Diagnostic Manual Supro Maxitruck

EMS MAN - 00313
DIAGNOSTIC MANUAL
ENGINE !
SUPRO/SUPRO MAXITRUCK
THE NEW GENERATION
NOTHING ELSE WILL DO
REVISION - 1
OCT - 2015
Published by - Service Engineering
Technical Hub
Diagnostic Manual MAN-00313
SUPRO/SUPRO MAXITRUCK EMS OCT - 2015/Rev 1
Table of Content
1 HOW TO USE THIS MANUAL ............................................................................................ 9

2 ABBREVIATIONS .....................................................................................................................10
3 WARRANTY & OTHER INFORMATION .....................................................................11
4 RECOMMENDED TROUBLE SHOOTING PROCESS...........................................12
5 EMS ECU PIN DETAILS .......................................................................................................13
6 IQA CODE PROGRAMMING..............................................................................................16
6.1 IMPORTANT SWITCH STATUS — LIVE DATA ............................................................19
7 EMS ECU FLASHING .............................................................................................................22

8 DTC BASED DIAGNOSIS .....................................................................................................30
8.1 P0704— CLUTCH NON PLAUSIBLE ERROR ..........................................................31
8.2 P0100—BATTERY VOLTAGE ERROR OF HFM SENSOR ..................................37
8.3 P0101— AFS LOW IDLE CORRECTION EXCEEDING THE MAXIMUM
DRIFT LIMIT ................................................................................................................39
8.4 P1100—HFM SENSOR OPEN LOAD ERROR ........................................................41
8.5 P0103—SRC HIGH ERROR FOR RAW VALUE IN HFM SENSOR ...................49
8.6 P0102—SRC LOW ERROR FOR RAW VALUE IN HFM SENSOR ....................55
8.7 P06A0—NO LOAD ERROR ON POWER STAGE FOR THE AC
COMPRESSOR/DEMISTER .................................................................................63
8.8 P1610— OVER TEMPERATURE ERROR ON POWERSTAGE FOR THE
AC COMPRESSOR/DEMISTER ...........................................................................67
8.9 P06A2— SHORT CIRCUIT TO BATTERY ERROR ON POWER STAGE
FOR THE AC COMPRESSOR/DEMISTER .......................................................69
8.10 P062F— ECU EEPROM ERASE ERROR .................................................................73
8.11 P162F— ECU EEPROM READ ERROR ...................................................................75
8.12 P1630— ECU EEPROM WRITE ERROR .................................................................77
8.13 P0403— EGR VALVE OPEN LOAD ERROR...........................................................79
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., 3
will amount to unauthorized use and shall be liable for penalty/prosecution© 2015 Mahindra & Mahindra Ltd.
8.14 P1403— EGR VALVE OVER TEMPERATURE ERROR .......................................85

8.15 P0406— EGR VALVE SHORT TO BATTERY ERROR .........................................87
8.16 P0405— EGR VALVE SHORT TO GROUND ERROR ..........................................93
8.17 P062B— ECU MONITORING ERROR FOR INJECTION CUT OFF
DEMAND .....................................................................................................................99
8.18 P1138—PLAUSIBILITY CHECK BETWEEN ACCELERATOR PEDAL
AND BRAKE............................................................................................................. 101
8.19 P1389 —GLOW PLUG OPEN LOAD ERROR ..................................................... 103
8.20 P1390— GLOW PLUG OVER TEMPERATURE ERROR ................................. 109
8.21 P1387— GLOW PLUG SHORT TO BATTERY ERROR .................................... 111
8.22 P1388— GLOW PLUG SHORT TO GROUND ERROR..................................... 117
8.23 P0563— SIGNAL RANGE CHECK FOR BATTERY SENSOR SIGNAL
ABOVE MAXIMUM LIMIT ................................................................................... 123
8.24 P0562— SIGNAL RANGE CHECK FOR BATTERY SENSOR SIGNAL
BELOW MINIMUM LIMIT ................................................................................... 125
8.25 P0504—BRAKE SWITCH PLAUSIBILITY ERROR............................................ 129
8.26 P0117— SIGNAL RANGE CHECK FOR COOLANT TEMPERATURE
SENSOR BELOW MINIMUM LIMIT ................................................................ 137
8.27 P0118— SIGNAL RANGE CHECK FOR COOLANT TEMPERATURE
SENSOR ABOVE MAXIMUM LIMIT ................................................................ 145
8.28 P0336— CRANKSHAFT SENSOR SIGNAL ERROR ........................................ 153
8.29 P0335— CRANKSHAFT SENSOR NO SIGNAL ERROR ................................ 161
8.30 P0480 — FAN 1 OPEN LOAD ERROR ................................................................. 169
8.31 P0481 — FAN 2 OPEN LOAD ERROR ................................................................. 175
8.32 P1480— FAN 1 OVER TEMPERATURE ERROR .............................................. 181
8.33 P1481— FAN 2 OVER TEMPERATURE ERROR .............................................. 183
8.34 P0692— FAN 1 SHORT TO BATTERY ERROR ................................................ 185
8.35 P0694— FAN 2 SHORT TO BATTERY ERROR ................................................ 191
8.36 P0691—FAN 1 SHORT TO GROUND ERROR ................................................. 197
8.37 P0692—FAN 2 SHORT TO GROUND ERROR ................................................. 203
8.38 P0201— CYLINDER 1 INJECTOR OPEN LOAD ERROR ............................... 209
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
4 written consent of Mahindra & Mahindra Ltd. The 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© 2015 Mahindra & Mahindra Ltd.
8.39 P0202— CYLINDER 2 INJECTOR OPEN LOAD ERROR ............................... 215

8.40 P0341— CAMSHAFT SENSOR SIGNAL ERROR ............................................. 221
8.41 P0340— CAMSHAFT SENSOR NO SIGNAL ERROR .................................... 225
8.42 P1341— CAMSHAFT SENSOR SIGNAL OFFSET ERROR ............................ 233
8.43 P2146— SHORT CIRCUIT IN BANK 0 ................................................................ 237
8.44 P0261— HIGH SIDE-LOW SIDE SHORT CIRCUIT FOR CYLINDER 1
INJECTOR ................................................................................................................. 245
INJECTOR ................................................................................................................. 251
8.46 P268C— CYLINDER 1 INJECTOR ADJUSTMENT CODE INCORRECT
ERROR ....................................................................................................................... 257
8.47 P268E— CYLINDER 2 INJECTOR ADJUSTMENT CODE INCORRECT
ERROR ....................................................................................................................... 259
8.48 P0113—SIGNAL RANGE CHECK FOR HFM TEMPERATURE SENSOR
8.50 P1652— MIL OPEN LOAD ERROR ....................................................................... 275
8.51 P1650— MIL SHORT CIRCUIT TO BATTERY ERROR .................................... 283
8.52 P1651— MIL SHORT CIRCUIT TO GROUND ERROR ..................................... 289
8.53 P1653— MIL OVER TEMPERATURE ERROR ................................................... 295
8.54 CONTINUOUS TORQUE MONITORING — LIST OF DTC’s — 1 .......................... 297
8.56 P1631— ECU MONITORING: START OF INJECTION PLAUSIBILITY
ERROR ....................................................................................................................... 301
8.57 P1632— ECU MONITORING: ZFC NON PLAUSIBILITY ERROR ................ 303
8.59 CONTINUOUS TORQUE MONITORING ................................................................... 307
8.60 P068A/P068B—MAIN RELAY EARLY OPENING ERROR / MAIN
RELAY STRUCK ERROR ........................................................................................ 309
8.61 P2229— SIGNAL RANGE CHECK FOR ENVIRONMENTAL PRESSURE

SENSOR ABOVE MAXIMUM LIMIT ................................................................ 315
SENSOR BELOW MINIMUM LIMIT ................................................................ 317
8.63 P0627— PSP OPEN LOAD ERROR ...................................................................... 319
8.64 P1611— PSP PWM OVER TEMPERATURE ERROR ...................................... 325
8.65 P0629— PSP PWM SHORT TO BATTERY ERROR ........................................ 327
8.66 P0628— PSP PWM SHORT TO GROUND ERROR ......................................... 333
8.67 P0191— RAIL PRESSURE OFFSET VALUE ABOVE MAXIMUM
LIMIT .......................................................................................................................... 339
8.68 P1191— RAIL PRESSURE OFFSET VALUE BELOW MINIMUM
LIMIT .......................................................................................................................... 341
8.69 P0193— SIGNAL RANGE CHECK FOR RAIL PRESSURE SENSOR
8.70 P0192— SIGNAL RANGE CHECK FOR RAIL PRESSURE SENSOR
8.71 P2123—SIGNAL RANGE CHECK FOR ACCELERATOR PEDAL
SENSOR 1 ABOVE MAXIMUM LIMIT ............................................................ 359
8.72 P2128—SIGNAL RANGE CHECK FOR ACCELERATOR PEDAL
SENSOR 2 ABOVE MAXIMUM LIMIT ............................................................ 367
8.73 P2122—SIGNAL RANGE CHECK FOR ACCELERATOR SENSOR 1
8.74 P2127—SIGNAL RANGE CHECK FOR ACCELERATOR SENSOR 2
8.75 P170D— STARTER RELAY SHORT CIRCUIT TO BATTERY
ERROR ....................................................................................................................... 391
8.76 P170E— STARTER RELAY SHORT CIRCUIT TO GROUND ERROR ............... 393
8.77 P170F— STARTER RELAY OPEN LOAD ............................................................. 397
8.78 P170C— STARTER RELAY OVER TEMPERATURE ERROR ......................... 401
8.79 P1656SVS NO LOAD ERROR ................................................................................ 403
8.80 P1655— SVS SHORT CIRCUIT TO BATTERY ERROR ................................... 411
8.81 P1654— SVS SHORT CIRCUIT TO GROUND ERROR .................................... 417

8.82 P1657— CHECK LAMP OVER TEMPERATURE ERROR ............................... 423
8.83 P2138—PLAUSIBILITY ERROR BETWEEN ACCELERATOR PEDAL
SIGNAL 1 AND SIGNAL 2 .................................................................................. 425
8.84 P1707— T50 SIGNAL ERROR ............................................................................... 427
8.85 P0501— VEHICLE SPEED SENSOR PLAUSIBILITY ERROR ........................ 429
8.86 P0641— SENSOR SUPPLY VOLTAGE 1 MONITORING ERROR ............... 437
8.87 P0697— ERROR SENSOR SUPPLIES 3 ............................................................. 447
8.88 P1608— COOLANT TEMPERATURE OUTPUT (ON DASH PANEL)
SHORT CIRCUIT TO BATTERY ERROR........................................................... 455
8.89 P1609— COOLANT TEMPERATURE OUTPUT (ON DASH PANEL)
SHORT CIRCUIT TO GROUND ERROR ........................................................... 461
8.90 P160A— COOLANT TEMPERATURE OUTPUT (ON DASH PANEL) NO
LOAD ERROR .......................................................................................................... 467
8.91 P160B— COOLANT TEMPERATURE OUTPUT(ON DASH PANEL)
OVER TEMP ERROR ............................................................................................. 473
8.92 P1503— PERFORMANCE LIMITER ERROR FOR LEVEL 0 .......................... 475
8.93 P0262— SHORT CIRCUIT ERROR FOR CYLINDER 1 INJECTOR .............. 477
8.94 P0265— SHORT CIRCUIT ERROR FOR CYLINDER 2 INJECTOR .............. 483
8.95 P1612— ERROR FOR OVER CURRENT DETECTION OF EKP ..................... 489
8.96 P1613— ERROR FOR ACTUAL CURRENT FOR EKP GREATER THAN
SECONDARY THRESHOLD ................................................................................ 491
8.97 P108D—ERROR FOR MINIMUM RAIL PRESSURE EXCEEDED................. 493
8.98 P108E—ERROR FOR MAXIMUM RAIL PRESSURE EXCEEDED ................ 495
8.99 P108A—ERROR FOR MAXIMUM POSITIVE DEVIATION OF RAIL
PRESSURE EXCEEDED ........................................................................................ 497
8.100 P108B—ERROR FOR MAXIMUM POSITIVE DEVIATION OF RAIL
PRESSURE EXCEEDED CONCERNING SET FLOW OF FUEL ................. 499
8.101 U1501EMS VARIANT CODE ERROR ............................................................... 501
8.102 U2801EMS FEATURE CODE ERROR ............................................................... 503
8.103 P108C—ERROR FOR MAXIMUM NEGATIVE DEVIATION WITH

METERING UNIT ON LOWER LIMIT IS EXCEEDED ................................... 505
9 SYMPTOM BASED DIAGNOSIS- WITH NO DTC CODES ............................. 507

9.1 REASON FOR TORQUE LIMITATION .......................................................................... 508
1 HOW TO USE THIS MANUAL

If the DTC code is known, then go to the INDEX OF DTC CODES, and click on the group under which
the DTC appears. The codes/groups are hyper linked to the respective trouble shooting chart/
pages.
The following is the structure of the EMS Diagnostic Manual
• DTC and a brief description of the system
• DTC Information & Causes
– Normal operation of the system
– DTC detecting conditions
– DTC reaction on vehicle and lamp status
– Healing Condition
– Probable causes of Failure
• Circuit Schematic
• Connector location
• Connector views and information
• DTC Checking Procedure
• Intermittent Problems
• Diagnostic Procedure
Always use the EMS Diagnostic Manual along with the vehicle’s Wiring Manual ( SUPRO MAN-
00311 / SUPRO MAXITRUCK MAN-00312).
2 ABBREVIATIONS
EMS Engine Management System

ECU Engine Control Unit
VSS Vehicle Speed Sensor
CTS Coolant Temperature Sensor
EGR Exhaust Gas Recirculation
PSP Pre Supply Pump
APP 1 Accelerator Pedal Sensor 1
APP 2 Accelerator Pedal Sensor 2
IC Instrument Cluster
ECU Electronic Control Unit
EPS Electrical power steering
OBD Onboard diagnostic
HLLD Head light levelling device
IGNITION CYCLE
Ignition ON — Ignition OFF — Ignition ON
DRIVING CYCLE
Ignition OFF — Ignition ON — CRANK — WAIT FOR FEW SECONDS
3 WARRANTY & OTHER INFORMATION

All failures/complaints encountered in 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)
4 RECOMMENDED TROUBLE SHOOTING PROCESS
Customer complaint � Record/Understand Customer Verbatim

• What happened?
• When did it happen?
• Were any specific events recorded/observed before the
complaint?
• Does it happen all the time?
• Does it happen only in certain conditions?
�
Verify the complaint and perform visual checks
�
Search for Published quick solution in TEKnet.
�
Follow DTC based diagnosis
�
Follow Symptom based diagnosis (If available)
�
Contact TEKliner with TAR
(Technical Assistance Request)
5 EMS ECU PIN DETAILS
ECU FUNCTION CONNECTED TO CONNECTOR NO

CONNECTOR PIN NO
PIN NO
1 GROUND GROUND G5 1
2 GROUND GROUND G5 1
3 SUPPLY ELECTRIC FEED C199
4
PUMP
4 SUPPLY MAIN RELAY L11 6
5 GROUND ELECTRIC FEED C199
3
PUMP
7 LOW SIDE INJECTOR 2 C28 2
8 SUPPLY APP1 C124 3
9 SUPPLY CAM SHAFT C24
3
SENSOR
OBD LAMP IC
13 (GROUND) C119 15
COMPRESSOR
15 SUPPLY L12 2
RELAY
16 ENGINE (GROUND) IC C119 1
21 SIGNAL HFM SENSOR C19 4
23 SUPPLY IGNITION SWITCH C113B 1
26 SUPPLY IGNITION SWITCH C113A 1
27 CAN HIGH DLC CONNECTOR C104 14
28 CAN LOW DLC CONNECTOR C104 6
29 LOW SIDE INJECTOR 1 C27 2
32 SUPPLY EGR VALUE C25
POSITION SENSOR 4
(EGR)
33 SUPPLY APP2 C124 6
36 COOLANT IC C119
TEMPERATURE 12
SIGNAL
43 SUPPLY RAIL PRESSURE C33
3
SENSOR

CONNECTOR PIN NO
PIN NO
45 SIGNAL EGR VALUE C25
POSITION SENSOR 6
(EGR)
49 SIGNAL VEHICLE SPEED C247
1
SENSOR
51 HIGH SIDE INJECTOR 2 C28 1
52 SIGNAL STARTER RELAY L1 2
60 LOW HIGH SIDE TRIPLE PRESSURE C95
2
SWITCH
63 GROUND APP2 C124 5
64 GROUND RAIL PRESSURE C33
1
SENSOR
65 SIGNAL RAIL PRESSURE C33
2
SENSOR
66 GROUND EGR VALUE C25
POSITION SENSOR 4
(EGR)
67 SIGNAL COOLANT C43
TEMPERATURE 1
SENSOR
70 GROUND COOLANT C43
TEMPERATURE 2
SENSOR
73 HIGH SIDE INJECTOR 1 C27 1
74 GROUND EGR ACTUATOR C63 1
76 SUPPLY RADIATOR FAN L2
2
RELAY HIGH
78 GROUND CRANKSHAFT C37
1
SENSOR
79 SIGNAL CRANKSHAFT C37
2
SENSOR
80 SIGNAL CAMSHAFT C24
1
SENSOR
81 SIGNAL CAMSHAFT C24
2
SENSOR
82 SUPPLY RADIATOR FAN L3
2
RELAY LOW

CONNECTOR PIN NO
PIN NO
84 GROUND APP1 C124 2
85 SIGNAL APP1 C124 1
86 SIGNAL APP2 C124 4
88 SIGNAL BRAKE MAIN C105
2
SWITCH
89 GROUND HFM SENSOR C19 1
90 SIGNAL TRIPLE PRESSURE C95
4
SWITCH
91 SIGNAL CLUTCH SWITCH C401 2
93 SIGNAL BRAKE C105
REDUNDANT 4
SWITCH
6 IQA 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 an 6-character alphanumeric code. This is known as an
IQA code . IQA stands for Injector Quantity Adjustment. For optimal performance of the engine, the
ECU needs to know the IQA 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
for that new injector has to be updated in the ECU.
• Selected the injector by clicking on the check-button next to the number, the IQA should be
entered in the box provided.
• 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 code is keyed in. IQA codes are
case sensitive.
• Programming IQA codes is an extremely important activity. Ensure that the correct code has
been entered and that it has been entered in the correct cylinder.
Ensure to program IQA codes when you replace an Injector, ECU or Engine
IQA PROGRAMMING
Follow the steps given below:
1 Once the flashing process has been successfully completed, click on “CONFIG” shown below.
2 The IQA codes are to be written by entering the 6 digit IQA code in the space provided After
ticking the respective check box “WRITE IQA VALUES”
6.1 IMPORTANT SWITCH STATUS — LIVE DATA

The Clutch and brake switch status can be checked thru LIVE DATA in iSmart.
Understanding the switch status could be useful for diagnostics
CLUTCH SWITCH STATUS
• CLUTCH PEDAL RELEASED CONDITION
Clutch signal – 64
• CLUTCH PEDAL PRESSED CONDITION

