SCORPIO VLX DIAGNOSTIC MANUAL mHAWK Rev1

SCORPIO Vlx
DIAGNOSTIC MANUAL - mHAWK
Revision 1
MAN-00029
922MHKR011107EN-DM
CONFIDENTIAL
• ONLY FOR INTERNAL CIRCULATION WITHIN RELEASED BY :
M&M AUTHORISED DEALERS & SERVICE CENTRES
• PASSING ON TO THRID PARTY IS NOT PERMITTED
• ALWAYS CHECK FOR THE LATEST VERSION
TECHNICAL PUBLICATION CELL
MAHINDRA & MAHINDRA LTD
Rev 1 – NOVEMBER 2007
The reproduction, translation, transmission, in part of whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. © 2007 Mahindra & Mahindra Ltd
MAN-00029
922MHKR011107EN-DM
TABLE OF CONTENTS
1. HOW TO USE THIS MANUAL 2
2. BRIEF ENGINE SPECIFICATIONS 3
3. GUIDELINES FOR TROUBLE-SHOOTING 4
4. DTC CODES – HYPERLINKED INDEX 10
5. DTC BASED DIAGNOSTICS 21
ACCELERATOR PEDAL – CIRCUIT 1 21

ACCELERATOR PEDAL – CIRCUIT 2 27
BOOST PRESSURE ACTUATOR 32
BOOST PRESSURE SENSOR 39
CAMSHAFT PHASE SENSOR 43
CRANK POSITION SENSOR (TDC SENSOR) 49
AIR FLOW SENSOR 53
INTAKE AIR TEMPERATURE SENSOR 59
RAIL PRESSURE SENSOR 64
NO COMMUNICATION WITH ECU 72
EGR POWER STAGE 74
FUEL TEMPERATURE SENSOR 81
METERING UNIT IN HP PUMP 87
CRDe MAIN RELAY 91
CRUISE CONTROL 95
BATTERY 100
BRAKE SWITCH 102
CLUTCH SWITCH 106
COOLANT TEMPERATURE SENSOR 111
COOLANT OVERHEAT LAMP 118
ATMOSPHERIC PRESSURE SENSOR 121
INJECTOR 123
AIRCONDITIONER POWER STAGE 134
VEHICLE SPEED SENSOR 154
IMMOBILISER 162
6. ACTUATOR TESTS 163
7. SYMPTOM BASED DIAGNOSTICS 170

MAN-00029
922MHKR011107EN-DM
Automotive Sector
How to Use this manual
Before starting to use the diagnostic manual, it is recommended that
the General Guidelines for Trouble shooting is completely read.
If the DTC code is known, then go to the Index of DTC code, note the
page number. Then click on the group. The codes are hyperlinked and
will go into that page. In the first page of each group, a sketch of the
sensor/ actuator is shown.
The structure of the diagnostic for each code is in 1st page. The General
description is given. The tabular box has two rows which gives the
proper operating conditions, when the DTC codes are generated and the
vehicle reaction once the DTC code is generated. The right column gives
the probable cause. In the beginning of each group a sketch of the
sensor is given
The page gives the block diagram of the sensor/actuator; this also gives
which is the voltage, which is the signal and the ground. The Page 2/3
will give the circuit diagram of the concerned code. Next the flow
diagram to resolve the concern
In the circuit diagram, the color codes, the view of the connector, and
the affected pin (in yellow is shown). Wherever possible the top view of
vehicle is shown which gives the location of the interconnector. If the
top view is not possible then the legend is given in bottom which tells;
interconnector no, description, location, type of connector and the no
of pins.
The Diagnostic tester is having the ability to test certain actuators. The
actuator test gives the test condition, how to actuate and the expected
result.
There are certain complaints for which no DTC codes are generated.
The trouble shooting procedure for the same is covered in the Symptom
based Diagnosis.
All copyrights reserved by

Mahindra & Mahindra Ltd Scorpio M-Hawk Diagnostic Manual
Confidential- For Internal Circulation Only Page 2 of 177
Nov. 07
MAN-00029
922MHKR011107EN-DM
BRIEF SPECIFICATIONS (m-HAWK ENGINE)
Type 4-cylinder, 4-stroke, Turbo-charged, Inter-cooled, Direct

