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MAN-00057 Diagnostic Manual EMS Scorpio VLX Sle LX PDF
MAN-00057 Diagnostic Manual EMS Scorpio VLX Sle LX PDF
Vlx/Sle/Lx
MAN-00057
RELEASED BY -
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.
2009Mahindra&MahindraLtd.Allrightsreserved.Thisbookmaynotbereproducedorcopied,inwholeorinpart,without
thewrittenpermissionofMahindra&MahindraLtd.
The EMS(Engine Management System) diagnostic manual outlines the detailed procedures to troubleshoot
complaints related to the Common Rail Diesel Engine and its controller (EMS ECU) fitted on Scorpio
Vlx/Sle/Lx (Refresh) vehicle. Procedures to treat each DTC retrieved from the EMS ECU is given in a
step by step , trouble-shooting tree structure.
Actuator tests
The EMS ECU is linked to Engine immobilizer ECU(ICU) system and hence it is recommended that only
trained CoTEKs carryout re-programming operations in the system, if required.
This Diagnostic manual supersedes all earlier manuals vis-a-viz MAN-00029, MAN-00030 and MAN-00038.
For issues related to non-Transponder based immobilizer (Mahindra Secure) systems, refer to the section
Analog Based Immobilizer in the manual MAN-00057.
In spite of our best efforts to make the manual error-free, a few errors could have inadvertently crept in. If
you identify errors, functional or typographical , please inform your TEKline or pillay.ajay@mahindra.com.
Suggestions to improve the manual and make it more user-friendly are also welcome.
2009Mahindra&MahindraLtd.Allrightsreserved.Thisbookmaynotbereproducedorcopied,inwholeorinpart,without
thewrittenpermissionofMahindra&MahindraLtd.
MAN-00057-1
March 2009/Rev 3
Contents
How to use this manual
Over view of the vehicle communication network
Brief Specification- Engine.
Note on Engine Stop-Start (Micro Hybrid)
Recommended trouble shooting procedure
IQA code
Warranty & Other Information
EMS ECU Programming /Flashing
Reprogramming procedure
List of DTC codes
DTC Codes.
Actuator Tests
Symptom Based Diagnosis
Conformity Check / Resistance Values.
Analog Based Immobilizer (Applicable to Scorpio Vlx non-refresh models only)
Release Notes
MAN-00057-2
March 2009/Rev 3
Always use the diagnostic manual along with the vehicles wiring manual (MAN-00058).
The Diagnostic tester has the ability to test certain actuators.
For GEN3 Immobilizer related errors, the DTCs in the Engine EMS and along with that the
DTCs in the Immobilizer ECU(ICU) need to be analyzed together. Refer to the Diagnostic
Manual (Immobilizer) MAN-00056 for details. The possible causes and corrective action
are to be taken based on the combination of the codes.
There are certain complaints for which no DTC codes are generated. The trouble shooting
procedure for the same is covered in the Symptom based Diagnosis.
The Micro-hybrid (Engine Stop-Start) is variant specific and will not be available in all
models. At present, the micro-hybrid feature is available only in the Vlx variant.
Introduction of this feature in other variants will be communicated through TSB.
Note :
Prior to introduction of transponder based immobilizer , Scorpio Vlx vehicles sold between
Dec 2007 and March 2009, had Analog immobilizer linked to the Security system and EMS
ECU. The details of trouble shooting of this system are appended under the chapter Analog
based immobilizer. Use the corresponding wiring manual, MAN-00028, while troubleshooting.
MAN-00057-3
March 2009/Rev 3
Engine
Diagnostic
Connector
(EMS ECU)
KLine
(DLC)
CAN
IMMOBILIZER
(ICU)
MAN-00057-4
March 2009/Rev 3
: 85 mm
: 96 mm
- Max 86.7 kW BHP @ 3800
-Max 277 Nm@1800
1-3-4-2
: Bosch EDC 16C39
The block diagram of how the ESS functions is given in the next page.
ESS is controlled from the EMS ECU. If any of the sensors malfunction then the ESS is
disabled and an error code generated.
For details of each sensor electrical function refer the section on brief description,
associated with the relevant Defect Trouble Code (DTC).
MAN-00057-5
March 2009/Rev 3
AcceleratorpedalFullyreleased
EngineSpeedIdlingrange
GearBoxNeutral
FuelTemperature<60C
CoolantTemperature
20C<TemperatureCoolant<100C
BatteryVoltage>12.6V
BonnetClosed
VehicleSpeedShouldhave
achieved>2Km/hrbefore/
betweenstops.
waitsfor2seconds
ESSswitchEnabled
EMSStopStart
I/O of ESS
EngineStops
VehicleSpeed<2Kms/hr
ClutchpedalFullyreleased
MAN-00057-6
March 2009/Rev 3
I/O of ESS
GearboxNeutral
EngineSpeedZero
BonnetClosed
EMSStopStart
VehicleInautostopmode
EngineStarts
ClutchpedalFullypressed
Note:
1) If the feature selection switch is reset (From ON OFF ON) when
vehicle is in auto stop mode, then clutch start will not be possible but key
crank would be possible.
2) If Bonnet is opened when the vehicle is in auto-stop mode, clutch start
would be disabled and only key crank would be possible.
However under both the above conditions, auto stop / start would be possible if all
required conditions for auto-stop are met again.
MAN-00057-7
March 2009/Rev 3
Customer complaint
MAN-00057-8
March 2009/Rev 3
The following are the fonts of the alphanumeric characters of the IQA/IMA code, as
etched on the injectors.
MAN-00057-9
March 2009/Rev 3
MAN-00057-10
March 2009/Rev 3
BLANK ECU
1. Procure blank EMS ECU from spare part dept.
0315CM0031N
C39**
Model
Scorpio Vlx (Refresh)
TBI ESS MT - BS III
Software
Version
ECU Type
Plant Dataset
ID
Field Dataset
ID
V76
EDC16C39
1037397155
Will be released
through a TSB
V76
EDC16C39
1037397191
Will be released
through a TSB
V71
EDC16C39
1037397093
1037397128
V71
EDC16C39
1037397090
1037397127
V75
EDC16C39
1037397150
Will be released
through a TSB
V64
EDC16C39
1037392587
1037392587
V52
EDC16C39
1037392417
1037392417
V52
EDC16C39
1037392423
1037392423
MAN-00057-11
March 2009/Rev 3
Notes
1. Ensure that the there is no communication breakdown once the flashing
begins. Check Python connections are secure.
2. Ensure that the SMART tester has Enough battery reserve/Connected to AC power
Screen saver/Battery saver mode turned off,
Vehicles ignition is ON
Battery terminals connected securely.
Battery earth connection is good.
3. Never touch the ECU pins by hand/finger.
RE-PROGRAMMING PROCEDURE
Caution while flashing on vehicles with ESS feature: Before switching
ON the ignition with a blank ECU for start of flashing, ensure that the starter
relay is disconnected. This is a safety precaution.
MAN-00057-12
March 2009/Rev 3
MAN-00057-13
March 2009/Rev 3
MAN-00057-14
March 2009/Rev 3
MAN-00057-15
March 2009/Rev 3
Index
Group
Code
P-0123
APP1
APP2
P-0122
P-1120
P-0223
P-0222
P-1220
P-0340
P-0341
P-0335
P-0336
P-0103
P-0102
P-0113
P-1221
BPA
P-1604
P-1605
P-1606
P-1607
P-235
P-236
BPS
P-1236
Camshaft
Crankshaft
Label
Voltage above upper limit
K Line
28
33
40
45
48
57
Air temperature
Rail pressure
deviation
23
51
Air Flow
Rail Pressure
Page No
P-0112
P-0193
P-0192
P-1192
61
65
68
69
70
MAN-00057-16
March 2009/Rev 3
EGR
Error path of
offset
Fuel Temperature
Sensor
Metering Unit
P-0406
P-0405
P-0403
P-0404
P-1340
P-0182
P-0183
P-1252
P-0575
P-0563
P-0562
P-1792
P-1253
P-1250
P-1251
P-121A
Main relay
P-121B
P-0577
Cruise
P-0576
Brake Switch
P-1791
Coolant Temp
Sensor(CTS)
P-0704
P-0118
79
83
87
90
96
99
102
P-0117
P-2558
106
P-165E
Minimum temperature or
temperature raise no
reached within time limit
Short Circuit to Battery
P-165F
P-1660
P-1661
P-1126
Overheat lamp
75
95
Battery
Clutch Switch
72
108
MAN-00057-17
March 2009/Rev 3
Atm pressure
sensor
P-0108
P-0107
P1623
P1625
Injector
Energizing Time
P161F
P1621
Communication
monitoring
Controller & TPU
Monitoring
ECU Monitoring
P-162A
P-1659
P-1638
Coolant
temperature
output
P-160D
P-160E
P-1608
P-1609
No Load
Short circuit to battery
Short circuit to ground
P-160A
P-160B
P-1530
No load
Excess temperature
Short circuit to battery
112
113
114
115
116
117
120
P-1531
Air condition
P-160C
P-162C
P-162D
Tachometer
Signal
111
P-162B
EEPROM
Monitoring
P-1532
P-1533
MAN-00057-18
March 2009/Rev 3
P-1210
P-1211
P-1212
P-1213
Injector Power
Stage
P-1214
P-1215
P-1216
P-1217
Monitoring
communication
P-1664
P-1641
Power stage
Monitoring
P-1642
P-1643
P-1631
Power Stage
Voltage
Monitoring
P-1632
Chip-specific errors :
CY33X internal reset /
clock loss / under voltage
Chip-specific errors:
CY33X is unlocked /
CY33X init error
Chip-specific
errors:CY33X is in Test
mode
Chip-specific errors:
CY33X SPI
communication error
/checksum/read back
Chip-specific errors >CY33X internal parity
error
Chip-specific errors >CY33X internal program
flow error
Chip-specific errors >CY33X check of inv.
YSEL during ON failed
Chip-specific errors >CY33X ON timeout for at
least 1 cylinder
125
126
127
128
MAN-00057-19
March 2009/Rev 3
Sensor Supply
Monitoring 1
Sensor Supply
Monitoring 2
System Lamp
Terminal 15 (
Ignition Switch)
P-1644
P-1645
P-1646
P-1647
P-1654
P-1655
P-1656
P-1657
P-1387
P-1388
P-1389
No Load
P-1390
P-0513
Excess temperature
Invalid key error
Communication wire may
open
Signature Mismatch
EMS is locked.
