Mahindra Bolero Maxitruck Plus BS III 2013, Bolero Maxitruck Plus BS IV 2013 Diagnostic Manual
MAN - 00226
EMS
DIAGNOSTIC MANUAL
BOLERO MAXITRUCK PLUS
m2DiCR
BS III & BS IV
REVISION - 1
MAY - 2013
Published by - Service Engineering
Technical Hub
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
CONTENTS
HOW TO USE THIS MANUAL 2
EMS OVERVIEW 2
WARRANTY & OTHER INFORMATION 3
RECOMMENDED TROUBLE SHOOTING PROCESS 4
INTERMITTENT PROBLEMS 4
EMS ECU CIRCUITS 5
IQA/IMA CODE PROGRAMMING 7
EMS ECU FLASHING 8
INDEX OF DTC CODES 11
DTC BASED TROUBLESHOOTING 15
SYMPTOM BASED DIAGNOSIS- WITH NO DTC CODES 242
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
1
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
HOW TO USE THIS MANUAL
If the DTC code is known, then go to the Index of DTC code, and click on the group under which the
DTC appears. The codes/groups are hyperlinked to the respective trouble shooting chart/pages.
The following is the structure of the EMS Diagnostic Manual –
DTC and its description
Component location in the vehicle
Normal operation of the system
DTC detecting conditions
Probable causes
Lamp status
DTC reaction on vehicle
Healing Condition
Connector views and information
Diagnostic tree
Always use the diagnostic manual along with the vehicle’s wiring manual (MAN-00222).
EMS OVERVIEW
The EMS ECU uses the following sensors and actuators to govern all engine parameters for optimized
engine performance
Sensors/Switches
Engine Coolant Temperature Sensor
Ambient Air Pressure Sensor
Camshaft Position Sensor
Crankshaft Speed Sensor
Boost Pressure Sensor
Rail Pressure Sensor
Accelerator Pedal Module
Vehicle Speed Sensor
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
2
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
Brake Switch
Clutch Sensor
Gear neutral Switch
Boost Temperature Sensor
EGR feedback sensor
Actuators
EGR Actuator
Injectors
Fuel Metering Unit
WARRANTY & OTHER INFORMATION
All failures/complaints encountered on EMS ECU and other system components should be reported
through Service Complaint Report (SCR).Replacement of any of the EMS ECU and other system
components requires approval of the TEKline. Ensure that a TAR is raised# in the TEKnet website for
approval, attaching the SCR. While raising a warranty claim, the TAR number should be quoted on the
warranty claim.
# Only a trained and certified CoTEK can raise a TAR (in TEKnet website)
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
3
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
RECOMMENDED TROUBLE SHOOTINGPROCESS
Customer complaint
Record/Understand Customer Verbatim
What happened?
When it happened?
What was the event before that?
Does it happen all the time?
Does it happen only in some condition?
Search for Published quick solution in TEK
net
.
Follow DTC based diagnosis
Contact TEKliner with TAR
(Technical Assistance Request)
INTERMITTENT PROBLEMS
Check the following for intermittent problems
Poor mating of the connector halves/damage of connector locking
Terminals not fully seated in the connector body
Damage of harness and terminals
Connector pin separation from wire
Corrosion on pin contact points
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
4
DIAGNOSTIC MANUAL
EMS
MAN- 00226
MAY 2013/Rev1
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 © 2013 Mahindra & Mahindra Ltd.
5
DIAGNOSTIC MANUAL
EMS
MAN- 00226
MAY 2013/Rev1
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 © 2013 Mahindra & Mahindra Ltd.
6
DIAGNOSTIC MANUAL MAN-00226
7
EMS
MAY 2013/Rev 1
IQA/IMA CODE PROGRAMMING
An ECU controlled engine needs precise metering of fuel. Due to manufacturing tolerances, each injector
deviates slightly from its idealized behavior. Thus, each injector has a correction factor, which is
engraved on top of it, in the form of a 7-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), then the IQA
code/IMA code for that new injector has to be updated in the ECU. The cylinder number starts from the
right side of the vehicle.