Injection, Common Rail Diesel Engine
Bore 85 mm
Stroke 96 mm
Capacity 2179 cc
Max Power 120 hp @ 4000 rpm
Max Torque 29.5 Kg-m @ 1800 – 2800 rpm
Emission Bharat Stage 3
Features :
Fuel system – Bosch Common Rail fuel injection controlled by Bosch EDC
16C39 controller.
Turbocharger – Variable Geometry Turbocharger (VGT) , controlled by engine

controller.
Valve Mechanism – Double overhead camshaft (DOHC), operating 4-valves per

cylinder – 16 Valve engine with hydraulic lash adjuster and chain drive.
Exhaust System – Closed-coupled oxidation catalyst.

MAN-00029
922MHKR011107EN-DM
Automotive Sector
Guidelines for Troubleshooting
The most basic check that has to be done by the technician is the check
lamp status. (This has also to be done by customer.)
When the Ignition is switched ON. Then the System lamp & overheat
lamp glows for 2-3 sec after turning ON the ignition. If the light does not
glow OFF but remains either blinking or is continuously ON. Then the
fault has to be analyzed using the “Smart Tester”. However before
going into the fault diagnosis per se it is worthwhile to do some basic
(and the most common mistakes) checks.
For the Fault diagnosis, besides the diagnostic tool “Smart Tester”, a
good multimeter is essential (we recommend use of digital mutimeter)
During the fault diagnosis, under no circumstance, the traditional

method of shorting on to the ground is acceptable. If that practice is
resorted to then it may led to sensor failure.
If any arc welding has to be done then it is essential that besides

removing the battery cable, it is essential that the separate body earth
attached to the ECU has been removed. If not done then the spikes
during welding will cause ECU damage.
At this point of time we would also like to caution that for any trouble
shooting, please avoid the shortcut of jumping the steps and directly
replacing the suspect sensor/actuator.
If the root cause e.g. a terminal loose in the connector is not addressed,
then the problem will get repeated. It will lead to higher cost of repair
as well higher customer dissatisfaction.
The trouble-shooting manual is done in a manner that all the trouble

codes relevant to a sensor/ function are grouped together. After giving
the label of the codes, a brief description of the working, then what are
the conditions under which the DTC can occur. The wiring along with

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
the socket view is given. The trouble-shooting guide for that group of
codes is in the last.
Preliminary trouble shooting (common for all trouble codes)

• Before checking for any wiring connections for faults, check that all
the FUSES are OK.
• Ensure that the connectors are tightened properly to the sensors.
• Ensure battery voltage is between 8 to 16 Volts. It should not go

below 8 volt, even during cranking.
• Communication to the diagnostic tester will not be established in

following conditions:
1. Main relay not working (In this case engine will not start & no lamp
test)
2. Ignition switch to T15 connection has problems.
3. Diagnostic connector continuity problem (In this case engine will
start & lamp test OK.)
4. Charging for the Smart Tester very low.
5. Interface box failure (In this case engine will start)
• Following errors can be checked only when Engine is being
cranked/ attempted to crank.
1. Crankshaft
2. Camshaft
3. EGR No load
4. Injector related.
6. If no errors are registered with ignition on, (In diagnostic tester)

attempt to crank & while cranking check for error codes of the
above.

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
The following errors can only be checked when the vehicle is
being driven:
1. Vehicle speed sensor.