Clutch signal— 65
BRAKE SWITCH STATUS
• BRAKE PEDAL RELEASED CONDITION

Status of Brake – 0
Undebounced status of the main brake read from hardware – 0
Undebounced status of the redundant brake read from hardware – 0
• BRAKE PEDAL SLIGHTLY PRESSED (PRESSED TILL THE BRAKE PEDAL PLAY)
Status of Brake – 1
Undebounced status of the main brake read from hardware –1
Undebounced status of the redundant brake read from hardware — 0
• BRAKE PEDAL FULLY PRESSED CONDITION

Status of Brake — 3
Undebounced status of the main brake read from hardware — 1
Undebounced status of the redundant brake read from hardware — 1
7 EMS ECU FLASHING

The EMS ECU needs to be flashed in the following conditions:
BLANK ECU
1. Procure blank EMS ECU from spare part dept.
EMS ECU PART NUMBER : 0315CAU00161N -ENGINE CONTROL UNIT
* Check for the correct / latest part no in parts catalogue /Technical service bulletins.
2. Flash the EMS ECU dataset with a latest dataset as per TSB or at the advice of TEKline.
3. Ensure that the there is no communication breakdown once the flashing begins. Check
Garuda connections are secure.
4. Ensure that the i-SMART has:
• Enough battery reserve/Connected to AC power
• Screen saver/Battery saver mode turned off
• Vehicle’s ignition is ON
• Battery terminals connected securely
• Battery earth connection is good
5. Never touch the ECU pins by hand/finger
PROCEDURE FOR FLASHING EMS ECU
Ensure to download and install the latest version of the i-Flash Tool and Garuda Drivers before
starting the procedure.
Refer www.teknetmahindra.com for the latest version of the Flashing tool.
1 Click on“i-FLASH_FLASHING_TOOL_ V 2.9”. Select F2 and click on START. The following window
will appear
2 Click on “READ VIN NO” and the following screen appears:
3 Click on SELECT _VARIANT and select the variant the following screen appears:
4 Click on “START” and the following screen appears:
5 Click on “ENGINE MANAGEMENT SYSTEM” and the following screen appears:
6 Select “Auto Mode” and the following screen appears:
7 Click on “START FLASHING” The following window appears.
8 Press “YES”to initiate the flashing process:

Click on YES.If the software in the EMS ECU is not the latest, then software flashing will happen. If
the software in the tool and EMS ECU are same, then only the calibration parameters will be
written.
If its a new EMS ECU replacement, write the IQA codes. (Refer previous section on procedure to
write IQA
9 Once flashing is done successfully, switch OFF the ignition and wait for 40 seconds and then
switch ON the ignition:
8 DTC BASED DIAGNOSIS
8.1 P0704— CLUTCH NON PLAUSIBLE ERROR

8.1.1 CLUTCH SWITCH
The clutch switch is located on the clutch pedal assembly. The Clutch signal is checked for
plausibility using gear information. Clutch switch is a normally closed switch which opens when the
clutch pedal is depressed.
DTC INFORMATION PROBABLE CAUSES OF FAILURE

NORMAL OPERATION
• Ignition ON
• The clutch switch input is received during every gear shifts.
DTC DETECTING CONDITIONS

• Open / short wiring harness
• Ignition ON
• No change in clutch switch status during 50 gear shifts
continuously • Improper clutch switch
adjustment
• Faulty Clutch switch
DTC REACTIONS
• Nil
HEALING CONDITION
• Fault absent
P0704
8.1.1.1 CIRCUIT SCHEMATIC
P0704
8.1.2 CONNECTOR LOCATION
P0704
8.1.3 CONNECTOR VIEWS AND INFORMATION
P0704
CONNECTOR
CONNECTOR DESCRIPTION PIN NO FUNCTION
NO
C4 EMS ECU 91 CLUTCH SIGNAL
1 SUPPLY
C401 CLUTCH SWITCH
2 GROUND
8.1.4 DTC CHECKING PROCEDURE
• Turn the ignition ON and Initialise i-SMART tool

• Record the DTC and clear
• Turn ignition OFF then ON
• Proceed to DIAGNOSTIC PROCEDURE if P0704 is present
• If not present, then check for any intermittent problem
8.1.5 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
8.1.6 DIAGNOSTIC PROCEDURE
STEP A – CHECK VOLTAGE IN CLUTCH SWITCH
P0704
PRE CONDITION
• Ignition ON
• Clutch switch connector (C401) DISCONNECTED
TEST PROCEDURE
• Check the voltage between pin 1 of C401 and battery ground
ACCEPTANCE CRITERIA
• Voltage = bat V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Examine the open/short circuit in Clutch

switch signal wire to EMS ECU
• Replace the wiring harness
• Clear the DTC and verify
STEP B – CHECK OPEN CIRCUIT IN CLUTCH SWITCH GROUND WIRE
PRE CONDITION
• Ignition OFF
• Clutch switch connector (C401) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 2 of C401 and battery ground
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
OK NOT OK
• Replace the Clutch Switch with new one

• Examine the open circuit in Clutch switch
• Clear the DTC and verify ground wire to EMS ECU
• If the DTC still present ,replace the EMS ECU • Replace the wiring harness
with new one
8.2 P0100—BATTERY VOLTAGE ERROR OF HFM SENSOR

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

NORMAL OPERATION
• Ignition ON
• The HFM sensor outputs a voltage, which corresponds to
the intake airflow.
• The ECU checks whether this voltage is within a specified
range.
• Fault Battery
• Ignition ON
• Fault Charging system
• EMS ECU supply voltage 9–16V
• Malfunctioning EMS ECU
• The battery supply voltage to HFM sensor is more than
16.8V for few seconds
DTC REACTIONS
• Engine Check lamp blinking after 3 driving cycles
HEALING CONDITION
• Fault absent

P0100

STEP A – CHECK BATTERY VOLTAGE
PRE CONDITION
• Ignition ON
• Engine running at high idle
TEST PROCEDURE
• Check the voltage between battery positive and battery negative terminals
ACCEPTANCE CRITERIA
• Voltage > 8V < 16.5V
ACTION TO BE TAKEN
OK NOT OK
• Check for any loose connections in supply • Examine the charging circuit
wire to HFM sensor • Check and confirm the proper functioning of
• Clear the DTC and verify charging circuit
• Check and verify for any new DTC’s
8.3 P0101— AFS LOW IDLE CORRECTION EXCEEDING THE MAXIMUM DRIFT
LIMIT
8.3.1 HFM SENSOR

NORMAL OPERATION
• Ignition ON
• The HFM sensor outputs a voltage, which corresponds to the
intake airflow
range

• Leak in air intake system
• Ignition ON • Contaminated HFM sensor
• EMS ECU supply voltage 9-16V • Faulty EMS ECU
• The drift goes beyond the valve it can be compensated
DTC REACTIONS
• Engine Check lamp blinks continuously
HEALING CONDITION
• Ignition OFF/ON

• Run the vehicle for 3 driving cycles
P0101

• Check and rectify if leakage is noticed in the air intake system

• Clean the HFM sensor as per the procedure mentioned in repair manual
• If the DTC still exists, replace the HFM sensor with a new one
8.4 P1100—HFM SENSOR OPEN LOAD ERROR

8.4.1 HFM SENSOR

NORMAL OPERATION
• Ignition ON
• EMS ECU continuously monitors the HFM DTC’s and no
prolonged existence of HFM related DTC’s noticed
• Ignition ON • HFM (air mass) signal wire short

• EMS ECU supply voltage 9 –16V to ground /open
• Open circuit in HFM signal wire continuously for 500 ms • HFM ground wire open
DTC REACTIONS
• OBD lamp continuously ON after 3 driving cycles

• EGR shuts OFF
HEALING CONDITION
• Fault absent for 3 driving cycles
P1100
P1100
8.4.1.2 CONNECTOR LOCATION
P1100
8.4.1.3 CONNECTOR VIEWS AND INFORMATION
P1100
CONNECTOR
NO
58 SIGNAL (AIR MASS)
C4 EMS ECU
89 HFM GROUND
5 SIGNAL (AIR MASS)
C19 HFM SENSOR 1 HFM GROUND
3 SUPPLY


STEP A – CHECK SHORT CIRCUIT OF HFM SENSOR SIGNAL WIRE
P1100
PRE CONDITION
• Ignition OFF
• HFM sensor wiring harness connector (C19) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 5 and pin 1 of C19
ACCEPTANCE CRITERIA
• Resistance =∞Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of HFM sensor

signal wire to ground
• GO TO STEP B • Replace the wiring harness
STEP B – CHECK OPEN CIRCUIT OF HFM SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU wiring harness connector (C4) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 5 of C19 and pin 58 of C4
ACCEPTANCE CRITERIA
• Resistance < 1Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of HFM sensor

• GO TO STEP C • Replace the wiring harness
STEP C– CHECK OPEN CIRCUIT OF HFM SENSOR GROUND WIRE
P1100
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of HFM sensor

• Examine internal failure of HFM sensor
• Replace the HFM sensor with a new one
8.5 P0103—SRC HIGH ERROR FOR RAW VALUE IN HFM SENSOR

8.5.1 HFM SENSOR

NORMAL OPERATION
• Ignition ON
intake airflow
range
DTC DETECTING CONDITIONS • Open circuit in HFM ground wire

• HFM (air mass) signal wire
• Ignition ON short to battery
• EMS ECU supply voltage 9-16V • HFM sensor internal failure
• The measured output voltage of the sensor is more than • Faulty EMS ECU
5.25V for few seconds
DTC REACTIONS
• OBD lamp continuously ON after 3 driving cycle
HEALING CONDITION
P0103
P0103
P0103
P0103
CONNECTOR
NO
C19 HFM SENSOR 5 SIGNAL (AIR MASS)


STEP A – CHECK VOLTAGE IN SENSOR SUPPLY WIRE
P0103
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage > 5.25 V
ACTION TO BE TAKEN
OK NOT OK
• Examine internal failure of HFM sensor • Examine the short circuit of HFM sensor (air
mass) supply wire to battery
• Replace HFM sensor with a new one
• Clear the DTC and verify • Replace the wiring harness
8.6 P0102—SRC LOW ERROR FOR RAW VALUE IN HFM SENSOR

8.6.1 HFM SENSOR

NORMAL OPERATION
• Ignition ON
intake airflow
range
• HFM supply wire short to

DTC DETECTING CONDITIONS ground / open
• HFM signal wire short to
• Ignition ON ground/open
• EMS ECU supply voltage 9 -16V • HFM ground wire open
• The measured output voltage of the sensor is less than 0.5 V • HFM sensor internal failure
for 0.5 second • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
P0102
P0102
P0102
P0102
CONNECTOR
NO
21 SIGNAL (AIR MASS)
C4 EMS ECU
89 HFM GROUND
4 SIGNAL (AIR MASS)
C19 HFM SENSOR 1 HFM GROUND
3 SUPPLY


P0102
STEP A – CHECK SHORT TO GROUND/OPEN CIRCUIT OF HFM SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = Vbat
ACTION TO BE TAKEN
OK NOT OK
• Examine the short to ground/open circuit of

HFM sensor supply wire
• GO TO STEP B • Replace the wiring harness
STEP B – CHECK SHORT CIRCUIT OF HFM SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short to ground of HFM sensor

air mass signal wire
STEP C – CHECK OPEN CIRCUIT OF HFM SENSOR SIGNAL WIRE
P0102
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the Open circuit of HFM sensor air

mass signal wire
• GO TO STEP D • Replace the wiring harness
STEP D – CHECK OPEN CIRCUIT OF HFM SENSOR GROUND WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine internal failure of HFM sensor • Examine the Open circuit of HFM sensor air
mass ground wire
• Replace HFM sensor with a new one
• Clear the DTC and verify • Replace the wiring harness
8.7 P06A0—NO LOAD ERROR ON POWER STAGE FOR THE AC COMPRESSOR/

DEMISTER
8.7.1 AC COMPRESSOR POWER STAGE
The AC compressor is controlled by the EMS ECU with the feedback of the temperature sensing unit
in the HVAC system and pressure sensor measuring the pressure of the refrigerant flow in the air
conditioning circuit. The EMS monitor the status of the power stage (Actuator) of the compressor
clutch for monitoring hardware errors such as short circuit to battery, short circuit to ground and
open load

NORMAL OPERATION
• Ignition ON
• EMS ECU switches ON the compressor once it receives AC
switch ON signal thru thermoamplifier via high low pressure
switch
• No malfunction detected by EMS ECU in the AC compressor
power circuit

• Open in AC compressor relay
control circuit
• Ignition ON
• Fault AC compressor relay
• EMS ECU supply voltage 9 –16V
• Faulty EMS ECU
• A open load is detected in AC compressor relay control
circuit
DTC REACTIONS
• AC compressor Shuts OFF
HEALING CONDITION
• Fault absent

• Proceed to DIAGNOSTIC PROCEDURE if P06A0 is present
P06A0

STEP A – CHECK THE FUNCTIONING OF AC COMPRESSOR RELAY
PRE CONDITION
• Ignition OFF
• Ensure the AC compressor relay is fixed properly in the connector of the relay box
• Remove the AC compressor relay
TEST PROCEDURE
• Check the functioning of relay by providing 12V to terminal 85 and ground to terminal 86
ACCEPTANCE CRITERIA
• Clicking sound heard
ACTION TO BE TAKEN
OK NOT OK
• Replace the AC compressor relay with a new

• GO TO STEP B one
STEP B– CHECK THE OPEN CIRCUIT OF AC COMPRESSOR RELAY SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Check the proper functioning of 25A fuse (F23) and 30A fuse (F25)
• Ignition ON
TEST PROCEDURE
• Check the voltage between pin 6 of the AC compressor relay seating (L13) and battery ground
P06A0
ACCEPTANCE CRITERIA
• Voltage = V bat
ACTION TO BE TAKEN
OK NOT OK
• Examine the open/ short circuit of AC

compressor relay supply wire
STEP C – CHECK THE OPEN CIRCUIT OF AC COMPRESSOR RELAY CONTROL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 10 of L13 and pin 15 of C4
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of AC compressor

• Replace EMS ECU with a new one relay control wire from EMS ECU
• Check and verify for any new DTC’s • Replace the wiring harness
8.8 P1610— OVER TEMPERATURE ERROR ON POWERSTAGE FOR THE AC

COMPRESSOR/DEMISTER
open load

NORMAL OPERATION
• Ignition ON
• No error detected in AC compressor control circuit during
self check
• Ignition ON
• EMS ECU supply voltage 9 –16V
• Defective EMS ECU
• Power stage overheating is detected continuously for 3
driving cycles
DTC REACTIONS
• AC compressor shuts OFF
HEALING CONDITION
• Fault absent

P1610

• Clear the DTC and verify for 3 times

• If the DTC still exists, replace the EMS ECU with a new one
• Check for any new DTC’s
8.9 P06A2— SHORT CIRCUIT TO BATTERY ERROR ON POWER STAGE FOR THE
AC COMPRESSOR/DEMISTER
open load

NORMAL OPERATION
• Ignition ON
• EMS ECU switches ON the compressor once it receives AC
switch ON signal thru thermoamplifier via high low pressure
switch
• No malfunction detected by EMS ECU in the AC compressor
power circuit

• Short to battery in AC
• Ignition ON compressor relay control circuit
• EMS ECU supply voltage 9 –16V • Faulty EMS ECU
• Short to battery is detected in AC compressor relay control
circuit
DTC REACTIONS
• AC compressor shuts OFF
HEALING CONDITION
• Fault absent

• Proceed to DIAGNOSTIC PROCEDURE if P06A2 is present
P06A2

STEP A – CHECK THE FUNCTIONING OF AC COMPRESSOR RELAY
PRE CONDITION
• Ignition OFF
• Ensure the AC compressor relay is fixed properly in the connector of the relay box
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace the AC compressor relay with a new

• GO TO STEP B one
STEP B– CHECK VOLTAGE IN AC COMPRESSOR RELAY CONTROL WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
P06A2
• Voltage = V bat
ACTION TO BE TAKEN
OK NOT OK
• Examine the open/ short circuit of AC

compressor relay supply wire
STEP C – CHECK THE OPEN CIRCUIT OF AC COMPRESSOR RELAY CONTROL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one • Examine the open circuit of AC compressor
relay control wire from EMS ECU
8.10 P062F— ECU EEPROM ERASE ERROR

8.10.1 EEPROM MONITORING
EEPROM (Electrically Erasable Programmable Read Only Memory) is a storage device inside the
EMS ECU. It can be flashed , read and written

NORMAL OPERATION
• Ignition ON
• EEPROM can be flashed, read & written
• Ignition ON
• During flashing the sector erase cannot be performed.
DTC REACTIONS
• Engine Check lamp will be continuously ON

• Engine will shuts OFF
HEALING CONDITION
• Fault absent

• Turn ignition OFF
• Wait for 2 minutes
• Turn ignition ON
• If P062F is present. suspect EMS ECU EEPROM failure and replace EMS ECU with a new one.
8.11 P162F— ECU EEPROM READ ERROR

EMS ECU. It can be flashed , read and written.

NORMAL OPERATION
• Ignition ON
• EEPROM can be flashed,read & written
• Ignition ON
• The block cannot be read more than 3 times from the
EEPROM • Malfunctioning EMS ECU
DTC REACTIONS

HEALING CONDITION
• Ignition Off then On

• If P162F is present, suspect EMS ECU EEPROM failure and replace EMS ECU with a new one.
8.12 P1630— ECU EEPROM WRITE ERROR

EMS ECU. It can be flashed , read and written.

