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DIAGNOSTIC MANUAL

MAN-00152

EMS

OCT 2011/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

© 2011 Mahindra & Mahindra Ltd.

7

EMS ECU PIN DETAILS

ECU

Connector

Pin no

Function

Connected To

Pin no

1 GROUND

GROUND

G3

2 GROUND

GROUND

G3

3

POWER HIGH SIDE

INJECTOR 1 - INJECTOR 4

1

4 POWER

MAIN

RELAY

87

6 POWER

MAIN

RELAY

87

6

POWER HIGH SIDE

INJECTOR 3 - INJECTOR 2

1

7

POWER LOW SIDE

INJECTOR 4

2

10 POWER

CLUTCH

SENSOR

4

11 GROUND

COOLANT

TEMPERATURE

SENSOR

2

12 SIGNAL

FUEL

TEMPERATURE SENSOR

1

18 POWER

ACCELERATOR

PEDAL(APP1)

2

19

OIL PRESSURE SWITCH

OIL PRESSURE SWITCH

1

20 SIGNAL-HIGH/LOW TRIPPLE

PRESSURE

SWITCH

2

22

SIGNAL

VEHICLE SPEED SENSOR

3

23

85% SIGNAL

CLUTCH SENSOR

1

23 POWER

GEAR

NEUTRAL

SENSOR

1

24 REDUNDANT

SIGNAL BRAKE

SWITCH

4

25 SIGNAL-MIDDLE

TRIPPLE

PRESSURE

SWITCH

3

29

POWER LOW SIDE

INJECTOR 3

2

30

SHIELD

CRANK SHAFT SPEED SENSOR

3

31

SIGNAL(AIR MASS)

HOT FILM AIR MASS SENSOR

5

32

POWER

RAIL PRESSURE SENSOR

3

33 SIGNAL

COOLANT

TEMPERATURE

SENSOR

1

34 GROUND

FUEL

TEMPERATURE SENSOR

2

35

POWER

BOOST PRESSURE SENSOR

3

40 POWER

ACCELERATOR

PEDAL(APP2)

1

41

15% SIGNAL

CLUTCH SENSOR

2

41 SIGNAL

GEAR

NEUTRAL

SENSOR

2

43 SIGNAL

REVERSE

SWITCH

2

44

GROUND

CAM SHAFT POSITION SENSOR

1

45

POWER

CAM SHAFT POSITION SENSOR

3

46

SIGNAL

CAM SHAFT POSITION SENSOR

2

49

SIGNAL

EXHAUST GAS RECIRCULATION ACTUATOR

2

50 SIGNAL

MAIN

RELAY

86

51

POWER LOW SIDE

INJECTOR 2

2

52

SIGNAL (+)

CRANK SHAFT SPEED SENSOR

1

53

GROUND

HOT FILM AIR MASS SENSOR

1

54

SIGNAL

RAIL PRESSURE SENSOR

2

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Summary of Contents for XUV500

Page 1: ...AL MAN 00152 www teknetmahindra com ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP TO DATE AT THE TIME OF PUBLICATION HOWEVER SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE THIS MANUAL IS STRICTLY MEANT FOR RESTRICTED INTERNAL CIRCULATION WITHIN M M AUTHORIZED DEALER SERVICE CENTERS RELEASED BY TECHNICAL PUBLICATION CELL MAHINDRA MAHINDRA LTD Rev1 OCTOBER 2011 ...

Page 2: ... 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 2011 Mahindra Mahindra Ltd 1 CONTENTS HOW TO USE THIS MANUAL 2 OVER VIEW OF THE VEHICLE COMMUNICATION NETWORK 3 EMS OVERVIEW 4 WARRANT...

Page 3: ...personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 2 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 i...

Page 4: ...t 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 ...

Page 5: ...td 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 2011 Mahindra Mahindra Ltd 4 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 M...

Page 6: ...personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 5 Actuators EGR Actuator Fan Control Injectors Fuel Metering Unit Turbo charger actuator Glow Plugs A C Compressor Boost Pressure Actuator WARRANTY OTHER INFORMATION All failures complaints encountered on EMS ECU and other system...

Page 7: ... 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 2011 Mahindra Mahindra Ltd 6 RECOMMENDED TROUBLE SHOOTINGPROCESS Customer complaint Record Understand Customer Verbatim...

Page 8: ...POWER HIGH SIDE INJECTOR 3 INJECTOR 2 1 7 POWER LOW SIDE INJECTOR 4 2 10 POWER CLUTCH SENSOR 4 11 GROUND COOLANT TEMPERATURE SENSOR 2 12 SIGNAL FUEL TEMPERATURE SENSOR 1 18 POWER ACCELERATOR PEDAL APP1 2 19 OIL PRESSURE SWITCH OIL PRESSURE SWITCH 1 20 SIGNAL HIGH LOW TRIPPLE PRESSURE SWITCH 2 22 SIGNAL VEHICLE SPEED SENSOR 3 23 85 SIGNAL CLUTCH SENSOR 1 23 POWER GEAR NEUTRAL SENSOR 1 24 REDUNDANT ...

Page 9: ...cution 2011 Mahindra Mahindra Ltd 8 ECU Connector Pin no Function Connected To Pin no 55 GROUND VEHICLE SPEED SENSOR 2 56 SIGNAL P BOOST PRESSURE SENSOR 4 59 SIGNAL CLOCK SPRING 4 60 SIGNAL ACCELERATOR PEDAL APP2 6 61 SIGNAL ACCELERATOR PEDAL APP1 4 65 CAN LOW DLC CONNECTOR 14 66 CAN HIGH DLC CONNECTOR 6 68 SIGNAL COOLING FAN HIGH RELAY 86 71 POWER IGNITION SWITCH IG1 72 SIGNAL COOLING FAN LOW REL...