As a first step, you need to select the cylinder number of the injector being replaced. After the cylinder
number is selected by clicking on the check-button next to the number, the IQA code/IMA code should
be entered in the box provided.
Caution
Even though on the injector, 7 character alphanumeric code is engraved , while writing the IQA
code only the first 6 digits need to be entered
Click the button to the right of the text box. If the Injector code is valid and accepted by the ECU, a
message is displayed, indicating that the operation is performed successfully.
A message “Invalid IQA code” will be displayed , if an incorrect IQA/IMA code is keyed in. IQA codes are
case sensitive.
Programming IQA codes is an extremely important activity. In order to ensure that the correct code has
been entered and that it has been entered in the correct cylinder, SMART tester allows you to verify the
codes that you have entered.
Select an injector, and click the button below the ”Verify” line in figure. The IQA codes present in the ECU
will be read back and displayed in the text box before this button. It is recommended that you carry out
the verification activity whenever you change an IQA code
Please ensure to program IQA/IMA codes when you replace an Injector, ECU or Engine.
.
The following are the fonts of the alphanumeric characters of the IQA/IMA code, as etched on the
injectors.
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
EMS ECU FLASHING
The EMS ECU required to be flashed in the following conditions
BLANK ECU
Procure blank EMS ECU from spare part dept.
Check for the correct/latest part no in parts catalogue/Technical Service Bulletins.
Flash the EMS ECU dataset with a latest dataset as per TSB or at the advice of TEKline.
NOTES -
1. Flash the EMS ECU with the correct/latest dataset. The matrix of the vehicles and the related
latest dataset will be released through TSB - if in doubt ask the TEKline.
2. Wrong dataset flashing may result in vehicle not starting and can lead to ECU failure.
Software
Version
EDC17C55 1037535124
EDC17C55 1037535125
ECU Type Dataset ID Type Model
Factory/
Refalshing
Factory/
Refalshing
Bolero Maxitruck Plus
BS3 Variant
Bolero Maxitruck Plus
BS4 Variant
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 saver/Battery saver mode turned off
5. Ensure that
Ignition is ON
Battery terminals connected securely.
Battery earth connection is good.
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
8
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
6 . Never touch the ECU pins by hand/finger
FLASHING PROCEDURE
Connect using the “Python 1BConfig0404"
Click the “EDC17 C55 field flashing tool V3.0” icon present on the desktop
The following window appears
Click on Manual Link for the Options to Open.
Enter the Following Details:
Model Name (As per VIN Plate, Not Mandatory)
VIN Number:
Engine Number: (Not Mandatory)
IQA Codes for all 4 Injectors.
Select the Corresponding Dataset Using the Browse Link as Provided.
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
9
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
Select the Hex File from the link up box as shown in the Picture above
Link = C:\Program Files\EDC17C55ECUFlashTool\HEXFILE
Click on Flash for the EMS ECU Flashing Process to Begin.
Once Flashing is Complete Turn OFF ignition for 60 Secs and then Turn in ON.