EEPROM error
Injector bank 1: short
circuit
Injector bank 1: short
circuit on Low Side to
ground
Injector bank 1 specific
error depending on
application
Injector bank 1 notclassifiable error
Injector bank 1specific
warning : depending on
application
Injector bank 1specific
warning : depending on
application
Injector bank 1specific
warning open load
Injector bank 1specific
warning depending on
application
129
P-1658
P-0503
P-0500
Vehicle Speed
P-0501
Glow Control
(if applicable)
Immobilser
Codes
P1832
P-183A
P-183B
P-183E
P-1201
P-1203
P-1204
P-1205
135
137
139
141
P-201
132
P-1206
P-1207
P-1208
144
145
148
150
152
153
154
MAN-00057-20
March 2009/Rev 3
P-1400
Pressure control
Regulation (VGT
control)
P-1401
CAN error
Transmission
clutch signalCAN
TCU error
EMS ECU Mute
Error
CAN Vehicle
speed not valid
Gear Neutral
Switch
P-1705
P-0704
P-0302
155
155
157
158
159
P-1827
161
P-1704
163
P-0073
P-168E
P-170D
160
166
169
P-170E
P-1710
Gear Neutral
Switch Relay
Redundant Clutch
Switch
P-1712
P-1714
P-170A
P-1AE9
P-1AEA
P-1AEB
P-1AEC
T 50 (Ignition
Switch)
P-1715
172
Excess Temperature
No Load
GNS Relay Sticking
Clutch signal is not
plausible
Short Circuit Battery
Short Circuit to Ground
No Load
Excess Temperature
Terminal 50 Always
pressed.
171
173
176
180
183
184
185
187
188
MAN-00057-21
March 2009/Rev 3
Actuator Test
Symptom Based
Diagnosis
Code
Label
Home Screen for Actuator
System lamp
ACT # 1
Actuator test
Coolant Overheat
ACT # 2
Lamp
ACT # 3
Air Conditioning
ACT # 4
EGR
Boost Pressure
ACT # 5
Actuator (BPA)
Vehicle not starting
SBD #1
& no error codes
Vehicle not starting
SBD # 2
also may get
P1192/1193
Page No
189
190
192
193
194
195
196
198
For Analog Immobilizer Code (Applicable for Scorpio VLX without Transponder
Based Immobilizer, sold between Dec 2007 to March 2009)
Group
Code
P-1828
P-1829
P-182A
P-182B
P-182C
Label
Immobilizer
communication
wire open or short
Immobilizer
communication
wire short to
ground.
Immobilizer signal
in error zone
ECU is locked
completely
Immobilizer
controller has not
received correct
pattern (RF signal )
Page No
205
207
211
213
215
MAN-00057-22
March 2009/Rev 3
P-0123
P-0122
P-1120
MAN-00057-23
March 2009/Rev 3
P-0123
P-0122
P-1120
Description:
The Accelerator pedal module (APM) mounts in place of accelerator pedal and is
connected to the ECU by wires. The APM sensor is a variable resistor (potentiometer)
whose resistance changes according to the pedal position. ECU applies a reference
voltage to the APM sensor and then measures the voltage that is present on the APM
sensor signal circuit. The ECU uses the APM sensor signal for further calculation of
fuelling & other engine operational parameters.
DTC
P-0123
P-0122
P-1120
Diagnostic item
Voltage above upper limit
Voltage below lower limit.
Plausibility with APP2 violated.
Probable cause
Open or shorted
Accelerator pedal
module circuits, loose
or wrongs
connections.
Accelerator pedal
module failed or
maladjusted.
Proper Performance
Sensor output voltage has continued to between 0 to 5V,
varying accelerator pedal position.
Malfunction; out-of-range
With the changing Accelerator pedal position, the
sensor output voltage has continued to be 5V or 0V.
Reaction:
The engine speed not varying with changing
accelerator pedal position. (Constant 1200 rpm)
The system lamp is continuously on.
MAN-00057-24
March 2009/Rev 3
P-0123
P-0122
P-1120
ECU
K45
R-W
K09
K46
K31
K08
Gr-B
G-R
3-GND
Sb
W-R
4-O/P
K30
6-O/P
5-GND
Vcc
Vcc
APP1
APP2
MAN-00057-25
March 2009/Rev 3
P-0123
P-0122
P-1120
MAN-00057-26
March 2009/Rev 3
P-0123
P-0122
P-1120
Yes
No
Yes
Yes
Check the APP 1 resistance in both the state
0% & 100%
No
Clear code
Verify that the complaint has been
eliminated.
No
MAN-00057-27
March 2009/Rev 3
P-0123
P-0122
P-1120
Yes
Clear the code.
Verify that the complaint has been eliminated.
No
Replace the Accelerator pedal Module
MAN-00057-28
March 2009/Rev 3
P-0223
P-0222
P-1220
P-1221
Description:
Diagnostic item
Voltage above upper limit
Voltage below lower limit.
Plausibility with APP1 violated
Accelerator Pedal signal not plausible with brake
Probable cause
Open or shorted
Accelerator pedal
module circuits, loose or
wrong connections.
Accelerator pedal
module failed or
maladjusted.
Reaction
The engine speed not varying with changing
accelerator pedal position. (Constant 1200 rpm)
The system lamp is continuously on.
MAN-00057-29
March 2009/Rev 3
P-0223
P-0222
P-1220
P-1221
ECU
K45
R-W
K09
K46
K31
K08
Gr-B
G-R
3-GND
Sb
W-R
4-O/P
K30
6-O/P
5-GND
Vcc
Vcc
APP1
APP2
MAN-00057-30
March 2009/Rev 3
MAN-00057-31
March 2009/Rev 3
P-0223
P-0222
P-1220
P-1221
Yes
Yes
No
No
MAN-00057-32
March 2009/Rev 3
Repair the
damaged line/ connection.
Clear code.
Verify that the complaint
has been eliminated.
Yes
Check the APP 2 resistance in both the state
0% & 100%
Is it within the specifications
No
Yes
No
Replace the Accelerator pedal Module
Clear code.
Verify that the complaint has been eliminated.
P-0223
P-0222
P-1220
P-1221
MAN-00057-33
March 2009/Rev 3
P-1604
P-1605
P-1606
P-1607
MAN-00057-34
March 2009/Rev 3
Description
In normal operation and during an actuator test, the PWM power stage of
ECU is tested for short circuit to battery voltage, short circuit to ground,
open circuit and excess temperature. Once the errors are confirmed, the
power stage is switched off.
The BPA in turn controls the Variable vanes operation through vacuum.
P-1604
P-1605
P-1606
P-1607
Hint:
Short circuit to battery and excess temperature errors can be detected only when the
power stage is switched on.
Short circuit to ground and no load errors can be detected only when the power stage is
switched off.
DTC
P-1604
P-1605
P-1606
P-1607
Diagnostic item
Short circuit Battery
Short circuit Ground
No Load
Excess Temperature
DTC detection condition
Probable cause
Possible Causes
Proper Performance
The ECU monitors the Boost pressure actuator (
modulator) during the normal operation as well as during
Short circuit to battery
actuator test)
or ground.
Malfunction; out-of-range
Excess temperature
With the fully pressed Accelerator pedal module,
No load.
the sensor output voltage has continued to be
2.5V or 0 for 4 sec.
Reaction
Torque will be reduced
EGR is switched off.
System Check lamp is ON
MAN-00057-35
March 2009/Rev 3
P-1604
P-1605
P-1606
P-1607
A15
ECU
Diagn
nostic Ma
anual (EM
MS)
Scorpio
io Vlx, Sle, Lx (Refre
esh)
MAN-0005
57-36
Ma
arch 2009/Rev 3
P-16
604
P-16
605
P-16
606
P-16
607
MAN-00057-37
March 2009/Rev 3
P-1604
P-1605
P-1606
P-1607
No
MAN-00057-38
March 2009/Rev 3
Yes
No
Yes
Change the BPA with a known good one
Clear the code
Reconnect. Before reconnection check that
the pins are not bent or oxidation has not
taken place.
Clear the codes.
Does the problem persist?
Yes
Replace the VGT
No
No
Replace the Accelerator pedal Module
Clear code.
Verify that the complaint has been eliminated.
P-1604
P-1605
P-1606
P-1607
MAN-00057-39
March 2009/Rev 3
For Defect Codes P 1604 & P1607 Turn Ignition switches ON & connect BPA connector.
Turn the Ignition ON & measure voltage coming to the BPA it should
5 V.
Is it?
P-1604
P-1605
P-1606
P-1607
Is it OK ?
Yes
No
No
MAN-00057-40
March 2009/Rev 3
P-235
P-236
P-1236
Description:
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.
DTC
P-235
P-236
P-1236
Diagnostic item
Boost pressure sensor- Voltage above upper limit
Boost pressure sensor- Voltage below lower limit
Boost pressure sensor not plausible with atmospheric pressure
sensor.
Probable cause
Possible Causes
Malfunction; out-of-range
Monitors the pressure build up or decrease.
Also monitors the plausibility with the atmospheric
pressure sensor
Reaction
System Check lamp is ON
Engine torque is limited.
Air mass default values taken
MAN-00057-41
March 2009/Rev 3
P-235
P-236
P-1236
ECU
A13
A23
A40
U
P
MAN-00057-42
March 2009/Rev 3
P-235
P-236
P-1236
MAN-00057-43
March 2009/Rev 3
Yes
Yes
No
Clear code
Verify that the complaint has been
eliminated.
No
P-235
P-236
P-1236
MAN-00057-44
March 2009/Rev 3
P-0340
P-0341
MAN-00057-45
March 2009/Rev 3
P-0340
P-0341
Diagnostic item
No camshaft signal
Wrong camshaft signal
Description
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.
Probable cause
Open or shorted
camshaft position
sensor circuit,
loose or wrong
connection.
Camshaft Position
sensor malfunction.
Reaction
Engine will not start
System lamp will be continuously on.
Sensor
R-L
A 11
ECU
Vs
Vs
R-G
A50
Signal
1
Vs= Supply voltage- 5V
A20
GND.
MAN-00057-46
March 2009/Rev 3
P-0340
P-0341
Yes
Turn the Ignition OFF
Disconnect ECU connector A.
Measure the continuity of Ground (between
sensor pin no 1 & ECU terminal A20) in the
camshaft phase sensor harness.