Page 10: ...n 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 2011 Mahindra Mahindra Ltd 9 ABBREVIATIONS EMS Engine Management System ABS Antilock Braking System ESP Electronic Stability Program MBFM Mahindra Body Function Module IC Instrument Cluster SRS Supplementary Restraint System IS Inf...

Page 11: ... CAN SIGNALS Signals Transmitted by EMS ECU Sl no Signal Name Reciever 1 Accelerator pedal position ESP ITM MBFM IC IS 2 Engine speed ESP ITM MBFM IC IS 3 Status of cruise control regulation ESP 4 Cruise On Off status IC ESP 5 Current gear ESP MBFM IC IS RPAS SRS ITM 6 Glow plug on off control IC 7 Engine Oil Pressure IC IS 8 Engine Coolant Temperature IC HVAC 9 Vehicle Speed MBFM IC IS RPAS HVAC ...

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: ... 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 code as etched on the injectors EMS ECU FLASHING The EMS ECU required to ...

Page 14: ...her 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 2011 Mahindra Mahindra Ltd 13 3 Ensure that the there is no communication breakdown once the flashing begins Check Python connections are secure 4 Ensure that the SMART tester has Enough battery reserve Connected to AC power Screen sav...

Page 15: ... 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 2011 Mahindra Ma...

Page 16: ...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 2011 Mahindra Mahi...

Page 17: ...n 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 2011 Mahindra Mahindra Ltd 16 8 Select EMS from the drop down...

Page 18: ... 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 2011 Mahindra Mahindra Ltd 17 10 Once the EMS ECU is flashed successfully follow th...

Page 19: ...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 2011 Mahindra Mahindra Ltd 18 12 Fo...

Page 20: ...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 2011 Mahindra Mahindra Ltd 19 ...

Page 21: ... Compensation beyond the limit at Low Idle 41 P1101 HFM7 sensor drift Compensation beyond the limit at loaded condition 41 BATTERY P0563 Battery voltage high error 43 P0562 Battery voltage low error 45 COOLANT TEMPERATURE SENSOR P1128 Coolant Temperature Sensor Absolute Test non plausible error 50 P1126 Coolant Temperature Sensor Dynamic Test non plausible error P0118 Signal Range Check for coolan...

Page 22: ...rect error 140 P268E Cylinder 3 injector adjustment code incorrect error 142 P268F Cylinder4 injector adjustment code incorrect error 144 INJECTORS P0201 Cylinder1 injector open load error 146 P0202 Cylinder2 injector open load error 150 P0203 Cylinder3 injector open load error 154 P0204 Cylinder4 injector open load error 158 P0261 High side Low side short circuit for cylinder1 injector 162 P0264 ...

Page 23: ...sensor above maximum limit 248 P0112 Signal range check for HFM 7temperature sensor below minimum limit 253 BOOST PRESSURE MODULATOR P0045 Boost pressure modulator open load error 257 P0048 Boost pressure modulator short circuit to battery 261 P0047 Boost pressure modulator short circuit to ground 265 P1645 Boost pressure modulator over temperature error 269 VEHICLE SPEED SENSOR P0501 Vehicle spee...

Page 24: ...g ROM memory error P1623 ECU Monitoring CPU error P1625 ECU Monitoring Response time error in ECU P1626 ECU Monitoring Shut off path test SPI communication error P1628 ECU Monitoring Shut off path under voltage error 319 P1629 ECU Monitoring WDA not working P162A ECU Monitoring Time out error P162C ECU Monitoring Positive test failure error P162D ECU Monitoring Time out error for shut off path tes...

Page 25: ...ous 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 a...

Page 26: ...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 27: ...l range check for HFM7 sensor signal above maximum limit HOT FILM AIR MASS SENSOR HFM Mass air flow rate is measured by detection of heat transfer from a hot film probe because 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 5...

Page 28: ...mponent 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 sha...

Page 29: ... 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 pros...

Page 30: ... Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 29 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 STE...

Page 31: ...ignal below minimum limit HOT FIL AIR MASS SENSOR Mass air flow rate is measured by detection of heat transfer from a hot film probe because 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 voltage supplied from the engine c...

Page 32: ...mponent 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 sha...

Page 33: ...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 2011 Mahindra Mahindra L...

Page 34: ...0102 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Is the value Vbat NO Ignition OFF HFM sensor wiring harness connector DISCONNECTED Ignition ON Check the voltage between pin 3 of the HFM sensor wiring harness connector and battery ground YES Examine the short to ground open circuit of HFM sensor power supply wire Repair replace the wiring harness ...

Page 35: ...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 36: ...indra Ltd 35 P1100 Signal Error for HFM7 sensor HOT FIL AIR MASS SENSOR Mass air flow rate is measured by detection of heat transfer from a hot film probe because 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 voltage supp...

Page 37: ...mponent 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 sha...

Page 38: ...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 2011 Mahindra Mah...

Page 39: ...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 40: ... Mahindra Ltd 39 P0100 Battery voltage error of HFM7 sensor HOT FIL AIR MASS SENSOR Mass air flow rate is measured by detection of heat transfer from a hot film probe because 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 ...

Page 41: ...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 2011 Mahindra Mahindra Ltd 40 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 P0100 is present Is P0100 present Ignition ON Engi...

Page 42: ...1101 HFM7 sensor drift Compensation beyond the limit at loaded condition HOT FIL AIR MASS SENSOR Mass air flow rate is measured by detection of heat transfer from a hot film probe because 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 be...