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
10
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
INDEX OF DTC's
GROUP DTC DESCRIPTION
COOLANT
TEMPERATURE
SENSOR
ECU EEPROM
MONITORING
EGR
ENVIRONMENTAL
PRESSURE SENSOR
CAM PHASE SENSOR
CRANKSHAFT
SENSOR
FUEL TEMPERATURE
SENSOR
IQA CODE
MONITORING
PAGE
NO
COOLANT TEMPERATURE SENSOR ABSOLUTE TEST
P1128
NON PLAUSIBLE ERROR
COOLANT TEMPERATURE SENSOR DYNAMIC TEST
P1126
NON PLAUSIBLE ERROR
SIGNAL RANGE CHECK FOR COOLANT TEMPERATURE
P0118
SENSOR ABOVE MAXIMUM LIMIT
SIGNAL RANGE CHECK FOR COOLANT TEMPERATURE
P0117
SENSOR BELOW MINIMUM LIMIT
P062F ECU EEPROM ERROR
15
15
17
21
25
P162F ECU EEPROM ERROR 27
P1630 ECU EEPROM ERROR 29
ECU MONITORING ERROR FOR INJECTOR CUT OFF
P062B
DEMAND 31
P0403 EGR VALVE OPEN LOAD ERROR 33
P1403 EGR VALVE OVER TEMPERATURE ERROR. 36
P0406 EGR VALVE SHORT TO BATTERY ERROR 38
P0405 EGR VALVE SHORT TO GROUND ERROR. 41
SIGNAL RANGE CHECK FOR ENVIRONMENTAL
P2228
PRESSURE SENSOR BELOW MINIMUM LIMIT. 44
SIGNAL RANGE CHECK FOR ENVIRONMENTAL
P2229
P0340 CAMSHAFT SENSOR NO SIGNAL ERROR
PRESSURE SENSOR ABOVE MAXIMUM LIMIT. 46
48
P0341 CAMSHAFT SENSOR SIGNAL ERROR 52
P1341 CAMSHAFT SENSOR SIGNAL OFFSET ERROR. 55
P0336 CRANKSHAFT SENSOR SIGNAL ERROR. 57
P0335 CRANKSHAFT SENSOR NO SIGNAL ERROR. 61
P0183
SIGNAL RANGE CHECK FOR FUEL TEMPERATURE
SENSOR ABOVE MAXIMUM LIMIT.
65
SIGNAL RANGE CHECK FOR FUEL TEMPERATURE
P0182
SENSOR BELOW MINIMUM LIMIT 69
CYLINDER 1 INJECTOR ADJUSTMENT CODE
P268C
INCORRECT ERROR. 73
CYLINDER 2 INJECTOR ADJUSTMENT CODE
P268E
INCORRECT ERROR. 75
CYLINDER 3 INJECTOR ADJUSTMENT CODE
P268F
INCORRECT ERROR. 77
CYLINDER 4 INJECTOR ADJUSTMENT CODE
P268D
P0201 CYLINDER 1 INJECTOR OPEN LOAD ERROR
INCORRECT ERROR. 79
81
P0203 CYLINDER 2 INJECTOR OPEN LOAD ERROR 84
P0204 CYLINDER 3 INJECTOR OPEN LOAD ERROR 87
INJECTORS
P0202 CYLINDER 4 INJECTOR OPEN LOAD ERROR 90
P0261 CYLINDER 1 INJECTOR SHORT CIRCUIT ERROR 93
P0267 CYLINDER 2 INJECTOR SHORT CIRCUIT ERROR 96
P0270 CYLINDER 3 INJECTOR SHORT CIRCUIT ERROR 99
P0264 CYLINDER 4 INJECTOR SHORT CIRCUIT ERROR 102
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
11
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
P2146 SHORT CIRCUIT IN BANK 0 105
P0001 METERING UNIT OPEN LOAD ERROR 110
METERING UNIT OUTPUT SHORT CIRCUIT TO BATTERY
METERING UNIT
P0004
ERROR 113
METERING UNIT OUTPUT SHORT CIRCUIT TO GROUND
BOOST PRESSURE
SENSOR
P0003
P0238
P0237
ERROR 116
SRC HIGH FOR CHARGED AIR COOLER PRESSURE
(DOWN STREAM) 119
SRC LOW FOR CHARGED AIR COOLER PRESSURE
(DOWN STREAM) 123
SIGNAL RANGE CHECK FOR RAIL PRESSURE SENSOR
P0193
ABOVE MAXIMUM LIMIT 127
SIGNAL RANGE CHECK FOR RAIL PRESSURE SENSOR
RAIL PRESSURE
P0192
BELOW MINIMUM LIMIT 131
SENSOR
RAIL PRESSURE OFFSET VALUE ABOVE MAXIMUM
P0191
LIMIT 134
RAIL PRESSURE OFFSET VALUE ABOVE MINIMUM
P1191
LIMIT 136
SIGNAL RANGE CHECK FOR APP PEDAL SENSOR 1
ACCELERATOR
PEDAL MODULE
P2123
P2128
ABOVE MAXIMUM LIMIT 138
SIGNAL RANGE CHECK FOR APP PEDAL SENSOR 2
ABOVE MAXIMUM LIMIT 142