NORMAL OPERATION
• Ignition ON
• EEPROM can be flashed,read & written
• Ignition ON
• The block cannot be read more than 3 times from the
EEPROM • Malfunctioning EMS ECU
DTC REACTIONS

HEALING CONDITION

• If P1630 is present , suspect EMS ECU EEPROM failure and replace EMS ECU with a new one.
8.13 P0403— EGR VALVE OPEN LOAD ERROR

8.13.1 EGR VALVE
EGR Actuator (Modulator) controls the EGR valve. EMS ECU converts the air control output into duty
cycle and outputs a PWM signal to EGR actuator

NORMAL OPERATION
• Ignition ON
• No error detected in EGR actuator control circuit during self
check
• Engine runs as per the EGR mapping

• EGR actuator control wire open
• Ignition ON
• Open circuit in EGR actuator control circuit continuously for 3
driving cycles • Faulty EGR valve
DTC REACTIONS
• OBD check lamp continuously ON after 3 driving cycle

• EGR Shuts OFF
HEALING CONDITION
P0403
P0403
P0403
P0403
CONNECTOR
NO
C4 EMS ECU 74 CONTROL SIGNAL
1 CONTROL SIGNAL
C63 EGR ACTUATOR
2 SUPPLY


STEP A – CHECK FUSE AND VOLTAGE IN EGR ACTUATOR SUPPLY WIRE
P0403
PRE CONDITION
• Ignition OFF
• Check and confirm the proper function of 15A fuse (F21)
• EGR Actuator wiring harness connector (C63) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage =Vbat
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Examine the open/short to ground of EGR

Actuator supply wire from main relay
STEP B– CHECK OPEN CIRCUIT OF EGR ACTUATOR CONTROL WIRE
PRE CONDITION
• Ignition 0FF
• EMS ECU wiring harness connector(C4) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EGR actuator with a new one • Examine the open circuit of EGR actuator
control wire
8.14 P1403— EGR VALVE OVER TEMPERATURE ERROR

8.14.1 EGR VALVE

NORMAL OPERATION
• Ignition ON
• No error detected in EGR control circuit during self check
• Ignition ON
• Power stage overheating is detected continuously for 3
driving cycles • Defective EMS ECU
DTC REACTIONS
• Engine check lamp blinking

• EGR Shuts OFF
HEALING CONDITION
• Fault absent continuously for 3 driving cycles


P1403


8.15 P0406— EGR VALVE SHORT TO BATTERY ERROR

8.15.1 EGR VALVE

NORMAL OPERATION
• Ignition ON
• Ignition ON
• Short to battery in EGR actuator
• Short to battery in EGR actuator control circuit continuously
for 3 driving cycles
• Faulty EGR actuator
DTC REACTIONS

• EGR shuts OFF.
HEALING CONDITION
P0406
P0406
P0406
P0406
CONNECTOR
NO
1 CONTROL SIGNAL
C63 EGR ACTUATOR
2 POSITIVE


STEP A – CHECK SHORT CIRCUIT OF EGR ACTUATOR CONTROL WIRE
P0406
PRE CONDITION
• Ignition OFF
• EGR actuator wiring harness connector (C63) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage < 4V
ACTION TO BE TAKEN
OK NOT OK
• Replace EGR actuator with a new one. • Examine the short circuit of EGR actuator
control wire with battery
• If the DTC still exists, replace the EMS ECU • Replace the wiring harness
with a new one • Check and verify for any new DTC’s
8.16 P0405— EGR VALVE SHORT TO GROUND ERROR

8.16.1 EGR VALVE

NORMAL OPERATION
• Ignition ON
• Ignition ON • EGR actuator control wire short

• Short to ground in EGR actuator control circuit continuously to ground
for 3 driving cycles
• Faulty EGR actuator
DTC REACTIONS

• EGR shuts OFF.
HEALING CONDITION
P0405
P0405
P0405
P0405
CONNECTOR
NO
1 CONTROL SIGNAL
C63 EGR ACTUATOR
2 POSITIVE


STEP A – CHECK SHORT CIRCUIT OF EGR ACTUATOR CONTROL WIRE
P0405
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EGR actuator with a new one. • Examine the short circuit of EGR actuator
control wire with battery ground
8.17 P062B— ECU MONITORING ERROR FOR INJECTION CUT OFF DEMAND
8.17.1 MONITORING COMMUNICATION: ICO MONITORING
Engine speed is continuously monitored by EMS ECU. Whenever the engine speed goes above the
maximum threshold, injection driver stages gets disconnected in EMS ECU

NORMAL OPERATION
• Ignition ON
• The engine speed is less than or equal to the maximum
engine speed in injection cut off monitoring
• Ignition ON
• The engine speed exceeds the threshold speed in injection
• Erratic crank speed sensor
cut off monitoring and injection driver stage gets
disconnected continuously for one driving cycle • Malfunctioning EMS ECU
DTC REACTIONS

HEALING CONDITION

• If P062B is present , check for engine speed value in live data . If the value is more than the
maximum speed of the engine , then check for any external EMI/EMF influence — Replace the
crankshaft speed sensor
• Suspect EMS ECU EEPROM failure and replace EMS ECU with a new one.
8.18 P1138—PLAUSIBILITY CHECK BETWEEN ACCELERATOR PEDAL AND

BRAKE
8.18.1 ACCELERATOR PEDAL PLAUSIBILITY CHECK
EMS ECU checks for the plausibility of accelerator pedal input . If the accelerator pedal and brake
inputs are available at EMS ECU simultaneously, then a plausibility is registered

NORMAL OPERATION
• Ignition ON
• No plausibility between accelerator pedal and brake input
DTC DETECTING CONDITIONS • Improper mounting of
accelerator pedal
• Ignition ON • Improper adjustment of brake
• Accelerator pedal and brake inputs are available at EMS ECU switch
simultaneously • Sticky accelerator pedal
• Plausibility between accelerator pedal and brake input
DTC REACTIONS
• Engine check lamp continuously ON.
• Vehicle goes to limp home mode
HEALING CONDITION
• Fault absent


P1138
• Perform brake switch setting

• Check for proper mounting of accelerator pedal assembly
• Check for any short to battery in the accelerator pedal signal wires
• Check for any short to battery in brake switch circuit
• Check for sticky accelerator pedal assembly. Replace if required
8.19 P1389 —GLOW PLUG OPEN LOAD ERROR

8.19.1 GLOW PLUG
A glow plug is a heating device used to aid in cold starting. The glow plug is a pencil-shaped piece of
metal with a heating element at the tip. This heating element, when electrified, heats up due to its
electrical resistance

NORMAL OPERATION
• Ignition ON
• No malfunction detected by EMS ECU in the control
circuit of Glow plug relay

• Open circuit in Glow plug relay control
• Ignition ON wire
• EMS ECU supply voltage 9 – 16V • Faulty Glow plug relay
• Open circuit detected in glow plug relay • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Fault absent
P1389
8.19.2 CIRCUIT SCHEMATIC
P1389
P1389
P1389
CONNECTOR
NO
C4 EMS ECU 83 SIGNAL
L12 GLOW PLUG RELAY 2 GLOW PLUG RELAY SUPPLY


STEP A – CHECK THE FUNCTIONALITY OF GLOW PLUG RELAY
PRE CONDITION
• Ignition OFF
• Ensure the glow plug relay is fixed properly in the connector
• Remove the glow plug relay
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
P1389
OK NOT OK
• GO TO STEP B • Replace the glow plug relay with a new one

STEP B – CHECK OPEN CIRCUIT IN GLOW PLUG RELAY CONTROL WIRE
PRE CONDITION
• Ignition OFF
• Remove the Glow plug relay
• Ignition ON
• Ensure battery voltage is available at pin 8 of L12
• EMS ECU wiring harness (C4) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 2 of L12 and pin 83 of C 4
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of Glow plug relay

• Replace EMS ECU with a new one. control wire
8.20 P1390— GLOW PLUG OVER TEMPERATURE ERROR

8.20.1 GLOW PLUG RELAY

NORMAL OPERATION
• Ignition ON
• No malfunction detected by EMS ECU in the glow plug relay
circuit
• Ignition ON • Faulty EMS ECU

• Overheating detected in EMS ECU power stage
DTC REACTIONS
HEALING CONDITION
• Fault absent


P1390

8.21 P1387— GLOW PLUG SHORT TO BATTERY ERROR


NORMAL OPERATION
• Ignition ON
• No malfunction detected by EMS ECU in the control circuit of
glow plug relay

• Short to battery in glow plug
• Ignition ON relay control wire
• Short to battery is detected in the control circuit of glow plug • Faulty glow plug relay
relay • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Fault absent
P1387
P1387
P1387
P1387
CONNECTOR
NO


STEP A – CHECK THE FUNCTIONING OF GLOW PLUG RELAY
PRE CONDITION
• Ignition OFF
• Ensure the glow plug relay is fixed properly in the connector of the relay box
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
P1387
OK NOT OK
• Examine the short to battery of glow plug • Replace the glow plug relay with a new one
relay control wire from EMS ECU • Clear the DTC and verify
8.22 P1388— GLOW PLUG SHORT TO GROUND ERROR


NORMAL OPERATION
• Ignition ON
glow plug relay
• Ignition ON • Short to ground in glow plug

• Short to ground is detected in the control circuit of glow plug relay control wire
relay • Faulty EMS ECU
DTC REACTIONS

• Glow plug continuously ON
HEALING CONDITION
• Fault not present
P1388
P1388
P1388
P1388
CONNECTOR
NO


STEP A – CHECK THE FUNCTIONING OF GLOW PLUG RELAY
PRE CONDITION
• Ignition OFF
• Ensure the glow plug relay is fixed properly in the connector of the relay box
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
P1388
OK NOT OK
• GO TO STEP B • Replace the glow plug relay with a new one

STEP B– CHECK GLOW PLUG RELAY CONTROL CIRCUIT SHORT TO GROUND
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 2 of the glow plug relay seating and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of glow plug relay

• Replace EMS ECU with a new one. control signal wire with ground
8.23 P0563— SIGNAL RANGE CHECK FOR BATTERY SENSOR SIGNAL ABOVE
MAXIMUM LIMIT
8.23.1 BATTERY
Supro and Supro Maxitruck is equipped with 50AH lead acid battery . EMS ECU continuously
monitors the battery voltage . The normal operating voltage for EMS ECU is 9 –16 V. If the voltage is
lesser or greater than the range , then error gets registered.

NORMAL OPERATION
• Ignition ON
• EMS ECU receives a supply voltage of 9–16 V.
• Ignition ON • Faulty Charging system
• The supply voltage to EMS ECU is more than 16 V for few • Malfunctioning EMS ECU
seconds
DTC REACTIONS
• EGR shuts off
HEALING CONDITION
• Fault absent


STEP A– CHECK BATTERY VOLTAGE
P0563
PRE CONDITION
• Ignition ON
• Engine running at high idle
TEST PROCEDURE
• Check the voltage between battery positive and battery negative terminals
ACCEPTANCE CRITERIA
• Voltage >16 V
ACTION TO BE TAKEN
OK NOT OK
• Check and confirm the proper functioning of • Clear the DTC and verify
charging circuit
8.24 P0562— SIGNAL RANGE CHECK FOR BATTERY SENSOR SIGNAL BELOW
MINIMUM LIMIT
8.24.1 BATTERY
Supro and Supro Maxitruck is equipped with 50AH lead acid battery . EMS ECU continuously
monitors the battery voltage . The normal operating voltage for EMS ECU is 9 –16 V. If the voltage is
lesser or greater than the range , then error gets registered.

NORMAL OPERATION
• Ignition ON
• EMS ECU receives a supply voltage of 9 –16 V.
DTC DETECTING CONDITIONS • Faulty battery
• Ignition ON • Faulty charging system
• The supply voltage to EMS ECU is less than 9 V for few • Open/short in EMS ECU ignition
seconds. power wire
DTC REACTIONS • Malfunctioning EMS ECU
• EGR shuts off
HEALING CONDITION
• Fault absent


STEP A – CHECK VOLTAGE IN BATTERY
P0562
PRE CONDITION
• Ignition ON
TEST PROCEDURE
• Check the voltage between battery positive and battery negative post
ACCEPTANCE CRITERIA
• 11.0 to 14.5 V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Check and confirm the proper functioning of

charging system
STEP B– CHECK VOLTAGE IN PIN 26 OF EMS ECU CONNECTOR
PRE CONDITION
• Ignition 0FF
• Check and confirm the proper functioning of 5A fuse of the EMS ECU power supply wire from
ignition switch
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage >9V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP E • GO TO STEP C
STEP C– CHECK OPEN CIRCUIT OF EMS ECU SUPPLY WIRE
P0562
PRE CONDITION
• Ignition 0FF
• Ignition switch wiring harness connector ( C113A) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 26 of C4 and pin 1 of C113A
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • Examine the open circuit of EMS ECU power

supply wire from ignition switch
STEP D – CHECK SHORT CIRCUIT OF EMS ECU SUPPLY WIRE
PRE CONDITION
• Ignition 0FF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the battery positive and negative • Examine the short circuit of EMS ECU supply
cable for any loose connection wire from ignition
• Clear the DTC and verify • Repair/replace the wiring harness
STEP E– CHECK OPEN CIRCUIT OF EMS ECU GROUND WIRE
P0562
PRE CONDITION
• Ignition 0FF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Are both the resistance < 1 Ω
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine the open circuit of EMS ECU ground
• Check and verify for any new DTC’s wires
• Repair/replace the wiring harness
8.25 P0504—BRAKE SWITCH PLAUSIBILITY ERROR

8.25.1 BRAKE SWITCH
Brake switch fitted on the brake pedal has two switches internally. One redundant and one main
switch .The main and redundant brake signals are input to EMS ECU from the brake switch. They
are mutually and individually checked for plausibility.

NORMAL OPERATION
• Ignition ON
• The brake switch outputs a voltage which corresponds to the
brake position and is within the range.
• Main brake signal is ON and redundant signal is off and vice
versa.

• Open / short wiring harness
• Ignition ON
• The brake switch output remains same in spite of brake • Improper brake switch
pressed or not pressed adjustment
• The main and redundant switch status remains same • Faulty brake switch
DTC REACTIONS
• Brake lamp ON
HEALING CONDITION
• Fault absent
P0504
P0504
P0504
CONNECTOR
NO
88 MAIN SIGNAL
C4 EMS ECU
93 REDUNDANT SIGNAL
1 SUPPLY
2 MAIN SIGNAL
C105 BRAKE SWITCH
3 SUPPLY
4 REDUNDANT SIGNAL


P0504
STEP A – CHECK FOR OPEN / SHORT CIRCUIT IN BRAKE SWITCH SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Ensure that the brake switch is adjusted properly (refer repair manual for procedure)
• Ensure proper functioning of 15A fuse (F19)
• Brake switch connector (C105) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage =Vbat
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Examine the open /short circuit in brake

switch supply wires
STEP B – CHECK OPEN CIRCUIT IN BRAKE SWITCH SIGNAL WIRES
PRE CONDITION
• Ignition OFF
• Brake switch wiring harness connector (C105) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
P0504
OK NOT OK
• GO TO STEP C • Examine the open circuit in brake switch

signal wires to EMS ECU
STEP C– CHECK SHORT CIRCUIT IN BRAKE SWITCH SIGNAL WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • Examine the short circuit in brake switch

signal wires to ground
STEP D– CHECK INTERNAL SHORT IN BRAKE SWITCH
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 4 and pin 2 of brake switch
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
P0504
OK NOT OK
• Replace the EMS ECU • Replace the brake switch with a new one
• Check for any DTC • Clear the DTC and verify
8.26 P0117— SIGNAL RANGE CHECK FOR COOLANT TEMPERATURE SENSOR

BELOW MINIMUM LIMIT
8.26.1 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.

NORMAL OPERATION
• During ignition ON , the measured output voltage value

of the coolant temperature sensor is within the range
• Ignition ON
• Short coolant temperature sensor
• The measured output voltage of the coolant
wiring harness
temperature sensor is lower than the minimum range
• Faulty coolant temperature sensor

DTC REACTIONS
• Engine check lamp continuously ON
• Torque limitations
• Coolant temperature value set as 106 Deg C
HEALING CONDITION
• Ignition OFF then ON
P0117
P0117
P0117
P0117
CONNECTOR
NO
67 SIGNAL
C4 EMS ECU
70 GROUND
COOLANT TEMPERATURE 1 SIGNAL
C43
SENSOR 2 GROUND


STEP A – CHECK VOLTAGE OF SENSOR SIGNAL WIRE
P0117
PRE CONDITION
• Ignition OFF
• Coolant temperature sensor wiring harness connector (C43) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5 ±0.25V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP C • GO TO STEP B
STEP B – CHECK SHORT TO GROUND OF SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Coolant temperature sensor wiring harness connector(C43) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance=∞Ω
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine the short circuit of coolant
temperature sensor signal wire to ground
• Check and verify for any new DTCs
STEP C – CHECK INTERNAL SHORT OF SENSOR
PRE CONDITION
• Ignition OFF
• Coolant temperature sensor wiring harness connector C43 DISCONNECTED
TEST PROCEDURE
P0117
ACCEPTANCE CRITERIA
• Resistance >2.2 <2.7kΩ at 20°c
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Internal short in coolant temperature sensor
• Check and verify for any new DTCs • Replace the sensor with a new one
8.27 P0118— SIGNAL RANGE CHECK FOR COOLANT TEMPERATURE SENSOR

ABOVE MAXIMUM LIMIT
8.27.1 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.

NORMAL OPERATION
• During ignition ON , the measured output voltage value

of the coolant temperature sensor is within the range
• Ignition ON • Open coolant temperature sensor

wires
• The measured output voltage of the coolant
temperature sensor is higher than the maximum range. Short to battery of coolant temperature
wires
DTC REACTIONS
• Faulty coolant temperature sensor
• Engine check lamp continuously ON • Malfunctioning EMS ECU
• Coolant temperature value set as 106 Deg C
HEALING CONDITION
P0118
P0118
P0118
P0118
CONNECTOR
NO
67 SIGNAL
C4 EMS ECU
70 GROUND
COOLANT TEMPERATURE 1 SIGNAL
C43
SENSOR 2 GROUND


STEP A – CHECK VOLTAGE OF SENSOR SIGNAL WIRE
P0118
PRE CONDITION
• Ignition OFF
• Coolant temperature sensor wiring harness connector (C43) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5 ±0.25V
ACTION TO BE TAKEN
OK NOT OK
STEP B – CHECK OPEN CIRCUIT OF SENSOR SIGNAL WIRE
PRE CONDITION
• If the Voltage is greater than 5.25V , check for short to battery of the coolant temperature
signal wire
• Ignition OFF
• Coolant temperature sensor wiring harness connector(C43) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one • Examine the open circuit of coolant
• Check and verify for any new DTC’s temperature sensor signal wire
STEP C – CHECK OPEN CIRCUIT OF SENSOR GROUND WIRE
P0118
PRE CONDITION
• Ignition OFF
• EMS ECU Wiring harness connector C4 DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 70 C4 and pin 2 of C43
ACCEPTANCE CRITERIA
• Resistance < 1Ω
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • Examine the open circuit of coolant

temperature sensor ground wire
• Repair /Replace the wiring harness
STEP D – CHECK INTERNAL FAILURE OF SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 1 and pin 2 of coolant temperature sensor
ACCEPTANCE CRITERIA
• Resistance >2.2 <2.7kΩ at 20°c
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one • Examine open circuit in coolant temperature
sensor
• Repair/Replace the wiring harness
8.28 P0336— CRANKSHAFT SENSOR SIGNAL ERROR

8.28.1 CRANKSHAFT SPEED SENSOR
The Crankshaft speed sensor is an inductive type sensor. It measures the speed of the trigger wheel
mounted on the crankshaft. Crankshaft sensor produces AC voltage of different frequency based
upon the speed of the engine. Along with the engine speed , crankshaft speed sensor is used to
measure the compression TDC of the piston..