Is it OK?
Yes
Measure the continuity of signal (between
No
Repair the wires A 11 to Pin No.3 &A
20 to Pin No. 1.
Clear the error codes & verify.
No
Repair the connection.
MAN-00057-47
March 2009/Rev 3
Yes
Check for physical damage to pins or
oxidation.
Also check if the connectors are moving
backwards when inserted.
Is it OK?
Yes
No
Repair the connection.
Clear the error codes & verify.
No
MAN-00057-48
March 2009/Rev 3
P-0335
P-0336
MAN-00057-49
March 2009/Rev 3
P-0335
P-0336
Description - In order that the ECU can control the engine at all the position
of the crankshaft must be known so that the cylinder in compression and the timing of the
next fuel injection can be calculated. The CKP is an inductive pulse generator, which
scans protrusions on the flywheel. Two teeth are missing, and this gap is situated at 90
before TDC.
DTC
P-0335
P-0336
Diagnostic item
No crankshaft signal
Wrong crankshaft signal
Probable cause
Open, shorted or
wrong connection
crankshaft position
sensor circuit.
Failed or damaged
crankshaft position
sensor.
Sensor
N
ECU
Y
A 27
A 12
Positive
Negative
Shield
3
B-R
A 21
MAN-00057-50
March 2009/Rev 3
P-0335
P-0336
Yes
No
Is it OK ?
Yes
No
MAN-00057-51
March 2009/Rev 3
P-0103
P-0102
MAN-00057-52
March 2009/Rev 3
P-0103
P-0102
Description 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
control module. This results in the change of the temperature of the hot film probe and in
the change of resistance.
DTC
P-0103
P-0102
Diagnostic item
Voltage above upper Limit
Voltage below lower Limit
Probable cause
MAN-00057-53
March 2009/Rev 3
Bat+ 12V
MAN-00057-54
March 2009/Rev 3
P-0103
P-0102
Yes
No
MAN-00057-55
March 2009/Rev 3
P-0103
P-0102
Check fuses
Check continuity between
the A29 & 4 ( voltage)
Check continuity between A44 & 3 (
Ground)
Repair the open wire.
Clear codes and verify that the HFM
signal ratio is within limit.
Is it?
Yes
No
No
Check the resistance of the HFM sensor ( between 5 & 3) it should be between 5.119 to
5.892 KOhms
If not OK. Replace the HFM sensor.
Clear codes & verify that the error has been removed.
MAN-00057-56
March 2009/Rev 3
P-0113
P-0112
MAN-00057-57
March 2009/Rev 3
DTC
P-0113
P-0112
P-0113
P-0112
Diagnostic item
Voltage above upper limit.
Voltage below lower limit.
Description: The function acquires the raw voltage of the induction air temperature. The
raw value is linearised and monitored for compliance with the signal range.
The sensor is mounted in HFM.
DTC detection condition
Normal Operation
The HFM temperature sensor outputs a voltage,
which corresponds to the temperature of intake
airflow.
The ECU checks whether this voltage is within a
specified range.
Normal Operating Requirements
Ignition switch: ON
Malfunction lamp: OFF after 2 Sec
Battery voltage is 8V 16 V.
Probable cause
Failed HFM
temperature sensor.
Malfunction
The sensor output voltage has continued to be 5V
or higher.
The sensor output voltage has continued to be 0.2
V or lower.
Reactions
Engine will run with default air temp of 20 Degrees
Centigrade
System lamp status for this error is off.
MAN-00057-58
March 2009/Rev 3
P-0113
P-0112
ECU
A29
V cl
V-B
A42
G-B
Ignition
switch
Ground
R/G
A37
G
Air flow o/p
A44
Temperature
O/P
Bat+ 12V
10 Amp
MAN-00057-59
March 2009/Rev 3
P-0113
P-0112
No
Check fuses
Check continuity between the A29 & 4
( voltage)
Check continuity between A44 & 3 (
Ground)
Repair the open wire.
Clear codes and verify that error has
been eliminated.
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 2009 Mahindra & Mahindra Ltd.
MAN-00057-60
March 2009/Rev 3
P-0113
P-0112
No
Rectify
Clear codes & verify.
Yes
No
Rectify
Clear codes & verify.
MAN-00057-61
March 2009/Rev 3
P-0193
P-0192
Diagnostic item
Voltage above upper limit.
Voltage below lower limit.
Malfunction
Rail pressure output voltage is below
Probable cause
Open, shorted or
wrong connection of
rail pressure sensor
circuit.
Rail pressure sensor
failed.
Reaction
When ignition is ON system lamp is glowing.
Engine is not starting & error is set in ECU
Error memory.
MAN-00057-62
March 2009/Rev 3
P-0193
P-0192
ECU
A28
A43
O-B
3
V cc
2
V out
A08
1
GND
MAN-00057-63
March 2009/Rev 3
P-0193
P-0192
Yes
Check the continuity between the ECU
terminal A28 & pin no 3 of the RPS.
No
Repair the wire.
MAN-00057-64
March 2009/Rev 3
Yes
Connect the rail pressure sensor connector to
sensor.
Switch ON the Ignition.
Check the output of the RPS ( Should be in
range of 500 to 700 mVolts.
Is it?
Yes
No
Repair the wire.
(Check for pins contamination)
Clear the error codes & verify.
No
Yes
Clear codes & verify.
No
Replace rail.
Clear codes & verify.
P-0193
P-0192
MAN-00057-65
March 2009/Rev 3
DTC
P-1192
P-1193
P-1192
P-1193
Diagnostic item
Maximum positive Rail pressure deviation exceeded
Maximum positive Rail pressure deviation exceeded concerning the
set flow value
Probable cause
Possible Causes
Malfunction; out-of-range
If the deviation is more then error is generated.
Reaction
Engine will be switched OFF
Engine can not be started
System Check lamp is ON
MAN-00057-66
March 2009/Rev 3
P-1192
P-1193
Test Procedure Rail Pressure Deviation 1. Connect the Smart Tester to diagnostic connector.
2. Turn Ignition Switch ON.
3. Verify that either P1192/1193 is present.
MAN-00057-67
March 2009/Rev 3
P-1192
P-1193
Complaint < 2000 Kms. after filter
change.
Yes
No
Air lock-do
bleeding
Change Filter
assembly along
with copper
washer
Change Filter
& bleed
OK
No
Not
OK
OK
OK
Change
Injector
OK
Not
OK
Change
HPP
Not
OK
OK
DTC
P-1194
MAN-00057-68
March 2009/Rev 3
P-1194
Diagnostic item
Maximum negative rail pressure deviation with metering unit on lower
limit is exceeded.
Probable cause
Possible Causes
Malfunction; out-of-range
The error is reported if the negative rail pressure
deviation is more then the specified in the map
and at the same time the flow rate is also less
Reaction
* The fuelling is controlled
* System Check lamp is ON
MAN-00057-69
March 2009/Rev 3
DTC
P-1195
P-1195
Diagnostic item
Minimum rail pressure exceeded.
Probable cause
Possible Causes
Malfunction; out-of-range
If the rail pressure falls below engine speed threshold
Then the error is generated.
.
Reaction
* System Check lamp is ON
MAN-00057-70
March 2009/Rev 3
MAN-00057-71
March 2009/Rev 3
No
Remove the smart tester from the connector.
Switch on the Ignition.
Check the voltage of the pin no 4/5 & 7 of the
connector ( It should show 12 Volts when
Ignition is ON and show 0 Volts when Ignition
is switched OFF.
Is it OK?
No
Yes
Connect smart tester & confirm.
Yes
Diagnostic connector is OK.
Yes
No
Diagnostic hardware is faulty.
Change the hardware.
MAN-00057-72
March 2009/Rev 3
Description
A pulse-width-modulated signal is output for the Exhaust Gas Recirculation
actuator control. Converting the air control output into duty cycle carries this
out. The possible defects are short circuit to battery, ground & no load.
DTC
P-0406
P-0405
P-0403
P-0404
P-0406
P-0405
P-0403
P-0404
Diagnostic item
Short Circuit Battery
Short Circuit Ground
No Load
Excess Temperature
Probable cause
*
*
*
Open or shorted
EGR solenoid
circuit, loose or
wrong connection.
EGR solenoid
failed
EGR control
vacuum is too low
MAN-00057-73
March 2009/Rev 3
P-0406
P-0405
P-0403
P-0404
*- Twisted pair
Yes
Turn Ignition OFF.
No
Verify that the 15 Amp fuse is OK (
same fuse is also used for brake &
clutch switch).
Repair open or short to Ground on wire
MAN-00057-74
March 2009/Rev 3
Yes
Are the connectors OK ( check for bent pins
or oxidation).
No
Rectify the wiring.
Clear codes & verify.
Yes
No
P-0406
P-0405
P-0403
P-0404
MAN-00057-75
March 2009/Rev 3
P-1340
Error path of offset between camshaft and crankshaft
DTC
P-1340
*
*
Diagnostic item
Offset between camshaft and crankshaft
Probable cause
Malfunction
Normal signal pattern has not been input for
Mounting of phase
sensor, speed sensor
or flywheel is loose.
Manufacturing defect.
Sensors faulty or
damaged.
Reaction
Engine is not being cranked.
System lamp will continuously ON.
MAN-00057-76
March 2009/Rev 3
Sensor
P-1340
R-L
A 11
ECU
Vs
Vs
R-G
A50
Signal
1
C-39
2.2
BS III
A20
GND.
MAN-00057-77
March 2009/Rev 3
P-1340
ISS (Incremental speed sensor/ Crankshaft speed sensor)
Sensor
N
ECU
Y
A 27
A 12
Positive
Negative
Shield
3
B-R
A 21
MAN-00057-78
March 2009/Rev 3
P-1340
Yes
Check the sensor mounting of crank shaft
speed sensor.
Check the wiring harness continuity between
the cam sensor to ECU & also the crankshaft
speed sensor to ECU.
Flywheel mounting is OK.
Check the phase sensor for any nicks.
Yes
Check for any manufacturing defects.
Clear codes & verify that the signal is within
limit.
If it is not in limit, change the corresponding
sensor.
No
Correct the mounting.
Clear codes & verify that the signal is
within limit.
No
Correct the mounting.
Clear codes & verify that the signal is
within limit.