PLAUSIBILITY ERROR BETWEEN APP SIGNAL1 AND
P2138
SIGNAL2 146
P1138 ACC PEDAL PLAUSIBLE CHECK WITH THE BRAKE 152
VEHICLE SPEED
SENSOR
P0501 VEHICLE SPEED SENSOR PLAUSIBILITY ERROR 153
SENSOR SUPPLY
MONITORING
P0641 SENSOR SUPPLY VOLTAGE1 MONITORING ERROR 157
P0651 SENSOR SUPPLY VOLTAGE 2 MONITORING ERROR 159
P0697 SENSOR SUPPLY VOLTAGE 3 MONITORING ERROR 161
RAIL PRESSURE POSITIVE GOVERNOR DEVIATION
P1B87
ERROR IN METERING UNIT MODE 163
POSITIVE GOVERNOR DEVIATION AND SET POINT
VALUE OF THE FUEL VOLUME FLOW THROUGH THE
RAIL PRESSURE
GOVERNOR
P1C87
P1B88
METERING UNIT 166
RAIL PRESSURE NEGATIVE GOVERNOR DEVIATION
ERROR IN METERING UNIT MODE 169
RAIL PRESSURE BELOW MINIMUM LIMIT ERROR IN
P1D87
METERING UNIT MODE 171
RAIL PRESSURE ABOVE MAXIMUM LIMIT ERROR IN
MAIN RELAY
P1C88
P068A MAIN RELAY EARLY OPENING ERROR
METERING UNIT MODE 174
P068B MAIN RELAY STRUCK ERROR 176
BOOST PRESSURE
GOVERNOR
P0069 PLAUSIBILITY DEFECT BETWEEN CACDSP AND ENVP 180
BRAKE SWITCH
P0504 BRAKE SIGNAL PLAUSIBILITY ERROR. 181
CLUTCH SENSOR
P0704 CLUTCH NON PLAUSIBLE ERROR 185
P172A CLUTCH 90% SWITCH PLAUSIBLE ERROR 189
P171A CLUTCH 90% SWITCH PLAUSIBLE ERROR 192
176
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
12
DIAGNOSTIC MANUAL MAN-00226
g
EMS
MAY 2013/Rev 1
WATER IN FUEL
SENSOR
CONTINIOUS
TORQUE
MONITORING
P2269 WATER PRESENCE IN FUEL ERROR 195
P2265 WATER IN FUEL SENSOR FAULTY 197
P1900 NTP error in ADC monitoring
P163B ECU Monitoring: ADC test error
P163C ECU Monitoring: Voltage ratio error in ADC
P1621 ECU Monitoring: Query response communication error
P1622 ECU Monitoring: SPI communication error
P0605 ECU Monitoring: ROM memory error
P1623 ECU Monitoring: CPU error
P1625 ECU Monitoring: Response time error in ECU
ECU Monitoring: Shut off path test SPI communication
P1626
error
201
P1628 ECU Monitoring: Shut off path under voltage error
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 test
202
P060D ECU Monitoring: Accelerator position error
ECU Monitorin
: Engine speed error
P061C
ECU Monitoring: Rail pressure monitoring plausibility
P1638
error
CONTINUOUS
TORQUE
MONITORING
GNS
GNS RELAY
STARTER RELAY
ECU
T50
BATTERY
ECU Monitoring: Energising time plausibility error
P060A
203
P1631 ECU Monitoring: Start of Injection plausibility error 204
P1632 ECU Monitoring: ZFC non plausibility error 205
P1704 GEAR NEUTRAL SIGNAL IS NOT PLAUSIBLE 207
P1712 GNS RELAY NO LOAD 209
P1713 GNS RELAY SHORT TO BATTERY ERROR 211
P1714 GNS RELAY SHORT TO GROUND ERROR 213
P1716 GNS RELAY PLAUSIBLE ERROR 215
P170F STARTER RELAY OPEN LOAD 217
P170D STARTER RELAY SHORT CIRCUIT TO BATTERY ERROR 219
P170E STARTER RELAY SHORT CIRCUIT TO GROUND ERROR 221
P1641 SOFTWARE RESET ERROR 223
P1707 T50 signal error 224
SIGNAL RANGE CHECK FOR BATTERY SENSOR SIGNAL
P0071
ABOVE MAXIMUM LIMIT 225
SIGNAL RANGE CHECK FOR BATTERY SENSOR SIGNAL
P0562
BELOW MINIMUM LIMIT 227
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
13
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
EGR FEEDBACK
SENSOR