NORMAL OPERATION • Open crankshaft speed sensor
circuit
• During engine cranking and running, the EMS ECU receives
the output signal from the crankshaft speed sensor and is • Sensor mounting loosened
within the specified range
• Increased air gap between

DTC DETECTING CONDITIONS crankshaft speed sensor and the
trigger wheel
• Ignition ON
• While engine cranking/running, disturbance noticed in • Trigger wheel damaged/
crankshaft speed signal mounting loosened
DTC REACTIONS • EMI noise

• Engine will not start/Engine stops
HEALING CONDITION
• Fault absent
P0336
P0336
P0336
P0336
CONNECTOR
NO
78 GROUND
C4 EMS ECU
79 SIGNAL
1 GROUND
C24 CRANKSHAFT SENSOR
2 SIGNAL


P0336
STEP A – CHECK OPEN CIRCUIT OF CRANK SHAFT SPEED SENSOR SIGNAL WIRES
PRE CONDITION
• Ignition OFF
• Crankshaft speed sensor wiring harness connector (C37) DISCONNECTED
•
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Examine the open circuit of crank shaft speed

sensor signal wire
STEP B – CHECK LOOSE CONNECTIONS IN CRANKSHAFT SPEED SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check and correct if any loose connections noticed in the crankshaft speed sensor wiring
harness connector
• Check for proper fitment of the crank shaft speed sensor mounting bolt
ACCEPTANCE CRITERIA
• Is the fitment and connections are proper
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP C • Fix the bolt properly and tighten it to the

torque specified
• Clear DTC and verify
P0336
STEP C– CHECK FOR ANY DAMAGE ON THE CRANKSHAFT SPEED SENSOR
PRE CONDITION
• Ignition OFF
• Remove the crank shaft speed sensor
TEST PROCEDURE
• Check for any damage on the crankshaft speed sensor front face
ACCEPTANCE CRITERIA
• No damage in sensor
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • Identify the cause and rectify

• Replace the crankshaft speed sensor with a
new one
STEP D– CHECK THE CRANKSHAFT END PLAY
PRE CONDITION
• Refer repair manual for the crankshaft end play procedure
TEST PROCEDURE
• Check the crankshaft end play
•
ACCEPTANCE CRITERIA
• The end play with in the limits
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP E • Identify the root cause of the crank shaft end

play and rectify
STEP E– CHECK TRIGGER WHEEL FOR ANY DAMAGE
P0336
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check for any damage on the trigger wheel teeth
• Check for proper mounting of trigger wheel mounting screw
•
ACCEPTANCE CRITERIA
• No damage in trigger wheel
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP F • If the screws are loosened , tighten to torque

• If toner wheel damaged, replace it with a new
one
STEP F– CHECK THE ROUTING OF CRANKSHAFT SPEED SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check whether the crankshaft speed sensor wire routing is closer to starter motor
ACCEPTANCE CRITERIA
• The wire should not be closer to starter motor
ACTION TO BE TAKEN
OK NOT OK
• Suspect crankshaft speed sensor internal • Route the wires correctly

failure • Refer wiring manual for proper routing
• Replace crankshaft speed sensor with a with • Clear the DTC and verify
a new one
8.29 P0335— CRANKSHAFT SENSOR NO SIGNAL ERROR

8.29.1 CRANKSHAFT SPEED SENSOR
The Crankshaft speed sensor is an inductive type sensor. It measures the speed of the trigger wheel
mounted on the crankshaft. Crankshaft sensor produces AC voltage of different frequency based
upon the speed of the engine. Along with the engine speed , crankshaft speed sensor is used to
measure the compression TDC of the piston.

NORMAL OPERATION
• Ignition ON
• During engine cranking and running, the EMS ECU receives
the output signal from the crankshaft speed sensor and is
within the specified range
DTC DETECTING CONDITIONS • Sensor mounting loosened
• Ignition ON
• Open/short crankshaft speed
• While engine cranking/running, no crankshaft speed signal sensor circuit
received by the EMS ECU
• Faulty crankshaft speed sensor
• Trigger wheel damaged/
DTC REACTIONS mounting loosened

• Engine will not start/engine stops
HEALING CONDITION
• Fault absent
P0335
P0335
P0335
P0335
CONNECTOR
NO
78 GROUND
C4 EMS ECU
79 SIGNAL
1 GROUND
C24 CRANKSHAFT SENSOR
2 SIGNAL


P0335
STEP A – CHECK PROPER FITMENT OF CRANKSHAFT SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check and correct if any loose connections noticed in the crankshaft speed sensor wiring
harness connector
• Check for proper fitment of the crank shaft speed sensor mounting bolt
ACCEPTANCE CRITERIA
• Fitment and connection are proper
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Fix the bolt properly and tighten it to the

torque specified
STEP B – CHECK SHORT CIRCUIT BETWEEN SENSOR SIGNAL WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
•
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP C • Examine the short circuit between the

crankshaft speed sensor signal wires
STEP C – CHECK OPEN CIRCUIT OF SENSOR SIGNAL WIRES
P0335
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Are both the resistance < 1 Ω
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • Examine the open circuit of crankshaft speed

sensor signal wires
• Repair /replace the wiring harness
STEP D– CHECK INTERNAL FAILURE OF SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 1 and pin 2 of Crankshaft speed sensor
ACCEPTANCE CRITERIA
• Resistance value= 890 ±25Ω
ACTION TO BE TAKEN
OK NOT OK
• Check and ensure the trigger wheel is intact • Suspect internal failure of crankshaft speed
sensor
• Replace EMS ECU with a new one.
• Check and verify for any new DTC’s • Replace the crank shaft speed sensor
8.30 P0480 — FAN 1 OPEN LOAD ERROR

8.30.1 RADIATOR COOLING FAN
The cooling fan is controlled by EMS ECU. The low speed cooling fan will be ON ( through the low
speed fan relay) whenever 1. AC is switch ON and middle pressure switch is OFF 2. Coolant
temperature more than 90°C and lesser than 94°C

NORMAL OPERATION
• Ignition ON
• When the engine coolant temperature rises above 90°
C, ECU actuates the low speed fan relay and the Fan
starts functioning. When the coolant temperature goes
below 86°C, ECU will deactivates the relay and the fan
stops functioning.
circuit of low speed fan relay
• Open circuit in low speed fan relay
control wire
DTC DETECTING CONDITIONS Faulty low speed Fan relay
• Ignition ON
• Faulty EMS ECU
• Open circuit detected in cooling fan low speed relay
DTC REACTIONS
• Low speed fan will not work
HEALING CONDITION
• Fault absent
P0480
P0480
P0480
P0480
CONNECTOR
NO
L3 LOW SPEED FAN RELAY 2 SIGNAL


STEP A – CHECK THE FUNCTIONALITY OF LOW SPEED FAN RELAY
P0480
PRE CONDITION
• Ignition OFF
• Ensure the Low speed fan relay is fixed properly in the connector
• Remove the low speed fan relay
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Replace the low speed fan relay with a new

one
STEP B – CHECK OPEN CIRCUIT IN LOW SPEED FAN RELAY CONTROL WIRE
PRE CONDITION
• Ignition OFF
• Remove the low speed fan relay
• Ignition ON
• Ensure 12 V is available at pin 8 of L3
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine the open circuit of Low speed fan
relay control wire
8.31 P0481 — FAN 2 OPEN LOAD ERROR

8.31.1 HIGH SPEED COOLING FAN
The cooling fan is controlled by EMS ECU. The high speed cooling fan will be ON whenever the
cooling temperature is more than 94°C or A/C middle pressure switch is ON.

NORMAL OPERATION
• Ignition ON
• Depending upon the coolant temperature. The EMS
ECU controls the high speed cooling fan.
• Ignition ON • Open circuit in high speed fan relay

• Electrical fan driver detects open load in high speed fan control wire
relay Faulty high speed fan relay
DTC REACTIONS • Faulty EMS ECU

• Torque Limitation
• High speed fan will not work
HEALING CONDITION
• Fault absent
P0481
P0481
P0481
P0481
CONNECTOR
NO
L2 HIGH SPEED FAN RELAY 2 SIGNAL


STEP A – CHECK THE FUNCTIONALITY OF HIGH SPEED FAN RELAY
P0481
PRE CONDITION
• Ignition OFF
• Ensure the High speed fan relay is fixed properly in the connector
• Remove the high speed fan relay
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Replace the high speed fan relay with a new

one
STEP B – CHECK OPEN CIRCUIT IN HIGH SPEED FAN RELAY CONTROL WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
• Ensure 12 V is available at pin 8 of L2
TEST PROCEDURE
• Check the resistance between pin 2 of L2 and pin 76 OF C4
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine the open circuit of High speed fan
relay control wire
8.32 P1480— FAN 1 OVER TEMPERATURE ERROR


NORMAL OPERATION
• Ignition ON
• When the engine coolant temperature rises above 90°C,
ECU actuates the low speed fan relay and the Fan starts
functioning. When the coolant temperature goes below 86°C,
ECU will deactivates the relay and the fan stops functioning.
• No malfunction detected by EMS ECU in radiator fan circuit
• Faulty EMS ECU

• Ignition ON
• Overheating detected in power stage
DTC REACTIONS
• Fan low speed will not work
HEALING CONDITION
• Fault absent


P1480


8.33 P1481— FAN 2 OVER TEMPERATURE ERROR


NORMAL OPERATION
• Ignition ON
• Depending upon the coolant temperature. The EMS ECU
controls the high speed cooling fan.
• Ignition ON
• Faulty EMS ECU
DTC REACTIONS

• Torque limitation
• Fan high will not work
HEALING CONDITION
• Fault absent


P1481


8.34 P0692— FAN 1 SHORT TO BATTERY ERROR

8.34.1 COOLING FAN
temperature more than 90°C and lesser than 94°C.

NORMAL OPERATION
• Ignition ON
stops functioning.
circuit of low speed fan relay
• Short to battery in Low speed fan
relay control wire
• Faulty Low speed Fan relay
• Ignition ON
• Short circuit to battery is detected in the control circuit • Faulty EMS ECU
of low speed fan relay
DTC REACTIONS
• Nil
HEALING CONDITION
• Fault absent
P0692
P0692
P0692
P0692
CONNECTOR
NO


STEP A – CHECK THE FUNCTIONALITY OF LOW SPEED FAN RELAY
P0692
PRE CONDITION
• Ignition OFF
• Remove the Radiator fan relay
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Replace the Low speed fan relay with a new

one
STEP B– CHECK SHORT CIRCUIT OF LOW SPEED FAN RELAY CONTROL WIRE AND POWER
WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the voltage between pin 8 of L3 and battery ground
ACCEPTANCE CRITERIA
• Voltage = 0V
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine the short circuit of Low speed fan
relay signal and positive wires
8.35 P0694— FAN 2 SHORT TO BATTERY ERROR

8.35.1 COOLING FAN

NORMAL OPERATION
• Ignition ON
circuit of high speed fan relay

• Short to battery in high speed fan
• Ignition ON relay control wire
• Short circuit to battery is detected in the control circuit • Faulty high speed Fan relay
of high speed fan relay
• Faulty EMS ECU
DTC REACTIONS

• Torque limitation
• High speed fan will not work
HEALING CONDITION
• Fault absent
P0694
P0694
P0694
P0694
CONNECTOR
NO


STEP A – CHECK THE FUNCTIONALITY OF HIGH SPEED FAN RELAY
P0694
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Replace the HIGH speed fan relay with a new

one
STEP B– CHECK SHORT CIRCUIT OF HIGH SPEED FAN RELAY CONTROL WIRE AND POWER
WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the voltage between pin 8 of L2 and battery ground
ACCEPTANCE CRITERIA
• Voltage = 0V
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine the short circuit of High speed fan
relay signal and positive wires
8.36 P0691—FAN 1 SHORT TO GROUND ERROR


NORMAL OPERATION
• Ignition ON
stops functioning.
circuit of radiator fan relay
• Short to ground in low speed cooling
fan relay control wire
• Faulty low speed cooling Fan relay
• Ignition ON
• Short to ground is detected in the control circuit of low • Faulty EMS ECU
speed cooling fan relay
DTC REACTIONS
• Low speed fan continuously ON
HEALING CONDITION
• Fault absent
P0691
P0691
P0691
P0691
CONNECTOR
NO


STEP A – CHECK SHORT CIRCUIT OF RADIATOR FAN RELAY SIGNAL WIRE
P0691
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 86 of the radiator fan relay seating and battery ground
ACCEPTANCE CRITERIA
• Resistance = ∞Ω
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine the short circuit of radiator fan relay
• Check and verify for any new DTC’s signal wire with ground
• Replace the Radiator fan relay with a new one
8.37 P0692—FAN 2 SHORT TO GROUND ERROR

8.37.1 COOLING FAN

NORMAL OPERATION
• Ignition ON
circuit of high speed fan relay

• Short to ground in high speed fan
relay control wire
• Ignition ON
• Faulty high speed Fan relay
• Short to ground is detected in the control circuit of high
speed fan relay
• Faulty EMS ECU
DTC REACTIONS

HEALING CONDITION
• Fault absent
P0692
P0692
P0692
P0692
CONNECTOR
NO


STEP A – CHECK SHORT CIRCUIT OF HIGH SPEED FAN RELAY SIGNAL WIRE
P0692
PRE CONDITION
• Ignition OFF
• Ensure the High speed fan relay is fixed properly in the connector
TEST PROCEDURE
• Check the resistance between pin 2 of the High speed fan relay seating and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine the short circuit of high speed fan
• Check and verify for any new DTC’s relay signal wire with ground
• Replace the high speed fan relay with a new
one
8.38 P0201— CYLINDER 1 INJECTOR OPEN LOAD ERROR

8.38.1 INJECTORS
The injector are solenoid actuated and controlled by EMS ECU. Both high and low side of the
injectors are controlled by EMS ECU. The EMS ECU continuously monitors the low side and high side
of the injector.

NORMAL OPERATION
• Ignition ON
• The control signals of the injector is monitored and is within
the range.

• Open in injector circuit
• Ignition ON
• A open load is detected in injector circuit • Faulty injector
• OBD lamp ON after one driving cycle

• Engine shuts off
HEALING CONDITION
• Fault absent for 3 driving cycle
P0201
P0201
P0201
CONNECTOR
NO
73 POWER HIGH SIDE INJECTOR
C4 EMS ECU
29 POWER LOW SIDE INJECTOR
1 POWER HIGH SIDE
INJECTOR
C 27 INJECTOR
2 POWER LOW SIDE
INJECTOR

P0201

STEP A – CHECK OPEN CIRCUIT OF INJECTOR HIGH SIDE WIRE
PRE CONDITION
• Ignition OFF
• Injector wiring harness connector (C27)DISCONNECTED
•
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance < 1 Ω
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Examine the open circuit of injector high side

wire
STEP B – CHECK OPEN CIRCUIT OF INJECTOR LOW SIDE WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
P0201
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine the open circuit of injector low side
wire
8.39 P0202— CYLINDER 2 INJECTOR OPEN LOAD ERROR

8.39.1 INJECTORS
of the injector.

NORMAL OPERATION
• Ignition ON
• The control signals of the injector is monitored and is within
the range.

• Open in injector circuit
• Ignition ON
• A open load is detected in injector circuit • Faulty injector
• OBD lamp ON
HEALING CONDITION
P0202
P0202
P0202
CONNECTOR
NO
C4 EMS ECU
1 POWER HIGH SIDE
INJECTOR
C 28 INJECTOR
2 POWER LOW SIDE
INJECTOR

P0202

STEP A – CHECK OPEN CIRCUIT OF INJECTOR 2 HIGH SIDE WIRE
PRE CONDITION
• Ignition OFF
• Injector 2 wiring harness connector (C28)DISCONNECTED
•
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Examine the open circuit of injector 2high

side wire
STEP B – CHECK OPEN CIRCUIT OF INJECTOR LOW SIDE WIRE
PRE CONDITION
• Ignition OFF
• Injector 2 wiring harness connector (C28)DISCONNECTED
TEST PROCEDURE
P0202
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine the open circuit of injector 2 low side
wire
8.40 P0341— CAMSHAFT SENSOR SIGNAL ERROR

8.40.1 CAMSHAFT SENSOR
The Hall Effect camshaft position sensor senses the Top dead center (TDC) point of the #1 cylinder
in the compression stroke , which allows the ECU to determine when to start the injection. The
trigger is mounted in the exhaust camshaft

NORMAL OPERATION
• Ignition ON
• During engine cranking, the output signal received from cam
shaft sensor to ECU is within the range
• Ignition ON
• EMS ECU supply voltage 9–16V • Increased air gap between cam
• While engine cranking disturbance noticed in camshaft shaft position sensor and the
position signal trigger wheel.
• Cam shaft position sensor
mounting loosened
DTC REACTIONS
• Increased cam shaft end play
• Faulty cam shaft position sensor
• Engine will not start
• If this failure occurs when the engine is running then engine
will keep on running
HEALING CONDITION
• Fault absent

P0341

STEP A – CHECK FLYWHEEL, CAMSHAFT AND CRANKSHAFT MOUNTING BOLTS FOR

TIGHTNESS
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the flywheel mounting bolts for tightness
• Check the camshaft/crankshaft mounting bolts for tightness
ACCEPTANCE CRITERIA
• Are the bolts tight
ACTION TO BE TAKEN
OK NOT OK
• Tighten the bolts to the torque specified

• GO TO STEP B
STEP B – CHECK CAMSHAFT TRIGGER WHEEL FOR ANY DAMAGE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check for any damage on the Camshaft trigger wheel teeth
ACCEPTANCE CRITERIA
• No damage on camshaft trigger wheel teeth
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP C • If toner wheel damaged, replace it with a new

one
P0341
STEP C– CHECK CRANKSHAFT TRIGGER WHEEL FOR ANY DAMAGE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check for proper mounting of trigger wheel mounting screws
ACCEPTANCE CRITERIA
• No damage on trigger wheel teeth
• Trigger wheel teeth screws intact
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • If toner wheel damaged, replace it with a new

one
STEP C– CHECK THE SPROCKETS AND CHAIN
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the sprockets and chain for any damage
ACCEPTANCE CRITERIA
• Is there any damage
ACTION TO BE TAKEN
OK NOT OK
• Replace the chain/sprocket assembly with a • Check for proper functioning of hydraulic
new one chain tensioner
• Clear the DTC and verify • If not functioning properly , replace with a new
one
8.41 P0340— CAMSHAFT SENSOR NO SIGNAL ERROR


NORMAL OPERATION
• Ignition ON
• During engine cranking, the output signal received from
camshaft position sensor to ECU is within the range
• Ignition ON
• Open/short cam shaft position
• EMS ECU supply voltage 9–16V sensor circuit
• While engine cranking, no valid signal from camshaft position • Faulty cam shaft position sensor
sensor
DTC REACTIONS
HEALING CONDITION
• Ignition OFF/ON
P0340
P0340
P0340
CONNECTOR
NO
80 GROUND
9 SUPPLY
1 GROUND
C24 CAMSHAFT SENSOR 2 SIGNAL
3 SUPPLY


P0340
STEP A – CHECK VOLTAGE IN CAMSHAFT SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Camshaft sensor wiring harness connector (C24 DISCONNECTED
• Ignition ON
TEST PROCEDURE
• Check the Voltage between pin 3 of C24 and battery ground
ACCEPTANCE CRITERIA
• Voltage = 5 ± 0.25 V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • GO TO STEP B
STEP B – CHECK SHORT CIRCUIT OF CAMSHAFT SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Camshaft sensor wiring harness connector (C24) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 3 of C 24 and ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of camshaft sensor

supply wire to ground
STEP C – CHECK OPEN CIRCUIT OF CAMSHAFT SENSOR SUPPLY WIRE
P0340
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one • Examine the open circuit of camshaft sensor
• Check and verify for any new DTC’s supply wire
STEP D– CHECK SHORT CIRCUIT OF SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 2 of C81 and ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of camshaft sensor