Page 43: ...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 44: ...s 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 2011 Mahindra Mahindra Ltd 43 P0563 Battery voltage high error BATTERY The system voltage has to guarantee to perform diagnosis functions The Electronic Control Unit ECU monitors battery voltage COMPONENT LOC...

Page 45: ...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 46: ...y 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 2011 Mahindra Mahindra Ltd 45 P0562 Battery voltage low error BATTERY The system voltage has to guarantee to perform diagnosis functions The Electronic Control Unit ECU monitors battery voltage COMPONENT LOCATION NORMAL ...

Page 47: ...mponent 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 sha...

Page 48: ...ch 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 2...

Page 49: ...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 50: ...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 51: ...td 50 P1128 Coolant Temperature Sensor Absolute Test non plausible error P1126 Coolant Temperature Sensor Dynamic Test non plausible error ABSOLUTE DYNAMIC PLAUSIBILTY 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 slope COMPONENT LOCATION NORMAL OPERATION...

Page 52: ...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 53: ... sensor 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 smoo...

Page 54: ...mponent 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 sha...

Page 55: ...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 2011...

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: ...all be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 56 STEP 4 Ignition OFF Coolant temperature sensor wiring harness connector DISCONNECTED EMS ECU wiring harness connector DISCONNECTED Check the resistance between pin 11 EMS ECU wiring harness connector and pin 2 of the of the coolant temperature sensor wiring harness connector Is the value 1Ω Examine the open circuit of coolant temp...

Page 58: ...eck for coolant 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 t...

Page 59: ...mponent 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 sha...

Page 60: ...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 2011...

Page 61: ...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 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 NO Ignition OFF Coolant temperature sensor wiring harness connector DISCONNECTED Ignition ON Check the ...

Page 62: ...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 63: ...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 2011 Mahindra Mahindra Ltd 62 P062F ECU EEPROM error EEPROM EEPROM Electrically Erasable Programmable Read Only Memory is a storage device inside the EMS ECU COMPONENT LOCATION NORM...

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 2011 Mahindra Mahindra Ltd 63 STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Tu...

Page 65: ...indra 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 2011 Mahindra Mahindra Ltd 64 P162F ECU EEPROM error EEPROM EEPROM Electrically Erasable Programmable Read Only Memory is a storage device inside the EMS ECU COMPONENT LOCATION NORMAL ...

Page 66: ...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 2011 Mahindra Mahindra Ltd 65 STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record the DTC and clear Tu...

Page 67: ...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 2011 Mahindra Mahindra Ltd 66 P1630 ECU EEPROM error EEPROM EEPROM Electrically Erasable Programmable Read Only Memory is a storage device inside the EMS ECU COMPONENT LOCATION ...

Page 68: ...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 69: ...nt 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 2011 Mahindra Mahindra Ltd 68 P062B ECU monitoring error for Injector cut off demand ICO MONITORING Injection cut off monitoring is used to limit the engine speed to a controllable engine speed band COMPONENT LOCATIO...

Page 70: ...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 71: ...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 2011 Mahindra Mahindra Ltd 70 P0403 EGR Valve open load error EGR A pulse width modulated signal is output for the Exhaust Gas Recirculation actuator control Converting the air control output into duty cycle carries...

Page 72: ...a L ble for penalty prosecutio sed on the technical spe essories from which the v Ltd The use of this docu n 2011 Mahindra Ma EMS ecifications current at th vehicles are manufacture ument by any person othe ahindra Ltd he time of release The m ed The reproduction tra er than the trained perso methods may be modifie anslation transmission i onnel at the Authorized S MAN 00 OCT 201 ed as a result of...

Page 73: ...ehicles 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 2011 Mahi...

Page 74: ...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 75: ... 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 2011 Mahindra Mahindra Ltd 74 P1403 EGR Valve over temperature error EGR A pulse width modulated signal is output for the Exhaust Gas Recirculation actuator control Converting the air control output into duty cycle carries th...

Page 76: ...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 77: ...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 2011 Mahindra Mahindra Ltd 76 P0406 EGR Valve short to battery error EGR A pulse width modulated signal is output for the Exhaust Gas Recirculation actuator control Converting the air control output into duty cycle carries...

Page 78: ...a L ble for penalty prosecutio sed on the technical spe essories from which the v Ltd The use of this docu n 2011 Mahindra Ma EMS ecifications current at th vehicles are manufacture ument by any person othe ahindra Ltd he time of release The m ed The reproduction tra er than the trained perso methods may be modifie anslation transmission i onnel at the Authorized S MAN 00 OCT 201 ed as a result of...

Page 79: ...ehicles 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 2011 Mahi...

Page 80: ...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 81: ... 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 2011 Mahindra Mahindra Ltd 80 P0405 EGR Valve short to ground error EGR A pulse width modulated signal is output for the Exhaust Gas Recirculation actuator control Converting the air control output into duty cycle carries...

Page 82: ...a L ble for penalty prosecutio sed on the technical spe essories from which the v Ltd The use of this docu n 2011 Mahindra Ma EMS ecifications current at th vehicles are manufacture ument by any person othe ahindra Ltd he time of release The m ed The reproduction tra er than the trained perso methods may be modifie anslation transmission i onnel at the Authorized S MAN 00 OCT 201 ed as a result of...

Page 83: ...ehicles 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 2011 Mahi...

Page 84: ...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 85: ...ndra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 84 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 gives the atmospheric pressure value The ECU checks the sensor signal for the range If it is outside...

Page 86: ...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 87: ...ndra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 86 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 gives the atmospheric pressure value The ECU checks the sensor signal for the range If it is outside...

