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Diagnostic Manual ( EMS)  

  

LCV MDI BSIII CRDe  

 

 

Rev 01- Mar 14 

All copyrights reserved by  
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 whole of the present 
document, are prohibited without the prior written consent of   2014 Mahindra & Mahindra Ltd (Truck & Bus Division)  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for Cosmo

Page 1: ...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 m...

Page 2: ...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...

Page 3: ...ivision Conditions where Engine will not start 1 No Check Lamp Battery Voltage less than 9 Volts Engine does not start Maxi Fuse 60 A Fuses Engine does not start Fuse no 7 in Main fuse box fuses Engin...

Page 4: ...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...

Page 5: ...r no signal error P0341 Camshaft sensor signal error Boost Pressure Sensor P0236 Calculated Boost pressure is not in the expected range P0237 Signal range check for intercooler downstream pressure sen...

Page 6: ...e to Digital Convertor fault P0194 Rail Pressure sensor Pressure drop P1191 Rail pressure signal sensor drift P1192 Rail pressure signal falls below the calibrated min value Ignition ON P1193 Rail pre...

Page 7: ...P1655 System lamp short circuit to ground P1656 System lamp short circuit to battery Injector P2147 Injector bank short circuit to battery P2148 Injector bank short circuit to ground P0201 Cylinder1 i...

Page 8: ...en on 3rd Cylinder P0268F Incorrect or No I2C I3C written on 4th Cylinder P0268D Incorrect or No I2C I3C written on 2nd Cylinder Fuel Pump P0627 Feed pump relay Open circuit P0629 Feed pump relay Shor...

Page 9: ...n the production of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of whole of the present document are prohibit...

Page 10: ...lso for shield of camshaft crank shaft At the same time it is earth for APP Hence due to APP it goes to limp home and then due to synchronization issue land up with engine not starting Vehicle goes in...

Page 11: ...n translation transmission in part of whole of the present document are prohibited without the prior written consent of 2014 Mahindra Mahindra Ltd Truck Bus Division and the last known good rail press...

Page 12: ...s protrusions on the flywheel Two teeth are missing and this gap is situated at 90 before TDC DTC Diagnostic item P 0335 P 0336 P 0371 P 0372 Crankshaft sensor No signal Error Crankshaft sensor signal...

Page 13: ...ive cable Corrective Action Check for Open circuit between 2 15 1 14 P 0336 Crankshaft sensor signal error Possible cause This error can only come if any teeth signal is missing or Improper Corrective...

Page 14: ...anufactured The reproduction translation transmission in part of whole of the present document are prohibited without the prior written consent of 2014 Mahindra Mahindra Ltd Truck Bus Division TO CHEC...

Page 15: ...e ECU to determine when to start the injection DTC Diagnostic item P 0340 P 0341 Camshaft sensor no signal error Camshaft sensor signal error DTC detection condition Probable cause Normal Operating co...

Page 16: ...pen circuit or short to ground Possible cause If the Ground wire is having problem If the vehicle is running then the engine will go into limp home mode and then after igniation OFF the engine can not...

Page 17: ...accessories from which the vehicles are manufactured The reproduction translation transmission in part of whole of the present document are prohibited without the prior written consent of 2014 Mahind...

Page 18: ...check for intercooler downstream pressure sensor below minimum limit Boost pressure exceeds the calibrated max threshold Analogue to Digital convertor fault Boost pressure variation exceeds the max b...

Page 19: ...some delay there is engine switch off then it is indication fault is in Ground line It will also give other error refer the list of the other errors Check for pin back out or open circuit of the volta...

Page 20: ...temperatures sensor below the upper limit Reason This error is registered when the value is less then the range or when there is an electrical fault Effect 1 Torque reduction and System Check lamp ON...

Page 21: ...nslation transmission in part of whole of the present document are prohibited without the prior written consent of 2014 Mahindra Mahindra Ltd Truck Bus Division Note Pin no 69 is the signal for the Bo...

Page 22: ...or resistance is low The ECU checks WTF voltage and uses the information to help smoothen the engine operation DTC Diagnostic item P0117 P0118 P0119 P0115 Signal Range Check for coolant temperature se...

Page 23: ...sent document are prohibited without the prior written consent of 2014 Mahindra Mahindra Ltd Truck Bus Division P 0117 Signal Range Check for coolant temperature sensor below minimum limit Possible ca...

Page 24: ...ion ON Rail pressure signal exceeds the calibrated min value Ignition ON Rail pressure does not build within the speculated time Rail pressure exceeds the Calibrated pressure limit in absence of fault...

Page 25: ...ground i e Pin 16 Pin 40 are short to each other either at the pin end or the wires Corrective action Check for pin bend Check for the wires getting short to each other Defective sensor P 0193 Signal...

Page 26: ...ol error pressure error too high Negative P1254 Rail pressure control error pressure error too high Positive P1256 Rail pressure control error IMV current trim drift Low fuel low fault P1257 Rail pres...

Page 27: ...ehicles are manufactured The reproduction translation transmission in part of whole of the present document are prohibited without the prior written consent of 2014 Mahindra Mahindra Ltd Truck Bus Div...

