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DIAGNOSTIC MANUAL MAN-00201

QUANTO

EMS

SEP 2012/Rev 1

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the 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 Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution

© 2012 Mahindra & Mahindra Ltd.

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GROUP

DTC

DISCRIPTION

PAGE

NO

VEHICLE SPEED SENSOR

VEHICLE SPEED SENSOR PLAUSIBILITY ERROR

SENSOR SUPPLY MONITORING

SENSOR SUPPLY VOLTAGE1 MONITORING ERROR

SENSOR SUPPLY VOLTAGE2 MONITORING ERROR

SENSOR SUPPLY VOLTAGE 3 MONITORING ERROR

RAIL PRESSURE GOVERNOR

RAIL PRESSURE POSITIVE GOVERNOR DEVIATION ERROR
IN METERING UNIT MODE

POSITIVE GOVERNOR DEVIATION AND SETPOINT VALUE
OF THE FUEL VOLUME FLOW THROUGH THE METERING
UNIT.

RAIL PRESSURE NEGATIVE GOVERNOR DEVIATION
ERROR IN METERING UNIT MODE

RAIL PRESSURE BELOW MINIMUM LIMIT ERROR IN
METERING UNIT MODE

RAIL PRESSURE ABOVE MAXIMUM LIMIT ERROR IN
METERING UNIT MODE

MAIN RELAY EARLY OPENING ERROR

MAIN RELAY STRUCK ERROR

BOOST PRESSURE GOVERNOR

BOOST PRESSURE CONTROLLER DEVIATION ABOVE
MAXIMUM LIMIT

BOOST PRESSURE CONTROLLER DEVIATION

PLAUSIBILITY DEFECT BETWEEN CACDSP AND ENVP

BRAKE SIGNAL PLAUSIBILITY ERROR.

CLUTCH NON PLAUSIBLE ERROR

CLUTCH 90% SWITCH PLAUSIBLE ERROR

WATER IN FUEL SENSOR

Water presence in Fuel Sensor

Water in Fuel Sensor Faulty

CONTINUOUS TORQUE

ECU Monitoring: Start of Injection plausibility error

ECU Monitoring: ZFC non plausibility error

No load error on power stage for the compressor

Short circuit to battery error on power stage for the
compressor

SHORT CIRCUIT TO GROUND ERROR ON POWER STAGE
FOR THE COMPRESSOR

FAN 1 CONTROL CIRCUIT

FAN 1 CONTROL CIRCUIT HIGH

FAN 1 CONTROL CIRCUIT LOW

FAN 2 CONTROL CIRCUIT

FAN 2 CONTROL CIRCUIT HIGH

FAN 2 CONTROL CIRCUIT LOW

GEAR NEUTRAL SIGNAL IS NOT PLAUSIBLE

GNS RELAY NO LOAD

GNS RELAY SHORT TO BATTERY ERROR

GNS RELAY SHORT TO GROUND ERROR

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Summary of Contents for Quanto

Page 1: ... 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 SEPTEMBER 2012 ...

Page 2: ...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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONTENTS HOW TO USE THIS MANUAL 3 OVER VIEW OF THE CAN NETWORK 3 EMS OVERVIEW 4 WA...

Page 3: ...t the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd HOW TO USE THIS MANUAL If the DTC code is known then go to the Index of DTC code and click on the group under which the DTC appears The codes groups are hyperlinked to the respective trouble shooting chart pages The following is the structu...

Page 4: ...ny 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 Ltd EMS OVERVIEW The EMS ECU uses the following sensors and actuators to govern all engine parameters for optimized engine performance Sensors Switches Hot Film Air Mass Flow Sensor Engine Coolant Tem...

Page 5: ...nd shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd WARRANTY OTHER INFORMATION All failures complaints encountered on EMS ECU and other system components should be reported through Service Complaint Report SCR Replacement of any of the EMS ECU and other system components requires approval of the TEKline Ensure that a TAR is raised in the TEKnet website for approval attaching the ...

Page 6: ...TOR 4 1 4 POWER MAIN RELAY 87 5 POWER HIGH SIDE INJECTOR 2 INJECTOR 3 1 6 POWER MAIN RELAY 87 7 POWER LOW SIDE INJECTOR 4 2 10 POWER CLUTCH SENSOR 1 11 GROUND COOLANT TEMPERATURE SENSOR 2 12 SIGNAL FUEL TEMP SENSOR 1 16 POWER VEHICLE SPEED SENSOR 1 18 POWER ACCELERATOR PEDAL MODULE 1 2 20 SIGNAL AC PRESSURE SWITCH 4 22 SIGNAL VEHICLE SPEED SENSOR 3 23 SIGNAL CLUTCH SENSOR 10 Signal 2 24 SIGNAL RED...

Page 7: ...12 Mahindra Mahindra Ltd ECU Connector Pin no Function Connected To Pin no 59 SIGNAL CLOCK SPRING 8 CHANNEL CRUISE CONTROL F 60 SIGNAL ACCELERATOR PEDAL MODULE 2 6 61 SIGNAL ACCELERATOR PEDAL MODULE 1 4 65 CAN LOW DLC CONNECTOR 2 66 CAN HIGH DLC CONNECTOR 3 67 SIGNAL STARTER RELAY 85 71 SIGNAL T15 INPUT T15 73 POWER LOW SIDE INJECTOR 1 2 74 SIGNAL Negative CRANK SHAFT SENSOR 2 75 SIGNAL HFM SENSOR...

Page 8: ...icles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahind...

Page 9: ...re manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahi...

Page 10: ...vice Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd MAN 00201 SEP 2012 Rev1 QUANTO LC4 EMS K ECU U LC66 FUEL TEMPERATURE SENSOR 12 1 2 34 1 t 0 U LC43 COOLANT TEMPERATURE SENSOR 2 33 11 1 2 16 55 LC201 VEHICLE SPEED SENSOR 3 22 1 2 74 52 LC37 INCREMENT SPEED SENSOR LC178 IMMOBILIZER 2 3 65 66 P U LC33 RAIL PRES...

Page 11: ...nd shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd MAN 00201 SEP 2012 Rev 1 QUANTO DIAGNOSTIC MANUAL L1 EMS ECU RELAY 4 30 86 87 85 6 8 4 1 50 04 06 10A F13 10A F14 30A F2 R B 2 5 R W 2 5 R 4 00 P L 0 5 LC4 EMS K ECU W 4 0 W 0 5 2 C9 C9 ECU K 06 SUPPLY ECU K 04 SUPPLY L2 Starter Relay R 4 0 86 30 85 87 SB B 0 5 M LG B 0 5 67 L 4 0 1 50 30 Starter Motor C59 25 1 4 C70 C70 2 3 L24...

Page 12: ...ction factor which is engraved on top of it in the form of a 8 character alphanumeric code out of which the last character W is a dummy value This is known as an IQA code IMA code For optimal performance of the engine the ECU needs to know the IQA code IMA code of each injector This information is programmed into the ECU when the vehicle is manufactured However if you need to replace an injector s...

Page 13: ...ick the button below the Verify line in figure The IQA codes present in the ECU will be read back and displayed in the text box before this button It is recommended that you carry out the verification activity whenever you change an IQA code PLEASE ENSURE TO PROGRAM IQA IMA CODES WHEN YOU REPLACE AN INJECTOR ECU or ENGINE The following are the fonts of the alphanumeric characters of the IQA IMA co...

Page 14: ...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 2012 Mahindra Mahindra Ltd Software Version ECU Type Dataset ID Type Model EDC17 C55 1037527539 For C4 C6 and C8 variant 1037527514 For C2 variant Factory Reflashing Quanto 3 Ensure that the there is no co...

Page 15: ...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 unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd FLASHING PROCEDURE Connect using the Python 1BConfig0404 Click the EDC17 C55 field flashing tool V3 0 icon present on th...

Page 16: ...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 to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Select the Hex File from the link up box as shown in the Picture above Link C Program Files EDC17C55ECUFlashT...

Page 17: ... manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahind...

Page 18: ...W IDLE CORRECTION EXCEEDING THE MAXIMUM DRIFT LIMIT 38 P1101 AFS LOAD CORRECTION EXCEEDING THE MAXIMUM DRIFT LIMIT BATTERY P0563 BATTERY VOLTAGE HIGH ERROR 40 P0562 BATTERY VOLTAGE LOW ERROR 42 COOLANT TEMPERATURE SENSOR P1128 COOLANT TEMPERATURE SENSOR ABSOLUTE TEST NON PLAUSIBLE ERROR 45 P1126 COOLANT TEMPERATURE SENSOR DYNAMIC TEST NON PLAUSIBLE ERROR P0118 SIGNAL RANGE CHECK FOR COOLANT TEMPER...