• GO TO STEP E • Replace the wiring harness
STEP E– CHECK OPEN CIRCUIT OF SENSOR GROUND/ AND OR SIGNAL WIRE
P0340
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace camshaft sensor with a new one

• Check and verify for any new DTC’s • Examine the open circuit of camshaft sensor
ground and/ or signal wire
• If the DTC still exist, check for proper fitment
of camshaft sensor mounting bolt • Replace the wiring harness
• Check for any internal damage in camshaft • Clear the DTC and verify
trigger wheel
8.42 P1341— CAMSHAFT SENSOR SIGNAL OFFSET ERROR


NORMAL OPERATION
• Ignition ON
• During engine cranking , the EMS ECU compares the
crankshaft sensor signal and cam shaft position sensor signal
and the deviation is within the range
• Ignition ON
• Increased air gap between cam
• EMS ECU supply voltage 9–16V shaft position sensor and the
• While engine cranking, the cam shaft position sensor and trigger wheel.
crankshaft speed sensor are not synchronized. • Increased air gap between
crank shaft speed sensor and the
trigger wheel.
DTC REACTIONS
• Sensor mountings loosened
• Engine check lamp continuously ON • Timing disturbed

HEALING CONDITION

P1341

STEP A – CHECK FLYWHEEL, CAMSHAFT AND CRANKSHAFT MOUNTING BOLTS FOR

TIGHTNESS
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the flywheel mounting bolts for tightness
• Check the camshaft/crankshaft mounting bolts for tightness
ACCEPTANCE CRITERIA
• Are the bolts tight
ACTION TO BE TAKEN
OK NOT OK
• Tighten the bolts to the torque specified

• GO TO STEP B
STEP C – CHECK CAMSHAFT TRIGGER WHEEL FOR ANY DAMAGE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check for any damage on the camshaft trigger wheel teeth
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
P1341
OK NOT OK
• GO TO STEP C • If toner wheel damaged, replace it with a new

one
STEP C– CHECK TRIGGER WHEEL FOR ANY DAMAGE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check for proper mounting of trigger wheel mounting screws
ACCEPTANCE CRITERIA
• Trigger wheel teeth screws intact
ACTION TO BE TAKEN
OK NOT OK
• If the screws are loosened , tighten to torque

• If toner wheel damaged, replace it with a new
• GO TO STEP C one
STEP C– CHECK THE SPROCKETS AND CHAIN
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the sprockets and chain for any damage
ACCEPTANCE CRITERIA
• Is there any damage
ACTION TO BE TAKEN
P1341
OK NOT OK
• Replace the chain/sprocket assembly with a • Check for proper functioning of hydraulic
new one chain tensioner
• Clear the DTC and verify • If not functioning properly , replace with a new
one
8.43 P2146— SHORT CIRCUIT IN BANK 0

8.43.1 INJECTORS
of the injector

NORMAL OPERATION
• Ignition ON
• The injector bank is checked while initialization and running
and found normal.
• Injector high side control wire

short to ground
• Injector high side control wire
• Ignition ON
short to battery
• Short in injector bank
• Faulty Injectors
DTC REACTIONS
• Faulty EMS ECU
• OBD check lamp continuously ON
HEALING CONDITION
P2146
P2146
P2146
P2146
P2146
CONNECTOR
NO
C4 EMS ECU
1 POWER HIGH SIDE
INJECTOR
C 27 INJECTOR 1
2 POWER LOW SIDE
INJECTOR
1 POWER HIGH SIDE

INJECTOR
C 28 INJECTOR 2
2 POWER LOW SIDE
INJECTOR
P2146


STEP A—CHECK SHORT CIRCUIT OF INJECTOR HIGH SIDE WIRE TO BATTERY
PRE CONDITION
• Ignition OFF
• Injector wiring harness connector (C27,C28)DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Examine short circuit of injector high side

wire to battery positive
STEP B —CHECK SHORT CIRCUIT OF INJECTOR HIGH SIDE WIRE TO GROUND
P2146
PRE CONDITION
• Ignition OFF
• Injector wiring harness connector (C27,C28)DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace the injector and check for DTC’s • Examine short circuit of injector high side
wire to battery ground
• If the problem still exists, replace the EMS
ECU • Replace the wiring harness
• Check and verify for any new DTC’s • Clear the DTC and verify

INJECTOR
8.44.1 INJECTORS
of the injector

NORMAL OPERATION
• During Ignition ON, EMS ECU monitors the control signal of

injector 1 and is within range
• Short circuit between injector 1

• Ignition ON
high and low side
• A short circuit between high side and low side is detected in
the injector 1 circuit.
• Malfunctioning injector 1
DTC REACTIONS
• OBD lamp continuously ON
HEALING CONDITION
P0261
P0261
P0261
CONNECTOR
NO
C4 EMS ECU
1 POWER HIGH SIDE
INJECTOR
C 27 INJECTOR 1
2 POWER LOW SIDE
INJECTOR

P0261

STEP A – CHECK SHORT CIRCUIT BETWEEN HIGH SIDE AND LOW SIDE WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace injector with a new one • Examine short circuit of injector high side and
• If problem persists, replace the EMS ECU low side wires
with a new one • Replace the wiring harness
• Clear DTC and verify • Clear the DTC and verify

INJECTOR
8.45.1 INJECTORS
author author
of the injector

NORMAL OPERATION
• During Ignition ON, EMS ECU monitors the control signal of

injector 2 and is within range
• Short circuit between injector 2

• Ignition ON
high and low side
• A short circuit between high side and low side is detected in
the injector 2 circuit.
• Malfunctioning injector 2
DTC REACTIONS
HEALING CONDITION
P0267
P0267
P0267
CONNECTOR
NO
C4 EMS ECU
1 POWER HIGH SIDE
INJECTOR
C 28 INJECTOR 2
2 POWER LOW SIDE
INJECTOR

P0267

STEP A – CHECK SHORT CIRCUIT BETWEEN HIGH SIDE AND LOW SIDE WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace injector 2 with a new one • Examine short circuit of injector 2 high side
• If problem persists, replace the EMS ECU and low side wires
• Clear DTC and verify • Clear the DTC and verify
8.46 P268C— CYLINDER 1 INJECTOR ADJUSTMENT CODE INCORRECT ERROR

8.46.1 INJECTOR IQA MONITORING
IQA monitoring monitors the missing or faulty programming of individual IQA values and registers an
error if it is missing or faulty. in SUPRO/SUPRO MAXITRUCK the injectors are with 6 digit IQA code

NORMAL OPERATION
• Ignition ON
• ECU monitors the checksum of cylinder 1 IQA code and is
within the range

• Cylinder 1 IQA code not written
• Ignition ON
• No cylinder 1 IQA code read by EEPROM • Cylinder 1 IQA code wrongly
• The checksum of cylinder 1 IQA code is not correct written
• Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION

• Proceed to DIAGNOSTIC PROCEDURE if P268C is present

P268C

STEP A – CHECK THE IQA CODE
PRE CONDITION
• Ignition ON
TEST PROCEDURE
• Using iSmart , check whether the cylinder 6 digit IQA code is written properly
ACCEPTANCE CRITERIA
• IQA code written correctly
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new • Write the correct IQA code
8.47 P268E— CYLINDER 2 INJECTOR ADJUSTMENT CODE INCORRECT ERROR

8.47.1 INJECTOR IQA MONITORING
IQA monitoring monitors the missing or faulty programming of individual IQA values and registers an
error if it is missing or faulty. in SUPRO/SUPRO MAXITRUCK the injectors are with 6 digit IQA code

NORMAL OPERATION
• Ignition ON
• ECU monitors the checksum of cylinder 2 IQA code and is
within the range

• Cylinder 2 IQA code not written
• Ignition ON
• No cylinder 2 IQA code read by EEPROM • Cylinder 2 IQA code wrongly
• The checksum of cylinder 2 IQA code is not correct written
• Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION

• Proceed to DIAGNOSTIC PROCEDURE if P268D is present

P268E

STEP A – CHECK THE IQA CODE
PRE CONDITION
• Ignition ON
TEST PROCEDURE
• Using iSmart , check whether the cylinder 6 digit IQA code is written properly
ACCEPTANCE CRITERIA
• IQA code written correctly
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new • Write the correct IQA code

ABOVE MAXIMUM LIMIT
8.48.1 HFM TEMPERATURE SENSOR
The HFM temperature sensor is a variable resistor whose resistance changes as the temperature
of the air flowing past the sensor changes ( NTC resistor ) when the intake air temperature is low.
The sensor resistance is high. When the intake air temperature is high, the sensor resistance is low

NORMAL OPERATION
• Ignition ON
• The measured output voltage value of the intake air
temperature sensor is within the specified range
DTC DETECTING CONDITIONS • Open HFM temperature sensor

wiring harness
• Ignition ON • Short to battery of HFM
• EMS ECU supply voltage 9 -16V temperature sensor wiring
harness
• The measured output voltage of the intake air temperature
sensor is more than the maximum range • Faulty HFM temperature
• Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
P0113
P0113
P0113
P0113
CONNECTOR
NO
58 TEMPERATURE SIGNAL
C4 EMS ECU
89 GROUND
3 POWER
C19 HFM TEMPERATURE SENSOR 5 TEMPERATURE SIGNAL

1 GROUND


P0113
STEP A – CHECK VOLTAGE IN HFM SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5 ± 0.25 V
ACTION TO BE TAKEN
OK NOT OK
STEP B – CHECK OPEN CIRCUIT IN HFM SENSOR SIGNAL WIRE
PRE CONDITION
• If the Voltage is greater than 5.25V , check for short to battery of the HFM air temperature
signal wire
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of HFM sensor air

• Replace EMS ECU with a new one intake temperature sensor signal wire
STEP C – CHECK OPEN CIRCUIT IN HFM SENSOR GROUND WIRE
P0113
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace the HFM sensor with a new one • Examine the open circuit of HFM sensor air
• Check and verify for any new DTC’s intake temperature sensor signal wire

BELOW MINIMUM LIMIT
8.49.1 HFM TEMPERATURE SENSOR
The HFM temperature sensor is a variable resistor whose resistance changes as the temperature
of the air flowing past the sensor changes ( NTC resistor ) when the intake air temperature is low.
The sensor resistance is high. When the intake air temperature is high, the sensor resistance is low

NORMAL OPERATION
• Ignition ON
• The measured output voltage value of the intake air
temperature sensor is within the specified range
• Ignition ON • Short HFM temperature sensor

wiring harness
• EMS ECU supply voltage 9 -16V
• Faulty HFM temperature sensor
• The measured output voltage of the intake air temperature
sensor is less than the minimum range • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
P0112
P0112
P0112
P0112
CONNECTOR
NO
58 TEMPERATURE SIGNAL
C4 EMS ECU
89 GROUND
3 POWER
C19 HFM TEMPERATURE SENSOR 5 TEMPERATURE SIGNAL

1 GROUND


• Terminals not fully seated in the connector body
P0112
STEP A – CHECK VOLTAGE IN SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage > 5 ± 0.25 V
ACTION TO BE TAKEN
OK NOT OK
• Replace HFM sensor with a new one • GO TO STEP B

STEP B – CHECK SHORT CIRCUIT IN SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of HFM sensor air

intake temperature sensor signal wire to
• Replace EMS ECU with a new one ground
• Check and verify for any new DTC’s • Repair/replace the wiring harness
8.50 P1652— MIL OPEN LOAD ERROR

8.50.1 MIL (OBD) LAMP
OBD lamp indicates a malfunction in emission control system. During ignition ON, the OBD lamp is
ON and goes OFF after the engine starts. The lamp illuminates continuously for any malfunction in
emission control system

NORMAL OPERATION
• Ignition ON
• OBD lamp glows during Ignition ON, and goes OFF after
starting the engine
• Open circuit in OBD lamp circuit

• Ignition ON
• Open load detected in OBD lamp signal to IC
• Faulty IC
• Faulty EMS ECU
DTC REACTIONS
• Engine check lamp continuously ON after 3 driving cycles

• OBD lamp remains OFF always
HEALING CONDITION
P1652
P1652
P1652
P1652
CONNECTOR
NO
C4 EMS ECU 13 OBD LAMP SIGNAL WIRE
P4 INSTRUMENT CLUSTER 15 OBD LAMP SIGNAL WIRE


STEP A – CHECK THE OBD LAMP BY ACTUATOR TEST
PRE CONDITION
• Ignition ON
• Go to the actuator test in iSmart tool
• Actuate the OBD lamp
TEST PROCEDURE
P1652
• Check If the OBD lamp works with the actuator test.
ACCEPTANCE CRITERIA
• OBD lamp glows
ACTION TO BE TAKEN
OK NOT OK
• Clear the DTC and verify • GO TO STEP B
STEP B – CHECK OPEN CIRCUIT OF OBD LAMP SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Instrument cluster wiring harness connector (C119) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 15 of C119 and pin 13 Of C4
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP C • Examine the open circuit between the ECU

and cluster OBD lamp signal wire
STEP C– CHECK THE FUNCTIONALITY OF OBD LAMP
PRE CONDITION
• Ignition ON
• Coolant temperature sensor connector (C43) DISCONNECTED
TEST PROCEDURE
• Crank the engine
ACCEPTANCE CRITERIA
• OBD lamp glows
P1652
ACTION TO BE TAKEN
OK NOT OK
• Check for damage/oxidation in instrument • OBD Lamp failed

cluster and ECU connector pins • Replace the instrument cluster with new one
8.51 P1650— MIL SHORT CIRCUIT TO BATTERY ERROR

ON and goes OFF after the engine starts. If the lamp illuminates continuously for any malfunction in

NORMAL OPERATION
• Ignition ON
• OBD lamp glows during ignition ON, and goes OFF after
starting the engine

• Short to battery in OBD lamp
circuit
• Ignition ON
• Faulty IC
• Short circuit battery detected in OBD lamp signal to IC
• Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Fault absent
P1650
P1650
P1650
P1650
CONNECTOR
NO
C119 INSTRUMENT CLUSTER 15 OBD LAMP SIGNAL WIRE


P1650
STEP A – CHECK SHORT TO BATTERY OF OBD LAMP SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0V
ACTION TO BE TAKEN
OK NOT OK
• OBD Lamp failed • Examine the short to battery of OBD lamp

signal wire
• Replace the instrument cluster with a new
one • Replace the wiring harness
• Clear the DTC and verify • Clear the DTC and verify
8.52 P1651— MIL SHORT CIRCUIT TO GROUND ERROR


NORMAL OPERATION
• Ignition ON
• OBD lamp glows during ignition ON, and goes OFF after
starting the engine

• Short to ground in OBD lamp
• Ignition ON circuit
• The OBD lamp glows continuously • Faulty IC
• Faulty EMS ECU
DTC REACTIONS

HEALING CONDITION
• Fault absent
P1651
P1651
P1651
P1651
CONNECTOR
NO
C119 INSTRUMENT CLUSTER 15 OBD LAMP SIGNAL WIRE


STEP A – CHECK SHORT TO GROUND OF OBD LAMP SIGNAL WIRE
P1651
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• OBD Lamp failed • Examine the short to ground of OBD lamp

signal wire
8.53 P1653— MIL OVER TEMPERATURE ERROR


NORMAL OPERATION
• Ignition ON
• No malfunction detected by EMS ECU in the OBD lamp circuit
• Loosen OBD lamp wiring

• Ignition ON
harness connector
• Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Fault absent


P1653

8.54 CONTINUOUS TORQUE MONITORING — LIST OF DTC’s — 1
DTC DESCRIPTION MONITORED COMPONENT MALFUNCTION
P1900 NTP error in ADC The ADC ( Analog to Digital

monitoring Controller ) of the micro
controller is monitored
P163B ECU Monitoring: ADC Test voltage of ADC Error in plausibility of the
test error monitoring test voltage
P163C ECU Monitoring: Ratio metry correction Error in plausibility of

Voltage ratio error in monitored ratiometry correction
ADC
P1621 ECU Monitoring: Query Function controller monitored Error in plausibility of

response function controller and
communication error monitoring module
P1622 ECU Monitoring: SPI SPI communication monitored Interrupted SPI

communication error communication
P0605 ECU Monitoring: ROM ROM memory monitored Multiple error in

memory error complete ROM test
during post drive
P1623 ECU Monitoring: CPU MM response to CPU is Too less bytes received
error monitored by MM from CPU as
response
P1625 ECU Monitoring: MM response time is Error in MM response

Response time error in monitored time
ECU
P1626 ECU Monitoring: Shut SPI communication monitored Error detected in SPI
off path test SPI communication
communication error
Lamp Status — Engine check lamp continuously ON

DTC Reaction- Engine shuts OFF
DIAGNOSTIC PROCEDURE
P1628 ECU Monitoring: Shut Shut off path test monitored Error in shut off path test
off path under voltage for under voltage of the under voltage
error detection
P1629 ECU Monitoring: WDA Shut off path check monitored Error in shut off path
not working check monitoring
P162A ECU Monitoring: Time Time out in calling operative Error in calling operative
out error system services system services
P162C ECU Monitoring: Error during positive test is Error during positive test
Positive test failure monitored
error
P162D ECU Monitoring: Time Error in time monitoring of Error in time monitoring
out error for shut off shut off path test of shut off path test
path test

DIAGNOSTIC PROCEDURE
8.56 P1631— ECU MONITORING: START OF INJECTION PLAUSIBILITY ERROR

8.56.1 INJECTION PLAUSIBILITY
EMS ECU monitors the injector energizing time continuously. Any change in actual injection timing
with respect to desired injection is considered as an error

NORMAL OPERATION
• Ignition ON
• The start of the energizing time is monitored
• Ignition ON • EMI interference in injection
• If the start of the energizing time is outside the plausible valid signals ( look at the starter motor
range then this error is registered cable & starter motor condition.)
DTC REACTIONS
• Engine Check lamp will be continuously ON • Faulty EMS ECU
HEALING CONDITION
8.56.1.1 DIAGNOSTIC PROCEDURE
• Check and rectify if any EMI interference in injection signals ( possible cause can be starter
motor cable or starter motor taking extra load )
8.57 P1632— ECU MONITORING: ZFC NON PLAUSIBILITY ERROR

8.57.1

NORMAL OPERATION
• Ignition ON
• The maximum plausible energizing time of the ZFC results,
depending on the rail pressure is compared with a
predetermined curve and is within the range
• The minimum energizing time is also compared with a
predetermined curve and is within the range
• If the actual value is beyond the curves then this error is set • Injector worn/ stuck
• • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Check for injector stuck or worn ( thru fuel leak off test)
P060D ECU Monitoring: Two voltage values of Implausible accelerator

Accelerator position accelerator pedal is pedal voltage
error monitored
P061C ECU Monitoring: Offset between calculated Non-permissible offset

Engine speed error engine speed and engine between the engine
speed with low resolution is speed of level 2 and level
monitored 1
P1638 ECU Monitoring: Rail Rail pressure level 1 an level 2 Error in the plausibility
pressure monitoring values are monitored for check of rail pressure
plausibility error plausibility
P060A ECU Monitoring: Plausibility of injection If the difference between