Page 88: ...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 89: ...1 Mahindra Mahindra Ltd 88 P0340 Camshaft sensor no signal error CAM SHAFT POSITION SENSOR The 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 COMPONENT LOCATION NORMAL OPERATION During engine running the EMS ECU receives...

Page 90: ...mponent 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 sha...

Page 91: ...es 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 2011 Mahindra ...

Page 92: ...t Is P0340 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Is the value 5 0 25 V NO Ignition OFF Camphase sensor wiring harness connector DISCONNECTED Ignition ON Check the voltage between pin 3 of the cam phase sensor wiring harness connector and battery ground YES STEP 3 Go to STEP 5 YES NO STEP 4 Ignition OFF Camphase sensor wiring harness connecto...

Page 93: ...Camphase sensor wiring harness connector DISCONNECTED Check the resistance between between pin 2 of the cam phase sensor wiring harness connector and ground Is the value 1Ω NO YES Examine the short circuit of cam phase sensor signal wire to ground Repair replace the wiring harness Clear the DTC and verify STEP 6 Ignition OFF Camphase sensor wiring harness connector DISCONNECTED EMS ECU wiring harn...

Page 94: ...t sensor signal error CAM SHAFT POSITION SENSOR The 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 COMPONENT LOCATION NORMAL OPERATION During engine running the EMS ECU receives the output signal from cam shaft position ...

Page 95: ...mponent 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 sha...

Page 96: ...es 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 2011 Mahindra ...

Page 97: ...C and clear Turn ignition OFF Turn ignition ON Crank the engine Verify if P0341 is present Is P0341 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Is the bolt fitted properly NO Ignition OFF Camphase sensor wiring harness connector DISCONNECTED Check for proper fitment of the cam phase sensor mounting bolt YES STEP 3 YES NO STEP 4 Ignition OFF Campha...

Page 98: ...1 Camshaft sensor signal offset error CAM SHAFT POSITION SENSOR The 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 COMPONENT LOCATION NORMAL OPERATION During engine starting the EMS ECU compares the crankshaft sensor sig...

Page 99: ...the 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 NO Check the flywheel mounting bolts for tightness Check the cam shaft crankshaft mounting bolts for tightness YES STEP 3 YES...

Page 100: ...a Ltd 99 P0336 Crankshaft sensor signal error CRANKSHAFT 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 COMPONENT LOCATION NORMAL OPERATION During engine cranking and running the EMS ECU receives the output signal from crankshaft speed sensor and is within...

Page 101: ...ponent 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 shal...

Page 102: ... 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 2011 Mahindra Ma...

Page 103: ...nt problem exists Refer the intermittent problem inspection procedure STEP 2 Ignition OFF Crankshaft speed sensor wiring harness connector DISCONNECTED EMS ECU wiring harness connector 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 Is the value 1Ω Examine the open circuit of crank shaft spee...

Page 104: ...rized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 103 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 Is the end...

Page 105: ...enalty prosecution 2011 Mahindra Mahindra Ltd 104 P0335 Crankshaft sensor no signal error CRANKSHAFT 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 COMPONENT LOCATION NORMAL OPERATION During engine cranking and running the EMS ECU receives the output signa...

Page 106: ...ponent 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 shal...

Page 107: ... 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 2011 Mahindra Ma...

Page 108: ...dra Ltd 107 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 NO YES STEP 3 Ignition OFF Check and correct if any loose connections noticed in the crankshaft s...

Page 109: ...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 110: ...trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 109 P0480 Low speed fan open load LOW SPEED COOLING FAN The cooling fan is controlled by EMS ECU The low speed cooling fan will be ON whenever A C is switched ON middle pressure switch is OFF or coolant temperature is mor...

Page 111: ...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 prosecutio...

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: ...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 2011 Mahindra Mahindra Ltd 112 P0481 High speed fan open load HIGH SPEED COOLING FAN The cooling fan is controlled by EMS ECU The high speed cooling fan will be ON whenever the cooling temperature is more than 101 C or A C midd...

Page 114: ...ich 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 ...

Page 115: ...ord the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0481 is present Is P0481 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 NO YES STEP 3 Ignition OFF Ensure the fan high speed relay is fixed properly in the connector of the engine compartment fuse box Remove the fan high speed relay Check the functioning of relay by providing 12V to ...

Page 116: ... at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 115 P0692 Low speed fan short to battery LOW SPEED COOLING FAN The cooling fan is controlled by EMS ECU The low speed cooling fan will be ON whenever A C is switched ON middle pressure switch is OFF or coolant temperature is more than 98 ...

Page 117: ...ich 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 ...

Page 118: ...le for penalty prosecution 2011 Mahindra Mahindra Ltd 117 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 NO YES STEP 3 Ignition OFF Ensure the fan low speed relay is fixed ...

Page 119: ...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 120: ...he trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 119 P0694 High speed fan short to battery HIGH SPEED COOLING FAN The cooling fan is controlled by EMS ECU The high speed cooling fan will be ON whenever the cooling temperature is more than 101 C or A C middle pressure...

Page 121: ...ich 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 ...

Page 122: ...for penalty prosecution 2011 Mahindra Mahindra Ltd 121 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 NO YES STEP 3 Ignition OFF Ensure the fan high speed relay is fixed pr...

Page 123: ...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 124: ...zed Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 123 P0691 Low speed fan short to ground LOW SPEED COOLING FAN The cooling fan is controlled by EMS ECU The low speed cooling fan will be ON whenever A C is switched ON middle pressure switch is OFF or coolant temperature is more than 98 C and less than ...

Page 125: ...essories 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 pena...