Page 19: ... CYLINDER 3 INJECTOR OPEN LOAD ERROR 128 P0261 CYLINDER 1 INJECTOR SHORT CIRCUIT ERROR 132 P0267 CYLINDER 2 INJECTOR SHORT CIRCUIT ERROR 136 P0270 CYLINDER 3 INJECTOR SHORT CIRCUIT ERROR 140 P2146 SHORT CIRCUIT IN BANK 0 144 METERING UNIT P0001 METERING UNIT OPEN LOAD ERROR 150 P0004 METERING UNIT OUTPUT SHORT CIRCUIT TO BATTERY ERROR 154 P0003 METERING UNIT OUTPUT SHORT CIRCUIT TO GROUND ERROR 15...

Page 20: ...OR DEVIATION ERROR IN METERING UNIT MODE 249 P1D87 RAIL PRESSURE BELOW MINIMUM LIMIT ERROR IN METERING UNIT MODE 251 P1C88 RAIL PRESSURE ABOVE MAXIMUM LIMIT ERROR IN METERING UNIT MODE 254 MAIN RELAY P068A MAIN RELAY EARLY OPENING ERROR 256 P068B MAIN RELAY STRUCK ERROR BOOST PRESSURE GOVERNOR P0299 BOOST PRESSURE CONTROLLER DEVIATION ABOVE MAXIMUM LIMIT 260 P0234 BOOST PRESSURE CONTROLLER DEVIATI...

Page 21: ...ission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd GROUP DTC DISCRIPTION PAGE NO STARTER RELA...

Page 22: ...XIMUM LIMIT HFM SENSOR Mass air flow rate is measured by detection of heat transfer from a hot film probe Because of the change of the mass air flow rate causes change in the amount of heat being transferred from the hot film probe surface to the air flow The airflow sensor generates a pulse so it repeatedly opens and closes between the 5V supplied from the engine control module This results in th...

Page 23: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 24: ...the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012...

Page 25: ...of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0103 is present Is P0103 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP...

Page 26: ...flow rate is measured by detection of heat transfer from a hot film probe Because of the change of the mass air flow rate causes change in the amount of heat being transferred from the hot film probe surface to the air flow The airflow sensor generates a pulse so it repeatedly opens and closes between the 5V supplied from the engine control module This results in the change of the temperature of t...

Page 27: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 28: ...production translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIE...

Page 29: ...nt Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Is the value Vbat Ignition OFF HFM sensor wiring harness connector C19 DISCONNECTED Ignition ON Check the voltage between pin 3 of the HFM sensor wiring harness connector and battery ground Examine the short to ground open circuit of HFM sensor power supply wire Replace the wiring harness Clear the DTC and ve...

Page 30: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 31: ...IGNAL ERROR FOR HFM7 SENSOR HFM SENSOR Mass air flow rate is measured by detection of heat transfer from a hot film probe Because of the change of the mass air flow rate causes change in the amount of heat being transferred from the hot film probe surface to the air flow The airflow sensor generates a pulse so it repeatedly opens and closes between the 5V supplied from the engine control module Th...

Page 32: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 33: ...d The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNE...

Page 34: ...ure STEP 2 Is the continuity exists Ignition OFF HFM sensor wiring harness connector C19 DISCONNECTED Check the continuity between pin 5 and pin 1 of the HFM sensor wiring harness connector STEP 3 STEP 4 Ignition OFF HFM sensor wiring harness connector C19 DISCONNECTED EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between between pin 5 of the HFM sensor wiring harness conne...

Page 35: ...NSOR HFM SENSOR Mass air flow rate is measured by detection of heat transfer from a hot film probe Because of the change of the mass air flow rate causes change in the amount of heat being transferred from the hot film probe surface to the air flow The airflow sensor generates a pulse so it repeatedly opens and closes between the 5V supplied from the engine control module This results in the chang...

Page 36: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 37: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 38: ... DRIFT LIMIT AFS LOAD CORRECTION EXCEEDING THE MAXIMUM DRIFT LIMIT HFM SENSOR Mass air flow rate is measured by detection of heat transfer from a hot film probe Because of the change of the mass air flow rate causes change in the amount of heat being transferred from the hot film probe surface to the air flow The airflow sensor generates a pulse so it repeatedly opens and closes between the 5V sup...

Page 39: ...se 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 2012 Mahindra Mahindra Ltd Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0101 or P1101 is present...

Page 40: ...son 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 P0563 BATTERY VOLTAGE HIGH ERROR BATTERY The Electronic Control Unit continuosly monitors the battery voltage for its proper functioning The normal operating voltage for ECU is 8 16 V DTC INFORMATION PR...

Page 41: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 42: ...ained 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 P0562 BATTERY VOLTAGE LOW ERROR BATTERY The Electronic Control Unit continuosly monitors the battery voltage for its proper functioning The normal operating voltage for EMS ECU is 8 16 V DTC INFORMATION PROBABLE CAUSES OF F...

Page 43: ...562 is present Is P0562 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Is the value 11 0 to 14 5V STEP 3 Ignition OFF Check and confirm the proper functioning of 5 A fuse F47 of the EMS ECU power supply wire from Ignition switch EMS ECU wiring harness connector C4 DISCONNECTED Ignition ON Check the voltage between pin 71 of the EMS ECU wiring harness...

Page 44: ... Mahindra Mahindra Ltd Ignition OFF EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between pin 71 of the EMS ECU wiring harness connector and battery ground STEP 5 Is the continuity exists Examine the short circuit of EMS ECU power supply wire from ignition switch to ground Replace the wiring harness Clear the DTC and verify Examine the battery positive and negative cables f...

Page 45: ...C TEST NON PLAUSIBLE ERROR COOLANT TEMPERATURE SENSOR ABSOLUTE DYNAMIC TEST When the engine is switched ON then the ECU detects the temperature After that when the engine runs then the temperature output on a time frame is detected and compared against predetermined values DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Engine running The coolant temperature rises to a specified temper...

Page 46: ... Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P1128 P1126 is present Is P1128 P1126 present Intermittent problem exists Refer the intermittent problem inspection proc...

Page 47: ...SOR ABOVE MAXIMUM LIMIT COOLANT TEMPERATURE SENSOR The CTS sensor is a variable resistor whose resistance changes as the temperature of the engine coolant flowing past the sensor changes NTC resistor When the coolant temperature is low the sensor resistance is high when the coolant temperature is high the sensor resistance is low The ECU checks CTS voltage and uses the information to help smoothen...

Page 48: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 49: ...ctured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd ...

Page 50: ...nd clear Turn ignition OFF Turn ignition ON Verify if P0118 is present Is P0118 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Is the value 5 0 25 V Ignition OFF Coolant temperature sensor wiring harness connector C43 DISCONNECTED Ignition ON Check the voltage between pin 1 of the coolant temperature sensor wiring harness connector and battery ground...

Page 51: ...able for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 4 Ignition OFF Coolant temperature sensor wiring harness connector C43 DISCONNECTED EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between pin 11 EMS ECU wiring harness connector and pin 2 of the of the coolant temperature sensor wiring harness connector Is the continuity exists Examine the open circuit of coolant ...

Page 52: ...ANT TEMPERATURE SENSOR BELOW MINIMUM LIMIT COOLANT TEMPERATURE SENSOR The CTS sensor is a variable resistor whose resistance changes as the temperature of the engine coolant flowing past the sensor changes NTC resistor When the coolant temperature is low the sensor resistance is high when the coolant temperature is high the sensor resistance is low The ECU checks CTS voltage and uses the informati...

Page 53: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 54: ...ctured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd ...

Page 55: ...the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0117 is present Is P0117 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Is the value 5 0 25 V STEP 4 Ignition OFF Coolant temperature sensor wiring harness connector C43 DISCONNECTED Ignition ON Check the voltage...

Page 56: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 57: ...is 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 2012 Mahindra Mahindra Ltd P062F ECU EEPROM ERROR EEPROM MONITORING EEPROM Electrically Erasable Programmable Read Only Memory is a storage device inside the EMS ECU EEPROM can be flashed read and written DT...

Page 58: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 59: ...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 2012 Mahindra Mahindra Ltd P162F ECU EEPROM ERROR EEPROM MONITORING EEPROM Electrically Erasable Programmable Read Only Memory is a storage device inside the EMS ECU EEPROM can be flashed read and written DTC I...