Energising time quantities monitored the programmed
plausibility error energizing time and the
measured energizing
time exceeds a limit then
this error will be
registered


8.59 CONTINUOUS TORQUE MONITORING
DTC DESCRIPTION
P1633 ECU Monitoring: PoI2 qty error
P1634 ECU Monitoring:PoI2 shut off error
P1635 ECU Monitoring:PoI3 efficiency factor error
P1636 ECU Monitoring: Overrun monitoring error
P1637 ECU Monitoring: Injection quantity correction error
P061B ECU Monitoring: Torque comparison error
P163E ECU Monitoring: Torque monitoring level2 error
P1639 ECU Monitoring: Lead torque monitoring level2 error
P163D ECU Monitoring: Set torque monitoring level2 error

NORMAL OPERATION
• The voltage monitoring of the injector energizing time is found
OK
DTC DETECTING CONDITIONS • Faulty EMS ECU
• If the difference between the programmed energizing time
and the measured energizing time exceeds a limit then this
error will be registered
DTC REACTIONS
• Engine will shuts off
HEALING CONDITION
• Fault absent

8.60 P068A/P068B—MAIN RELAY EARLY OPENING ERROR / MAIN RELAY

STRUCK ERROR
8.60.1 MAIN RELAY
Main relay controls the battery supply voltage to EMS ECU. Main relay is energized by EMS ECU
after getting the ignition input

NORMAL OPERATION
• Ignition ON
• EMS ECU checks the main relay actuation time during
initialization and is within the range
• ECU checks the main relay during operation and no sticky
operation noticed
DTC DETECTING CONDITIONS • Open / short wiring harness
• Ignition ON • Loosen wiring harness
connectors
• The main relay is not operating in the set time
• Sticky relay
DTC REACTIONS
• Engine shuts OFF
HEALING CONDITION
• Nil
This DTC’s may be viewed in the diagnostic tool in healed condition only
The EMS main relay will reset 20 seconds after ignition off
P068A/
P068B

• Proceed to DIAGNOSTIC PROCEDURE if P068A/P068B is present

P068A/
P068B
STEP A – CHECK FUNCTIONING OF RELAY
PRE CONDITION
• Ignition OFF
• Ensure the main relay is fixed properly in the connector (L11)
• Remove the main relay
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Replace the main relay with a new one

STEP B – CHECK OPEN/SHORT CIRCUIT IN BATTERY POSITIVE TO MAIN RELAY WIRING

CIRCUIT
PRE CONDITION
• Ignition OFF
• Ensure the 30A fuse (F25) is functioning properly
TEST PROCEDURE
• Check the voltage at pin 4 of L11 and battery ground
• Check the voltage at pin 8 of L11 and battery ground
ACCEPTANCE CRITERIA
• Voltage = 12 V ?
ACTION TO BE TAKEN
P068A/
P068B
OK NOT OK
• GO TO STEP C • Examine the short/open circuit in battery

power supply to main relay
STEP C– CHECK OPEN CIRCUIT IN MAIN RELAY TO EMS ECU WIRING CIRCUIT
PRE CONDITION
• Ignition OFF
• EMS wiring harness connector DISCONNECTED ( C4)
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance < 1Ω?
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • Examine the open circuit in main relay to EMS

ECU wiring circuit
• Replace the wiring harness with a new one
STEP D – CHECK SHORT CIRCUIT IN MAIN RELAY TO EMS ECU WIRING CIRCUIT
PRE CONDITION
• Ignition OFF
• EMS wiring harness connector DISCONNECTED ( C4)
TEST PROCEDURE
ACCEPTANCE CRITERIA
• R Resistance =∞Ω?
P068A/
P068B
ACTION TO BE TAKEN
OK NOT OK
• Replace the EMS ECU with a new one • Examine the short circuit in main relay to
EMS ECU wiring circuit
• Replace the wiring harness with a new one

SENSOR ABOVE MAXIMUM LIMIT
8.61.1 ENVIRONMENT PRESSURE SENSOR
The environment pressure sensor is located on the EMS ECU. The sensor provides the atmospheric
pressure value to the EMS ECU. This is 5V reference sensor In built inside the EMS ECU and cannot
be serviced separately

NORMAL OPERATION
• Ignition ON
• EMS ECU receives an output voltage signal from environment
pressure sensor and is within the range.
• Ignition ON • Faulty Environment Pressure
sensor
• The output voltage signal received from the environment
pressure sensor is higher than the maximum value.
DTC REACTIONS
• OBD lamp will be continuously ON
HEALING CONDITION

• Replace the EMS ECU with a new one
8.61.2.1 INTERMITTENT PROBLEMS

STEP A – SUSPECT ENVIRONMENT PRESSURE SENSOR
P2229
• Suspect environment pressure sensor internal failure

• Replace EMS ECU with a new one

SENSOR BELOW MINIMUM LIMIT
8.62.1 ENVIRONMENT PRESSURE SENSOR
The environment pressure sensor is located on the EMS ECU. The sensor provides the atmospheric
pressure value to the EMS ECU. This is 5V reference sensor built inside the EMS ECU and cannot be
serviced separately

NORMAL OPERATION
• Ignition ON
• EMS ECU receives an output voltage signal from environment
pressure sensor and is within the range.
• Ignition ON • Faulty Environment Pressure
sensor
• The output voltage signal received from the environment
pressure sensor is lower than the minimum value.
DTC REACTIONS
• OBD lamp will be continuously ON
HEALING CONDITION

• Replace the EMS ECU with a new one
8.62.2.1 INTERMITTENT PROBLEMS

8.62.2.1.2 DIAGNOSTIC PROCEDURE
STEP A – SUSPECT ENVIRONMENT PRESSURE SENSOR
P2228
• Suspect environment pressure sensor internal failure

• Replace EMS ECU with a new one
8.63 P0627— PSP OPEN LOAD ERROR

8.63.1 ELECTRIC INTANK PUMP
The Electric intank pump is located inside the fuel tank. It is an electrical pump and controlled by
EMS ECU. It creates a positive suction pressure for the high pressure pump. Based on the load
requirements of the engine , EMS ECU controls the duty cycle of the pump and inturn controls the
flow rate of the pump

NORMAL OPERATION
• Ignition ON
• The PWM control signal of the electric intank pump is
monitored and is within the range.
DTC DETECTING CONDITIONS • Open in Electric intank pump
circuit
• Ignition ON • Faulty Electric intank pump
• A open load is detected in Electric intank pump circuit • Faulty EMS ECU
DTC REACTIONS
• OBD lamp continuously ON after one driving cycle
• Engine shuts OFF.
HEALING CONDITION
P0627
P0627
P0627
P0627
CONNECTOR
NO
3 CONTROL SIGNAL
C4 EMS ECU
5 GROUND
4 CONTROL SIGNAL
C199 ELECTRIC INTANK PUMP
3 GROUND


STEP A – CHECK OPEN CIRCUIT OF ELECTRIC INTANK PUMP CONTROL WIRES
P0627
PRE CONDITION
• Ignition OFF
• Electric intank pump wiring harness connector (C199) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
OK NOT OK
• Replace the Electric intank pump • Examine the open circuit of Electric intank
• Clear the DTC and verify pump control wires
• If the DTC still exits , replace the EMS ECU • Replace the wiring harness
with a new one • Clear the DTC and verify
8.64 P1611— PSP PWM OVER TEMPERATURE ERROR


NORMAL OPERATION
• Ignition ON
• No malfunction detected by EMS ECU in the Electric intank
pump circuit
• Overheating detected in EMS ECU power stage
DTC REACTIONS
HEALING CONDITION


P1611

8.65 P0629— PSP PWM SHORT TO BATTERY ERROR


NORMAL OPERATION
• Ignition ON
• No malfunction detected by EMS ECU in electric intank pump
circuit
DTC DETECTING CONDITIONS • Short to battery in electric
intank pump control wires
• Short circuit to battery is detected in electric intank pump • Faulty EMS ECU
control circuit
DTC REACTIONS
HEALING CONDITION
P0629
P0629
P0629
P0629
CONNECTOR
NO
3 SUPPLY
C4 EMS ECU
5 GROUND
4 SUPPLY
3 GROUND
P0629


STEP A – CHECK SHORT CIRCUIT OF ELECTRIC INTANK PUMP CONTROL WIRES
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage > 7.8 to 11.5 V
ACTION TO BE TAKEN
OK NOT OK
• Replace Electric intank pump with a new one. • Examine the short circuit of Electric intank
• Clear the DTC and verify pump control wire with battery positive
8.66 P0628— PSP PWM SHORT TO GROUND ERROR


NORMAL OPERATION
• Ignition ON
• No malfunction detected in Electric intank pump circuit
DTC DETECTING CONDITIONS • Short to ground in Electric
intank pump control wires
• Short to ground detected in electric intank pump control • Faulty EMS ECU
circuit
DTC REACTIONS
• Engine will shuts OFF.
HEALING CONDITION
P0628
P0628
P0628
P0628
CONNECTOR
NO
3 SUPPLY
C4 EMS ECU
5 GROUND
4 SUPPLY
3 GROUND


STEP A – CHECK SHORT TO GROUND OF ELECTRIC INTANK PUMP CONTROL WIRE
P0628
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace Electric intank pump with a new one. • Examine the short circuit of Electric intank
• Clear the DTC and verify pump control wire with battery ground
8.67 P0191— RAIL PRESSURE OFFSET VALUE ABOVE MAXIMUM LIMIT

8.67.1 RAIL PRESSURE SENSOR
The rail pressure sensor is mounted on the fuel distribution block and is used to measure the rail
pressure. The EMS ECU determine the optimum fuel injection quantity at specific engine condition
based on rail pressure sensor. The fuel rail pressure sensor has a 5-volt reference circuit, a signal
circuit, and a ground circuit. EMS ECU monitors the fuel pressure . When the fuel pressure is high,
the signal voltage is high. When the fuel pressure is low, the signal voltage is low.

NORMAL OPERATION
• Ignition ON
• During after run the EMS ECU monitors the raw value of the
rail pressure and is within the limits.
• Ignition ON
• Kinked /Blocked return line
• The raw value of the rail pressure sensor is above the
maximum set point during after run
• Faulty rail pressure sensor
DTC REACTIONS

HEALING CONDITION
• Fault absent

P0191

STEP A – CHECK THE FUEL RETURN LINE

• Ignition OFF
• Check and rectify if any kinks/blockage noticed in the fuel return line
• If the DTC still exits replace the rail pressure sensor with a new one.
8.68 P1191— RAIL PRESSURE OFFSET VALUE BELOW MINIMUM LIMIT


NORMAL OPERATION
• Ignition ON
• During after run the EMS ECU monitors the raw value of the
rail pressure and is within the limits.
• Ignition ON
• The raw value of the rail pressure sensor is above the
maximum set point during after run • Faulty rail pressure sensor
DTC REACTIONS

HEALING CONDITION

P1191

• Replace the rail pressure sensor with a new one
8.69 P0193— SIGNAL RANGE CHECK FOR RAIL PRESSURE SENSOR ABOVE
MAXIMUM LIMIT

NORMAL OPERATION
• Ignition ON
• EMS ECU receives an output voltage signal from rail pressure
sensor and is within the range. • Short to battery in rail pressure
sensor circuit
• Short in rail pressure sensor
• Ignition ON signal and power supply wire
• The output voltage signal received from the rail pressure
sensor is above the maximum limit. • Open in rail pressure sensor
ground circuit
DTC REACTIONS
• Faulty rail pressure sensor
• OBD check lamp continuously ON after one driving cycle
• Engine switches off • Faulty EMS ECU
HEALING CONDITION
P0193
P0193
P0193
P0193
CONNECTOR
NO
64 GROUND
43 SUPPLY
1 GROUND
C33 RAIL PRESSURE SENSOR 2 SIGNAL
3 SUPPLY
P0193


STEP A –CHECK SHORT TO BATTERY OF RAIL PRESSURE SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Rail pressure sensor wiring harness connector (C33) DISCONNECTED
• Ignition ON
•
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5±0.25 V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • Examine the short circuit of rail pressure

sensor supply wire with battery positive
`
STEP B – CHECK SHORT TO BATTERY OF RAIL PRESSURE SENSOR SIGNAL WIRE
P0193
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP C • Examine the short circuit of rail pressure

sensor supply wire with battery positive
STEP C– CHECK OPEN CIRCUIT OF RAIL PRESSURE SENSOR GROUND WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • Examine the open circuit of rail pressure

sensor ground wire
STEP D – CHECK SHORT CIRCUIT B/W SUPPLY AND SIGNAL WIRE OF RAIL PRESSURE
SENSOR
P0193
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace the rail pressure sensor and check • Examine the short circuit of rail pressure
• If the DTC still exists , replace the EMS ECU sensor supply and signal wires
8.70 P0192— SIGNAL RANGE CHECK FOR RAIL PRESSURE SENSOR BELOW
MINIMUM LIMIT

NORMAL OPERATION
• Ignition ON
• EMS ECU receives an output voltage signal from rail pressure
sensor and is within the range.
• Open / short to ground circuit

DTC DETECTING CONDITIONS in rail pressure sensor power
wire.
• Ignition ON
• The output voltage signal received from the rail pressure • Short to ground circuit in rail
sensor is below the minimum limit. pressure sensor signal wire.
DTC REACTIONS • Faulty rail pressure sensor
• OBD check lamp continuously ON after one driving cycle • Faulty EMS ECU
• Engine switches off
HEALING CONDITION
P0192
P0192
P0192
P0192
CONNECTOR
NO
64 GROUND
43 SUPPLY
1 GROUND
C199 RAIL PRESSURE SENSOR 2 SIGNAL
3 SUPPLY


STEP A – CHECK VOLTAGE OF RAIL PRESSURE SENSOR SUPPLY WIRE
P0192
PRE CONDITION
• Ignition OFF
• Ignition ON
•
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5±0.25 V
ACTION TO BE TAKEN
OK NOT OK
STEP B – CHECK SHORT CIRCUIT OF RAIL PRESSURE SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP C • Examine the short circuit of rail pressure

sensor supply wire with battery ground
STEP C– CHECK OPEN CIRCUIT OF RAIL PRESSURE SENSOR SUPPLY WIRE
P0192
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine the open circuit of rail pressure
• Check and verify for any new DTC’s sensor supply wire
STEP D – CHECK SHORT CIRCUIT OF RAIL PRESSURE SENSOR SIGNAL WIRE WITH GROUND
WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace rail pressure sensor with a new one. • Examine the short circuit of rail pressure
• Clear the DTC and verify sensor signal wire with ground
• If the DTC still present , replace the EMS ECU • Replace the wiring harness
with a new one • Clear the DTC and verify
8.71 P2123—SIGNAL RANGE CHECK FOR ACCELERATOR PEDAL SENSOR 1

ABOVE MAXIMUM LIMIT
8.71.1 ACCELERATOR PEDAL PLAUSIBILITY
The Accelerator pedal module (APM) is mounted in the accelerator pedal and is connected to the
ECU by wires. The module consists of two potentiometers. EMS ECU receives the signals from both
the potentiometers and compares them for plausibility . If the difference between both the signals
goes beyond the maximum range then it is taken as a failure.

NORMAL OPERATION
• Ignition ON
• EMS ECU receives an output voltage signal from the
accelerator pedal module sensor 1 and is within the specified
range

• Short /open in accelerator
• Ignition ON pedal module sensors 1 circuit
• The output voltage signal received from the accelerator pedal
module sensor 1 is above the maximum limit.
• Faulty accelerator pedal module
• Faulty EMS ECU
DTC REACTIONS

HEALING CONDITION
P2123
P2123
P2123
P2123
CONNECTOR
NO
8 APP1 SUPPLY
C4 EMS ECU 84 APP1 GROUND
85 APP1 SIGNAL
3 SUPPLY
C124 APP1 2 GROUND
1 SIGNAL


STEP A – CHECK SHORT CIRCUIT OF APP1 SENSOR SUPPLY WIRE WITH BATTERY
P2123
PRE CONDITION
• Ignition OFF
• Accelerator pedal wiring harness connector (C124) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage < 5.25V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Examine the short circuit of accelerator pedal

sensor 1 supply wire with battery positive
• If the DTC still exists, replace the EMS ECU
with a new one
STEP B – CHECK SHORT CIRCUIT OF APP1 SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP C • Examine the short circuit of accelerator pedal

sensor 1 signal wire with supply
STEP C– CHECK OPEN CIRCUIT OF APP1 SIGNAL AND GROUND WIRES
P2123
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 1of C124 and pin 85 of C4
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace accelerator pedal with a new one • Examine the open circuit of accelerator pedal
• Clear the DTC and verify sensor 1 signal wire and/or ground wire
8.72 P2128—SIGNAL RANGE CHECK FOR ACCELERATOR PEDAL SENSOR 2

ABOVE MAXIMUM LIMIT
goes beyond the maximum range then it is taken as a failures

NORMAL OPERATION
• Ignition ON
range

• Ignition ON pedal module sensors 2 circuit
• The output voltage signal received from the accelerator pedal
module sensor 2 is above the maximum limit.
• Faulty EMS ECU
DTC REACTIONS

• Torue Limitation
HEALING CONDITION
P2128
P2128
P2128
P2128
CONNECTOR
NO
63 APP2 GROUND
C4 EMS ECU 86 APP2 SIGNAL
33 APP2 SUPPLY
6 SUPPLY
C124 APP2 5 GROUND
4 SIGNAL


STEP A – CHECK SHORT CIRCUIT OF APP2 SENSOR SUPPLY WIRE WITH BATTERY
P2128
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage < 5.25V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Examine the short circuit of accelerator pedal

sensor 2 supply wire with battery positive
• If the DTC still exists, replace the EMS ECU
with a new one
STEP B – CHECK SHORT CIRCUIT OF APP2 SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

sensor 2 signal wire with supply
STEP C– CHECK OPEN CIRCUIT OF APP2 SIGNAL AND GROUND WIRES
P2128
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace accelerator pedal with a new one • Examine the open circuit of accelerator pedal
• Clear the DTC and verify sensor 2 signal wire and/or ground wire
8.73 P2122—SIGNAL RANGE CHECK FOR ACCELERATOR SENSOR 1 BELOW

MINIMUM LIMIT

NORMAL OPERATION
• Ignition ON
range
DTC DETECTING CONDITIONS • Open /short to ground in

accelerator pedal 1 power wire
• Ignition ON • Short to ground circuit in
• The output voltage signal received from the accelerator pedal accelerator pedal 1 signal wire
module sensor 1 is below the minimum limit.