Page 126: ...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 127: ... the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 126 P0693 High speed fan short to ground HIGH SPEED COOLING FAN The cooling fan is controlled by EMS ECU The high speed cooling fan will be ON whenever the cooling temperature is more than 101 C or A C middle pressur...

Page 128: ...ich 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 ...

Page 129: ...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 130: ...dra Mahindra Ltd 129 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 COMP...

Page 131: ...es 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 2011 Mahindra ...

Page 132: ...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 133: ...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 134: ...ty prosecution 2011 Mahindra Mahindra Ltd 133 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 sens...

Page 135: ...es 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 2011 Mahindra ...

Page 136: ...he 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 2011 ...

Page 137: ...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 138: ...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 139: ...y 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 2011 Mahindra Mahindra Ltd 138 P268C Cylinder 1 injector adjustment code incorrect error IQA MONITORING IQA monitoring monitors the missing or faulty programming of IQA values COMPONENT LOCATION NORMAL OPERATION During i...

Page 140: ...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 141: ...y 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 2011 Mahindra Mahindra Ltd 140 P268D Cylinder 2 injector adjustment code incorrect error IQA MONITORING IQA monitoring monitors the missing or faulty programming of IQA values COMPONENT LOCATION NORMAL OPERATION During i...

Page 142: ...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 143: ...y 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 2011 Mahindra Mahindra Ltd 142 P268E Cylinder 3 injector adjustment code incorrect error IQA MONITORING IQA monitoring monitors the missing or faulty programming of IQA values COMPONENT LOCATION NORMAL OPERATION During i...

Page 144: ... 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 2011 Mahindra Mahindra Ltd 143 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 ...

Page 145: ...y 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 2011 Mahindra Mahindra Ltd 144 P268F Cylinder 4 injector adjustment code incorrect error IQA MONITORING IQA monitoring monitors the missing or faulty programming of IQA values COMPONENT LOCATION NORMAL OPERATION During i...

Page 146: ... 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 2011 Mahindra Mahindra Ltd 145 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 ...

Page 147: ...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 2011 Mahindra Mahindra Ltd 146 P0201 Cylinder1 injector open load error INJECTORS The injectors are solenoid actuated and controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it COMP...

Page 148: ...ponent 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 shal...

Page 149: ...duction 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 2011 Mahindra Mahindra Ltd 148 CONNECTOR VI...

Page 150: ...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 151: ...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 2011 Mahindra Mahindra Ltd 150 P0202 Cylinder 2 injector open load error INJECTORS The injectors are solenoid actuated and controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it COMP...

Page 152: ...ponent 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 shal...

Page 153: ...duction 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 2011 Mahindra Mahindra Ltd 152 CONNECTOR VI...

Page 154: ...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 155: ...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 2011 Mahindra Mahindra Ltd 154 P0203 Cylinder 3 injector open load error INJECTORS The injectors are solenoid actuated and controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it COMP...

Page 156: ...ponent 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 shal...

Page 157: ...duction 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 2011 Mahindra Mahindra Ltd 156 CONNECTOR VI...

Page 158: ...the DTC and 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 NO YES Ignition OFF Injector 3 wiring harness connector DISCONNECTED EMS ECU wiring harness connector DISCONNECTED Check the resistance between pin 2 of Injector 3 wiring harness connector and pin 29 of the EMS ECU w...

Page 159: ...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 2011 Mahindra Mahindra Ltd 158 P0204 Cylinder 4 injector open load error INJECTORS The injectors are solenoid actuated and controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it COMP...

Page 160: ...ponent 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 shal...

Page 161: ...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 2011 Mahindra Mahindra Ltd 160 CONNECTOR V...

Page 162: ...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 163: ...the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 162 P0261 High side Low side short circuit for cylinder 1 injector INJECTORS The injectors are solenoid actuated an controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it C...

Page 164: ...ponent 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 shal...

Page 165: ...duction 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 2011 Mahindra Mahindra Ltd 164 CONNECTOR VI...

Page 166: ...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 167: ...the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 166 P0264 High side Low side short circuit for cylinder 2 injector INJECTORS The injectors are solenoid actuated and controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it ...

Page 168: ...ponent 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 shal...

Page 169: ...duction 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 2011 Mahindra Mahindra Ltd 168 CONNECTOR VI...

Page 170: ...hindra Ltd 169 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 P0264 is present Is P0264 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 NO YES Ignition OFF Injector 2 wiring harness connector DISCONNECTED Check the resistance between pin 2 and pi...

Page 171: ...the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 170 P0267 High side Low side short circuit for cylinder 3 injector INJECTORS The injectors are solenoid actuated and controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it ...

Page 172: ...ponent 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 shal...

Page 173: ...duction 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 2011 Mahindra Mahindra Ltd 172 CONNECTOR VI...

Page 174: ...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 175: ...the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 174 P0270 High side Low side short circuit for cylinder 4 injector INJECTORS The injectors are solenoid actuated and controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and controls it ...

Page 176: ...ponent 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 shal...

Page 177: ...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 2011 Mahindra Mahindra Ltd 176 CONNECTOR V...

Page 178: ...hindra Ltd 177 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 NO YES Ignition OFF Injector 4 wiring harness connector DISCONNECTED Check the resistance between pin 2 and pi...

Page 179: ...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 2011 Mahindra Mahindra Ltd 178 P2146 Short circuit in bank 0 INJECTORS The injectors are solenoid actuated and controlled by EMS ECU The EMS ECU measures the voltage drop through fixed resistors and con...