BOOST
TEMPERATURE
SENSOR
P1406
P1405
P007D
P007C
SIGNAL RANGE CHECK FOR EGR FEEDBACK SENSOR
ABOVE MAXIMUM LIMIT 230
SIGNAL RANGE CHECK FOR EGR FEEDBACK SENSOR
ABOVE MAXIMUM LIMIT 233
SIGNAL RANGE CHECK FOR INTERCOOLER
DOWNSTREAM TEMPERATURE SENSOR ABOVE
MAXIMUM LIMIT 237
SIGNAL RANGE CHECK FOR INTERCOOLER
DOWNSTREAM TEMPERATURE SENSOR BELOW
MINIMUM LIMIT 240
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
14
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
P1128
P1126
COOLANT TEMPERATURE SENSOR ABSOLUTE TEST NON PLAUSIBLE ERROR
COOLANT TEMPERATURE SENSOR DYNAMIC TEST NON PLAUSIBLE ERROR
COOLANT TEMPERATURE SENSOR: ABSOLUTE & DYNAMIC TEST
Thermostat
When the engine is switched ON then the ECU detects the coolant temperature. After that when the
engine runs then the temperature output on a time frame is detected and compared against
predetermined values.
DTC INFORMATION PROBABLE CAUSES OF FAILURE
NORMAL OPERATION
Engine running
The coolant temperature rises to a specified temperature
within a specific time period.
The coolant temperature rises to a specified temperature
within a specific time period - Absolute test
The coolant temperature rises to a minimum temperature
within a specific time period - Dynamic test
DTC DETECTING CONDITIONS
Engine running
EMS ECU supply voltage 8-16 V
The coolant temperature do not rise enough within a
specific time period,
The coolant temperature do not reach a warmed-up fuel
control temperature within a specific time period
DTC REACTIONS
No lamp indication
HEALING CONDITION
Ignition Off/On
Defective temperature sensor.
Thermostat stuck in open
condition
Thermostat removed.
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
15
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
STEP2
Check and ensure the coolant
temperature sensor is
functioning properly
Check for proper fittment of
thermostat in thermostat
housing
STEP1
Connect the smart tester
Turn the ignition ON
Initialise the diagnostic tool
Record the DTC and clear
Turn ignition OFF
Turn ignition ON
Verify if P1128/P1126 is
present?
IsP1128/P1126
present?
P1128
P1126
NOYES
Intermittent problem exists
Refer the intermittent problem
inspection procedure
Remove the thermostat and
check whether thermostat is
strucked in open position.
Replace the thermostat with a
new one
Clear the DTC and verify
Is the thermostat
properly fitted ?
NOYES
Fix the thermostat in its correct
positon
Clear the DTC and verify
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
16
DIAGNOSTIC MANUAL MAN-00226
7
EMS
MAY 2013/Rev 1
P0118
SIGNAL RANGE CHECK FOR COOLANT TEMPERATURE 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 smoothen the engine operation.
DTC INFORMATION PROBABLE CAUSES OF FAILURE
NORMAL OPERATION
Ignition ON
The measured output voltage value of the coolant
temperature sensor is within the range
DTC DETECTING CONDITIONS
Ignition ON
EMS ECU supply voltage 8-16V
The measured output voltage of the coolant temperature
sensor is higher than the maximum range.