Page 28: ...PM sensor signal for further calculation of fuelling other engine operational parameters DTC Diagnostic item P0122 P0123 P2135 P1120 Signal range check for APP1 below minimum limit Signal range check...

Page 29: ...n Check for pin back out at IC or the APP module or EMS Check for pin bend or oxidation Wire cut P 0123 Signal range check for APP1 above maximum limit Possible causes 1 Pin 37 76 are short i e the si...

Page 30: ...Mahindra Ltd Truck Bus Division Open circuit of either ground or voltage is combined with other errors Refer to the table Symptom Behavior Codes Possible Pin Reason Engine will go into limp home but...

Page 31: ...further calculation of fuelling other engine operational parameters DTC Diagnostic item P0222 P0223 P1220 Signal range check for APP pedal sensor2 below minimum limit Signal range check for APP pedal...

Page 32: ...ack out at IC or the APP module or EMS Check for pin bend or oxidation Wire cut P 0223 Signal range check for APP2 above maximum limit Possible causes 1 Pin 38 16 are short i e the signal and the eart...

Page 33: ...n of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of whole of the present document are prohibited without the...

Page 34: ...Pump This ensures that the pump does not pump extra quantity to higher pressure Thus reducing the energy being consumed by the pump and improve the system performance DTC Diagnostic item P0001 P0003 P...

Page 35: ...in back out at metering unit or loose connector Check for pin bend or oxidation Wire cut P 0004 Metering unit short circuit to battery error This error is registered the short circuit to battery is de...

Page 36: ...of the various component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of whole of the present document are prohibited without the pr...

Page 37: ...ehicle DTC Diagnostic item P1654 P1655 P1656 System lamp short circuit to System lamp short circuit to ground System lamp no load DTC detection condition Probable cause Normal Operation In normal cond...

Page 38: ...ter connector or IC or loose connector Check for pin bend or oxidation Wire cut P1654 System lamp short circuit to battery This error is registered the short circuit to battery is detected Effect Lamp...

Page 39: ...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 i...

Page 40: ...ce DTC Diagnostic item P2147 P2148 Injector bank short circuit to battery Injector bank short circuit to ground DTC detection condition Probable cause Normal Operation No abnormality Normal Operating...

Page 41: ...les are manufactured The reproduction translation transmission in part of whole of the present document are prohibited without the prior written consent of 2014 Mahindra Mahindra Ltd Truck Bus Divisio...

Page 42: ...prior written consent of 2014 Mahindra Mahindra Ltd Truck Bus Division Injector Description The EMS ECU s injector bank are monitored for performance DTC Diagnostic item P0201 P0203 P0204 P0202 Cylind...

Page 43: ...ts and accessories from which the vehicles are manufactured The reproduction translation transmission in part of whole of the present document are prohibited without the prior written consent of 2014...

Page 44: ...rmance DTC Diagnostic item P0261 P0267 P0270 P0264 P0263 P0272 P0266 P0269 High side Low side short circuit for cylinder1 injector High side Low side short circuit for cylinder2 injector High side Low...

Page 45: ...hicles are manufactured The reproduction translation transmission in part of whole of the present document are prohibited without the prior written consent of 2014 Mahindra Mahindra Ltd Truck Bus Divi...

Page 46: ...al to or less than the calibrated threshold Value INJECTOR Cyl 1 Measured resistance value equal to or less than the calibrated threshold Value INJECTOR Cyl 1 Measured resistance value equal to or les...

Page 47: ...part of whole of the present document are prohibited without the prior written consent of 2014 Mahindra Mahindra Ltd Truck Bus Division TO CHECK TO RECTIFY 1 Disconnect Injector and check connector 1...

Page 48: ...of 2014 Mahindra Mahindra Ltd Truck Bus Division Fuel Pump Drive Description The fuel pump gets energised once the ignition is turned ON and the main relay gets energized DTC Diagnostic item P0627 P0...

Page 49: ...onsistant erratic Vehicle speed sensor fault speed too high Vehicle speed sensor fault signal lost Vehicle speed fault global DTC detection condition Probable cause Normal Operation The vehicle speed...

Page 50: ...production translation transmission in part of whole of the present document are prohibited without the prior written consent of 2014 Mahindra Mahindra Ltd Truck Bus Division Water in fuel sensor DTC...

Page 51: ...lation transmission in part of whole of the present document are prohibited without the prior written consent of 2014 Mahindra Mahindra Ltd Truck Bus Division ECU DTC Diagnostic item P0685 P1685 P1603...

Page 52: ...resent document are prohibited without the prior written consent of 2014 Mahindra Mahindra Ltd Truck Bus Division Battery voltage signal DTC Diagnostic item P0562 P0563 P1560 Battery Voltage falls bel...

Page 53: ...of 2014 Mahindra Mahindra Ltd Truck Bus Division Battery voltage signal Vext 1 Vext 2 DTC Diagnostic item P0642 P0643 P1641 P0652 P0653 P1651 Sensor Supply voltage falls below the calibrated value Sen...

Page 54: ...its and accessories from which the vehicles are manufactured The reproduction translation transmission in part of whole of the present document are prohibited without the prior written consent of 2014...

Page 55: ......

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