Page 60: ...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 unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ...

Page 61: ...cument 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 Mahindra Ltd P1630 ECU EEPROM ERROR EEPROM MONITORING EEPROM Electrically Erasable Programmable Read Only Memory is a storage device inside the EMS ECU EEPROM can be flashed read and written DTC INF...

Page 62: ...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 unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ...

Page 63: ...hindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P062B ECU MONITORING ERROR FOR INJECTOR CUT OFF DEMAND MONITORING COMMUNICATION ICO MONITORING Engine speed is continuosly monitored by EMS ECU Whenever the engine speed goes above the maximum threshold injection driver stages gets disconnected in EMS ECU DTC INFORMATION PROBABLE CAUSE...

Page 64: ...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 unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ...

Page 65: ...rsonnel 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 P0403 EGR VALVE OPEN LOAD ERROR EGR MODULATOR EGR modulator controls the EGR valve EMS ECU converts the air control output into duty cycle and outputs a PWM signal to EGR modulator DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL ...

Page 66: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 67: ...factured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Lt...

Page 68: ... ignition ON Verify if P0403 is present Is P0403 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Check and confirm the proper function of 15 A fuse F15 in engine compartment fuse box EGR modulator wiring harness connector C42 DISCONNECTED Ignition ON Check the voltage between between pin 2 of EGR modulator wiring harness connector and bat...

Page 69: ...erson 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 P1403 EGR VALVE OVER TEMPERATURE ERROR EGR MODULATOR EGR modulator controls the EGR valve EMS ECU converts the air control output into duty cycle and outputs a PWM signal to EGR modulator DTC INFORMAT...

Page 70: ...ited 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 amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and ...

Page 71: ...sonnel 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 P0406 EGR VALVE SHORT TO BATTERY ERROR EGR MODULATOR EGR modulator controls the EGR valve EMS ECU converts the air control output into duty cycle and outputs a PWM signal to EGR modulator DTC INFORMATION PROBABLE CAUSES OF FAILURE N...

Page 72: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 73: ...factured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Lt...

Page 74: ... unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0406 is present Is P0406 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF EGR modulator wiring ha...

Page 75: ...onnel 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 P0405 EGR VALVE SHORT TO GROUND ERROR EGR MODULATOR EGR modulator controls the EGR valve EMS ECU converts the air control output into duty cycle and outputs a PWM signal to EGR modulator DTC INFORMATION PROBABLE CAUSES OF FAILURE NOR...

Page 76: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 77: ...factured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Lt...

Page 78: ...indra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0405 is present Is P0405 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ign...

Page 79: ...ntre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P2228 SIGNAL RANGE CHECK FOR ENVIRONMENTAL PRESSURE SENSOR BELOW MINIMUM LIMIT ENVIRONMENT PRESSURE SENSOR The atmospheric pressure sensor is located on the EMS ECU The sensor provides the atmospheric pressure value to the EMS ECU DTC INFORMATION PROBABLE CAUSES OF F...

Page 80: ...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 unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ig...

Page 81: ...ntre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P2229 SIGNAL RANGE CHECK FOR ENVIRONMENTAL PRESSURE SENSOR ABOVE MAXIMUM LIMIT ENVIRONMENT PRESSURE SENSOR The atmospheric pressure sensor is located on the EMS ECU The sensor provides the atmospheric pressure value to the EMS ECU DTC INFORMATION PROBABLE CAUSES OF F...

Page 82: ...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 unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ig...

Page 83: ...secution 2012 Mahindra Mahindra Ltd P0340 CAMSHAFT SENSOR NO SIGNAL ERROR CAMSHAFT SEGMENT SPEED SENSOR Hall Effect camshaft position sensor senses the Top dead center TDC point of the 1 cylinder in the compression stroke which allows the ECU to determine when to start the injection The trigger is mounted in the exhaust camshaft DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ...

Page 84: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 85: ...he reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTO...

Page 86: ... Refer the intermittent problem inspection procedure STEP 2 Is the value 5 0 25 V Ignition OFF Camshaft position sensor wiring harness connector C24 DISCONNECTED Ignition ON Check the voltage between pin 3 of the camshaft position sensor wiring harness connector and battery ground STEP 3 Go to STEP 5 STEP 4 Ignition OFF Camshaft position sensor wiring harness connector C24 DISCONNECTED Check the c...

Page 87: ...he DTC and verify STEP 7 Ignition OFF Camshaft position sensor wiring harness connector C24 DISCONNECTED EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between between pin 2 of the camshaft position sensor wiring harness connector and pin 46 of the EMS ECU wiring harness connector Check the continuity between between pin 1of the camshaft position sensor wiring harness connec...

Page 88: ...41 CAMSHAFT SENSOR SIGNAL ERROR CAMSHAFT SEGMENT SPEED SENSOR Hall Effect camshaft position sensor senses the Top dead center TDC point of the 1 cylinder in the compression stroke which allows the ECU to determine when to start the injection The trigger is mounted in the exhaust camshaft DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON During engine cranking the output signa...

Page 89: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 90: ...he reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTO...

Page 91: ... ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Crank the engine Verify if P1341 is present Is P1341 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Are the bolts tight Check the flywheel mounting bolts for tightness Check the cam shaft crankshaft mounting bolts for tightness STEP 3 STEP 4 Check ...

Page 92: ...AFT SEGMENT SPEED SENSOR Hall Effect camshaft position sensor senses the Top dead center TDC point of the 1 cylinder in the compression stroke which allows the ECU to determine when to start the injection The trigger is mounted in the exhaust camshaft DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON During engine cranking the EMS ECU compares the crankshaft sensor signal and...

Page 93: ...cord the DTC and clear Turn ignition OFF Turn ignition ON Crank the engine Verify if P1341 is present Is P1341 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Are the bolts tight Check the flywheel mounting bolts for tightness Check the cam shaft crankshaft mounting bolts for tightness Check the crankshaft speed sensor and camshaft position sensor mou...

Page 94: ...prosecution 2012 Mahindra Mahindra Ltd P0336 CRANKSHAFT SENSOR SIGNAL ERROR CRANKSHAFT INCREMENT SPEED SENSOR The crankshaft speed sensor is an inductive type sensor It is mounted on front LH bottom side of the engine and measures the speed of the trigger wheel mounted on the crankshaft DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON During engine cranking and running the E...

Page 95: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 96: ...red The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CON...

Page 97: ...exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Crankshaft speed sensor wiring harness connector C37 DISCONNECTED EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between pin 2 of the crankshaft speed sensor wiring harness connector and pin 74 of the EMS ECU wiring harness connector I Is the continuity exists Examine the open circuit of crank sha...

Page 98: ...l be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 6 Check for any damage on the trigger wheel teeth Check for proper mounting of trigger wheel mounting screw Is there any damage screws loosened If the screws are loosened tighten to torque If toner wheel damaged replace it with a new one Clear the DTC and verify STEP 5 Check the crankshaft end play Refer repair manual for the proc...

Page 99: ...o unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0335 CRANKSHAFT SENSOR NO SIGNAL ERROR CRANKSHAFT INCREMENT SPEED SENSOR The crankshaft speed sensor is an inductive type sensor It is mounted on front LH bottom side of the engine and measures the speed of the trigger wheel mounted on the crankshaft DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATIO...

Page 100: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 101: ...The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECT...

Page 102: ...ra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Crank the engine Verify if P0335 is present Is P0335present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 STEP 3 Ignition OFF Check and correct if any loose connections noticed in the crankshaft speed sensor ...

Page 103: ...s the continuity exists STEP 4 Suspect EMS ECU malfunction Replace EMS ECU with a new one Check and verify for any new DTC s STEP 5 Ignition OFF Crankshaft speed sensor wiring harness connector C37 DISCONNECTED EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between pin 1 of the crankshaft speed sensor wiring harness connector and pin 52 of the EMS ECU wiring harness connecto...

Page 104: ...ra Mahindra Ltd P0183 SIGNAL RANGE CHECK FOR FUEL TEMPERATURE SENSOR ABOVE MAXIMUM LIMIT FUEL TEMPERATURE SENSOR The fuel temperature sensor is a variable resistor whose resistance changes as the temperature of the fuel flowing past the sensor changes NTC resistor When the fuel temperature is low the sensor resistance is high when the fuel temperature is high the sensor resistance is low DTC INFOR...

Page 105: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 106: ...actured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd...

Page 107: ...the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0183 is present Is P0183 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Is the value 5 0 25 V Ignition OFF Fuel temperature sensor wiring harness connector C66 DISCONNECTED Ignition ON Check the voltage between pin 1 of the fuel temperature sensor wiring harness connector and battery gro...

