENT DESCRIPTION The ECU controls the injection quantity and injection timing based on the system...

Page 166: ...tten consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use...

Page 167: ...written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized u...

Page 168: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 169: ...se and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 169 Is continuity exits Ignition OFF Repair the short circuit Clear the error codes and verify Go to Step 2 Turn ignition OFF...

Page 170: ...nalty prosecution 2012 Mahindra Mahindra Ltd 170 Ignition OFF Injector 2 connector DISCONNECTED ECU connector DISCONNECTED Check the continuity between pin 2 of the injector connector and pin 7 of the...

Page 171: ...e of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 171 Ignition OFF Check the resistance between pin 1 and pin 2 of the i...

Page 172: ...d personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 172 SHORT CIRCUIT OF INJECT...

Page 173: ...he ignition ON Initialize the diagnostic tool Record the error codes and clear Turn ignition OFF Turn ignition ON Verify if P0262 or P0265 or P0202 is present Turn ignition OFF Injector 1 connector DI...

Page 174: ...tre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 174 OFFSET BETWEEN CRANKSHAFT AND CAMSHAFT DTC Detecting Condition P...

Page 175: ...nt of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall...

Page 176: ...ten consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use a...

Page 177: ...sent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shal...

Page 178: ...prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthor...

Page 179: ...ution 2012 Mahindra Mahindra Ltd 179 Check the crank Check the crankshaft sensor and its wiring harness refer crankshaft speed sensor section Check the crankshaft speed sensor for any nicks Check the...

Page 180: ...mount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 180 NO Step 4 YES Is the camphase sensor mounting bolt loose YES Tighten the mounting bolt Clear the er...

Page 181: ...ture After that when the engine runs then the temperature output on a time frame is detected and compared against predetermined slope NORMAL OPERATION The Engine coolant temperature raises to a specif...

Page 182: ...ature sensor Repair the wiring harness if the problem is in wiring harness Clear the error codes and verify Install a new thermostat in the cooling circuit Clear the error codes and verify Check for p...

Page 183: ...ngine check lamp ON TEST PROCEDURE 1 Switch ON Ignition 2 Using Smart Tester clear the ECU faults 3 Switch OFF Ignition key and wait for 2 minutes 4 Switch ON Ignition 5 Using smart tester check wheth...

Page 184: ...EEPROM access An incorrect IQA IMA codes is programmed into the ECU LAMP STATUS Engine check lamp ON TEST PROCEDURE Program the IQA codes whenever an Injector ECU or Engine is replaced Smart Tester h...

Page 185: ...mistake for example you type AHH48BE instead of AHH48EB the software will accept the code and send it to the ECU However the ECU will reject it and display a message saying IQA code NOT flashed Progr...

Page 186: ...E ECU LAMP STATUS Engine check lamp ON TEST PROCEDURE 1 Switch ON Ignition 2 Using Smart Tester clear the ECU faults 3 Switch OFF Ignition key and wait for 2 minutes 4 Switch ON Ignition 5 Using smart...

Page 187: ...N 1 P0108 Environment Pressure Sensor voltage above upper limit 2 P0107 Environment Pressure Sensor voltage below lower limit LAMP STATUS Engine check lamp OFF FAULT REACTION No reaction TEST PROCEDUR...

Page 188: ...03 Diagnostic fault check to report the error in Voltage ratio in ADC monitoring 5 P1904 Diagnostic fault check to report errors in query response communication 6 P1905 interrupted SPI communication 7...

Page 189: ...enalty prosecution 2012 Mahindra Mahindra Ltd 189 FAULT REACTION Engine shuts off TEST PROCEDURE 9 Switch ON Ignition 10 Using Smart Tester clear the ECU faults 11 Switch OFF Ignition key and wait for...

Page 190: ...d 190 LAMP STATUS Engine check lamp ON FAULT REACTION ECU Reset Injection cut off above 1500 RPM Engine shut off above 1720 RPM Sl No DTC DESCRIPTION 1 P1912 Impermissible offset between the engine sp...

Page 191: ...hall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 191 TEST PROCEDURE 1 Switch ON Ignition 2 Using Smart Tester clear the ECU faults 3 Switch OFF Ignition key and wait for 2 minutes 4 S...

Page 192: ...sed to do so it takes cognizance of the injections which are supposed to take place due to ZFC and FBC this is above that If it is more than 8 times then the reaction is injection cut off ECU Failure...

Page 193: ...Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 193 LAMP STATUS Engine check lamp ON FAULT REACTION Torque limitation Sl No DTC DES...

Page 194: ...hall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 194 TEST PROCEDURE 1 Switch ON Ignition 2 Using Smart Tester clear the ECU faults 3 Switch OFF Ignition key and wait for 2 minutes 4 S...

Page 195: ...n the cluster In normal operation the PWM power stage is tested for short circuit to battery to ground open circuit and excess temperature NORMAL OPERATION The coolant temperature output voltage which...