MAN-00057-79
March 2009/Rev 3
P-0182
P-0183
MAN-00057-80
March 2009/Rev 3
P-0182
P-0183
Description
Fuel temperature sensor acquires the raw value of the fuel temperature. The raw value is
linearised and monitored for compliance with the signal range. The sensor is a NTC type
DTC
P-0182
P-0183
Diagnostic item
Voltage above upper limit
Voltage below lower limit
Probable cause
Open or shorted
Engine fuel
temperature sensor
circuit, loose or wrong
connection
Fuel temperature
sensor failed.
ECU
A 52
A 51
MAN-00057-81
March 2009/Rev 3
P-0182
P-0183
Yes
No
MAN-00057-82
March 2009/Rev 3
Yes
Yes
No
No
P-0182
P-0183
MAN-00057-83
March 2009/Rev 3
P-1252
P-1253
P-1250
P-1251
Diagnostic item
Short Circuit to Battery
Short Circuit to Ground
No Load
Excess Temperature
Probable cause
Open, shorted or
wrong connection of
pump circuit.
Malfunction
When ignition is ON pump is not getting PWM signal
from ECU.
Reaction
Engine is not starting & error is recorded in ECU error
memory.
Fuel output is not available from pump.
System lamp will remain ON.
MAN-00057-84
March 2009/Rev 3
P-1252
P-1253
P-1250
P-1251
ECU
A19
A 49
W
Y
MAN-00057-85
March 2009/Rev 3
P-1252
P-1253
P-1250
P-1251
Yes
No
MAN-00057-86
March 2009/Rev 3
No
Error observed due to loose/ intermittent
connection.
Ensure that the connections are proper.
Clear codes and verify the error.
Yes
There is a possibility of short circuit of
battery to ground.
Repair the connections.
Clear codes & verify.
Hint: The Error Code P 1251 can also be generated if there is leakage in the HPP
adaptor.
P-1252
P-1253
P-1250
P-1251
MAN-00057-87
March 2009/Rev 3
P-121A
P-121B
Main relay
DTC
P-121A
P-121B
Diagnostic item
Main relay does not open in time
Main relay opens too early
Malfunction
Supply will not come to ECU input.
Reaction
Engine will not start.
No communication with smart tester.
System check lamp will be on.
Probable cause
Open, shorted or
wrong connection of
main relay.
Main relay fuse is
blown.
Relay is not working
MAN-00057-88
March 2009/Rev 3
P-121A
P-121B
MAN-00057-89
March 2009/Rev 3
P-121A
P-121B
Yes
Switch ON the Ignition.
Measure the voltage at terminal K72 of ECU
or terminal 85 of the relay.
Is it showing 0 Volts ?
Yes
Measure the voltage at ECU terminal
K05/K01. Or at terminal 87 of the relay.
No
Check the wiring harness.
Repair the main relay connections (
check the 30 Amp fuse)
Clear codes & verify that the main relay
is working properly.
No
Check that the terminal K 28 of ECU is
showing 12 Volts. If not repair the
connection.
Yes
No
MAN-00057-90
March 2009/Rev 3
P-0577
P-0576
P-0575
Cruise Control
DTC
P-0577
P-0576
P-0575
Diagnostic item
SRC MAX error for analog signal
SRC MIN error for analog signal
Plausibility error for analog signal
Probable cause
*
Open, shorted or
wrong connection
of cruise control
circuit.
Brake or clutch
error is set into
ECU.
Switches are not
responding or
faulty.
Engine RPM less
than 1200.
Malfunction
By pressing any of the cruise control switch vehicle will
not go into cruise mode.
Vehicle will not respond to set +, Set -, OFF or resume
switch when vehicle is in cruise mode.
MAN-00057-91
March 2009/Rev 3
P-0577
P-0576
P-0575
ECU
K35
K58
K32
W-B
K80
On/off
P-B
K17
Br
Br-B
Redunda
nt brake
switch
On/O
ff Set Set -
Set +
Set +
Main
brake
switch
Coast/Resu
Coast /
Reset
Cruise
control
activator
C-39
2.2
BS III
Clutch
15A
15
Batte
Batte
MAN-00057-92
March 2009/Rev 3
P-0577
P-0576
P-0575
MAN-00057-93
March 2009/Rev 3
P-0577
P-0576
P-0575
Resistance
4.323 K
150
1.63 K
810
420 K
Voltage
4.35 V
0.9823 V
3.61 V
2.845 V
2.035 V
Yes
Yes
No
No
Yes
No
MAN-00057-94
March 2009/Rev 3
P-0563
P-0562
MAN-00057-95
March 2009/Rev 3
P-0563
P-0562
Description:
The system voltage has to guarantee to perform diagnosis functions. The
Electronic Control Unit (ECU) monitors battery voltage. If this code is set, the System
Lamp is off.
DTC
P-0563
P-0562
Diagnostic item
Voltage above upper limit
Voltage below lower limit.
Probable cause
Charging system
not working.
Wiring harness to
ECU faulty.
Repair or replace.
MAN-00057-96
March 2009/Rev 3
P-1792
P-1791
Description:
The function acquires and processes the information via the brake contact and the
redundant brake contact. The status message of the brake position is the output.
DTC
P-1792
P-1791
Diagnostic item
Brake signal is defective
Brake signals not plausible
Probable cause
Malfunction
* The sensor output voltage has continued to be 0V
in spite of brake pedal being pressed/not pressed
* The sensor output voltage has continued to 12V in
spite of brake pedal being pressed/not pressed
* Main or redundant switch is not working.
Reaction
* System lamp will be off.
Cruise control will not work.
MAN-00057-97
March 2009/Rev 3
P-1792
P-1791
MAN-00057-98
March 2009/Rev 3
P-1792
P-1791
Yes
Turn the Ignition OFF.
Connect the brake switch connector.
Check the voltage at K80 of ECU input pin
when the brake is in released position.
When the brake pedal is pressed then it
should be checked at K17.
It should be 12 V.
Is it?
No
Check the 15 Amp fuse after the main
relay.
Check the supply to K01 & K05.
(Fuses of K01 & K05)
Repair connections as necessary.
Yes
No
No
Yes
MAN-00057-99
March 2009/Rev 3
P-0704
Diagnostic item
Clutch signal is not plausible
Description
The clutch signal is acquired as a hardware signal. The signal is checked for plausibility
using gear information. Error is detected, if there is a valid gear change without the clutch
being pressed during the time that elapsed since the last gear change.
DTC detection condition
Normal Operation
* The clutch switch outputs a voltage, which
corresponds to the clutch position.
* The ECU checks whether this voltage is within a
specified range (0 or 12V).
Probable cause
Malfunction
* The sensor output voltage has continued to be 0V
in spite of clutch pedal being pressed/not pressed.
* The sensor output voltage has continued to 12V in
spite of clutch pedal being pressed/not pressed.
Reaction:
* System lamp will be off.
* Cruise control will not work.
15 Amp
4
R
Br-B
G
Clutch switch
(normally closed)
K58
4
ECU
MAN-00057-100
March 2009/Rev 3
P-0704
Verify that no error related to vehicle speed (vehicle speed sensor related) is present. If
present, first attend to those complaints then verify if the error P 0704 is present and then
proceed.
Disconnect clutch switch connector.
Turn the ignition ON.
Check supply voltage to clutch switch on connector.
It should be 12 V, when Ignition is ON. Is it?
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 2009 Mahindra & Mahindra Ltd.
MAN-00057-101
March 2009/Rev 3
P-0704
Yes
Turn Ignition OFF.
Yes
No
Check the 15 Amp fuse after the main
relay ( this fuse also controls EGR &
Brake switch).
Check the supply to K01 & K05.
Repair the connections as necessary.
Clear codes & verify.
No
No
Yes
MAN-00057-102
March 2009/Rev 3
MAN-00057-103
March 2009/Rev 3
P-0118
P-0117
Diagnostic item
Voltage above upper limit
Voltage below lower limit
Probable cause
*
Open or shorted
Engine Coolant
Temperature
sensor circuit, or
loose or wrong
connection
Engine Coolant
Temperature
sensor failed.
Reaction:
* System lamp will be on.
Engine will continue to run with water
temperature of 120 deg C.
MAN-00057-104
March 2009/Rev 3
P-0118
P-0117
ECU
A 58
W-R
A41
G-R
MAN-00057-105
March 2009/Rev 3
P-0118
P-0117
Yes
Turn the Ignition OFF
Measure continuity between A 58 of ECU &
connector terminal 1
Measure continuity between A 41 of ECU &
connector terminal 2
Is it OK
Yes
No
Open or short between CTS signal
terminal 1 and ECU
Repair as necessary.
No
Yes
No
MAN-00057-106
March 2009/Rev 3
P-2558
P-1126
Description - 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.
DTC
P-2558
P-1126
Diagnostic item
Minimum Temperature not reached within time limit.
Minimum temperature or temperature raise no reached within time
limit
Probable cause
Defective temperature
sensor.
Thermostat stuck in
open condition
Malfunction; out-of-range
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.
Thermostat removed.
Reaction
System check lamp : OFF
MAN-00057-107
March 2009/Rev 3
P-2558
P-1126
Test Procedure -
Not Ok
Replace the
temperature sensor
Not
Present
Present
Check if thermostat
opening is OK
Not Ok
Replace
OK
MAN-00057-108
March 2009/Rev 3
P-165E
P-165F
P-1660
P-1661
Diagnostic item
Short Circuit to Battery
Short Circuit to Battery
No Load
Excess Temperature
Probable cause
MAN-00057-109
March 2009/Rev 3
P-165E
P-165F
P-1660
P-1661
MAN-00057-110
March 2009/Rev 3
P-165E
P-165F
P-1660
P-1661
Yes
Switch ON the Ignition
Check if the supply is coming to the overheat
lamp
Is it OK
Yes
No
Repair the connection
Clear codes and verify that the
overheat lamp is working correctly.
No
Lamp failure.
Change the lamp
MAN-00057-111
March 2009/Rev 3
P-0108
P-0107
*
*
*
*
*
*
Diagnostic item
Voltage above upper limit
Voltage below lower limit
Probable cause
Failed atmospheric
pressure sensor.
Normal Operation
Ignition switch: ON
Malfunction lamp: OFF after 2 Sec
Battery voltage is 8V to 12V.
No error reported in error memory.
Malfunction
The sensor output voltage has continued to be 5V
or higher.
The sensor output voltage has continued to be 0V
or lower.