Page 108: ...shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 4 Ignition OFF Fuel temperature sensor wiring harness connector C66 DISCONNECTED EMS ECU wiring harness connector DISCONNECTED C4 Check the continuity between pin 34 EMS ECU wiring harness connector and pin 2 of the of the fuel temperature sensor wiring harness connector Is the continuity exists Examine the open circuit of fue...

Page 109: ... prosecution 2012 Mahindra Mahindra Ltd P0182 SIGNAL RANGE CHECK FOR FUEL TEMPERATURE SENSOR BELOW MINIMUM LIMIT FUEL TEMPERATURE SENSOR The fuel temperature sensor is a variable resistor whose resistance changes as the temperature of the fuel flowing past the sensor changes NTC resistor When the fuel temperature is low the sensor resistance is high when the fuel temperature is high the sensor res...

Page 110: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 111: ...actured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd...

Page 112: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 113: ...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 unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Ignition OFF Fuel temperature sensor wiring harness connector C66 DISCONNECTED Check the resistance between pin 1 and pin...

Page 114: ...ndra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P268C CYLINDER 1 INJECTOR ADJUSTMENT CODE INCORRECT ERROR INJECTOR IQA MONITORING IQA monitoring monitors the missing or faulty programming of individual IQA values and registers an error if it is missing or faulty DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Igni...

Page 115: ... 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 STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P268C is present Is P268C present Intermittent prob...

Page 116: ...ndra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P268E CYLINDER 2 INJECTOR ADJUSTMENT CODE INCORRECT ERROR INJECTOR IQA MONITORING IQA monitoring monitors the missing or faulty programming of individual IQA values and registers an error if it is missing or faulty DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Igni...

Page 117: ... 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 STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P268E is present Is P268E present Intermittent prob...

Page 118: ...ndra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P268F CYLINDER 3 INJECTOR ADJUSTMENT CODE INCORRECT ERROR INJECTOR IQA MONITORING IQA monitoring monitors the missing or faulty programming of individual IQA values and registers an error if it is missing or faulty DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Igni...

Page 119: ... 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 STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P268F is present Is P268F present Intermittent prob...

Page 120: ...Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0201 CYLINDER 1 INJECTOR OPEN LOAD ERROR INJECTORS The injectors are solenoid actuated and controlled by EMS ECU Both high and low side of the injectors are controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it DTC INF...

Page 121: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 122: ...tion transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEWS AND INFORMATION...

Page 123: ...clear Turn ignition OFF Turn ignition ON Verify if P0201 is present Is P0201 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Injector 1 wiring harness connector C27 DISCONNECTED EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between pin 2 of Injector 1 wiring harness connector and pin 73 of the EMS ECU wiring harnes...

Page 124: ...Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0203 CYLINDER 2 INJECTOR OPEN LOAD ERROR INJECTORS The injectors are solenoid actuated and controlled by EMS ECU Both high and low side of the injectors are controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it DTC INF...

Page 125: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 126: ...tion transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEWS AND INFORMATION...

Page 127: ...clear Turn ignition OFF Turn ignition ON Verify if P0203 is present Is P0203 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Injector 2 wiring harness connector C30 DISCONNECTED EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between pin 2 of Injector 2 wiring harness connector and pin 51 of the EMS ECU wiring harnes...

Page 128: ...Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0204 CYLINDER 3 INJECTOR OPEN LOAD ERROR INJECTORS The injectors are solenoid actuated and controlled by EMS ECU Both high and low side of the injectors are controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it DTC INF...

Page 129: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 130: ...tion transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEWS AND INFORMATION...

Page 131: ...clear Turn ignition OFF Turn ignition ON Verify if P0204 is present Is P0204 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Injector 3 wiring harness connector C29 DISCONNECTED EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between pin 2 of Injector 3 wiring harness connector and pin 29 of the EMS ECU wiring harnes...

Page 132: ...e of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0261 CYLINDER 1 INJECTOR SHORT CIRCUIT ERROR INJECTORS The injectors are solenoid actuated and controlled by EMS ECU Both high and low side of the injectors are controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it DTC INFO...

Page 133: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 134: ...tion transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEWS AND INFORMATION...

Page 135: ...td STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0261 is present Is P0261 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Injector 1 wiring harness connector C27 DISCONNECTED Check the continuity between pin 2 and pin 1 of Injector...

Page 136: ...e of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0267 CYLINDER 2 INJECTOR SHORT CIRCUIT ERROR INJECTORS The injectors are solenoid actuated and controlled by EMS ECU Both high and low side of the injectors are controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it DTC INFO...

Page 137: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 138: ...tion transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEWS AND INFORMATION...

Page 139: ...td STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0267 is present Is P0267 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 YES Ignition OFF Injector 2 wiring harness connector C30 DISCONNECTED Check the continuity between pin 2 and pin 1 of Inje...

Page 140: ...ahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0270 CYLINDER 3 INJECTOR SHORT CIRCUIT ERROR INJECTORS The injectors are solenoid actuated and controlled by EMS ECU Both high and low side of the injectors are controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it DTC INFORMATIO...

Page 141: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 142: ...tion transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEWS AND INFORMATION...

Page 143: ...td STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0270 is present Is P0270 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Injector 3 wiring harness connector C29 DISCONNECTED Check the continuity between pin 2 and pin 1 of Injector...

Page 144: ...nnel 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 P2146 SHORT CIRCUIT IN BANK 0 INJECTORS The injectors are solenoid actuated and controlled by EMS ECU Both high and low side of the injectors are controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and ...

Page 145: ...omponent units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and sh...

Page 146: ...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 liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR NO CONNECTOR DESCRIPTION PIN NO FUNCTION C4 EMS ECU 3 Power high side injector 1 73 Power low side injector 1 3 Power high side injecto...

Page 147: ... Is P2146 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 STEP 3 Ignition OFF Injector 1 2 and 3 wiring harness connector C27 C30 and C29 DISCONNECTED Check the continuity between pin 2 of Injector 1 wiring harness connector and battery ground Check the continuity between pin 2 of Injector 2 wiring harness connector and battery ground Check the contin...

Page 148: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 149: ...iring harness connector C27 C30 and C29 DISCONNECTED Check the resistance between pin 2 and pin1 of Injector 1 Check the resistance between pin 2 and pin 1 of Injector 2 Check the resistance between pin 2 and pin1 of Injector 3 Examine the short circuit of injector s solenoid Replace the injector with a new one Clear the DTC and verify Suspect EMS ECU malfunction Replace EMS ECU with a new one Che...

Page 150: ...Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0001 METERING UNIT OPEN LOAD ERROR METERING UNIT The component driver for the metering unit regulates the opening and closing of the metering unit based on the rail pressure set point and the actual value Metering unit controls the fuel flow to the high pr...

Page 151: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 152: ...roduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEW...

Page 153: ...P0001 is present Is P0001 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Check and confirm the proper function of 15 A fuse F15 in ECU fuse box Fuel metering unit wiring harness connector C35 DISCONNECTED Ignition ON Check the voltage between between pin 2 of fuel metering unit wiring harness connector and battery ground Examine the open...

Page 154: ...ndra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0004 METERING UNIT OUTPUT SHORT CIRCUIT TO BATTERY ERROR METERING UNIT The component driver for the metering unit regulates the opening and closing of the metering unit based on the rail pressure set point and the actual value Metering unit controls the fuel flow to the high pr...

Page 155: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 156: ...roduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEW...

Page 157: ...a Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0004 is present Is P0004 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Fue...

Page 158: ...ra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0003 METERING UNIT OUTPUT SHORT CIRCUIT TO GROUND ERROR METERING UNIT The component driver for the metering unit regulates the opening and closing of the metering unit based on the rail pressure set point and the actual value Metering unit controls the fuel flow to the high press...

Page 159: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 160: ...roduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEW...

Page 161: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 162: ... SRC HIGH FOR CHARGED AIR COOLER PRESSURE DOWN STREAM BOOST PRESSURE SENSOR The boost pressure signal is continuosly monitored by EMS ECU This signal is used as a feedback for the control of the twin turbo two way valve and also for the EGR The boost pressure sensor is mounted on the outlet of the intercooler DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON EMS ECU receives ...

Page 163: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 164: ...roduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEW...

Page 165: ...se the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0238 is present Is P0238 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Boost pressure sensor wiring harness connector C339 DISCONNECTED Ignition ON Check the voltage between pin 3 of boost pressure sensor wiring harness connector and battery gr...