Page 180: ...ermittent problem inspection procedure STEP 2 NO YES Ignition OFF Injector 1 2 3 and 4 wiring harness connector DISCONNECTED Ignition ON Check the voltage between pin 2 of Injector 1 wiring harness connector and ground Check the voltage between pin 2 of Injector 2 wiring harness connector and ground Check the voltage between pin 2 of Injector 3 wiring harness connector and ground Check the voltage...

Page 181: ...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 182: ...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 2011 Mahindra Mahindra Ltd 181 P0001 Metering unit open load error METERING UNIT The component driver for the metering unit regulates the opening and closing f the metering unit based on the rail pressure set point and the act...

Page 183: ...ponent 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 shal...

Page 184: ...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 2011 Mahindra Mahindra Ltd 183 CONN...

Page 185: ...ion ON Verify if P0001 is present Is P0001 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 NO YES Ignition OFF Check and confirm the proper function of fuse EF7 in engine compartment fuse box Fuel metering unit wiring harness connector DISCONNECTED Ignition ON Check the voltage between between pin 1 of fuel metering unit wiring harness connector and b...

Page 186: ...han the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 185 P0004 Metering unit output short circuit to battery error METERING UNIT The component driver for the metering unit regulates the opening and closing f the metering unit based on the rail pressure set point and...

Page 187: ...ponent 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 shal...

Page 188: ...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 2011 Mahindra Mahindra Ltd 187 CONN...

Page 189: ...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 190: ...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 2011 Mahindra Mahindra Ltd 189 P0003 Metering unit output short circuit to ground error METERING UNIT The component driver for the metering unit regulates the opening and closing f the metering unit based on the rail pressure set point and...

Page 191: ...ponent 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 shal...

Page 192: ...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 2011 Mahindra Mahindra Ltd 191 CONN...

Page 193: ...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 194: ...l amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 193 P0238 Signal range check for manifold absolute pressure sensor above maximum limit BOOST PRESSURE SENSOR The boost pressure signal is monitored This signal is used as a feedback for the control of the VGT and also for the EGR The boost pressure sensor is mounted on the outlet of the intercooler ...

Page 195: ...ponent 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 shal...

Page 196: ... 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 2011 Mahindra Ma...

Page 197: ...Initialise 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 NO YES Ignition OFF Boost pressure sensor wiring harness connector DISCONNECTED Ignition ON Check the voltage between pin 3 of boost pressure sensor wiring harness connector and ...

Page 198: ...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 199: ...nt to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 198 P0237 Signal range check for intake manifold absolute pressure sensor below minimum limit BOOST PRESSURE SENSOR The boost pressure signal is monitored This signal is used as a feedback for the control of the VGT and also for the EGR The boost pressure sensor is mounted on the outlet of the intercooler...

Page 200: ...ponent 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 shal...

Page 201: ...s 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 2011 Mahindra M...

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: ...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 204: ...nd shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 203 P007D Signal range check for intercooler downstream temperature sensor above maximum BOOST PRESSURE TEMPERATURE SENSOR The boosted pressure temperature sensor is an integral part of boost pressure sensor and is used to monitor the intercooler downstream temperature COMPONENT LOCATION NORMAL OPERATION During Ignition ON EMS E...

Page 205: ...ponent 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 shal...

Page 206: ...e 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 2011 M...

Page 207: ...ostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P007D is present Is P007D present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 Is the value 5 0 25 V NO Ignition OFF Boost pressure sensor wiring harness connector DISCONNECTED Ignition ON Check the voltage between pin 2 of the boost pressure sensor wiring harness connector an...

Page 208: ...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 209: ...o unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 208 P007C Signal range check for intercooler downstream temperature sensor below minimum limit BOOST PRESSURE TEMPERATURE SENSOR The boosted pressure temperature sensor is an integral part of boost pressure sensor and is used to monitor the intercooler downstream temperature COMPONENT LOCATION NORMAL OPERATIO...

Page 210: ...ponent 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 shal...

Page 211: ...e 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 2011 M...

Page 212: ...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 213: ... will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 212 P0193 Signal range check for rail pressure sensor below 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 pre...

Page 214: ...ponent 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 shal...

Page 215: ...les 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 2011 Mahindra...

Page 216: ...ON Initialise the diagnostic tool Record the DTC and clear Turn ignition OFF Turn ignition ON Verify if P0193 is present Is P0193 present Intermittent problem exists Refer the intermittent problem inspection procedure STEP 2 NO YES Ignition OFF Rail pressure sensor wiring harness connector DISCONNECTED Ignition ON Check the voltage between pin 3 of rail pressure sensor wiring harness connector and...

Page 217: ...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 218: ...ill amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 217 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 press...

Page 219: ...ponent 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 shal...

Page 220: ...les 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 2011 Mahindra...

Page 221: ...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 222: ...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 223: ...Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 222 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...

Page 224: ...ponent 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 shal...

Page 225: ...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 226: ...e of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 225 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...

Page 227: ...ponent 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 shal...

Page 228: ...e 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 2011 Mahindra Mahindra Ltd 227 STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Record ...

Page 229: ...nt RAIL PRESSURE SENSOR A loose contact in the rail pressure sensor wiring can lead to incorrect measuring of the rail pressure If this does occur it is typical for the measure pressure to increase considerably for a brief time jumps in the magnitude of greater than 100 bar in a 10 ms time This kind of extreme pressure increases does not occur in the system when the rail pressure sensor is functio...

Page 230: ...ponent 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 shal...

Page 231: ...ahindra 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 2011 Mahindra Mahindra Ltd 230 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 ...

Page 232: ...check for APP sensor 1 above maximum 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 use...

Page 233: ...ponent 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 shal...

Page 234: ...ed 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 2011 Mahindra Mahindra Ltd 233 ...