Page 196: ...ibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will...

Page 197: ...2012 Mahindra Mahindra Ltd 197 Turn ignition OFF Instrument cluster connector DISCONNECTED ECU connector DISCONNECTED Check the continuity between pin 12 of the instrument cluster connector and pin 7...

Page 198: ...Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 198 Step 2 Check and clear any error codes relevant to the coolan...

Page 199: ...nalty prosecution 2012 Mahindra Mahindra Ltd 199 SENSOR SUPPLY MONITORING 1 The sensor supply voltage is monitored by an comparator If the sensor supply voltage lies outside the thresholds an error is...

Page 200: ...nt of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall...

Page 201: ...ten consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use a...

Page 202: ...are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra...

Page 203: ...n consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and...

Page 204: ...en consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use an...

Page 205: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 206: ...Mahindra Ltd 206 YES Step 3 NO Clear the error codes and verify Is continuity exists Go to Step 4 Is voltage 4 7 to 5 25V NO Turn ignition OFF Rail pressure sensor connector DISCONNECTED Turn ignition...

Page 207: ...alty prosecution 2012 Mahindra Mahindra Ltd 207 Suspect ECU Contact TEKliner Go to Step 5 Ignition OFF Rail pressure sensor connector DISCONNECTED ECU Connector DISCONNECTED Check the continuity betwe...

Page 208: ...for penalty prosecution 2012 Mahindra Mahindra Ltd 208 Ignition OFF Cam phase sensor connector DISCONNECTED ECU connector CONNECTED Check the continuity between pin 3 and pin 1 of the cam phase senso...

Page 209: ...be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 209 Does continuity exist NO Suspect ECU Contact TEKliner YES Ignition OFF Cam phase sensor connector DISCONNECTED ECU Connector DISCONNECT...

Page 210: ...2 The sensor supply voltage is monitored by a comparator If the sensor supply voltage lies outside the thresholds an error is registered NORMAL OPERATION ECU monitors the supply voltage of the APP2 se...

Page 211: ...of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be...

Page 212: ...consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and s...

Page 213: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 214: ...C04 and 4 75 to 5 25V for C55 NO Ignition OFF Accelerator pedal sensor connector DISCONNECTED ECU connector CONNECTED Check the continuity between pin A and pin B of the accelerator pedal sensor conn...

Page 215: ...l be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 215 Ignition OFF Accelerator pedal sensor connector DISCONNECTED ECU Connector DISCONNECTED Check the continuity between pin A of acceler...

Page 216: ...G 3 The sensor supply voltage is monitored by an comparator If the sensor supply voltage lies outside the thresholds an error is registered NORMAL OPERATION ECU monitors the supply voltage of the APP1...

Page 217: ...of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be...

Page 218: ...ten consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use a...

Page 219: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 220: ...d the error codes and clear Turn ignition OFF Turn ignition ON Verify if P1648 is present Is voltage 3 0 to 3 5V for C04 and 4 75 to 5 25V for C55 NO Does continuity exist YES Go to Step 4 Go to Step...

Page 221: ...e liable for penalty prosecution 2012 Mahindra Mahindra Ltd 221 Ignition OFF Accelerator pedal sensor connector DISCONNECTED ECU Connector DISCONNECTED Check the continuity between pin D of accelerato...

Page 222: ...document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra...

Page 223: ...a hall effect type sensor It is located on the rear housing of the transmission It uses the speedo wheel fitted on the output shaft of the transmission to sense the vehicle speed Sl No DTC Description...

Page 224: ...nt of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall...

Page 225: ...Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be li...

Page 226: ...without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amoun...

Page 227: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 228: ...to Step 3 Is the speed values same NO Go to step 5 Clear the error codes and verify Start the engine Drive the vehicle Compare the values of speed visible in the speedometer with the values in the sma...

Page 229: ...nstrument cluster for malfunction Replace with a new one Clear the error codes and verify Step 4 Step 5 Ignition OFF Examine the open circuit of the signal line to instrument cluster Repair replace th...

Page 230: ...n pin 2 of the VSS connector and battery negative Ignition OFF Examine the reverse light 10 A fuse If fuse is found OK examine the open circuit of the reference voltage line Repair the open circuit Cl...

Page 231: ...ndra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 231 IGNITION KEY STATUS Sl No DTC Description 1 P1658 Ignition key status wrong...

Page 232: ...nt document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahind...

Page 233: ...indra Ltd 233 Ignition ON Check whether main relay is getting energized To check the main relay hear for the clicking sound from the main relay when the ignition is ON Is clicking sound noticed NO YES...

Page 234: ...entre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 234 COOLANT TEMPERATURE ABOVE CRITICAL LIMIT DTC Detecting Conditi...

Page 235: ...by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahin...