• If the battery voltage falls below 8 Volts, the ECU will stop
functioning. And since it stops functioning, it will not even register
the complaint.
• Check if the Diagnostic is showing any error. Also check the status if
it is healed or if it is present. A healed error will be in green font. A
present font will be in red font. Clear the memory and check if the
error reappears.
At this point of time it will be worthwhile to note that if an error has

become healed by itself. It is indicating that there was an error, which
went off by itself. Normally that indicates loose connection. Or
oxidation of the connectors
If this step is skipped than it is highly probable that since no
corrective action has been taken the problem will occur
again. And the next time the problem may not get healed
automatically. As a general thumb rule, any loose connection
if not attended tends to become worst over a period of time.
Try to see if the problem can be recreated, either by shaking
the wires/ slight twisting or in the worst case, slight spraying
of the water. Or blowing a dryer on top of the suspect
components.
Please take care to touch only the affected wires (not any
random wire).
Refer to the circuit diagrams. It has to be remembered that

unnecessary removal and refitting the connectors can cause bent
pins/ loose connection/ higher probability of oxidation. Causing

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
no or intermittent connection. Thus the Technician may land up
with a new set of problems)
• For errors causing dis-comfort to driver, system lamp will be ON. For
less severe error, (Which will only deteriorate the performance)
system lamp will blink. For some of the faults, which are least
severe, the system lamp will remain off, (but those errors can be
seen through tester).
• Check for the connector’ conditions. Many times continuity is not

obtained if the connectors are contaminated/ oxidation.
• Engine will go to limp home in following condition:

1. Accelerator pedal errors ( it will run with constant engine speed of
1200 rpm)

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
• General sequence of trouble shooting: (To be done after basic checks
of Fuse, Battery voltage)
1. Check for connector’ tightness with respect to the sensor.
2. Check for connector’ conditions. (e.g. pins getting
corroded/oxidized)
3. Check for continuity between the sensor/ component & the
corresponding ECU connectors.
4. Check for input / output voltage (Check voltages are within
specification)
5. Check resistance values (Where ever applicable)
6. Still the problem not solved, replace the corresponding sensor/
component with the known OK same type component & check
whether error get solved (After clearing memory status). If yes then
only remove the faulty component.
• For the below mention errors, there is no electrical fault but the
cause is leakage in diesel line (high pressure or low-pressure circuit)
or air lock in diesel line.
1. P1192
2. P1193
3. P1194
4. P1195
5. P1196
• These errors are related to hydraulics system. For e.g. due to air lock
in the diesel line, rail pressure does not build up and the error P1192
highlighted.
• For errors like voltage above/below limits or short circuit to
ground/battery, checking the corresponding output voltage from
Smart Tester can do confirmation.

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
For e.g. if error related to Rail pressure sensor voltage above upper
limit comes, check the Rail pressure sensor raw voltage through
“Smart Tester”
• Before changing any components, ensure that the error is cleared at

least 2-3 times, if after that also the error reappears, the error
reappears.
• Trouble shooting methods related to Turbocharger (Noise, loss of pick

up, smoke) & EGR valve will continue to be same as existing chain
drive engine.

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
Index of DTC codes
Group Code Label Page No

P-0123 Voltage above upper
limit
Accelerator
pedal Module 1 P-0122 Voltage below lower 21-26
(APP1) limit.
Plausibility with APP2
P-1120
violated.
limit
P-0222 Voltage below lower
Accelerator limit.
pedal Module 2 P-1220 Plausibility with APP1 27-31
APP2 violated
Accelerator Pedal
P-1221 signal not plausible
with brake
P-1604 Short circuit Battery
Boost Pressure
P-1605 Short circuit Ground
actuator 32-38
P-1606 No Load
(BPA)
P-1607 Excess Temperature
Boost pressure sensor-
P-235
Voltage above upper
limit
Boost pressure sensor-
Boost Pressure P-236
Voltage below lower
Sensor 39-42
limit
(BPS)
Boost pressure sensor
P-1236 not plausible with
atmospheric pressure
sensor.