Reaction
1. System lamp will blink.
2. Engine will run with default atmospheric Pressure
of 800hPa
Yes
No
Repeat the clear error, for 3 times.
Replace the ECU
MAN-00057-112
March 2009/Rev 3
P1623
P1625
P161F
P1621
Diagnostic item
Below lower limit of enegising time- Injector # 1
Below lower limit of enegising time- Injector # 2
Below lower limit of enegising time- Injector # 3
Below lower limit of enegising time- Injector # 4
MAN-00057-113
March 2009/Rev 3
P-162A
DTC
P-162A
Diagnostic item
Communication error of CJ940
Switch ON Ignition
Using smart tester, clear the ECU faults.
Switch OFF Ignition key and wait for 2 minutes.
Switch ON Ignition.
Using smart tester check whether any of the above mentioned fault is present.
If fault is still present, switch OFF ignition.
Replace the ECU with a new one and repeat steps 4 & 5.
If fault is not present in the new ECU, then the old ECU is defective and has to be sent
back to M&M.
MAN-00057-114
March 2009/Rev 3
P-1659
Diagnostic item
Deviation between TPU and system time
Switch ON Ignition
Using smart tester, clear the ECU faults.
Switch OFF Ignition key and wait for 2 minutes.
Switch ON Ignition.
Using smart tester check whether any of the above mentioned fault is present.
If fault is still present, switch OFF ignition.
Replace the ECU with a new one and repeat steps 4 & 5.
If fault is not present in the new ECU, then the old ECU is defective and has to be sent
back to M&M.
MAN-00057-115
March 2009/Rev 3
P-1638
ECU Monitoring
Description: Monitoring module inside ECU reports a defect.
DTC
P-1638
Diagnostic item
Set, if error-counter of Watchdog or controller are not plausible or the
system must shut down
Switch ON Ignition.
Using Smart Tester, clear the ECU faults.
Switch OFF Ignition key and wait for 2 minutes.
Switch ON Ignition.
Using smart tester check whether any of the above mentioned fault is present.
If fault is still present, switch OFF ignition.
Replace the ECU with a new one and repeat steps 4 & 5.
If fault is not present in the new ECU, then the old ECU is defective and has to be sent
back to M&M.
MAN-00057-116
March 2009/Rev 3
P-162B
P-162C
P-162D
Diagnostic item
EEPROM: error during last read operation
EEPROM: error during last write operation
EEPROM: default value used
Switch ON Ignition.
Using Smart Tester, clear the ECU faults.
Switch OFF Ignition key and wait for 2 minutes.
Switch ON Ignition.
Using smart tester check whether any of the above mentioned fault is present.
If fault is still present, switch OFF ignition.
Replace the ECU with a new one and repeat steps 4 & 5.
If fault is not present in the new ECU, then the old ECU is defective and has to be sent
back to M&M.
MAN-00057-117
March 2009/Rev 3
P-160C
P-160D
P-160E
Diagnostic item
Short Circuit to Battery
Short Circuit to Ground
No Load
Probable cause
*
Open, shorted or
wrong connection
of tachometer
circuit.
Malfunction
When engine is running it wouldn't show
corresponding engine speed on dash panel.
Reaction
3. No impact on vehicle performance. Only engine
speed indication on dash panel can not be seen.
4. Cruise control will not work.
MAN-00057-118
March 2009/Rev 3
P-160C
P-160D
P-160E
Is it OK?
MAN-00057-119
March 2009/Rev 3
No
Is it?
Yes
No
P-160C
P-160D
P-160E
MAN-00057-120
March 2009/Rev 3
P-1608
P-1609
P-160A
P-160B
Description
The component driver for the coolant temperature outputs the variable as a
PWM signal to the power stage. (Output on the cluster) In normal operation, the PWM
power stage is tested for short circuit to battery, to ground, open circuit and excess
temperature.
DTC
P-1608
P-1609
P-160A
P-160B
*
*
*
*
Diagnostic item
Short circuit to battery
Short circuit to ground
No load
Excess temperature
Probable cause
Open or shorted
Engine Coolant
Temperature
output sensor
circuit, or loose or
wrong connection.
MAN-00057-121
March 2009/Rev 3
P-1608
P-1609
P-160A
P-160B
Test Procedure Coolant temperature output -1. Connect the Smart Tester to diagnostic connector.
2. Turn Ignition Switch ON.
3. Verify that the either of the error codes P1608 or P1609 or P160A or P160B is present.
Yes
No
MAN-00057-122
March 2009/Rev 3
P-1608
P-1609
P-160A
P-160B
Check the cluster lamp fuse
Yes
No
MAN-00057-123
March 2009/Rev 3
Diagnostic item
Short circuit to battery
Short circuit to ground
No load
Excess temperature
DTC detection condition
Normal Operation
* AC relay is OFF when the AC switch & blower
switch is OFF.
* The ECU checks whether AC switch is ON then it
will try to switch ON the AC relay provided blower is
ON.
* When AC relay is energized then it will switch ON
the AC compressor.
Normal Operation
* Ignition switch: ON
* Engine is ON
* System lamp: OFF after 2Sec
* Battery voltage is 8V 16V.
* AC switch & blower switches are ON.
Malfunction
* ECU not recognizing 12V when AC switch is ON.
* ECU output to AC relay has continued to 0.5V or
more.
Reaction
* System lamp will blink continuously.
* AC will not work.
Yes
No
P-1530
P-1531
P-1532
P-1533
MAN-00057-124
March 2009/Rev 3
Yes
Yes
No
No
P-1530
P-1531
P-1532
P-1533
MAN-00057-125
March 2009/Rev 3
Diagnostic item
Chip-specific errors : CY33X
internal reset / clock loss / under voltage
Chip-specific errors: CY33X is unlocked / CY33X init error
Chip-specific errors:CY33X is in Test mode
Chip-specific errors: CY33X SPI communication error /checksum/read
back
Chip-specific errors ->CY33X internal parity error
Chip-specific errors ->CY33X internal program flow error
Chip-specific errors ->CY33X check of inv. YSEL during ON failed
Chip-specific errors ->CY33X ON timeout for at least 1 cylinder
P-1217
Reaction: The System Check lamp will be continuously ON.
Engine stops.
Test Procedure
1.
2.
3.
4.
5.
6.
7.
Switch ON Ignition.
Using Smart Tester clear the ECU faults.
Switch OFF Ignition key and wait for 2 minutes.
Switch ON Ignition.
Using diagnostic tester check whether any of the above mentioned fault is present.
If fault is still present, switch OFF ignition.
Replace the ECU with a new one and repeat steps 4 & 5.
8. If fault is not present in the new ECU, then the old ECU is defective and has to be sent
back to M&M.
P-1210
P-1211
P-1212
P-1213
P-1214
P-1215
P-1216
P-1217
MAN-00057-126
March 2009/Rev 3
P-1664
Diagnostic item
The fault path contains the supervision of the SPI-Handler
Set, if SPI-communication failed
1.
2.
3.
4.
5.
6.
7.
8.
Switch ON Ignition.
Using Smart Tester, clear the ECU faults.
Switch OFF Ignition key and wait for 2 minutes.
Switch ON Ignition.
Using smart tester check whether any of the above mentioned fault is present.
If fault is still present, switch OFF ignition.
Replace the ECU with a new one and repeat steps 4 & 5.
If fault is not present in the new ECU, then the old ECU is defective and has to be sent
back to M&M.
MAN-00057-127
March 2009/Rev 3
P-1641
P-1642
P-1643
Diagnostic item
Test of redundant shut off paths during initialization: Watch dog switch
off path defect
Test of redundant shut off paths during initialization: Voltage
monitoring upper limit shut off path defect
Test of redundant shut off paths during initialization: Voltage
monitoring lower limit shut off path defect
1.
2.
3.
4.
5.
6.
7.
8.
Switch ON Ignition.
Using Smart Tester, clear the ECU faults.
Switch OFF Ignition key and wait for 2 minutes.
Switch ON Ignition.
Using smart tester check whether any of the above mentioned fault is present.
If fault is still present, switch OFF ignition.
Replace the ECU with a new one and repeat steps 4 & 5.
If fault is not present in the new ECU, then the old ECU is defective and has to be sent
back to M&M.
MAN-00057-128
March 2009/Rev 3
P-1631
P-1632
Diagnostic item
(Hardware) CJ940 upper limit: internal supply voltage upper limit
(Hardware) CJ940 lower limit: internal supply voltage lower limit
P-1632
Reaction: The System Check lamp will be continuously ON.
Test Procedure
1.
2.
3.
4.
5.
6.
7.
8.
Switch ON Ignition.
Using Smart Tester, clear the ECU faults.
Switch OFF Ignition key and wait for 2 minutes.
Switch ON Ignition.
Using smart tester check whether any of the above mentioned fault is present.
If fault is still present, switch OFF ignition.
Replace the ECU with a new one and repeat steps 4 & 5.
If fault is not present in the new ECU, then the old ECU is defective and has to be sent
back to M&M.
MAN-00057-129
March 2009/Rev 3
P-1644
P-1645
Diagnostic item
Voltage above upper limit
Voltage below lower limit
Probable cause
Malfunction
The voltages are beyond the range.
Reactions
System lamp status for this error is ON.
MAN-00057-130
March 2009/Rev 3
P-1644
P-1645
This is related to the cam shaft sensor supply & also APP1 supply voltage.
Check the connection of the cam shaft sensor supply & accelerator pedal connector.
Is it OK?
Yes
Remove the sensor connections of the
No
Repair the connection.
No
Clear the codes & verify.
MAN-00057-131
March 2009/Rev 3
Yes
Check the continuity between the ECU
connector A11 and the camshaft
terminal 3.
&
Between ECU connector K 45 and
Accelerator pedal Terminal 2.
Repair the connection.
Reconnect everything.
Clear codes and check cam phase
sensor and Accelerator pedal are
working properly.
P-1644
P-1645
MAN-00057-132
March 2009/Rev 3
P-1646
P-1647
Diagnostic item
Voltage above upper limit
Voltage below lower limit
Probable cause
Malfunction
The voltages are beyond the range.
Reactions
System lamp status for this error is ON.
MAN-00057-133
March 2009/Rev 3
P-1646
P-1647
1.
2.
3.
Yes
No
MAN-00057-134
March 2009/Rev 3
P-1646
P-1647
No
Clear the codes & verify.