HEALING CONDITION
P2122
P2122
P2122
P2122
CONNECTOR
NO
8 APP1 SUPPLY
C4 EMS ECU 84 APP1 GROUND
85 APP1 SIGNAL
3 SUPPLY
C124 APP1 2 GROUND
1 SIGNAL


• Terminals not fully seated in the connector body
STEP A – CHECK VOLTAGE OF APP1 SENSOR SUPPLY WIRE
P2122
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage =5±0.25 V?
ACTION TO BE TAKEN
OK NOT OK
STEP B – CHECK SHORT CIRCUIT OF APP1 SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

sensor 1 supply wire with battery ground
STEP C– CHECK OPEN CIRCUIT OF APP1 SENSOR SUPPLY WIRE
P2122
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one • Examine the open circuit of accelerator pedal
• Check and verify for any new DTC’s sensor 1 Supply wire
STEP D—CHECK SHORT CIRCUIT OF APP1 SENSOR SIGNAL WIRE WITH GROUND WIRE
PRE CONDITION
• Ignition OFF
• Accelerator pedal wiring harness connector (P3) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace accelerator pedal with a new one • Examine the short circuit APP1 sensor signal
• Clear the DTC and verify wire with ground wire
8.74 P2127—SIGNAL RANGE CHECK FOR ACCELERATOR SENSOR 2 BELOW

MINIMUM LIMIT

NORMAL OPERATION
• Ignition ON
range
DTC DETECTING CONDITIONS • Open /short to ground in

accelerator pedal 2 power wire
• Ignition ON • Short to ground circuit in
• The output voltage signal received from the accelerator pedal accelerator pedal 2 signal wire
module sensor 2 is below the minimum limit.

HEALING CONDITION
P2127
P2127
P2127
P2127
CONNECTOR
NO
63 APP2 GROUND
C4 EMS ECU 86 APP2 SIGNAL
33 APP2 SUPPLY
6 SUPPLY
C124 APP2 5 GROUND
4 SIGNAL


STEP A – CHECK VOLTAGE OF APP2 SENSOR SUPPLY WIRE
P2127
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage =5±0.25 V?
ACTION TO BE TAKEN
OK NOT OK
STEP B – CHECK SHORT CIRCUIT OF APP2 SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

sensor 2 supply wire with battery ground
STEP C– CHECK OPEN CIRCUIT OF APP2 SENSOR SUPPLY WIRE
P2127
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one • Examine the open circuit of accelerator pedal
• Check and verify for any new DTC’s sensor 2 power supply wire
STEP D—CHECK SHORT TO GROUND OF APP2 SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Accelerator pedal wiring harness connector (124) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 4 and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace accelerator pedal with a new one • Examine the short circuit APP2 sensor signal
• Clear the DTC and verify wire with ground
8.75 P170D— STARTER RELAY SHORT CIRCUIT TO BATTERY ERROR

8.75.1 STARTER RELAY
Starter relay is used to control the starter motor . Whenever T 50 input is available at EMS ECU , it
energizes the starter relay to engage the starter motor.

NORMAL OPERATION
• Ignition ON
starter relay
• Short to battery in starter relay

• Ignition ON control wire
• Short to battery is detected in the control circuit of starter
relay
• Faulty starter relay
• Faulty EMS ECU
DTC REACTIONS

HEALING CONDITION
• Fault absent


P170D

STEP A – CHECK THE FUNCTIONING OF RELAY
PRE CONDITION
• Ignition OFF
• Ensure the starter relay is fixed properly in the connector of the relay box
• Remove the starter relay
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short to battery of starter relay • Replace the starter relay with a new one
control wire from EMS ECU • Clear the DTC and verify
8.76 P170E— STARTER RELAY SHORT CIRCUIT TO GROUND ERROR


NORMAL OPERATION
• Ignition ON
starter relay
• Ignition ON • Short to ground in starter relay

• Short to ground is detected in the control circuit of starter control wire
relay
• Faulty EMS ECU
DTC REACTIONS

HEALING CONDITION
• Fault not present

• Proceed to DIAGNOSTIC PROCEDURE if P170E is present

P170E

STEP A – CHECK THE FUNCTIONING OF STARTER RELAY
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Replace the starter relay with a new one

STEP B– CHECK STARTER RELAY CONTROL CIRCUIT SHORT TO GROUND
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 2 of the starter relay seating and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
P170E
OK NOT OK
• Replace EMS ECU with a new one. • Examine the short circuit of starter relay
• Check and verify for any new DTC’s control signal wire with ground
8.77 P170F— STARTER RELAY OPEN LOAD


NORMAL OPERATION
• Ignition ON
starter relay
DTC DETECTING CONDITIONS • Open circuit in starter relay

control wire
• Ignition ON • Open circuit in starter relay
• Open circuit is detected in the control circuit of starter relay supply wire
• Faulty starter relay
DTC REACTIONS
• Faulty EMS ECU
HEALING CONDITION

• Proceed to DIAGNOSTIC PROCEDURE if P170F is present

P170F

STEP A – CHECK THE FUNCTIONING OF RELAY
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Replace the starter relay with a new one

STEP B– CHECK THE OPEN CIRCUIT OF STARTER RELAY CONTROL WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
• Hold the ignition switch in crank position and ensure battery voltage is available at pin 8 of
starter relay connector
TEST PROCEDURE
• Check the resistance between pin 2 of the starter relay seating and pin 52 of C4
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
P170F
OK NOT OK
• Replace EMS ECU with a new one • Examine the open circuit of starter relay
• Check and verify for any new DTC’s control wire from EMS ECU
8.78 P170C— STARTER RELAY OVER TEMPERATURE ERROR

8.78.1 STARTER MOTOR RELAY
energizes the starter relay to engage the starter motor

NORMAL OPERATION
• Ignition ON
starter relay

• Short to ground in starter relay
• Ignition ON control wire
• Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Fault absent


P170C

8.79 P1656SVS NO LOAD ERROR

8.79.1 ENGINE CHECK LAMP
Engine check lamp indicates a malfunction in engine management system. During ignition ON, the
engine check lamp is ON and goes OFF in few seconds. The lamp illuminates continuously or blinks
for any malfunction in engine management system. During every ignition ON, IC carries out self-
check for confirming proper functioning of engine check lamp.

NORMAL OPERATION
• Ignition ON
• The Engine check lamp glow ON for 02 seconds and
Switches OFF. lamp remains ON for any EMS error

• Open circuit in Engine check
lamp circuit
• Ignition ON
• Open load detected in Engine check lamp signal to IC
• Faulty IC
• Faulty EMS ECU
DTC REACTIONS
• Engine check lamp remains OFF always
HEALING CONDITION
• Fault absent
P1656
P1656
P1656
P1656
CONNECTOR
NO
ENGINE CHECK LAMP SIGNAL
C4 EMS ECU 1
WIRE
C119 INSTRUMENT CLUSTER 16
WIRE


STEP A – CHECK THE ENGINE CHECK LAMP BY ACTUATOR TEST
P1656
PRE CONDITION
• Ignition ON
• Go to the actuator test in i-smart tool
• Actuate the Engine check lamp
TEST PROCEDURE
• Check If the Engine check lamp works with the actuator test.
ACCEPTANCE CRITERIA
• Engine check lamp glows
ACTION TO BE TAKEN
OK NOT OK
• Clear the DTC and verify • GO TO STEP B
STEP B – CHECK OPEN CIRCUIT OF ENGINE CHECK LAMP SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit between the ECU

and cluster engine check lamp signal wire
STEP C– CHECK THE FUNCTIONALITY OF ENGINE CHECK LAMP
P1656
PRE CONDITION
• Ignition ON
• Crankshaft speed sensor connector (C37) DISCONNECTED
TEST PROCEDURE
• Crank the engine
ACCEPTANCE CRITERIA
• Engine check lamp glows
ACTION TO BE TAKEN
OK NOT OK
• Check for damage/oxidation in instrument • Engine check Lamp failed

cluster and ECU connector pins
• Replace the instrument cluster with new one
8.80 P1655— SVS SHORT CIRCUIT TO BATTERY ERROR

engine check lamp is ON and goes OFF in few seconds.The lamp illuminates continuously or blinks

NORMAL OPERATION
• Ignition ON
• The Engine check lamp glows ON for 02 seconds and
switches OFF. Lamp remains ON for any EMS error

• Short to battery in Engine check
lamp circuit
• Ignition ON
• Faulty IC
• Short circuit battery detected in OBD lamp signal to IC
• Faulty EMS ECU
DTC REACTIONS
• Nil
HEALING CONDITION
• Fault absent
P1655
P1655
P1655
P1655
CONNECTOR
NO
C4 EMS ECU 16
WIRE
WIRE


STEP A – CHECK SHORT TO BATTERY OF ENGINE CHECK LAMP SIGNAL WIRE
P1655
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0V
ACTION TO BE TAKEN
OK NOT OK
• Engine check Lamp failed • Examine the short to battery of Engine check
• Replace the instrument cluster with a new lamp signal wire
8.81 P1654— SVS SHORT CIRCUIT TO GROUND ERROR

engine check lamp is ON and goes OFF in few seconds. If the lamp illuminates continuously or blinks

NORMAL OPERATION
• Ignition ON
• The Engine check lamp will glow ON for 02 seconds and will
get switched OFF if no DTC is set in the ECU.

• Short to ground in Engine check
lamp circuit
• Ignition ON
• Faulty Engine check lamp
• The Engine check lamp glows continuously
• Faulty EMS ECU
DTC REACTIONS
• Nil
HEALING CONDITION
• Fault absent
P1654
P1654
P1654
P1654
CONNECTOR
NO
C4 EMS ECU 16
WIRE
WIRE


STEP A – CHECK SHORT TO GROUND OF ENGINE CHECK LAMP SIGNAL WIRE
P1654
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Engine check Lamp failed • Examine the short to ground of Engine check
lamp signal wire
8.82 P1657— CHECK LAMP OVER TEMPERATURE ERROR

engine check lamp is ON and goes OFF in few seconds. If the lamp illuminates continuously or blinks

NORMAL OPERATION
• Ignition ON
• No malfunction detected by EMS ECU in the Engine check
lamp circuit

DTC REACTIONS
• Nil
HEALING CONDITION
• Fault absent


P1657


8.83 P2138—PLAUSIBILITY ERROR BETWEEN ACCELERATOR PEDAL SIGNAL

1 AND SIGNAL 2

NORMAL OPERATION
• Ignition ON
• EMS ECU compares both APP1 and APP2 signals and the
difference is within the maximum range

• Ignition ON
pedal module sensors circuit
• The difference between APP1 and APP2 signals is more than
the maximum range
• Faulty EMS ECU
DTC REACTIONS
• Limp Home mode

HEALING CONDITION

P2138

• Ensure no loose connections in APP1 and APP2 ground wires

• Check for proper mounting of the accelerator pedal
• If the DTC still exists , replace the Accelerator Pedal with a new one
8.84 P1707— T50 SIGNAL ERROR

8.84.1 T50 INPUT
T50 is the crank or run position of the ignition switch . Whenever the key is rotated to crank position
, the EMS ECU monitors the time at which the key is in crank position . If the time exceeds the pre
determined time , then EMS ECU sets this error

NORMAL OPERATION
• Ignition ON
• The T50 input (crank) is monitored by EMS ECU is with in the
allowable duration
• Short to battery in T50 input to

DTC DETECTING CONDITIONS EMS ECU
• Ignition switch malfunction
• The T50 input is available at EMS ECU continuously for 7
seconds
• Continuos cranking
DTC REACTIONS
• Faulty EMS ECU
HEALING CONDITION
• Fault absent
• Check the battery for short to battery in T50 input to EMS ECU
• Check for ignition switch malfunction
• Check for mechanical failure in engine which results in lengthy continuos cranking
• Replace the EMS ECU
8.85 P0501— VEHICLE SPEED SENSOR PLAUSIBILITY ERROR

8.85.1 VEHICLE SPEED SENSOR (VSS)
Vehicle Speed Sensor(VSS) is hall sensor type and senses the rotating speed of the transaxle output
shaft . Comparing engine speed with vehicle speed calculated based on vehicle speed sensor signal,
ECU recognizes engaged gear. Based on the information about engaged gear, ECU performs
optimum fuel injection quantity correction

NORMAL OPERATION
• Ignition ON
• When the vehicle is driven , VSS outputs a pulse signal
to the EMS ECU and is within the range
• Ignition ON
• Clutch is engaged and gear not in neutral but the VSS • Short /open in VSS circuit
sensor output remains same for more than calibrated
time
• Faulty Vehicle Speed sensor
DTC REACTIONS
• Cluster Display FFFFh

HEALING CONDITION
• Fault absent
P0501
P0501
P0501
CONNECTOR
NO
1 SUPPLY
C247 VEHICLE SPEED SENSOR 2 GROUND
3 SIGNAL

P0501

STEP A – CHECK OPEN CIRCUIT/SHORT CIRCUIT IN VEHICLE SPEED SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• VSS wiring harness connector (C247) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage =12 V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP B • Examine the open/short circuit to ground of

the VSS Supply Wire
STEP B – CHECK OPEN CIRCUIT IN VSS SENSOR GROUND WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 2 of C 247 and battery ground
ACCEPTANCE CRITERIA
• Resistance <1Ω
P0501
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP C • Examine the open circuit of VSS ground wire

Repair/replace the wiring harness
Clear the DTC and verify
STEP C – CHECK OPEN CIRCUIT OF VSS SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance < 1Ω
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • Examine the open circuit of VSS signal wire

Repair /Replace the wiring harness
STEP D – CHECK SHORT CIRCUIT TO GROUND OF VSS SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
P0501
OK NOT OK
• Replace the vehicle speed sensor • Examine the short circuit of the VSS signal
• Clear the DTC and verify wire
• If the DTC still present , replace the EMS ECU • Repair/Replace the wiring harness
• Check for any new DTC’s • Clear the DTC and verify
8.86 P0641— SENSOR SUPPLY VOLTAGE 1 MONITORING ERROR

8.86.1 SENSOR SUPPLY VOLTAGE 1 MONITORING
EMS ECU monitors the supply voltage of Accelerator Pedal position sensor 2 (APP2) , EGR value
position sensor and registers a DTC if the voltage is not within the range.

NORMAL OPERATION
• Ignition ON
• EMS ECU monitors the supply voltage of the Accelerator
Pedal position sensor 2 (APP2),EGR value position sensor and
is within the range

• Short to ground/battery of
• Ignition ON supply wire of APP2 and EGR
value position sensor
• The supply voltage of Accelerator Pedal position sensor 2
(APP2),EGR value position sensor are out of the range
• Faulty sensor APP2 and EGR
value position sensor
DTC REACTIONS

HEALING CONDITION
• Fault absent
P0641
P0641
P0641
P0641
P0641
P0641
CONNECTOR
NO
33 APP2 SUPPLY
C4 EMS ECU
74 EGR ACTUATOR
C 124 APP2 6 SUPPLY
C 63 EGR 2 SUPPLY

P0641

STEP A – CHECK SHORT TO BATTERY OF APP2 / EGR ACTUATOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• EGR wiring harness connector (C63) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5.0±0.25 V
ACTION TO BE TAKEN
OK NOT OK
• If the Voltage is greater than 5.25V , check

for short to battery of the APP2 /EGR
actuator supply wire
• If it is less than 4.75 ,examine the short to
ground of APP2 /EGR actuator supply wire
• GO TO STEP B
• If the DTC still exists ,replace the EMS ECU
with a new one
STEP B – CLEAR THE DTC
P0641
PRE CONDITION
• Ignition OFF
• Disconnect one sensor wiring harness connector at a time (out of EGR actuator and APP2
sensor
• Ignition ON
TEST PROCEDURE
• Try to clear the DTC
ACCEPTANCE CRITERIA
• DTC cleared
ACTION TO BE TAKEN
OK NOT OK
• Replace the sensor with a new one • Try the same test for other sensor. If the DTC
• Clear the DTC and verify still exists , replace the EMS ECU with a new
one
8.87 P0697— ERROR SENSOR SUPPLIES 3

8.87.1 SENSOR SUPPLY VOLTAGE 3 MONITORING
EMS ECU monitors the supply voltage of Accelerator Pedal position sensor 1 (APP1) ,Rail pressure
sensor and registers a DTC if the voltage is not within the range.

NORMAL OPERATION
• Ignition ON
• EMS ECU monitors the supply voltage of the Accelerator
Pedal position sensor 1 (APP1),Rail pressure sensor and is
within the range

• Short to ground/battery of
• Ignition ON supply wire of APP1 and Rail
pressure sensor
• The supply voltage of Accelerator Pedal position sensor 1
(APP1),Rail pressure sensor are out of the range
• Faulty sensor APP1 and Rail
pressure sensor
DTC REACTIONS

HEALING CONDITION
• Fault absent
P0697
P0697
P0697
P0697
P0697
CONNECTOR
NO
8 APP1 SUPPLY
C4 EMS ECU RAIL PRESSURE SENSOR
43
SUPPLY
c124 APP1 43 SUPPLY
C33 RAIL PRESSURE SENSOR 3 SUPPLY

P0697

STEP A – CHECK SHORT TO BATTERY OF APP1 / RAIL PRESSURE SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5.0 ± 0.25 V
ACTION TO BE TAKEN
OK NOT OK
• If the Voltage is greater than 5.25V , check

for short to battery of the APP1 / Rail
pressure sensor supply wire
• If it is less than 4.75 ,examine the short to
ground of APP1 / Rail pressure sensor supply
• GO TO STEP B wire
• If the DTC still exists ,replace the EMS ECU
with a new one
STEP B – CLEAR THE DTC
P0697
PRE CONDITION
• Ignition OFF
• Disconnect one sensor wiring harness connector at a time (out of Rail pressure and APP1
sensor)
• Ignition ON
TEST PROCEDURE
• Try to clear the DTC
ACCEPTANCE CRITERIA
• DTC cleared
ACTION TO BE TAKEN
OK NOT OK
• Replace the sensor with a new one • Try the same test for other sensor. If the DTC
• Clear the DTC and verify still exists, replace the EMS ECU
8.88 P1608— COOLANT TEMPERATURE OUTPUT (ON DASH PANEL) SHORT

CIRCUIT TO BATTERY ERROR
8.88.1 ENGINE TEMPERATURE TELL TALE LAMP
The Engine temperature tell tale lamp indicates the high temperature of the engine coolant
When the coolant temperature reaches 105 to 110° C 6 bars in the temperature gauge ON/blinks
and Engine temperature tell tale lamp continuously ON
When the coolant temperature reaches 111 °C and above all the 7 bars in the temperature gauge
ON and Engine temperature tell tale lamp continuously ON

NORMAL OPERATION
• Ignition ON
• No error detected in Engine temperature tell tale lamp
control circuit during self check

• Short to battery in Engine
• Ignition ON temperature tell tale lamp circuit
• Short to battery in Engine temperature tell tale lamp circuit • Faulty Engine temperature tell
tale lamp
• Faulty EMS ECU
DTC REACTIONS
• coolant temperature Coolant temperature gauge blinking

with beep sound
• Engine temperature tell tale lamp ON
HEALING CONDITION
• Fault absent
P1608
P1608
P1608
P1608
CONNECTOR
NO
ENGINE TEMPERATURE TELL
C4 EMS ECU 36
TALE LAMP SIGNAL WIRE


STEP A – CHECK SHORT TO BATTERY OF ENGINE TEMPERATURE TELL TALE LAMP SIGNAL
WIRE
P1608
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0V
ACTION TO BE TAKEN
OK NOT OK
• Engine temperature tell tale Lamp failed • Examine the short to battery of Engine
• Replace the instrument cluster with a new temperature tell tale lamp signal wire
8.89 P1609— COOLANT TEMPERATURE OUTPUT (ON DASH PANEL) SHORT