Page 166: ...re of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Ignition OFF Boost pressure sensor wiring harness connector C339 DISCONNECTED EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between pin 3 of boost pressure sensor wiring harness connector and pin 56 of the EMS ECU wiring harness connector Check ...

Page 167: ...012 Mahindra Mahindra Ltd P0237 SRC LOW FOR CHARGED AIR COOLER PRESSURE DOWN STREAM BOOST PRESSURE SENSOR The boost pressure signal is continuosly monitored by EMS ECU This signal is used as a feedback for the control of the twin turbo two way valve and also for the EGR The boost pressure sensor is mounted on the outlet of the intercooler DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION...

Page 168: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 169: ...roduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEW...

Page 170: ...ists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Boost pressure sensor wiring harness connector C339 DISCONNECTED Ignition ON Check the voltage between pin 3 of boost pressure sensor wiring harness connector and battery ground Is the value 5 0 25 V STEP 3 I Is the continuity exists Examine the short circuit of boost pressure sensor power wire with battery ground Replace...

Page 171: ... 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 penalty prosecution 2012 Mahindra Mahindra Ltd STEP 5 Ignition OFF Boost pressure sensor wiring harness connector C339 DISCONNECTED Check the continuity between pin 3 and pin 2 of boost pressure senso...

Page 172: ...2012 Mahindra Mahindra Ltd P0193 SIGNAL RANGE CHECK FOR RAIL PRESSURE SENSOR ABOVE MAXIMUM LIMIT RAIL PRESSURE SENSOR The rail pressure sensor is mounted on the common rail and is used to measure the rail pressure The EMS ECU determines the optimum fuel injection quantity at specific engine condition based on rail pressure sensor DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition...

Page 173: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 174: ... The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNEC...

Page 175: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 176: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 177: ...l amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0192 SIGNAL RANGE CHECK FOR RAIL PRESSURE SENSOR BELOW MINIMUM LIMIT RAIL PRESSURE SENSOR The rail pressure sensor is mounted on the common rail and is used to measure the rail pressure The EMS ECU determines the optimum fuel injection quantity at specific engine condition based on rail pressure se...

Page 178: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 179: ... The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNEC...

Page 180: ...lem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Rail pressure sensor wiring harness connector C33 DISCONNECTED Ignition ON Check the voltage between pin 3 of rail pressure sensor wiring harness connector and battery ground Is the value 5 0 25 V STEP 3 I Is the continuity exists Examine the short circuit of rail pressure sensor power wire with battery ground Repla...

Page 181: ...dra 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 penalty prosecution 2012 Mahindra Mahindra Ltd STEP 5 Ignition OFF Rail pressure sensor wiring harness connector C33 DISCONNECTED Check the continuity between pin 2 and pin 1 of rail pressure senso...

Page 182: ...nt to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0191 RAIL PRESSURE OFFSET VALUE ABOVE MAXIMUM LIMIT RAIL PRESSURE SENSOR The rail pressure sensor is mounted on the common rail and is used to measure the rail pressure The EMS ECU determines the optimum fuel injection quantity at specific engine condition based on rail pressure sensor DTC INFORMATION PR...

Page 183: ...onsent 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 liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ign...

Page 184: ...Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P1191 RAIL PRESSURE OFFSET VALUE ABOVE MINIMUM LIMIT RAIL PRESSURE SENSOR The rail pressure sensor is mounted on the common rail and is used to measure the rail pressure The EMS ECU determines the optimum fuel injection quantity at specific engine condition based on rail pressure sensor DTC I...

Page 185: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 186: ...IMUM LIMIT ACCELERATOR PEDAL The Accelerator pedal module APM is mounted in place of accelerator pedal and is connected to the ECU by wires The APM is a potentiometer whose output voltage changes according to the pedal position ECU applies a reference voltage to the APM sensor and then measures the voltage that is present on the APM sensor signal circuit The ECU uses the APM sensor signal for furt...

Page 187: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 188: ...actured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd...

Page 189: ...se the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P2123 is present Is P2123 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Accelerator pedal wiring harness connector C124 DISCONNECTED Ignition ON Check the voltage between pin 2 of accelerator pedal wiring harness connector and battery ground Is ...

Page 190: ...Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Ignition OFF Accelerator pedal wiring harness connector C124 DISCONNECTED EMS ECU wiring harness connector DISCONNECTED Check the continuity between pin 4 of accelerator pedal wiring harness connector and pin 61 of the EMS ECU wiring harness connector Check the con...

Page 191: ...MUM LIMIT ACCELERATOR PEDAL The Accelerator pedal module APM is mounted in place of accelerator pedal and is connected to the ECU by wires The APM is a potentiometer whose output voltage changes according to the pedal position ECU applies a reference voltage to the APM sensor and then measures the voltage that is present on the APM sensor signal circuit The ECU uses the APM sensor signal for furth...

Page 192: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 193: ...actured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd...

Page 194: ...alise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P2128 is present Is P2128 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Accelerator pedal wiring harness connector C124 DISCONNECTED Ignition ON Check the voltage between pin 1 of accelerator pedal wiring harness connector and battery ground ...

Page 195: ...Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Ignition OFF Accelerator pedal wiring harness connector C124 DISCONNECTED EMS ECU wiring harness connector DISCONNECTED Check the continuity between pin 6 of accelerator pedal wiring harness connector and pin 60 of the EMS ECU wiring harness connector Check the con...

Page 196: ...Y ERROR BETWEEN APP SIGNAL1 AND SIGNAL2 ACCELERATOR PEDAL PLAUSIBILITY The Accelerator pedal module APM is mounted in place of accelerator pedal and is connected to the ECU by wires The function checks both the acceleration pedal signals for plausibility and makes the test result The ECU also checks the ratio of both the signals If the difference between both the signals goes beyond the maximum ra...

Page 197: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 198: ...roduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEW...

Page 199: ...blem exists Refer the intermittent problem inspection procedure STEP 2 NO YES Ignition OFF Accelerator pedal wiring harness connector C124 DISCONNECTED Ignition ON Check the voltage between pin 2 of accelerator pedal wiring harness connector and battery ground Is the value 5 0 25 V STEP 3 I Is the continuity exists Examine the short circuit of accelerator pedal sensor 1 power wire with battery gro...

Page 200: ...rator pedal wiring harness connector C124 DISCONNECTED EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between pin 4 of accelerator pedal wiring harness connector and pin 61 of the EMS ECU wiring harness connector I Is the continuity exists Examine the open circuit of accelerator pedal sensor 1 signal wire Replace the wiring harness Clear the DTC and verify STEP 6 Ignition OF...

Page 201: ...ahindra Ltd Ignition OFF Accelerator pedal wiring harness connector C124 DISCONNECTED EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between pin 1 of accelerator pedal wiring harness connector and pin 40 of the EMS ECU wiring harness connector STEP 8 I Is the continuity exists Examine the open circuit of accelerator pedal sensor 2 power wire Replace the wiring harness Clear ...

Page 202: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 203: ...ANGE CHECK FOR HFM TEMPERATURE SENSOR ABOVE MAXIMUM LIMIT AIR TEMPERATURE SENSOR The HFM temperature sensor is a variable resistor whose resistance changes as the temperature of the air flowing past the sensor changes NTC resistor When the intake air temperature is low the sensor resistance is high when the intake air temperature is high the sensor resistance is low DTC INFORMATION PROBABLE CAUSES...

Page 204: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 205: ...oduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEWS...

Page 206: ...ic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0113 is present Is P0113 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Is the value 5 0 25 V Ignition OFF HFM sensor wiring harness connector C19 DISCONNECTED Ignition ON Check the voltage between pin 4 of the HFM sensor wiring harness connector and battery ground STEP 3 ...

Page 207: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 208: ...a Mahindra Ltd P0112 SIGNAL RANGE CHECK FOR HFM TEMPERATURE SENSOR BELOW MINIMUM LIMIT AIR TEMPERATURE SENSOR The HFM temperature sensor is a variable resistor whose resistance changes as the temperature of the air flowing past the sensor changes NTC resistor When the intake air temperature is low the sensor resistance is high when the intake air temperature is high the sensor resistance is low DT...

Page 209: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 210: ...oduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEWS...

Page 211: ...tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0112 is present Is P0112 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Is the value 5 0 25 V Ignition OFF HFM sensor wiring harness connector DISCONNECTED Ignition ON Check the voltage between pin 4 of the HFM sensor wiri...