Yes
Check the continuity between the ECU
connector A 29 and the HFM terminal 4.
Check the continuity between the Rail
pressure connector terminal 3 and
terminal A14 of the ECU
Check the continuity of between
terminal 1 of the Accelerator pedal
(APP2) and K 46 of the ECU.
Repair the connection.
Reconnect everything.
Clear codes and verify.
MAN-00057-135
March 2009/Rev 3
P-1654
P-1655
P-1656
P-1657
Diagnostic item
Short Circuit to Battery
Short Circuit to Battery
No Load
Excess Temperature
Probable cause
Open, shorted or
wrong connection of
system lamp circuit.
Malfunction
When ignition is switched ON the system lamp does
not glow ON.
MAN-00057-136
March 2009/Rev 3
P-1654
P-1655
P-1656
P-1657
Yes
Turn the Ignition OFF
Disconnect ECU connector A
Measure the continuity of Ground (between
sensor pin no 1 & ECU terminal A20) in the
camshaft phase sensor harness.
Is it OK?
Yes
Lamp failure
Replace lamp
No
Check the fuse.
Repair the wire.
Clear the error codes & verify
No
Repair the connection.
Clear codes and verify that the system
lamp is working properly.
MAN-00057-137
March 2009/Rev 3
P-1658
DTC
P-1658
Diagnostic item
No Terminal T15 signals detected
Probable cause
Open, shorted or
wrong connection of
T15 circuit.
Malfunction
When ignition is ON supply is not coming to ECU.
Main relay coil will not get energized.
Engine will not start.
MAN-00057-138
March 2009/Rev 3
P-1658
Yes
Turn the Ignition OFF.
Measure the continuity of the wire between
the K28 terminal of the ECU and the Ignition
switch (Terminal 15).
No
Follow the Main relay fault finding
procedure.
Clear the error codes & verify.
Is it OK?
Yes
Check for loose or intermittent connection.
Repair the connection
No
Repair the connection.
Clear the codes and verify that the
vehicle is working perfectly.
MAN-00057-139
March 2009/Rev 3
P-0503
P-0500
P-0501
*
*
Diagnostic item
Exceeding of the maximum vehicle speed
HW signal for vehicle speed not valid
Vehicle speed not plausible with injection mass and engine speed
Probable cause
Malfunction
Sensor output voltage has not changed (No pulse
signal) for 4 sec.
MAN-00057-140
March 2009/Rev 3
P-0503
P-0500
P-0501
Yes
Yes
Disconnect VSS
Disconnect ECU connector
No
No
Repair the interface between he
speedometer & the VSS
Clear codes & verify that VSS signal is
within limit.
Yes
Check the open circuit between the sensor
Ground & positive supply
Is it OK
Yes
Verify that the ECU connections are OK
No
Repair the wire between VSS connector
& ECU terminal
Clear codes & verify that VSS signal is
within limit.
No
Repair short circuit to Ground or
another circuit in wire between VSS
harness connector
Clear codes and verify that the VSS
signal is within range.
MAN-00057-141
March 2009/Rev 3
P-1387
P-1388
P-1389
P-1390
Diagnostic item
Short Circuit to Battery
Short Circuit to Ground
No Load
Excess temperature
Probable cause
* Open, shorted or
wrong connection
of glow circuit.
* Fuse is blown.
* Relay is not
working.
Malfunction
When ignition is ON system lamp will be ON.
Relay will not get energized as per ECU logic.
MAN-00057-142
March 2009/Rev 3
P-1387
P-1388
P-1389
P-1390
Test Procedure
1.
2.
3.
MAN-00057-143
March 2009/Rev 3
P-1387
P-1388
P-1389
P-1390
Is it OK?
Yes
Check the contuinity between the ECU
terminal K 93 and terminal 85 of the relay.
When the supply is ON the supply is coming
to terminal 86 & 30 of the relay.
Check the 60 Amp fuse, if faulty, replace
fuse.
No
Repair the terminal of the
glow plug & relay.
Clear codes & verify that the glow plugs
are working properly.
Yes
Check as per the glow plug logic that the
glow plugs are working. ( the glow plug
light will glow ON for 15 seconds)
Check the relay is energizing.
Is it OK ?
No
Repair the connection.
Yes
No
MAN-00057-144
March 2009/Rev 3
P-0513
Immobilizer
DTC
P-0513
Diagnostic item
Invalid Key error
+ Immobilizer code
DTC
90A0
Diagnostic item
Key is rejected by Immobilser ECU
Vehicle behaviour: Engine does not start, check lamp will blink/ON
Probable Cause:
Invalid key error.
Key is rejected by Immobiliser ECU
Corrective Action:
Replace the key.
Perform the transponder learning
Clear error at both EMS ECU and Immobiliser ECU
Inform the customer about the theft attempt.
+ Immobilizer code
DTC
90A1
Diagnostic item
Invalid Transponder password is found.
Probable Cause:
Somebody duplicated the mechanical key and tried starting the vehicle.
Theft attempt is made
Corrective Action:
Clear the errors at EMS and ICU
Alert the customer.
If more than one error is found in EMS please follow the priority of the errors during. Here
below the errors are listed in the priority error.
EMS Errors
P0513
P183A
P0633
P183E
P183B
P1832
Priority
1
2
3
4
5
6
MAN-00057-145
March 2009/Rev 3
P-1832
Immobilizer
DTC
P-1832
Diagnostic item
Immobilized condition
+ Immobilizer code
DTC
90A3
Diagnostic item
No EMS ACK after the signature response
Vehicle behaviour: Engine does not start, check lamp will blink/ON
Probable Cause:
Immobilizer circuit is faulty
Immobiliser ECU is not working properly.
Transponder is not working/faulty
EMS is flashed with wrong dataset
Corrective Action:
Check the Immobilizer circuit.
Clear error at both EMS ECU and Immobiliser ECU
Inform the customer about the theft attempt.
If wrong dataset- flash the correct dataset.
+ Immobilizer code
DTC
90A4
90A5
90A6
Diagnostic item
Mismatch in checksum 1
Mismatch in Checksum 2
Mismatch in Checksum 3
Probable Cause:
EMS is responding in wrong manner
Invalid immobiliser
ICU-EMS not learned
Corrective Action:
Replace immobiliser ECU
Perform transponder learning
Perform ICU- EMS learning
Clear all errors in both EMS and ICU
If more than one error is found in EMS please follow the priority of the errors during. Here
below the errors are listed in the priority error.
EMS Errors
P0513
P183A
P0633
P183E
P183B
P1832
Priority
1
2
3
4
5
6
MAN-00057-146
March 2009/Rev 3
MAN-00057-147
March 2009/Rev 3
P-1832
Immobilizer
DTC
P-1832
Diagnostic item
Immobilized condition
+ Immobilizer code
DTC
90A3
Diagnostic item
No EMS ACK after the signature response
Vehicle behaviour: Engine does not start, check lamp will blink/ON
Probable Cause:
No EMS Ack after the signature mismatch
Theft attempt is made.
Corrective Action:
Clear all errors in both EMS and ICU
If more than one error is found in EMS please follow the priority of the errors during. Here
below the errors are listed in the priority error.
EMS Errors
P0513
P183A
P0633
P183E
P183B
P1832
Priority
1
2
3
4
5
6
MAN-00057-148
March 2009/Rev 3
P-183A
Immobilizer
DTC
P-183A
Diagnostic item
Signature Mismatch
+ Immobilizer code
DTC
90A3
Diagnostic item
No EMS ACK after the signature response
Vehicle behaviour: Engine does not start, check lamp will blink/ON
Probable Cause:
Invalid immobilizer/EMS.
Signature mismatch.
Corrective Action:
Check the CAN wiring if it is correct.
Perform ICU- EMS learning.
Clear all errors in both EMS and ICU
If more than one error is found in EMS please follow the priority of the errors during. Here
below the errors are listed in the priority error.
EMS Errors
P0513
P183A
P0633
P183E
P183B
P1832
Priority
1
2
3
4
5
6
MAN-00057-149
March 2009/Rev 3
P-183A
MAN-00057-150
March 2009/Rev 3
P-183B
Immobilizer
DTC
P-183B
Diagnostic item
EMS is locked
+ Immobilizer code
DTC
90A4
90A5
90A6
Diagnostic item
Mismatch in checksum 1
Mismatch in Checksum 2
Mismatch in Checksum 3
Vehicle behaviour: Engine does not start, check lamp will blink/ON
Probable Cause:
Invalid immobilizer.
CAN wiring related problem.
EMS is locked.
No EMS ACK from EMS.
Corrective Action:
Check the CAN wiring if it is correct- replace immobiliser.
Perform transponder learning.
Perform ICU EMS learning.
Clear all errors in both ICU & EMS.
+ Immobilizer code
DTC
90A2
Diagnostic item
No response from EMS ECU after signature mismatch
If more than one error is found in EMS please follow the priority of the errors during. Here
below the errors are listed in the priority error.
EMS Errors
P0513
P183A
P0633
P183E
P183B
P1832
Priority
1
2
3
4
5
6
MAN-00057-151
March 2009/Rev 3
P-183B
MAN-00057-152
March 2009/Rev 3
P-183E
Immobilizer
DTC
P-183E
Diagnostic item
EEPROM ERROR
Probable Cause:
EMS is flashed with different dataset
EMS is faulty.
Corrective Action:
Flash it with the correct the dataset.
Replace the EMS
Perform the ICU- EMS learning.
Clear all the errors in the EMS and ICU.
If more than one error is found in EMS please follow the priority of the errors during. Here
below the errors are listed in the priority error.
EMS Errors
P0513
P183A
P0633
P183E
P183B
P1832
Priority
1
2
3
4
5
6
MAN-00057-153
March 2009/Rev 3
P-201
P-1201
P-1203
P-1204
DTC
P-201
P-1201
P-1203
P-1204
Diagnostic item
Injector bank 1: short circuit
Injector bank 1: short circuit on Low Side to ground
Injector bank 1 specific error depending on application
Injector bank 1 not-classifiable error
Probable cause
Possible Causes
Malfunction; out-of-range
If rail pressure exceeds the limits specified in the map
then the error is generated
Reaction
The Engine is switched off.
System check lamp is ON
MAN-00057-154
March 2009/Rev 3
P-1205
P-1206
P-1207
P-1208
DTC
P-1205
P-1206
P-1207
P-1208
Diagnostic item
Injector bank 1specific warning : depending on application
Injector bank 1specific warning : depending on application
Injector bank 1specific warning open load
Injector bank 1specific warning depending on application
Probable cause
Possible Causes
Open load.