DTC REACTIONS
OBD lamp continuously ON.
Coolant temperature value set as 110 °C
Open coolant
temperature sensor
wires
Short to battery of
coolant temperature
wires
Faulty coolant
temperature sensor
Malfunctioning EMS ECU
HEALING CONDITION
Ignition Off/On
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
1
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
CONNECTOR VIEWS AND INFORMATION
P 0118
CONNECTOR DESCRIPTION PIN NO
33
EMS ECU
11
COOLANT TEMPERATURE
SENSOR
1
2
FUNCTION
SIGNAL
GROUND
SIGNAL
GROUND
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
18
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
STEP1
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 P0118 is present?
YES
STEP2
Check the voltage between pin
1 of the coolant temperature
sensor wiring harness
connector and battery ground
NO
STEP3
If the Voltage is greater than
5.25V , check for short to
battery of the coolant
temperature signal wire
Is P0118 present?
Is the value =5 ±
0.25 V?
NO
Intermittent problem exists
Refer the intermittent problem
inspection procedure
YES
Go to STEP 4
Check the continuity between
pin 33 of EMS ECU wiring
harness connector and pin 1 of
the of the coolant temperature
sensor wiring harness
connector
Is the continuity
exists?
Suspect EMS ECU malfunction
Replace EMS ECU with a new
one.
Check and verify for any new
DTC’s
NOYES
Examine the open circuit of
coolant temperature sensor
signal wire
Replace the wiring harness
Clear the DTC and verify
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
19
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
STEP 4
Check the continuity between
pin 11 EMS ECU wiring
harness connector and pin 2 of
the of the coolant temperature
sensor wiring harness
connector
YES
STEP 5
Check the resistance between
pin 1 and pin 2 of the coolant
temperature sensor
YES
Suspect EMS ECU malfunction
Replace EMS ECU with a new
one.
Check and verify for any new
DTC’s
Is the continuity
exists?
Is the value >2.2
<2.7 KΩ at 20°C?
NO
Examine the open circuit of
coolant temperature sensor
ground wire
Replace the wiring harness
Clear the DTC and verify
NO
Suspect open circuit in coolant
temperature sensor
Replace the sensor with a new
one
Clear the DTC and verify
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
20
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
P0117
SIGNAL RANGE CHECK 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 the information to help smoothen the engine operation.
DTC INFORMATION PROBABLE CAUSES OF FAILURE
NORMAL OPERATION
Ignition ON
The measured output voltage value of the coolant
temperature sensor is within the range
DTC DETECTING CONDITIONS
Ignition ON
EMS ECU supply voltage 8-16V
The measured output voltage of the coolant temperature
sensor is lower than the minimum range.
DTC REACTIONS
OBD lamp continuously ON.
Coolant temperature value set as 110 °C
Short coolant temperature
sensor wiring harness
Faulty coolant temperature
sensor
Malfunctioning EMS ECU
HEALING CONDITION
Ignition Off/On
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
21
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
CONNECTOR VIEWS AND INFORMATION
P 0117
CONNECTOR DESCRIPTION PIN NO
FUNCTION
33
EMS ECU
SIGNAL
11
GROUND
COOLANT TEMPERATURE
SENSOR
1
SIGNAL
2
GROUND
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
22
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
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 P0117 is present?
Is P0117 present?
P0117
STEP 2
Check the voltage between pin
1 of the coolant temperature
sensor wiring harness
connector and battery ground
STEP 3
Check the continuity between
pin 1 of the coolant
temperature sensor wiring
harness connector and battery
STEP 4
ground
Intermittent problem exists
Refer the intermittent problem
inspection procedure
Is the value =5 ±
0.25 V?
Go to STEP 4
Is the continuity
exists?
Suspect EMS ECU malfunction
Replace EMS ECU with a new
one.