Page 235: ...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 236: ...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 237: ...check for APP sensor 2 above maximum 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 use...

Page 238: ... 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 ...

Page 239: ...s 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 2011 Mahindra M...

Page 240: ...ON Initialise 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 NO YES Ignition OFF Accelerator pedal wiring harness connector DISCONNECTED Ignition ON Check the voltage between pin 1 of accelerator pedal wiring harness connector and batte...

Page 241: ...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 242: ...hall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 241 P2138 Plausibility error between APP signal 1 and signal 2 ACCELERATOR PEDAL PLAUSIBILITY 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 range then it is taken a...

Page 243: ...ponent 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 shal...

Page 244: ...n 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 2011 Mahindra Mahindra Ltd 243 CONNECTOR VIEWS AND INFORMATION CONNECTOR NOME...

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: ...ition OFF Accelerator pedal wiring harness connector DISCONNECTED EMS ECU wiring harness connector DISCONNECTED Check the resistance between pin 4 of accelerator pedal wiring harness connector and pin 61 of the EMS ECU wiring harness connector Is the value 1Ω YES Examine the open circuit of accelerator pedal sensor 1 signal wire Repair replace the wiring harness Clear the DTC and verify YES STEP 6...

Page 247: ...1 Mahindra Mahindra Ltd 246 Ignition OFF Accelerator pedal wiring harness connector DISCONNECTED EMS ECU wiring harness connector DISCONNECTED Check the resistance between pin 1 of accelerator pedal wiring harness connector and pin 40 of the EMS ECU wiring harness connector STEP 8 Is the value 1Ω Examine the open circuit of accelerator pedal sensor 2 power wire Repair replace the wiring harness Cl...

Page 248: ...rized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 247 STEP 10 Ignition OFF Accelerator pedal wiring harness connector DISCONNECTED Check the resistance between pin 4 and pin 3 of accelerator pedal wiring harness connector Is the value Ω Examine the short circuit of accelerator pedal sensor 1 signal wire with battery ground Repair replace the wiring harness Clear the ...

Page 249: ...ra Ltd 248 P0113 Signal range check for HFM temperature sensor above maximum limit HFM 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 COMPON...

Page 250: ...ponent 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 shal...

Page 251: ...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 2011...

Page 252: ...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 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: ...secution 2011 Mahindra Mahindra Ltd 253 P0112 Signal range check for HFM temperature sensor below minimum limit HFM 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 se...

Page 255: ...ponent 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 shal...

Page 256: ...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 2011...

Page 257: ...smart 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 NO Ignition OFF HFM sensor wiring harness connector DISCONNECTED Ignition ON Check the voltage between pin 4 of the HFM se...

Page 258: ...Mahindra Mahindra Ltd 257 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 gro...

Page 259: ...ponent 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 shal...

Page 260: ...es 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 2011 Mahindra ...

Page 261: ...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 262: ... Mahindra Ltd 261 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 gr...

Page 263: ...ponent 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 shal...

Page 264: ...es 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 2011 Mahindra ...

Page 265: ...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 266: ...a Mahindra Ltd 265 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 gr...

Page 267: ...ponent 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 shal...

Page 268: ...es 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 2011 Mahindra ...

Page 269: ...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 270: ... Mahindra Mahindra Ltd 269 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 circui...

Page 271: ...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 272: ...es 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 2011 Mahindra ...

Page 273: ...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 2011 Mahindra Mahindra Ltd 272 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...

Page 274: ...secution 2011 Mahindra Mahindra Ltd 273 P0501 Vehicle speed sensor plausibility error VEHICLE SPEED SENSOR Vehicle Speed Sensor VSS is hall sensor type and senses the rotating speed of differential gear mounted on transaxle Comparing engine speed with vehicle speed calculated based on vehicle speed sensor signal ECU recognizes engaged gear And based on the information about engaged gear ECU perfor...

Page 275: ...ponent 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 shal...

Page 276: ...ehicles 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 2011 Mahi...

Page 277: ...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 278: ...er than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 277 STEP 4 Ignition OFF VSS wiring harness connector DISCONNECTED EMS ECU wiring harness connector DISCONNECTED Check the resistance between pin 22 of the EMS ECU wiring harness connector and pin 3 of the VSS ...

Page 279: ...ra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 278 P0641 Sensor supply voltage1 monitoring error SENSOR SUPPLY VOLTAGE MONITORING EMS ECU monitors the reference voltage of the critical sensors and registers a DTC if the voltage is not within the range NORMAL OPERATION EMS ECU monitors the reference supply voltage to coolant te...

Page 280: ...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 281: ...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 282: ...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 283: ...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 2011 Mahindra Mahindra Ltd 282 P0651 Sensor supply voltage 2 monitoring error SENSOR SUPPLY VOLTAGE MONITORING EMS ECU monitors the reference voltage of the critical sensors and registers a DTC if the voltage is not within the...

Page 284: ...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 285: ...t 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 2011 Mahindra Mahindra Ltd 284 P0697 Error Sensor supplies 3 SENSOR SUPPLY VOLTAGE MONITORING EMS ECU monitors the reference voltage of the critical sensors and registers a DTC if the voltage is not within the range N...

Page 286: ...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 287: ...ained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 286 P1B87 Maximum positive Rail pressure deviation exceeded NORMAL OPERATION The ECU compares the rail pressure monitored through the rail pressure sensor against the expected pressure generated due to HPP Based on MPROP po...

Page 288: ...ty prosecution 2011 Mahindra Mahindra Ltd 287 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 NO YES STEP 2 Check and verify the last fuel filter change kilometers Is the DTC regis...