Malfunction; out-of-range
If rail pressure exceeds the limits specified in the map
then the error is generated
Reaction
The Engine is switched off.
System check lamp is ON
MAN-00057-155
March 2009/Rev 3
P-1400
P-1401
Diagnostic item
AirCtl permanent positive governor deviation: Positive governor
deviation above limit
P-1401
Probable cause
Air leak between TC and
inlet manifold
VGT stuck in open or
closed condition.
Vacuum leak between
modulator to VGT.
VGT modulator
defective
Vacuum supply to VGT
modulator intermittent
Intercooler leak
BPS mounting loose
MAN-00057-156
March 2009/Rev 3
Major air
leak/ VGT
stuck
Possible area:
Intercooler hose leak
Intercooler leak
VGT not operating due to
vacuum/modulator
VGT stuck
P-1400
P-1401
Minor air
leak
MAN-00057-157
March 2009/Rev 3
P-1705
Diagnostic item
Main Clutch CAN signal error
Probable cause
Open circuit in Can
network
Malfunction
* No signal received over the CAN network
Reaction
* Malfunction Indication lamp ( MIL) is Off.
* The TCU will go into a limp home mode
* Cruise control will not work
MAN-00057-158
March 2009/Rev 3
P-1704
Diagnostic item
Main Clutch signal not Plausible error
Probable cause
Can Hi and Can Low
shorted?
Malfunction
* The signal is not plausible
Reaction
* Malfunction indication lamp is Off.
* The TCU will go into a limp home mode
* Cruise control will not work
MAN-00057-159
March 2009/Rev 3
P-0302
Diagnostic item
TCU error state
Probable cause
Can Hi and Can Low
shorted ?
Reaction
* Malfunction indication lamp is ON.
* The TCU will go into a limp home mode
MAN-00057-160
March 2009/Rev 3
P-0073
DTC
P-0073
Diagnostic item
EMS ECU in confirmed Mute error
Probable cause
Malfunction
Reaction
* Malfunction indication lamp is ON.
MAN-00057-161
March 2009/Rev 3
P-1827
Diagnostic item
CAN signal for Vehicle speed not valid
Probable cause
Malfunction
Reaction
* Malfunction indication lamp is OFF.
* AC is switched off
* After run test is disabled.
* ECU programming cannot be done.
Diagn
nostic Ma
anual (EM
MS)
Scorpio
io Vlx, Sle, Lx (Refre
esh)
Gear Neutral Swittch
MAN-00057
7-162
Ma
arch 2009/Rev 3
P-1704
P-168E
d the installa
ation view of
o the Gear Neutral Sw
witch
3 D and
MAN-00057-163
March 2009/Rev 3
P-1704
Description:
The gear neutral switch is a hall effect based sensor, mounted on the gear shift selector.
The gap between sensor and magnet shall be 61mm. This gap has to be maintained
within the specification to ensure the proper function of gear neutral sensor.
DTC
P-1704
Diagnostic item
Gear Neutral signal is not plausible
Probable cause
Gear Neutral Switch
( GNS)defective/wrong
signal
Malfunction
When ECU detects gear change but no neutral position
then it takes it as an error
Reaction
* Check lamp does not glow, error is registered.
*
MAN-00057-164
March 2009/Rev 3
P-1704
Is the
Connector
Loose?
Yes
Fit it
properly.
No
Yes
GNS terminal
back out
Repair or
replace the
wiring
No
Yes
Wire Cut
Check for Continuity
between GNS
O/P and EMS ECU I/P.
Ref next page for sketch
Replace the
wiring
No
Magnet not
intact
Yes
Place the
magnet
properly.
Yes
Replace the
sensor
No
Hall element
failure
No
Magnet loses
its magnetic
property
Yes
Replace the
magnet
MAN-00057-165
March 2009/Rev 3
Wire Cut
P-1704
MAN-00057-166
March 2009/Rev 3
P-168E
The gear neutral switch is a Hall Effect based sensor, mounted on the gear shift selector.
The gap between sensor and magnet shall be 61mm. This gap has to be maintained
within the specification to ensure the proper function of gear neutral sensor.
DTC
P-168E
Diagnostic item
Gear Neutral signal is not plausible in Standstill Condition
Probable cause
1.GNS
2. Clutch 10% & 90%
switches
MAN-00057-167
March 2009/Rev 3
P-168E
Is the
Connector
Loose?
Yes
Fit it
properly.
No
Yes
GNS terminal
back out
Repair or
replace the
wiring
No
Yes
Wire Cut
Check for Continuity
between GNS
O/P and EMS ECU I/P.
Ref next page for sketch
Replace the
wiring
No
Magnet not
intact
Yes
Place the
magnet
properly.
Yes
Replace the
sensor
No
Hall element
failure
No
Magnet loses
its magnetic
property
Yes
Replace the
magnet
MAN-00057-168
March 2009/Rev 3
Wire Cut
P-168E
MAN-00057-169
March 2009/Rev 3
P-170D
P-170E
P-1710
Description:
The ECU has a power stage which controls the starter actuation when the ESS
Is ON. It also monitors the power stage.
DTC
P-170D
P-170E
P-1710
Diagnostic item
Short Circuit Battery
Short Circuit to Ground
Excess Temperature
Probable cause
Malfunction
Reaction
* Check lamp does not glow
* The Engine Start Stop system will not work..
MAN-00057-170
March 2009/Rev 3
GNS relay
contact on the
output shorted
with battery
P-170D
MAN-00057
7-171
Ma
arch 2009/Rev 3
Diagn
nostic Ma
anual (EM
MS)
Scorpio
io Vlx, Sle, Lx (Refre
esh)
P-1710. Starter po
ower stage excess temprature
P-1710
Diagno
ostic
Sw
witch OFF
ign
nition and
allo
ow the EMS
S
EC
CU to cool fo
or
30
0 minutes.
High
temperatture
@ K69 pin
p in
EMS EC
CU
Rep
place the
EMS
S ECU
If Error
repeats.
Now check
N
start stop
unctionality..
fu
Note : This
T
error will
w be registered only iff the ESS is
s enabled.
MAN-00057-172
March 2009/Rev 3
P-170E
P-170E
P 170E is registered when any of the wires are short to ground- replce the wiring.
MAN-00057-173
March 2009/Rev 3
P-1712
Description:
The gear neutral switch relay has to close when the gear is in neutral. When the gear is
engaged then relay has to open
DTC
P- 1712
Diagnostic item
No Load
Probable cause
1. Relay
2. Wiring
3. Instrument
cluster.
MAN-00057-174
March 2009/Rev 3
P-1712
Contact open
circuit?
Yes
Check and
replace relay
No
Yes
Repair or
replace the
wiring
No
Wire from GNS
relay contact to
EMS ECU K69 cut
Yes
Replace the
wiring
No
Yes
Replace the
wiring
No
Terminal back-out
from
a) Fuse Box
b) GNS Relay
c) Accessory cut-off
Yes
Replace the
wiring
No
Instrument
cluster not
activating the
relay
Yes
Replace the
cluster
MAN-00057-175
March 2009/Rev 3
MAN-00057-176
March 2009/Rev 3
P-1714
The gear neutral switch relay has to close when the gear is in neutral. When
the gear is engaged then relay has to open
DTC
P- 1714
Diagnostic item
GNS relay sticking.
Probable cause
a)Relay
b)Wiring
c) Instrument cluster
MAN-00057-177
March 2009/Rev 3
P-1714
Yes
Contact weld ?
Check and
replace relay
No
GNS relay
contact on the
Acc. Relay side
wire shorted with
supply
Yes
No
Instrument cluster
activating the relay always
Yes
Check and
replace the
cluster
No
Yes
Check the
continuity and
replace.
No
Instrument cluster
always keeping the
relay coil pulled to
ground.
Yes
Replace the
cluster
MAN-00057-178
March 2009/Rev 3
P-1714
GNS relay to
ACC load
MAN-00057-179
March 2009/Rev 3
P-170A
MAN-00057-180
March 2009/Rev 3
P-170A
Description
The ECU monitors the signal from the normal clutch switch- which is at 10% of the pedal
travel and also the redundant clutch switch ( which is at 90% clutch pedal travel)
DTC
P-170A
Diagnostic item
Clutch signal is not plausible
Probable cause
Malfunction
If the signal from the 10% switch has not come but the
90% switch has come then it is considered as a plausibility
error.
Reaction
* Check lamp does not glow, error is registered.
* ESS is disabled and will not work.
MAN-00057-181
March 2009/Rev 3
P-170A
Yes
90% clutch
switch
Connector loose
Make the
connection firmly.
No
Wire from
Clutch switch to
EMS ECU wire
cut
Yes
Check for
continuity and
replace.
No
Yes
Check for
continuity and
replace.
No
Yes
Switch
failure
Replace the
switch.
No
Yes
Connector
terminal back
out
Check the
terminal and
replace the
connector
MAN-00057
7-182
Ma
arch 2009/Rev 3
Diagn
nostic Ma
anual (EM
MS)
Scorpio
io Vlx, Sle, Lx (Refre
esh)
MAN-00057-183
March 2009/Rev 3
P- 1AE9
Description
The stop lamp of the ESS is driven by the ECUs power stage.
The output stage is monitored and checked for errors.
DTC
P-1AE9
Diagnostic item
Short Circuit Battery
Probable cause
Wiring short.
Reaction
* Check lamp does not glow, error is registered.
* .
MAN-00057-184
March 2009/Rev 3
P- 1AEA
Description
The stop lamp of the ESS is driven by the ECUs power stage.
The output stage is monitored and checked for errors.
DTC
P-1AEA
Diagnostic item
Short Circuit to Ground
Probable cause
Wiring short.
Malfunction
When it detects a short
Reaction
* Check lamp does not glow, error is registered.
* .
MAN-00057-185
March 2009/Rev 3
P- 1AEB
Description
The stop lamp of the ESS is driven by the ECUs power stage.
The output stage is monitored and checked for errors.
DTC
P-1AEB
Diagnostic item
No Load
Probable cause
Open circuit
Instrument cluster
Loose connector
Pin Backout
Malfunction
When the power stage is switched OFF and ignition is ON,
if +12V is not detected at Input to pin K68 (i.e, no load is
detected) this error is logged
Reaction
* Check lamp does not glow, error is registered.