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
P-0340 No camshaft signal
Camshaft Wrong camshaft 43-48
P-0341
signal
P-0335 No crankshaft signal
Crankshaft Wrong crankshaft 49-52
P-0336
signal
Limit
Air Flow 53-58
Voltage below lower
P-0102
Limit
Air limit.
59-63
temperature Voltage below lower
P-0112
limit.
limit.
Rail Pressure 64-68
Voltage below lower
P-0192
limit.
Maximum positive
P-1192
Rail pressure
deviation exceeded
Rail pressure Maximum positive
69-71
deviation Rail pressure
P-1193
deviation exceeded
concerning the set
flow value
K Line No communication with Diagnostic 72-73
P-0406 Short Circuit Battery
P-0405 Short Circuit Ground
EGR 74-76
P-0403 No Load
Error path of Offset between 77-80
P-1340 camshaft and crankshaft
offset

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
Voltage above upper
Fuel P-0182
limit
Temperature 81-86
Voltage below lower
Sensor P-0183
limit
P-1252 Short Circuit to
Battery
Short Circuit to
Metering Unit P-1253 87-90
Ground
P-1250 No Load
Main relay does not
P-121A
open in time
Main relay 91-94
Main relay opens too
P-121B
early
P-0577 SRC MAX error for
analog signal
SRC MIN error for
Cruise P-0576 95-99
analog signal
Plausibility error for
P-0575
analog signal
Voltage above upper
P-0563
limit
Battery 100-101
Voltage below lower
P-0562
limit.
Brake signal is
P-1792
defective
Brake Switch 102-105
Brake signals not
P-1791
plausible
Clutch signal is not 106-110
Clutch Switch P-0704
plausible

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector

Coolant Temp limit
111-115
Sensor(CTS) Voltage below lower
P-0117
limit
Minimum
P-2558 Temperature not
reached within time
limit.
CTS absolute &
Minimum 116-117
dynamic test
temperature or
P-1126 temperature raise
no reached within
time limit
P-165E Short Circuit to
Battery
Short Circuit to
Overheat lamp P-165F 118-120
Battery
P-1660 No Load
Voltage above upper
P-0108
Atm pressure limit
121-122
sensor Voltage below lower
P-0107
limit
Below lower limit of
P1623 enegising time- Injector
#1
P1625
Injector enegising time- Injector
Energizing #2 123
Time P161F
enegising time- Injector
#3
P1621 enegising time- Injector
#4

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector

Communication Communication 124
P-162A
monitoring error of CJ940
Deviation 125
Controller &
P-1659 between TPU
TPU Monitoring
and system time
Set, if error-
counter of
Watchdog or
ECU Monitoring P-1638 controller are 126
not plausible or
the system must
shut down
EEPROM: error
P-162B
during last read
operation
EEPROM EEPROM: error
P-162C 127
Monitoring during last write
operation
EEPROM: default
P-162D
value used
P-160C Short Circuit to
Battery
Tachometer
P-160D Short Circuit to 128-130
Signal
Ground
P-160E No Load
Short circuit to
P-1608
battery
Coolant P-1609 Short circuit to
temperature ground 131-133
output P-160A No load
Excess
P-160B
temperature

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
P-1530 Short circuit to
battery
Short circuit to
P-1531
Air condition ground 134-136
P-1532 No load
Excess
P-1533
temperature
P-1210 Chip-specific errors
: CY33X internal
reset / clock loss /
under voltage
Chip-specific
P-1211 errors: CY33X is
unlocked / CY33X
init error
Chip-specific
P-1212
errors:CY33X is in
Test mode
Chip-specific
errors: CY33X SPI
P-1213 communication
error
Injector Power 137
/checksum/read
Stage back
Chip-specific errors
P-1214
->CY33X internal
parity error
P-1215
->CY33X internal
program flow error
P-1216 ->CY33X check of
inv. YSEL during ON
failed
->CY33X ON
P-1217 timeout for at least
1 cylinder

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
The fault path
contains the
supervision of 138
Monitoring
P-1664 the SPI-Handler
communication
Set, if SPI-
communication
failed
Test of
redundant shut
P-1641
off paths during
initialization:
Watch dog
switch off path
defect
Test of
redundant shut
off paths during
P-1642 initialization:
Power stage
Voltage 139
Monitoring
monitoring
upper limit shut
off path defect
Test of
redundant shut
off paths during
initialization:
P-1643
Voltage
monitoring
lower limit shut
off path defect