Page 212: ...ndra Mahindra Ltd P0045 BOOST PRESSURE MODULATOR OPEN LOAD ERROR BOOST PRESSURE MODULATOR The boost pressure modulator controls the variable vanes of the VGT to attain the desired boost pressure thru controlling the vacuum to boost pressure actuator In normal operation and during an actuator test the PWM power stage of ECU is tested for short circuit to battery voltage short circuit to ground open...

Page 213: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 214: ...ured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CO...

Page 215: ...resent Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Check and confirm the proper function of 15A F15 boost pressure modulator fuse in ECU fuse box Boost pressure modulator wiring harness connector C67 DISCONNECTED Ignition ON Check the voltage between between pin 1 of boost pressure modulator wiring harness connector and battery ground Examine...

Page 216: ...a Ltd P0048 BOOST PRESSURE MODULATOR SHORT CIRCUIT TO BATTERY BOOST PRESSURE MODULATOR The boost pressure modulator controls the variable vanes of the VGT to attain the desired boost pressure thru controlling the vacuum to boost pressure actuator In normal operation and during an actuator test the PWM power stage of ECU is tested for short circuit to battery voltage short circuit to ground open ci...

Page 217: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 218: ...ured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CO...

Page 219: ...mount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0048 is present Is P0048 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Boost pressure ...

Page 220: ...d P0047 BOOST PRESSURE MODULATOR SHORT CIRCUIT TO GROUND BOOST PRESSURE MODULATOR The boost pressure modulator controls the variable vanes of the VGT to attain the desired boost pressure thru controlling the vacuum to boost pressure actuator In normal operation and during an actuator test the PWM power stage of ECU is tested for short circuit to battery voltage short circuit to ground open circuit...

Page 221: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 222: ...ured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CO...

Page 223: ...mount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0047 is present Is P0047 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Boost pressure ...

Page 224: ...cution 2012 Mahindra Mahindra Ltd P1645 BOOST PRESSURE MODULATOR OVER TEMPERATURE ERROR BOOST PRESSURE MODULATOR The boost pressure modulator controls the variable vanes of the VGT to attain the desired boost pressure thru controlling the vacuum to boost pressure actuator In normal operation and during an actuator test the PWM power stage of ECU is tested for short circuit to battery voltage short...

Page 225: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 226: ...ured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CO...

Page 227: ...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 prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P1645 is ...

Page 228: ... Mahindra Mahindra Ltd P0501 VEHICLE SPEED SENSOR PLAUSIBILITY ERROR VEHICLE SPEED SENSOR VSS Vehicle Speed Sensor VSS is hall sensor type and senses the rotating speed of the transmission output shaft Comparing engine speed with vehicle speed calculated based on vehicle speed sensor signal ECU recognizes engaged gear Based on the information about engaged gear ECU performs optimum fuel injection ...

Page 229: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 230: ...The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECT...

Page 231: ...ON Verify if P0501 is present Is P0501 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF VSS wiring harness connector C201 DISCONNECTED Ignition ON Check the voltage between pin 1 of the VSS wiring harness connector and battery ground Is the value 4 75 to 5 25 V STEP 4 Is the continuity exists NO YES STEP 3 Ignition OFF VSS wiring harness c...

Page 232: ...S wiring harness connector C201 DISCONNECTED EMS ECU wiring harness connector C4 DISCONNECTED Check the continuity between pin 22 of the EMS ECU wiring harness connector and pin 3 of the VSS wiring harness connector Check the continuity between pin 55 of the EMS ECU wiring harness connector and pin 2 of the VSS wiring harness connector Is the continuity exists Examine the open circuit of the VSS s...

Page 233: ...shaft sensor and registers a DTC if the voltage is not within the range DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON EMS ECU monitors the reference voltage of the Boost pressure sensor Rail pressure sensor Clutch sensor Vehicle speed sensor and Camshaft sensor and are within the range DTC DETECTING CONDITIONS Ignition ON EMS ECU supply voltage 8 16V The sensor supply vol...

Page 234: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 235: ...d Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0651 SENSOR SUPPLY VOLTAGE 2 MONITORING ERROR SENSOR SUPPLY VOLTAGE 2 MONITORING EMS ECU monitors the reference voltage of Accelerator Pedal position sensor 2 APP2 and registers a DTC if the voltage is not within the range DTC INFORMATION PROBABLE CAUSES...

Page 236: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 237: ... vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Ma...

Page 238: ...uthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0651 is present Is P0651 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Accelerator pedal wiring ha...

Page 239: ...d Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0697 SENSOR SUPPLY VOLTAGE 3 MONITORING ERROR SENSOR SUPPLY VOLTAGE 3 MONITORING EMS ECU monitors the reference voltage of Accelerator Pedal position sensor 1 APP1 and registers a DTC if the voltage is not within the range DTC INFORMATION PROBABLE CAUSES...

Page 240: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 241: ... vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Ma...

Page 242: ...ble for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0697 is present Is P0697 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Accelerator pedal wiring harness connector C124 DISCONNEC...

Page 243: ... for penalty prosecution 2012 Mahindra Mahindra Ltd P1B87 RAIL PRESSURE POSITIVE GOVERNOR DEVIATION ERROR IN METERING UNIT MODE RAIL PRESSURE MONITORING EMS ECU compares the rail pressure monitored through the rail pressure sensor against the expected pressure generated due to HPP DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON The ECU compares the rail pressure monitored t...

Page 244: ...ty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P1B87 is present Is P1B87 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Check and verify the last fuel filter change kilometers Is the DTC registered in 20...

Page 245: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 246: ...ndra Ltd P1C87 POSITIVE GOVERNOR DEVIATION AND SET POINT VALUE OF THE FUEL VOLUME FLOW THROUGH THE METERING UNIT RAIL PRESSURE MONITORING EMS ECU compares the rail pressure monitored through the rail pressure sensor against the expected pressure generated due to HPP DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON The ECU compares the rail pressure monitored through the rail...

Page 247: ...ty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P1C87 is present Is P1C87 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Check and verify the last fuel filter change kilometers Is the DTC registered in 20...

Page 248: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 249: ...secution 2012 Mahindra Mahindra Ltd P1B88 RAIL PRESSURE NEGATIVE GOVERNOR DEVIATION ERROR IN METERING UNIT MODE RAIL PRESSURE DEVIATION EMS ECU compares the rail pressure monitored through the rail pressure sensor against the expected pressure generated due to HPP DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON The ECU compares the rail pressure monitored through the rail p...

Page 250: ...n ON Verify if P1B88 is present Is P1B88 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Check and confirm the proper function of 15 A fuse F15 in ECU fuse box Fuel metering unit wiring harness connector C35 DISCONNECTED Ignition ON Check the voltage between between pin 2 of fuel metering unit wiring harness connector and battery ground I...

Page 251: ...use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P1D87 RAIL PRESSURE BELOW MINIMUM LIMIT ERROR IN METERING UNIT MODE RAIL PRESSURE EMS ECU compares the rail pressure monitored through the rail pressure sensor against the expected pressure generated due to HPP DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON The ECU compares the rail pressure monitor...

Page 252: ...ty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P1B87 is present Is P1D87 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Check and verify the last fuel filter change kilometers Is the DTC registered in 20...

Page 253: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 254: ...nauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P1C88 RAIL PRESSURE ABOVE MAXIMUM LIMIT ERROR IN METERING UNIT MODE RAIL PRESSURE EMS ECU compares the rail pressure monitored through the rail pressure sensor against the expected pressure generated due to HPP DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON The ECU compares the rail pres...

Page 255: ...n ON Verify if P1C88 is present Is P1C88 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Check and confirm the proper function of 15 A fuse F15 in ECU fuse box Fuel metering unit wiring harness connector C35 DISCONNECTED Ignition ON Check the voltage between between pin 2 of fuel metering unit wiring harness connector and battery ground I...

Page 256: ...e of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P068A P068B MAIN RELAY EARLY OPENING ERROR MAIN RELAY STRUCK ERROR DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON EMS ECU checks the main relay actuation time during initialization and is within the range ECU checks the main relay during operati...

Page 257: ...indra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Is the ECU communicates with the tool Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 STEP 3 Ignition OFF Ensure the main relay is fixed properly in the connector C9 Remove the main relay Check the functioning of relay by providing 12V to terminal 86 and ground to te...

Page 258: ...d fuse 10A F14 in ECU fuse box are functioning properly Remove the main relay EMS wiring harness connector DISCONNECTED C4 Check the continuity between pin 6 of the main relay connector C9 and pin 6 of the EMS ECU wiring harness connector Check the continuity between pin 6 of the main relay connector C9 and pin 4 of the EMS ECU wiring harness connector Check the continuity between pin 8 of the mai...