Check and verify for any new
DTC’s
Examine the short circuit of
coolant temperature sensor
signal wire to ground
Replace the wiring harness
Clear the DTC and verify
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
23
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
STEP 4
Check the resistance between
pin 1 and pin 2 of the coolant
temperature sensor
Is the value >2.2
<2.7 KΩ at 20°C?
P0117
Suspect EMS ECU malfunction
Replace EMS ECU with a new
one.
Check and verify for any new
DTC’s
Suspect internal short in
coolant temperature sensor
Replace the sensor with a new
one
Clear the DTC and verify
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
24
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
P062F ECU EEPROM ERROR
EEPROM MONITORING
EEPROM (Electrically Erasable Programmable Read Only Memory) is a storage device inside the EMS
ECU.
EEPROM can be flashed , read and written
DTC INFORMATION PROBABLE CAUSES OF FAILURE
NORMAL OPERATION
Ignition ON
EEPROM can be flashed, read & written
DTC DETECTING CONDITIONS
Ignition ON
Malfunctioning EMS ECU
EMS ECU supply voltage 8-16V
During flashing the sector erase cannot be performed.
DTC REACTIONS
Engine check lamp continuously ON.
EMS ECU Switches OFF
HEALING CONDITION
Ignition Off/On
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
25
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
STEP 1
Connect the smart tester
Turn the ignition ON
Initialise the diagnostic tool
Record the DTC and clear
Turn ignition OFF
Wait for 2 minutes
Turn ignition ON
Verify if P062F is present?
Is P062F present?
P 062F
Suspect EMS ECU EEPROM
failure
Replace EMS ECU with a new
one.
Check and verify for any new
DTC’s
Intermittent problem exists
Refer the intermittent problem
inspection procedure
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
26
DIAGNOSTIC MANUAL MAN-00226
7
EMS
MAY 2013/Rev 1
P162F ECU EEPROM ERROR
EEPROM MONITORING
EEPROM (Electrically Erasable Programmable Read Only Memory) is a storage device inside the EMS
ECU.
EEPROM can be flashed , read and written
DTC INFORMATION PROBABLE CAUSES OF FAILURE
NORMAL OPERATION
Ignition ON
EEPROM can be flashed, read & written
DTC DETECTING CONDITIONS
Ignition ON
Malfunctioning EMS ECU
EMS ECU supply voltage 8-16V
The block cannot be read more than 3 times from the
EEPROM
DTC REACTIONS
Engine check lamp continuously ON.
EMS ECU Switches OFF
HEALING CONDITION
Ignition Off/On
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
2
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
STEP 1
Connect the smart tester
Turn the ignition ON
Initialise the diagnostic tool
Record the DTC and clear
Turn ignition OFF
Wait for 2 minutes
Turn ignition ON
Verify if P162F is present?
Is P162F present?
P162F
Suspect EMS ECU EEPROM
failure
Replace EMS ECU with a new
one.
Check and verify for any new
DTC’s
Intermittent problem exists
Refer the intermittent problem
inspection procedure
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
28
DIAGNOSTIC MANUAL MAN-00226
EMS
MAY 2013/Rev 1
P1630 ECU EEPROM ERROR
EEPROM MONITORING
EEPROM (Electrically Erasable Programmable Read Only Memory) is a storage device inside the EMS
ECU.
EEPROM can be flashed , read and written
DTC INFORMATION PROBABLE CAUSES OF FAILURE
NORMAL OPERATION
Ignition ON
EEPROM can be flashed, read & written
DTC DETECTING CONDITIONS
Ignition ON
Malfunctioning EMS ECU
EMS ECU supply voltage 8-16V
The block cannot be written more than 3 times from the
EEPROM
DTC REACTIONS
Engine check lamp continuously ON.
EMS ECU Switches OFF
HEALING CONDITION
Ignition Off/On
The repair methods given by the manuf acturer in this document are based on the tec hnical specifications, c urrent at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the var ious component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra Ltd. The use of this document by any person ot her th an t he tr a i ned p ers onn el, at t he Authorized Service Centre of Mahindra & Mahi ndr a Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.
29
Loading...