CIRCUIT TO GROUND ERROR

NORMAL OPERATION
• Ignition ON

• Short to ground in Engine
temperature tell tale lamp circuit
• Ignition ON
• Faulty Engine temperature tell
• Short to ground in Engine temperature tell tale lamp circuit
tale lamp
• Faulty EMS ECU
DTC REACTIONS
• Coolant temperature gauge blinking with beep sound

HEALING CONDITION
• Fault absent
P1609
P1609
P1609
P1609
CONNECTOR
NO
C4 EMS ECU 36


STEP A – CHECK SHORT TO GROUND OF ENGINE TEMPERATURE TELL TALE LAMP SIGNAL
WIRE
P1609
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the Resistance between pin 12 of C119 and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Engine temperature tell tale Lamp failed • Examine the short to ground of Engine
• Replace the instrument cluster with a new temperature tell tale lamp signal wire
8.90 P160A— COOLANT TEMPERATURE OUTPUT (ON DASH PANEL) NO LOAD

ERROR

NORMAL OPERATION
• Ignition ON

• Open circuit in Engine
temperature tell tale lamp circuit
• Ignition ON
• Faulty Engine temperature tell
• Open circuit in Engine temperature tell tale lamp circuit
tale lamp
• Faulty EMS ECU
DTC REACTIONS

HEALING CONDITION
• Fault absent
P160A
P160A
P160A
P160A
CONNECTOR
NO
C4 EMS ECU 36

• Proceed to DIAGNOSTIC PROCEDURE if P160A is present

STEP A – CHECK OPEN CIRCUIT OF ENGINE TEMPERATURE LAMP SIGNAL WIRE
P160A
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
OK NOT OK
• Replace the instrument cluster • Examine the open circuit between the ECU
• Clear the DTC and verify and cluster Engine temperature lamp signal
wire
8.91 P160B— COOLANT TEMPERATURE OUTPUT(ON DASH PANEL) OVER

TEMP ERROR

NORMAL OPERATION
• Ignition ON
• No error detected in Engine temperature tell tale lamp circuit
during self check
• Ignition ON
• Power stage overheating is detected • Defective EMS ECU
DTC REACTIONS

HEALING CONDITION
• Fault absent
P160B

• Proceed to DIAGNOSTIC PROCEDURE if P160B is present


8.92 P1503— PERFORMANCE LIMITER ERROR FOR LEVEL 0

8.92.1 RAIL PRESSURE MONITORING
EMS ECU continuously monitors the rail pressure at any given RPM and compares the value with
the map . If the rail pressure at given rpm and other environmental conditions is not with the
threshold given in the map, then EMS ECU registers error

NORMAL OPERATION
• Ignition ON
• The rail pressure at the any given rpm and environmental
condition is with in the allowable threshold
DTC DETECTING CONDITIONS • Air lock in the fuel system

• Leakage in Fuel system
• Ignition ON
• Fuel filter chocked
• The rail pressure value at a given rpm and environment
condition is lesser than the allowable threshold • Restrictions in fuel line
• Pre supply pump internal leak
• High pressure pump faulty
DTC REACTIONS
HEALING CONDITION
• Fault absent

• Check and ensure no airlock in fuel system. Refer repair manual for the procedure to remove
airlock in the fuel system
• Check and ensure the no kinks/bend in the fuel supply hoses and pipes
• Check and ensure no any leaks in the fuel pipes and hoses
P1503
• Check for any restrictions in fuel pipes and hoses

• Check by replacing fuel filter
• Suspect presupply pump internal leak — replace and check
• Suspect high pressure pump internal leak — Replace and check
8.93 P0262— SHORT CIRCUIT ERROR FOR CYLINDER 1 INJECTOR

8.93.1 INJECTORS
of the injector .

NORMAL OPERATION
• Ignition ON
• No short detected in the low side of the injector 1

• Short to ground in injector 1 low
• Ignition ON side
• Short to ground detected in the low side of the injector 1
• Faulty Injectors 1
DTC REACTIONS
• Faulty EMS ECU
HEALING CONDITION
• Fault absent for one driving cycles
P0262
P0262
P0262
CONNECTOR
NO
C4 EMS ECU
1 POWER HIGH SIDE
INJECTOR
C 27 INJECTOR 1
2 POWER LOW SIDE
INJECTOR
P0262


STEP A— CHECK SHORT CIRCUIT OF INJECTOR LOW SIDE WIRE TO GROUND
PRE CONDITION
• Ignition OFF
• Injector wiring harness connector (C27) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine short circuit of injector low side wire
• Check and verify for any new DTC’s to battery ground
8.94 P0265— SHORT CIRCUIT ERROR FOR CYLINDER 2 INJECTOR

8.94.1 INJECTORS
of the injector .

NORMAL OPERATION
• Ignition ON
• No short detected in the low side of the injector 2

• Short to ground in injector 2 low
• Ignition ON side
• Short to ground detected in the low side of the injector 2
• Faulty Injectors 2
DTC REACTIONS
• Faulty EMS ECU
HEALING CONDITION
• Fault absent for one driving cycles
P0265
P0265
P0265
CONNECTOR
NO
C4 EMS ECU
1 POWER HIGH SIDE
INJECTOR
C 28 INJECTOR 2
2 POWER LOW SIDE
INJECTOR
P0265


STEP A— CHECK SHORT CIRCUIT OF INJECTOR LOW SIDE WIRE TO GROUND
PRE CONDITION
• Ignition OFF
• Injector wiring harness connector (C28) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with a new one. • Examine short circuit of injector 2 low side
• Check and verify for any new DTC’s wire to battery ground
8.95 P1612— ERROR FOR OVER CURRENT DETECTION OF EKP

The Electric in tank pump is located inside the fuel tank. It is an electrical pump and controlled by

NORMAL OPERATION
• Ignition ON

• Short to ground/battery in
• Ignition ON Electric intank pump control
wires
• Over current detected in electric intank pump control circuit
continuously
• Electric intank pump stuck
• Restriction in electric intank
DTC REACTIONS
pump output
• Faulty EMS ECU
• Engine Check lamp continuously ON
HEALING CONDITION
• Fault absent in next driving cycle


P1612

• Check for DTC’s P0629 and P0628 in EMS ECU. If present refer the diagnostic procedure and
rectify
• Check for any restrictions in electric intank pump output flow
• Replace the electrical intank pump and check — If the DTC still present , replace the EMS ECU
with new one
8.96 P1613— ERROR FOR ACTUAL CURRENT FOR EKP GREATER THAN
SECONDARY THRESHOLD
8.96.1 ELECTRIC IN TANK PUMP
The Electric in tank pump is located inside the fuel tank. It is an electrical pump and controlled by

NORMAL OPERATION
• Ignition ON

• Short to ground/battery in
• Ignition ON Electric intank pump control
wires
• Over current detected in electric intank pump control circuit
continuously
• Electric intank pump stuck
• Restriction in electric intank
DTC REACTIONS
pump output
• Faulty EMS ECU
HEALING CONDITION
• Fault absent in next driving cycle


P1613

• Check for DTC’s P0629 and P0628 in EMS ECU. If present refer the diagnostic procedure and
rectify
• Check for any restrictions in electric intank pump output flow
• Replace the electric intank pump and check —If the DTC still present , replace the EMS ECU with
new one
8.97 P108D—ERROR FOR MINIMUM RAIL PRESSURE EXCEEDED


NORMAL OPERATION • Air lock in the fuel system
• Overflow valve on filter assembly
• Ignition ON stucked open
• The rail pressure at the any given rpm and environmental • Leakage in Fuel system
DTC DETECTING CONDITIONS • Restrictions in fuel line
• Presupply pump internal leak
• Ignition ON
condition is lesser than the allowable threshold for 1 second • Injector struck open
DTC REACTIONS

HEALING CONDITION
• Fault absent

P108D
• Check and ensure overflow valve is not sticky

• Replace the injector and check
8.98 P108E—ERROR FOR MAXIMUM RAIL PRESSURE EXCEEDED


NORMAL OPERATION
• Ignition ON
• The rail pressure at the any given rpm and environmental
• Ignition ON
• Restriction in Fuel return line
condition is higher than the allowable threshold for 1 second • Electric intank pump relief valve
struck closed
DTC REACTIONS

HEALING CONDITION
• Fault absent

• Proceed to DIAGNOSTIC PROCEDURE if P108E is present
• Check and ensure no restriction in fuel return line

• Suspect electric intank pump relief valve struck closed — Replace the pump and check for the
DTC
8.99 P108A—ERROR FOR MAXIMUM POSITIVE DEVIATION OF RAIL PRESSURE

EXCEEDED
the map . If the set value of the rail pressure exceeds the actual value at a given rpm and if it is
beyond the allowable delta value for a calibrated time period , then rail pressure maximum positive
deviation error registers

NORMAL OPERATION • Air lock in the fuel system
• Ignition ON stucked open
• For any given engine rpm , the difference between the set • Leakage in Fuel system
value of the rail pressure at the any given load condition and
the actual value is with in the allowable threshold
• Restrictions in fuel line
• Ignition ON • Injector struck open
• The set value of the rail pressure at the any engine rpm is • High pressure pump faulty
above the actual value for a calibrated period of time
DTC REACTIONS

HEALING CONDITION
• Fault absent

• Proceed to DIAGNOSTIC PROCEDURE if P108A is present
P108A
8.100 P108B—ERROR FOR MAXIMUM POSITIVE DEVIATION OF RAIL

PRESSURE EXCEEDED CONCERNING SET FLOW OF FUEL
the map . If the set value of the rail pressure exceeds the actual value based on the rpm and the set
delivery quantity of the pre supply pump reaches above the maximum allowable limit , then this error
registers

NORMAL OPERATION
• Ignition ON
• The difference between the set value of the rail pressure at
the based on the rpm and the actual value is with in the
allowable threshold
• Also the set value of the pre supply pump delivery is within the
allowable limit • Air lock in the fuel system
stucked open
• Leakage in Fuel system
• Ignition ON
• The set value of the rail pressure is above the actual value • Fuel filter chocked
and the set value of the pre supply pump delivery is above the • Restrictions in fuel line
allowable limit for 3 seconds
• Injector struck open
DTC REACTIONS
HEALING CONDITION
• Fault absent

• Proceed to DIAGNOSTIC PROCEDURE if P108B is present
P108B
8.101 U1501EMS VARIANT CODE ERROR

8.101.1 VARIANT CODE MISMATCH
During ignition ON, EMS checks internally for a valid variant code

NORMAL OPERATION
• Ignition ON
• A valid variant code is available at EMS ECU
• Ignition ON
• No valid variant code in EMS ECU • No valid variant code written in
EMS ECU
DTC REACTIONS
• Degraded EMS functionality
HEALING CONDITION

• Proceed to DIAGNOSTIC PROCEDURE if U1501 is present
• Using i-flash , ensure Selection of correct VIN number and the variant
• Perform EMS ECU flashing (Write Variant and feature code is performed in the segment of
flashing
• Clear the DTC
• Switch OFF & ON ignition
• Check for any DTC
8.102 U2801EMS FEATURE CODE ERROR

8.102.1 FEATURE CODE MISMATCH
During ignition ON, EMS checks internally for a valid feature code

NORMAL OPERATION
• Ignition ON
• A valid feature code is available at EMS ECU
• Ignition ON
• No valid feature code in EMS ECU • No valid feature written in EMS
ECU
DTC REACTIONS
• Degraded EMS functionality
HEALING CONDITION

• Proceed to DIAGNOSTIC PROCEDURE if U2801 is present
• Using i-flash , ensure Selection of correct VIN number and the variant
• Perform EMS ECU flashing (Write Variant and feature code is performed in the segment of
flashing
• Clear the DTC
• Switch OFF & ON ignition
• Check for any DTC
8.103 P108C—ERROR FOR MAXIMUM NEGATIVE DEVIATION WITH METERING

UNIT ON LOWER LIMIT IS EXCEEDED
8.103.1 NEGATIVE DEVIATION —RAIL PRESSURE MONITORING
the map . If the actual value of the rail pressure exceeds the set value at a given rpm and the set
delivery quantity of the pre supply pump reaches below the minimum allowable limit , then negative
deviation error registers

NORMAL OPERATION
• Ignition ON
• The difference between the set value of the rail pressure and
the actual value based on the rpm is with in the allowable
threshold
• At the same time the set value of the pre supply pump
delivery is within the allowable limits
• Ignition ON • Restriction in Fuel return line

• The actual value of the rail pressure is above the set value • Electric intank pump relief valve
based on the rpm and the set value of the pre supply pump struck closed
delivery is below the allowable minimum limit for 3 seconds
DTC REACTIONS

HEALING CONDITION
• Fault absent

P108C
• Check and ensure no restriction in fuel return line

• Suspect electric intank pump relief valve struck closed — Replace the pump and check for the
DTC
9 SYMPTOM BASED DIAGNOSIS- WITH NO DTC CODES

Complaint —Engine not starting
Error codes —No error codes.
Caution:
• Open the "LIVE DATA" in EMS ECU .
• Check the "Service information for trouble in starting engine"
• Note the value

• Convert it into binary
• See the bit position of first occurrence of "1" from right and look against the bit position in the
table below
Bit Position Conditions to be met Implication Action to be taken
• Check the fuel level in

fuel tank
• Check for any
The engine speed is above restriction in fuel filter
the minimum threshold , No pressure built up in the
0 • Check injector back
but the pressure built up in fuel circuit
the FDB is not sufficient leaks.
• If all of the above is OK,
replace the Electric
intank pump
• Check for battery for

The pressure built up in less voltage
the rail is sufficient but the Cranking RPM less
1 • Check any loose
engine speed is below the
minimum threshold connections in starter
motor
P108C
Bit Position Conditions to be met Implication Action to be taken

• Check the starter
motor for any
malfunction
• Check for Engine partial
seizure/hydraulic lock
The pressure built up in

the FDB is sufficient but
Check for mechanical
the engine speed is above Engine synchronization not
2 failure of engine
the minimum threshold happening
components
but there is a problem with
synchronization of engine
Check the value of

There is a shut off request. Current limitations active
The application constant label in Monitoring live
3 determines which shut-off Shut off request
data pocket and refer
conditions are to be taken shut off request table
into account. given in next page
Status of the starter .

When there is a start
Starter engagement Check for any immobiliser
4 attempt a check is made
status related errors
whether the starter has
been released or not
9.1 REASON FOR TORQUE LIMITATION

• Note the value of Current limitations active label in Monitoring live data pocket
• Convert it into binary
• See the bit position of first occurrence of "1" from right and look against the bit position in the
table below
BIT POSITION REASON FOR TORQUE LIMITATION
Limiting torque due to torque limitation in the event of a system

0
error
1 Limiting torque for differential protection
2 Limiting torque for engine mechanics protection
3 Limiting torque for smoke limitation
Limiting torque due to quantity limitation in the event of a system

4
error
P108C
5 Limiting torque for protection against overheating
6 Limiting torque for the propulsion in the event of a system error
7 Maximum gearbox input torque
8 Limiting torque due to injection quantity limitation from T3Limr
9 Limiting torque due to high pressure pump unit
13 Limiting torque due to inner engine torque
14 Limiting torque for engine protection

Diagnostic Manual Supro Maxitruck

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Diagnostic Manual Supro Maxitruck

Uploaded by

Copyright:

Available Formats

EMS MAN - 00313

THE NEW GENERATION

NOTHING ELSE WILL DO

1 HOW TO USE THIS MANUAL ............................................................................................ 9

7 EMS ECU FLASHING .............................................................................................................22

8.14 P1403— EGR VALVE OVER TEMPERATURE ERROR .......................................85

8.39 P0202— CYLINDER 2 INJECTOR OPEN LOAD ERROR ............................... 215

8.61 P2229— SIGNAL RANGE CHECK FOR ENVIRONMENTAL PRESSURE

8.81 P1654— SVS SHORT CIRCUIT TO GROUND ERROR .................................... 417

8.103 P108C—ERROR FOR MAXIMUM NEGATIVE DEVIATION WITH

9 SYMPTOM BASED DIAGNOSIS- WITH NO DTC CODES ............................. 507

1 HOW TO USE THIS MANUAL

EMS Engine Management System

3 WARRANTY & OTHER INFORMATION

4 RECOMMENDED TROUBLE SHOOTING PROCESS

Customer complaint � Record/Understand Customer Verbatim

5 EMS ECU PIN DETAILS

ECU FUNCTION CONNECTED TO CONNECTOR NO

ECU FUNCTION CONNECTED TO CONNECTOR NO

ECU FUNCTION CONNECTED TO CONNECTOR NO

6 IQA CODE PROGRAMMING

6.1 IMPORTANT SWITCH STATUS — LIVE DATA

• CLUTCH PEDAL PRESSED CONDITION

BRAKE SWITCH STATUS

• BRAKE PEDAL RELEASED CONDITION

• BRAKE PEDAL FULLY PRESSED CONDITION

7 EMS ECU FLASHING

2 Click on “READ VIN NO” and the following screen appears:

4 Click on “START” and the following screen appears:

5 Click on “ENGINE MANAGEMENT SYSTEM” and the following screen appears:

6 Select “Auto Mode” and the following screen appears:

7 Click on “START FLASHING” The following window appears.

8 Press “YES”to initiate the flashing process:

8 DTC BASED DIAGNOSIS

8.1 P0704— CLUTCH NON PLAUSIBLE ERROR

DTC INFORMATION PROBABLE CAUSES OF FAILURE

DTC DETECTING CONDITIONS

8.1.1.1 CIRCUIT SCHEMATIC

8.1.2 CONNECTOR LOCATION

8.1.3 CONNECTOR VIEWS AND INFORMATION

8.1.4 DTC CHECKING PROCEDURE

• Turn the ignition ON and Initialise i-SMART tool

8.1.5 INTERMITTENT PROBLEMS

Check the following for intermittent problems

8.1.6 DIAGNOSTIC PROCEDURE

STEP A – CHECK VOLTAGE IN CLUTCH SWITCH

• GO TO STEP B • Examine the open/short circuit in Clutch

STEP B – CHECK OPEN CIRCUIT IN CLUTCH SWITCH GROUND WIRE

• Replace the Clutch Switch with new one

8.2 P0100—BATTERY VOLTAGE ERROR OF HFM SENSOR

DTC INFORMATION PROBABLE CAUSES OF FAILURE

DTC DETECTING CONDITIONS

• Engine Check lamp blinking after 3 driving cycles

8.2.2 DTC CHECKING PROCEDURE

• Turn the ignition ON and Initialise i-SMART tool

8.2.3 INTERMITTENT PROBLEMS

Check the following for intermittent problems

8.2.4 DIAGNOSTIC PROCEDURE

STEP A – CHECK BATTERY VOLTAGE

DTC INFORMATION PROBABLE CAUSES OF FAILURE

DTC DETECTING CONDITIONS

• Engine Check lamp blinks continuously

8.3.2 DTC CHECKING PROCEDURE

• Turn the ignition ON and Initialise i-SMART tool