* .
MAN-00057-186
March 2009/Rev 3
P- 1AEB
Instrument
cluster
connector loose
Yes
No
Instrument
cluster connector
terminal back out
Yes
No
Wire cut.
Yes
No
Yes
MAN-00057-187
March 2009/Rev 3
P- 1AEC
Description
The stop lamp of the ESS is driven by the ECUs power stage.
The output stage is monitored and checked for errors.
DTC
P-1AEC
Diagnostic item
Excess temperature
Probable cause
ECU
Malfunction
When it detects that there is excess temperature
Reaction
* Check lamp does not glow, error is registered.
* .
High
temperature @
K68 in EMS
ECU
Replace ECU
MAN-00057-188
March 2009/Rev 3
P- 1715
Description
The signal from the igniaton switch ( for cranking ) is monitored for duration
DTC
P-1715
Diagnostic item
T50 Always pressed ON
Probable cause
Malfunction
When the cranking signal is detected beyond the range
then it is assigned as the T50 is pressed ON.
Wiring
Ignition switch
Reaction
* Check lamp does not glow, error is registered.
* .
T50 input
shorted to
Supply
Yes
No
Ignition key
problem.
MAN-00057-189
March 2009/Rev 3
Actuator Tests
Home screen for the Actuator test
MAN-00057-190
March 2009/Rev 3
ACT#1
MAN-00057-191
March 2009/Rev 3
MAN-00057-192
March 2009/Rev 3
ACT#2
MAN-00057-193
March 2009/Rev 3
ACT#3
MAN-00057-194
March 2009/Rev 3
ACT#4
Test condition:
Engine Running at Idle
Note the quantity of the injection and the air mass.
Action: Put EGR quantity >80%. In the Enter duty cycle. Actuate
Expected result: The actual duty cycle will change.
The air mass quantity and the injection quantity should change. The value are very small
Air mass by around 4 and fuel quantity change of around 0.47.
Note: If not released manually, the system will automatically release the entered duty cycle
after 30 seconds
MAN-00057-195
March 2009/Rev 3
ACT#5
MAN-00057-196
March 2009/Rev 3
SBD#1
Bit
position
of
Conditions to be met
Implication
Problem in low
pressure circuit or
HPP
There is sufficient
pressure in the rail
but the
engine speed is
below the minimum
threshold
Cranking RPM
less
There is sufficient
pressure build-up in
the rail
and the engine speed
is above the minimum
threshold, but a
problem has arisen
with the
engine
synchronisation
Synchronisation
issue
There is a reversible
shut-off request
. The
application constant
determines which
shut-off conditions
are to be
taken into account.
4. Battery
5. Starter
6. Engine partial
seizure
MAN-00057-197
March 2009/Rev 3
There is an
irreversible shut-off
request
Please contact
tekliner/ tekhub.
SBD#1
Synchronisation state
Code Description
0
1
TIMEOUT: Engine stops or error case in which all engine speed sensors of system
are defective
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.
16
POLLING: The overall system behaves frq. Synchronous & waits for further events
to determine the phases.
32
33
VERIFY A unique positioning of the system has occurred. A plausibility test is run
on all sensor systems wrt each other in their status & angle info.
34
35
48
64
128
VERIFY_BACKUP
129
BACK UP
130
START_BACKUP
131
MAN-00057-198
March 2009/Rev 3
SBD#2
Applicable to
Scorpio CRDe 2.2, Xylo 2.49
DTC code
None
( Will happen when injectors stuck close)
P1193/P1192
( Will happen when injectors are stuck open)
Engine Status
Can not be started
Jumps from 3 to 48
MAN-00057-199
March 2009/Rev 3
SBD#2
Caution - The ID of the tube is important; hence please use this part number.
Start Engine.
MAN-00057
7-200
Ma
arch 2009/Rev 3
Diagn
nostic Ma
anual (EM
MS)
Scorpio
io Vlx, Sle, Lx (Refre
esh)
Insert th
he pipes op
pen end in to
o the test tu
ubes as sho
own in photo
ograph).
Idle for
f 1 minute
e
If any test tu
ube gets
ffilled during the test,
STOP
the test and
R
Replace
tha
at
c
cylinder
inje
ector.
If colle
ected fuel quantity is 5
5 to 20
ml, all injectors are OK.
Sta
art engine & repeat test
for exactly one
e minute.
MAN-00057-201
March 2009/Rev 3
The root cause for the injectors stuck open or close is the presence of water in the fuel or
poor fuel quality.
Investigate & advice the customer accordingly to avoid repeat failure.
In case of water please advise the customer how to drain water when the indicator
comes ON.
If it is suspected due to poor fuel quality- please advise accordingly.
MAN-00057-202
March 2009/Rev 3
Conformity Check
Coolant temperature Sensor/ Fuel Temperature sensor
Temperature
10
20
80
100
Resistance Min k
8.244
2.262
0.304
0.178
Resistance Max k
10.661
2.76
0.342
0.196
Accelerator pedal
Accelerator pedal:- 0%
Accelerator pedal :-100%
Poti 1
2.160KOhm,
1.321KOhm
Poti 2
2.672KOhm
2.112KOhm
Poti 1
1.2 k 0.4
1.7 k 0.4
R Min(Kohm)
7.942
5.119
1.573
0.565
0.238
0.184
R Max (Kohm)
9.3
5.892
1.752
0.654
0.285
0.222
MAN-00057-203
March 2009/Rev 3
MAN-00057-204
March 2009/Rev 3
Engine
Diagnostic
Connector
(EMS ECU)
KLine
(DLC)
Communication
Security System
ECU
(Nippon)
MAN-00057-205
March 2009/Rev 3
Diagnostic item
Immobilizer communication wire open or short
Probable cause
Open circuit
Improper earthing
Malfunction
Correct signal not received
Reaction
If Error present and active then
Check lamp is ON.
Engine will not start
MAN-00057-206
March 2009/Rev 3
Active
Error
status
Loose connection of
Immobilizer
communication wire
Earthing needs to
be checked.
Healed
Earthing needs to
be checked.
MAN-00057-207
March 2009/Rev 3
P-1828
Remove the washer ensure that the cutting edge is facing downwards. This will ensure
that the paint is removed and proper earthing takes place.A. If the washer is not there please add.
B. If reversed- correct the orientation.
C. If flattened- change.
MAN-00057-208
March 2009/Rev 3
Diagnostic item
Immobilizer communication wire short to ground.
Probable cause
Immobilizer
communication wire
short to ground.
Improper earthing
Reaction
If Error present and active then
Check lamp is ON.
Engine will not start
MAN-00057-209
March 2009/Rev 3
P-1829
Error
Active/Healed
MAN-00057-210
March 2009/Rev 3
P-1829
Remove the washer ensure that the cutting edge is facing downwards. This will ensure
that the paint is removed and proper earthing takes place.D. If the washer is not there please add.
E. If reversed- correct the orientation.
F. If flattened- change.
MAN-00057-211
March 2009/Rev 3
P-182A
Diagnostic item
Immobilizer signal in error zone
Probable cause
Malfunction
Correct signal not received
Reaction
Improper Earthing /
Grounding.
Loose Connection
of the any connectors
(from CDL to EMS
ECU)
Poor Battery / poor
starting system /
multiple cranking.
Possible causes
A. Improper Earthing / Grounding.
B. Loose Connection of the any connectors (from CDL to EMS ECU)
C. Poor Battery / poor starting system / multiple cranking.
Probable causes:
1.
2.
3.
4.
Both A & C
A alone
Both B & C
B alone
MAN-00057-212
March 2009/Rev 3
P-182A
Remove the washer ensure that the cutting edge is facing downwards. This will ensure
that the paint is removed and proper earthing takes place.G. If the washer is not there please add.
H. If reversed- correct the orientation.
I. If flattened- change.
MAN-00057-213
March 2009/Rev 3
P-182B
Diagnostic item
ECU is locked completely
Probable cause
Malfunction
Wrong signal received continuously hence the
ECU is locked. ( P182A with multiple crank/Ignition
ON)
Reaction
If Error present/healed then
Improper Earthing /
Grounding.
Loose Connection
of the any connectors
(from CDL to EMS
ECU)
Poor Battery / poor
starting system /
multiple cranking.
Wrong signal received
continuously.
Possible causes
This error will only occur if P182A happens multiple times.
A. Improper Earthing / Grounding.
B. Loose Connection of the any connectors (from CDL to EMS ECU)
C. Poor Battery / poor starting system / multiple cranking.
Probable causes:
1.
2.
3.
4.
Both A & C
A alone
Both B & C
B alone
MAN-00057-214
March 2009/Rev 3
P-182B
Remove the washer ensure that the cutting edge is facing downwards. This will ensure
that the paint is removed and proper earthing takes place.J. If the washer is not there please add.
K. If reversed- correct the orientation.
L. If flattened- change.
MAN-00057-215
March 2009/Rev 3
DTC
P-182C
P-182C
Diagnostic item
Immobilizer controller has not received correct pattern (RF signal )
Probable cause
Malfunction
This error is lodged when the vehicle has been
locked/ armed by the security system and has not
received the correct pattern of the remote signal
before an attempt to start the engine was made.
Reaction
If Error present/healed then
Note: The healing will occur if after hearing the remote siren the correct remote key is
pressed and the security system validates it. .
MAN-00057-216
March 2009/Rev 3
Healed
Active
Error
status
Mechanical Key used for unlocking the vehicle / RKE Remote NOT used
for unlocking the vehicle & IGN ON
MAN-00057-217
March 2009/Rev 3
Release Notes
This manual supersedes the following earlier versions
MAN -00029, Rev 1 : 2.2 L + non transponder based immobilser. EDC 16C39
MAN -00038 , Rev 2 : Revision 1 + AT
Changes incorporated in MAN -00057 , Rev 3 (EDC 16C39, AT, + TBI, ESS)
In BPA and BPS the voltage mentioned was 2.5, corrected to 4.5 V
Added DTC details : 1194,1195;P-201;P-1201;P-1203;P-1204;P-1205;P-1206;P-1207;P1208;
ESS related errors
P-1704;P-168E;P-170D;P-170E;P-170F;P-1710;P-1712;P-1714;P-170A;P-1AE9;P1AEA;P-1AEB;P-1AEC;P-1715
Corrected the code no for Glow plug controller relay.