Page 289: ...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 290: ...the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 289 P1C87 Positive governor deviation and set point value of the fuel volume flow through the metering unit NORMAL OPERATION The ECU compares the rail pressure monitored through the rail pressure sensor against the expected pressure generated...

Page 291: ...ty prosecution 2011 Mahindra Mahindra Ltd 290 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 NO YES STEP 2 Check and verify the last fuel filter change kilometers Is the DTC regis...

Page 292: ...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 293: ...orized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 292 P1B88 Rail pressure negative governor deviation error in Metering Unit mode NORMAL OPERATION The ECU compares the rail pressure monitored through the rail pressure sensor against the expected pressure generated due to HPP Based on MPROP position ...

Page 294: ...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 295: ...n the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 294 P1D87 Rail pressure below minimum limit error in Metering Unit mode NORMAL OPERATION The ECU compares the rail pressure monitored through the rail pressure sensor against the expected pressure generated due to H...

Page 296: ...on 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 2011 Mahindra Mahindra Ltd 295 P1C88 Rail pressure above maximum limit error in Metering Unit mode NORMAL OPERATION The ECU compares the rail pressure monitored through the rail pressure sensor against the expected pressure genera...

Page 297: ...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 298: ...the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 297 P068A Main relay early opening error P068B Main relay struck error COMPONENT LOCATION NORMAL OPERATION EMS ECU checks the main relay actuation time during initialization and is within the range ECU checks the main relay during operation a...

Page 299: ...ries 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 ...

Page 300: ...t 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 2011 Mahindra Mahindra Ltd 299 CONNECTOR VIEWS AND INFORMATION CONNECTOR NOMENCLAT...

Page 301: ...indra Ltd 300 STEP 1 Connect the smart tester Turn the ignition ON Initialise the diagnostic tool Is EMS 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 of the engine compartment fuse box Remove the main relay Check the functioning of relay by providing...

Page 302: ...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 303: ...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 304: ...le for penalty prosecution 2011 Mahindra Mahindra Ltd 303 P0504 Brake Signal plausibility error BRAKE SIGNAL The main and redundant brake signals are received from the brake switch to EMS ECU They are mutually and individually checked for plausibility COMPONENT LOCATION NORMAL OPERATION During ignition ON the brake switch outputs a voltage which corresponds to the brake position and is within the ...

Page 305: ...ponent 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 shal...

Page 306: ...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 2011 Mahindra Mahindra Ltd 305 CONN...

Page 307: ...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 308: ...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 309: ...amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 308 P0704 Clutch non plausible error CLUTCH SIGNAL 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 COMPONENT LOCATION NORMAL OPERATION During ignition ON the clutch pedal ...

Page 310: ...ponent 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 shal...

Page 311: ...r 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 2011 Mahindra Mahindra Ltd 310 CONNECTOR VIEWS AND INFORMATION CONNECTOR NOMENCLATURE PI...

Page 312: ...rn ignition 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 DISCONNECTED Ignition ON Check the voltage between pin 4 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 pow...

Page 313: ...ion 2011 Mahindra Mahindra Ltd 312 STEP 4 Ignition OFF EMS ECU wiring harness connector DISCONNECTED Clutch sensor wiring harness connector DISCONNECTED Check the resistance between pin 1 of the clutch sensor wiring harness connector and battery ground Check the resistance between pin 2 of the clutch sensor wiring harness connector and battery ground Is the value Ω Examine the short circuit in clu...

Page 314: ...e for penalty prosecution 2011 Mahindra Mahindra Ltd 313 P1704 Gear Neutral Signal is not plausible GEAR NEUTRAL SENSOR The gear neutral sensor is a inductive based sensor It is mounted on the transaxle and detects the movement of the of the shift sleeve through which it provides gear neutral position information COMPONENT LOCATION NORMAL OPERATION During ignition ON on every gear change the gear ...

Page 315: ...ponent 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 shal...

Page 316: ... 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 2011 Mahindra Ma...

Page 317: ...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 318: ...be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 317 STEP 4 Ignition OFF EMS ECU wiring harness connector DISCONNECTED Gear neutral sensor wiring harness connector DISCONNECTED Check the resistance between pin 2 of the gear neutral sensor wiring harness connector and battery ground Is the value Ω Examine the short circuit in gear neutral sensor signal wire to ground Repair replace the ...

Page 319: ...voltage 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 com...

Page 320: ... DTC Description 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 E...

Page 321: ...D ECU Monitoring 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 ...

Page 322: ...ecution 2011 Mahindra Mahindra Ltd 321 P1631 ECU Monitoring Start of Injection plausibility error CONTINOUS TORQUE MONITORING NORMAL OPERATION The start of the energizing time is monitored DTC DETECTING CONDITION If the start of the energizing time is outside the plausible valid range then this error is registered PROBABLE CAUSES EMI interference in the signal from the Engine speed sensor look at ...

Page 323: ...hindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 322 P1632 ECU Monitoring ZFC non plausibility error NORMAL OPERATION The maximum plausible energising time of the ZFC results depending on the rail pressure of level is compared with a curve while the minimum energizing time is also compared with a curve DTC DETECTING CONDITION If the ...

Page 324: ... 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 Monitoring Lead torque monitoring level2 error P163D ECU Monitoring Set torque mo...

Page 325: ...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 2011 Mahindra Mahindra L...

Page 326: ...on 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 2011 Mahindra Mahindra Ltd 325 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 327: ... 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 starte...

Page 328: ...ndra Mahindra Ltd 327 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 329: ...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 330: ...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 2011 Mahindra Mahindra Ltd 329 CONFORMITY CHECK Resistance Values Coolant temperature Sensor Fuel Temperature s...

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