Page 259: ...he various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorize...

Page 260: ...thorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0229 BOOST PRESSURE CONTROLLER DEVIATION ABOVE MAXIMUM LIMIT DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON The maximum permissible positive control deviation of the closed loop boost pressure control is with in the limit ...

Page 261: ...nalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0229 is present Is P0229 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Check the air filter for clogging NO YES Is the air filter clogged ...

Page 262: ...ra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0234 BOOST PRESSURE CONTROLLER DEVIATION BELOW MINIMUM LIMIT DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON The permissible negative control deviation of the closed loop boost pressure control is with in the limit DTC DETECTING CONDITIONS Ignition ON EMS ECU suppl...

Page 263: ...le for penalty prosecution 2012 Mahindra Mahindra Ltd P0069 PLAUSIBILITY DEFECT BETWEEN CACDSP AND ENVP DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON When engine running the difference in absolute value of atmospheric pressure and boost pressure is with in the limit DTC DETECTING CONDITIONS Ignition ON EMS ECU supply voltage 8 16V When engine running the difference in abs...

Page 264: ...ll be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0504 BRAKE SIGNAL PLAUSIBILITY ERROR BRAKE SWITCH The main and redundant brake signals are input to EMS ECU from the brake switch They are mutually and individually checked for plausibility DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON The brake switch outputs a voltage which corresponds to the brake positio...

Page 265: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 266: ...uction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEWS A...

Page 267: ... the intermittent problem inspection procedure STEP 2 STEP 3 Ignition OFF Ensure that the brake switch is adjusted properly refer repair manual for procedure Ensure proper functioning of 15A fuse F44 in engine compartment fuse box Brake switch wiring harness connector C112 DISCONNECTED Ignition ON Check the voltage between pin 3 of the brake switch wiring harness connector and battery ground Check...

Page 268: ...Mahindra Mahindra Ltd STEP 4 Ignition OFF EMS ECU wiring harness connector C4 DISCONNECTED Brake switch wiring harness connector C112 DISCONNECTED Check the continuity between pin 4 of the brake switch wiring harness connector and battery ground Check the continuity between pin 2 of the brake switch wiring harness connector and battery ground Is the continuity exists Examine the short circuit in b...

Page 269: ...dra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P0704 CLUTCH NON PLAUSIBLE ERROR CLUTCH SENSOR The clutch pedal sensor is a hall effect sensor encompassing two hall chips mounted on fixed part of the clutch pedal and a magnet mounted on the moving shank of the clutch pedal DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPER...

Page 270: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 271: ...slation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONNECTOR VIEWS AND INFORMAT...

Page 272: ...ion ON Verify if P0704 is present Is P0704 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 STEP 3 Ignition OFF Clutch sensor wiring harness connector C250 DISCONNECTED Ignition ON Check the voltage between pin 1 of the clutch sensor wiring harness connector and battery ground Is the value 5 0 25 V Examine the open short circuit in clutch sensor power ...

Page 273: ...Mahindra Mahindra Ltd STEP 4 Ignition OFF EMS ECU wiring harness connector C4 DISCONNECTED Clutch sensor wiring harness connector 250 DISCONNECTED Check the continuity between pin 2 of the clutch sensor wiring harness connector and battery ground Check the continuity between pin 5 of the clutch sensor wiring harness connector and battery ground Is the continuity exists Examine the short circuit in...

Page 274: ...mount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P172A CLUTCH 90 SWITCH PLAUSIBLE ERROR CLUTCH SENSOR The clutch pedal sensor is a hall effect sensor encompassing two hall chips mounted on fixed part of the clutch pedal and a magnet mounted on the moving shank of the clutch pedal DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON...

Page 275: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 276: ...anufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra...

Page 277: ... to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P172A is present Is P172A present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Clutch sensor wiring...

Page 278: ...an 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 P2269 WATER PRESENCE IN FUEL ERROR WATER IN FUEL The water in fuel signal is provided to EMS ECU to indicate the presence of water in fuel DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON No ...

Page 279: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 280: ...ufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra L...

Page 281: ...e and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P02269 is present Is P02269 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Drain the water from fuel filter Igni...

Page 282: ...ra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P2265 WATER IN FUEL SENSOR FAULTY WATER IN FUEL SENSOR The water in fuel signal indicates the presence of water in fuel It is fitted on the bottom of the fuel filter and gives the water in fuel signal to EMS ECU and Instrument Cluster it works on the difference of electric conduct...

Page 283: ...rious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use...

Page 284: ...ufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra L...

Page 285: ...alise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P2265 is present Is P2265 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 STEP 3 Ignition OFF Check and ensure the proper functioning of 5 A fuse F47 Water in fuel sensor wiring harness connector C38 DISCONNECTED Ignition ON Check the voltage between pin 3 ...

Page 286: ...on 2012 Mahindra Mahindra Ltd STEP 4 Ignition OFF EMS ECU wiring harness connector C4 DISCONNECTED Water in fuel sensor wiring harness connector C38 DISCONNECTED Check the continuity between pin 2 of the water in fuel sensor wiring harness connector and pin 25 of the EMS ECU wiring harness connector Is the continuity exists Examine the open circuit in water in fuel sensor signal wire Replace the w...

Page 287: ...of ADC monitoring Error in plausibility of the test voltage P163C ECU Monitoring Voltage ratio error in ADC Ratiometry correction monitored Error in plausibility of ratiometry correction P1621 ECU Monitoring Query response communication error Function controller monitored Error in plausibility of function controller and monitoring module P1622 ECU Monitoring SPI communication error SPI communicati...

Page 288: ...scription Monitored Component Malfunction P1628 ECU Monitoring Shut off path under voltage error Shut off path test monitored for under voltage Error in shut off path test of the under voltage detection P1629 ECU Monitoring WDA not working Shut off path check monitored Error in shut off path check monitoring P162A ECU Monitoring Time out error Time out in calling operative system services Error in...

Page 289: ...onitoring Accelerator position error Two voltage values of accelerator pedal is monitored Implausible accelerator pedal voltage P061C ECU Monitoring Engine speed error Offset between calculated engine speed and engine speed with low resolution is monitored Non permissible offset between the engine speed of level 2 and level 1 P1638 ECU Monitoring Rail pressure monitoring plausibility error Rail pr...

Page 290: ...enalty prosecution 2012 Mahindra Mahindra Ltd P1631 ECU MONITORING START OF INJECTION PLAUSIBILITY ERROR DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON The start of the energizing time is monitored DTC DETECTING CONDITIONS Ignition ON EMS ECU supply voltage 8 16V If the start of the energizing time is outside the plausible valid range then this error is registered DTC REAC...

Page 291: ...a Mahindra Ltd P1632 ECU MONITORING ZFC NON PLAUSIBILITY ERROR DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON The maximum plausible energising time of the ZFC results depending on the rail pressure is compared with a predetermined curve and is within the range The minimum energizing time is also compared with a predetermined curve and is within the range DTC DETECTING COND...

Page 292: ...e liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONTINIOUS TORQUE MONITORING DTC Description P1633 ECU Monitoring PoI2 qty error P1634 ECU Monitoring PoI2 shut off error P1635 ECU Monitoring PoI3 efficiency factor error P1637 ECU Monitoring Injection quantity correction error P061B ECU Monitoring Torque comparison error P163E ECU Monitoring Torque monitoring level2 error P1639 ECU Moni...

Page 293: ... in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Lamp Status Engine Check lamp Continiously ON Co...

Page 294: ...AGE FOR THE COMPRESSOR AC COMPRESSOR POWER STAGE The AC Compressor is controlled by the EMS ECU under the feedback of the temperature sensing unit in the HVAC system and pressure sensors measuring the pressure of the refrigerant flow in the air conditioning circuit The ECU monitors the status of the Power Stage Actuator of the Compressor Clutch for monitoring hardware errors such as short circuit ...

Page 295: ...tic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P06A0 is present Is P06A0 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 STEP 3 Ignition OFF Ensure the compressor relay is fixed properly in the connector of the ECU fuse box Remove the AC compressor relay Check the functioning of relay by providing 12V to terminal 86 and...

Page 296: ...ra 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 prosecution 2012 Mahindra Mahindra Ltd Is the continuity exists Examine the open circuit of of AC compressor relay control wire from EMS ECU Replace the wiring harness Clear the DTC and verify Suspec...