Page 236: ...rosecution 2012 Mahindra Mahindra Ltd 236 Clear the error codes and verify Connect the smart tester Turn the ignition ON Initialize the diagnostic tool Record the error codes and clear Turn ignition O...

Page 237: ...Mahindra Ltd 237 Check for the short to ground Repair or replace the wiring harness Turn ignition OFF Radiator Fan connector DISCONNECTED ECU connector DISCONNECTED Radiator Fan Relay DISCONNECTED Che...

Page 238: ...rained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 238 YES NO Does fan ro...

Page 239: ...orized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 239 FUEL TEMPERATURE ABOVE CRITICAL LIMIT DTC Dete...

Page 240: ...ent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahin...

Page 241: ...NECTED ECU connector CONNECTED Check the continuity between pin 2 and pin 1 of the fuel temperature sensor Turn ignition OFF Fuel temperature sensor connector DISCONNECTED ECU connector CONNECTED Turn...

Page 242: ...Fuel temperature sensor connector DISCONNECTED ECU connector DISCONNECTED Check the continuity between pin 1 of the fuel temperature sensor connector and pin 12 of the ECU connector Does continuity ex...

Page 243: ...Mahindra Mahindra Ltd 243 RESISTANCE OF THE FTS AT VARIOUS TEMPERATURES OF THE FUEL Temperature Min Resistance Max Resistance 20 C 2 351 K 2 649 K 40 C 1 118 K 1 231 K Ignition OFF Check for poor ter...

Page 244: ...ent are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahin...

Page 245: ...the air intake duct The sensor uses a thermistor which is sensitive to the change in temperature The thermistor resistance changes as the temperature of the atmosphere air near the sensor changes i e...

Page 246: ...other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 246 D...

Page 247: ...of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be...

Page 248: ...rior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthori...

Page 249: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 250: ...alize the diagnostic tool Record the error codes and clear Turn ignition OFF Turn ignition ON Verify if P 1633 or P1634 is present Clear the DTC and verify Is P 1633 or P1634 present NO YES Turn ignit...

Page 251: ...ition OFF Air temperature sensor connector DISCONNECTED ECU connector DISCONNECTED Check the continuity between pin 1 of the Air temperature sensor connector and pin 78 of the ECU connector Does conti...

Page 252: ...Mahindra Ltd 252 RESISTANCE OF THE ATS AT VARIOUS TEMPERATURE OF THE ATMOSPHERE Temperature Min Resistance Max Resistance 20 C 2 371 K 2 729 K 40 C 1 069 K 1 231 K 80 C 0 306 K 0 354 K Step 6 Ignition...

Page 253: ...d use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 253 WATER LEVEL SENSOR COMPONENT LOCATION Sl No DTC DESCRIPTION 1 P2265 Water presence in fuel error 2 P2269 Water in fuel...

Page 254: ...e of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution...

Page 255: ...ut the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to u...

Page 256: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 257: ...1 Clear the error codes and verify Connect the smart tester Turn the ignition ON Initialize the diagnostic tool Record the error codes and clear Turn ignition OFF Turn ignition ON Verify if P8809 and...

Page 258: ...disconnected Check the continuity between ECU pin no 19 and water level sensor pin no 1 STEP 3 Does continuity exists NO Check Rectify for the open circuit in the wiring harness Ignition OFF Check th...

Page 259: ...personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 259 Demister Circuit COMPONE...

Page 260: ...ster Circuit open load error 2 P1535 Demister Circuit Short circuit to ground 3 P1534 Demister Circuit Short circuit to battery 4 P1537 Demister Circuit over temperature Power Stage error NORMAL OPERA...

Page 261: ...esent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mah...

Page 262: ...nt of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall...

Page 263: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Ma...

Page 264: ...e present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of...

Page 265: ...d verify Turn ignition OFF Ensure that the fan relay is inserted properly in the connector Remove the relay Give 12 volts to terminal 86 and ground the terminal 85 of the relay A clicking sound to be...

Page 266: ...sition Turn ignition ON Check voltage between terminal 86 of Demister Blower relay connector and battery ground Is the voltage 12 Volts YES NO Step 3 Turn ignition OFF Demister Blower Relay REMOVED EC...

Page 267: ...ote Demister switch check points After the switch ON operation the corresponding lamp indication in the Cluster is visible Check the voltage between pin no 1 of the switch and pin no 16 of IC 2F 16 th...

Page 268: ...er than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 268 ACTUA...

Page 269: ...person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Lt...

Page 270: ...Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 270 ACTUATOR NO 3 EGR ACTUATOR Test Condition Engine running at i...

Page 271: ...ocument by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahind...

Page 272: ...dra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 272 CONFORMITY CHECK RESISTANCE VALUES COOLANT TEMPERATURE SENSOR FUEL TEMPERATURE SENSOR...

Page 273: ...e and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 273 Minimum rail pressure required to start the engine while cranking 275 to 325 bar Minimum cranking rpm required to start the...

Page 274: ......

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