Page 297: ...TAGE FOR THE COMPRESSOR AC COMPRESSOR POWER STAGE The AC Compressor is controlled by the EMS ECU under the feedback of the temperature sensing unit in the HVAC system and pressure sensors measuring the pressure of the refrigerant flow in the air conditioning circuit The ECU monitors the status of the Power Stage Actuator of the Compressor Clutch for monitoring hardware errors such as short circuit...

Page 298: ...t tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P06A2 is present Is P06A2 present Intermittent problem exists Refer the intermittent problem inspection procedure Ignition OFF Remove the AC compressor relay Ignition ON Check the voltage between pin 1 of the AC compressor relay seating C107 and battery ground Is the v...

Page 299: ...STAGE FOR THE COMPRESSOR AC COMPRESSOR POWER STAGE The AC Compressor is controlled by the EMS ECU under the feedback of the temperature sensing unit in the HVAC system and pressure sensors measuring the pressure of the refrigerant flow in the air conditioning circuit The ECU monitors the status of the Power Stage Actuator of the Compressor Clutch for monitoring hardware errors such as short circui...

Page 300: ...Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P06A2 is present Is P06A2 present Intermittent problem exists Refer the intermittent problem inspection...

Page 301: ... SPEED The cooling fans are controlled by EMS ECU Both the fans run either at low speed or at high speed The low speed of the cooling fans are controlled by pressure switch relay Based on the coolant temperature the EMS ECU controls the pressure switch relay to activate the low speed of the fans Fans are ON at low speed if the coolant temperature reaches 99 C DTC INFORMATION PROBABLE CAUSES OF FAI...

Page 302: ... diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0480 is present Is P0480 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 STEP 3 Ignition OFF Ensure the pressure switch relay is fixed properly in the connector of the relay box Remove the pressure switch relay Check the functioning of relay by providing 12V to ter...

Page 303: ...D The cooling fans are controlled by EMS ECU Both the fans run either at low speed or at high speed The low speed of the cooling fans are controlled by pressure switch relay Based on the coolant temperature the EMS ECU controls the pressure switch relay to activate the low speed of the fans Fans are ON at low speed if the coolant temperature reaches 99 C DTC INFORMATION PROBABLE CAUSES OF FAILURE ...

Page 304: ...a Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0692 is present Is P0692 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Ens...

Page 305: ...691 FAN 1 CONTROL CIRCUIT LOW COOLING FAN LOW SPEED The cooling fans are controlled by EMS ECU Both the fans run either at low speed or at high speed The low speed of the cooling fans are controlled by pressure switch relay Based on the coolant temperature the EMS ECU controls the pressure switch relay to activate the low speed of the fans Fans are ON at low speed if the coolant temperature reache...

Page 306: ...vice Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0691 is present Is P0691 present Intermittent problem exists Refer the intermittent problem inspection pr...

Page 307: ... are controlled by EMS ECU Both the fans run either at low speed or at high speed The high speed of the cooling fans are controlled by change over relay and cooling fan relay 2 Based on the coolant temperature the EMS ECU controls the by change over relay and cooling fan relay 2 to activate the high speed of the fans Fans are ON at high speed if the coolant temperature reaches 102 C DTC INFORMATIO...

Page 308: ...tion OFF Turn ignition ON Verify if P0481 is present Is P0481 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 STEP 3 Ignition OFF Ensure the changeover relay and cooling fan 2 relay are fixed properly in the connector of the relay box Remove the relays Check the functioning of relays by providing 12V to terminal 86 and ground to terminal 85 Is a click...

Page 309: ...are controlled by EMS ECU Both the fans run either at low speed or at high speed The high speed of the cooling fans are controlled by change over relay and cooling fan relay 2 Based on the coolant temperature the EMS ECU controls the by change over relay and cooling fan relay 2 to activate the high speed of the fans Fans are ON at high speed if the coolant temperature reaches 102 C DTC INFORMATION...

Page 310: ...td will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0694 is present Is P0694 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Ensure...

Page 311: ...y EMS ECU Both the fans run either at low speed or at high speed The high speed of the cooling fans are controlled by change over relay and cooling fan relay 2 Based on the coolant temperature the EMS ECU controls the by change over relay and cooling fan relay 2 to activate the high speed of the fans Fans are ON at high speed if the coolant temperature reaches 102 C DTC INFORMATION PROBABLE CAUSES...

Page 312: ...re of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0693 is present Is P0693 present Intermittent problem exists Refer the intermittent problem inspection procedure S...

Page 313: ... the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P1704 GEAR NEUTRAL SIGNAL IS NOT PLAUSIBLE GEAR NEUTRAL SWITCH The gear neutral switch is a normally closed switch located on the trasnsmission which provides information on gear neutral position to EMS ECU DTC INFORMATION PROBABLE CAUSES OF...

Page 314: ... will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P1704 is present Is P1704 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Neutral ...

Page 315: ...ent 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 Mahindra Ltd P1712 GNS RELAY NO LOAD GNS RELAY GNS relay along with starter relay runs the starter motor The GNS relay is controlled by EMS ECU DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATI...

Page 316: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 317: ...erson 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 P1713 GNS RELAY SHORT TO BATTERY ERROR GNS RELAY GNS relay along with starter relay runs the starter motor The GNS relay is controlled by EMS ECU DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPER...

Page 318: ...ntre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P1713 is present Is P1713 present Intermittent problem exists Refer the intermittent problem inspection procedure...

Page 319: ...erson 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 P1714 GNS RELAY SHORT TO GROUND ERROR GNS RELAY GNS relay along with starter relay runs the starter motor The GNS relay is controlled by EMS ECU DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERA...

Page 320: ...e Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P1714 is present Is P1714 present Intermittent problem exists Refer the intermittent probl...

Page 321: ...ahindra 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 penalty prosecution 2012 Mahindra Mahindra Ltd P170F STARTER RELAY OPEN LOAD DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON No malfunction detected by EMS ECU in the co...

Page 322: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the 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 Mahindra Mahindra Ltd will amount to unautho...

Page 323: ...ra 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 prosecution 2012 Mahindra Mahindra Ltd P170D STARTER RELAY SHORT CIRCUIT TO BATTERY ERROR DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON No malfunction detected by EMS ECU in...

Page 324: ...Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P170D is present Is P170D present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 ...

Page 325: ...indra 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 penalty prosecution 2012 Mahindra Mahindra Ltd P170E STARTER RELAY SHORT CIRCUIT TO GROUND ERROR DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON No malfunction detected by...

Page 326: ...horized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P170E is present Is P170E present Intermittent problem exists Refer the intermittent problem in...

Page 327: ...a Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P1641 SOFTWARE RESET ERROR DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON The monitored supply voltage monitored to EMS ECU is with in the range of 8 16 V DTC DETECTING CONDITIONS Ignition ON The EMS ECU supply voltage is less than 5 V and a software reset ...

Page 328: ...d Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd P1707 T50 SIGNAL ERROR DTC INFORMATION PROBABLE CAUSES OF FAILURE NORMAL OPERATION Ignition ON The T50 input crank is monitored by EMS ECU is with in the allowable duration DTC DETECTING CONDITIONS Ignition ON The T50 input is available at EMS ECU for a l...

Page 329: ...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 Ltd SYMPTOM BASED DIAGNOSTICS WITH NO DTC CODES Complaint Engine not starting Error codes No error codes Caution After dry run switch the Ignition OFF for 1 min and then switch it ON Follow the above ste...

Page 330: ...rail is not sufficient No pressure built up in the fuel circuit Check the fuel level in fuel tank Check for any restriction in fuel filter Check injector back leaks If all of the above is OK replace the HPP 1 The pressure built up in the rail is sufficient but the engine speed is below the minimum threshold Cranking RPM less Check for battery for less voltage Check any loose connections in starter...

Page 331: ...Mahindra Mahindra Ltd Reason for Torque Limitation Note the value of Current limitations active label in Monitoring live data pocket Convert it into binary See the bit position of first occurrence of 1 from right and look against the bit position in the table below Bit Position Reason for Torque Limitation 0 Limiting torque due to torque limitation in the event of a system error 1 Limiting torque ...

Page 332: ...NTERIMS Additional asynchronous interrupts which is generated when engine position is detected based on the time condition of system 4 WAIT_INC Plausibility test is done on the events of the redundant sensor system w o the mail sensor system delivering events Interrupts are generated with min system freq 5 PHASE_FREQ_CHK Plausibility test is done on the events of the redundant sensor system w o th...

Page 333: ...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 Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CONFORMITY CHECK Resistance Values Coolant temperature Sensor Fuel Temperature se...

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