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector

(Hardware)
CJ940 upper
P-1631
limit: internal
supply voltage
Power Stage
upper limit
Voltage 140
(Hardware)
Monitoring
CJ940 lower
limit: internal
P-1632
supply voltage
lower limit
P-1644 Voltage above
Sensor Supply upper limit
141-144
Monitoring 1 Voltage below
P-1645
lower limit
P-1646 Voltage above
Sensor Supply upper limit
145-148
Monitoring 2 Voltage below
P-1647
lower limit
Battery
System Lamp Battery 149-151
P-1656 No Load
Excess
P-1657
Temperature
Terminal 15 ( No Terminal T15 152-153
P-1658
Ignition Switch) signals detected

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector

Exceeding of the
P-0503
maximum
vehicle speed
HW signal for
P-0500
vehicle speed
Vehicle Speed not valid 154-157
Vehicle speed
not plausible
P-0501 with injection
mass and engine
speed
Battery
Short Circuit to
P-1888
Glow Control Ground
158-161
(if applicable) P-1889 No Load
Excess
P-1890
temperature

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector

Immobilizer
control:
indicates that
the received
P1812
pattern and the
transmitted
pattern is not
correct
Communication
P1828
wire may open
Communication
P1829 wire may be
short
Wrong
Immobilser communication,
162
Codes - Code
received
from CDL
P182A
may not be
correct
- Theft
made
attempt.
ECU is Locked
Completely (ECU
Locked due to
P182B continuous
occurrence of 3
immobilizer
errors)

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector

Home Screen for Actuator 163
System lamp 164-165
ACT # 1
Actuator test
Coolant 166
ACT # 2
Actuator Test Overheat Lamp
ACT # 3 Air Conditioning 167
ACT # 4 EGR 168
Boost Pressure 169
ACT # 5
Actuator (BPA)
Vehicle not 170-173
SBD #1 starting & no
error codes
Symptom Based
Vehicle not 174-177
Diagnosis
starting also
SBD # 2
may get
P1192/1193

Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM P-0123
2.2 P-0122
BS III P-1120
Automotive Sector
Accelerator Pedal Module 1

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0123
2.2 P-0122
BS III P-1120
Automotive Sector
Accelerator Pedal Module 1

Description: The Accelerator pedal module (APM) mounts in place of
accelerator pedal and is connected to the ECU by wires. The APM sensor
is a variable resistor (potentiometer) whose resistance changes
according to the pedal position. ECU applies a reference voltage to the
APM sensor and then measures the voltage that is present on the APM
sensor signal circuit. The ECU uses the APM sensor signal for further
calculation of fuelling & other engine operational parameters.
DTC Diagnostic item

P-0123 Voltage above upper limit
P-0122 Voltage below lower limit.
P-1120 Plausibility with APP2 violated.
DTC detection condition Probable cause

Normal Operation
• The Accelerator pedal module (APM) • Open or shorted
outputs a voltage, which is proportional Accelerator pedal
to the Position of accelerator pedal. module circuits,
• The ECU checks whether the voltage loose or wrongs
output by the Accelerator pedal module connections.
is within a specified range. • Accelerator pedal
In addition, it checks that the voltage module failed or
output does not become too large while maladjusted.
the engine is in idling.
Proper Performance
Sensor output voltage has continued to
between 0 to 5V, varying accelerator pedal
position.
Malfunction; out-of-range
• With the changing Accelerator pedal
position, the sensor output voltage has
continued to be 5V or 0V.
Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0123
2.2 P-0122
Automotive Sector
BS III P-1120
Reaction:
• The engine speed not varying with
changing accelerator pedal position.
(Constant 1200 rpm)
• The system lamp is continuously on.
ECU
K45 K09 K30 K46 K31 K08
Gr-B
G-R
R-W Sb
P W-R
5-GND
4-O/P 1 6-O/P
2 3-GND
Vcc Vcc
APP1 APP2

Nov. 07
P-1120
MAN-00029
922MHKR011107EN-DM
Automotive Sector

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0123
2.2 P-0122
Automotive Sector BS III P-1120
Test Procedure APP1 –
1. Connect the ‘Smart Tester’ to diagnostic connector.

2. Turn Ignition Switch ON.
3. Verify either P0123 or P122 or P1120 are present.
• Turn Ignition switch OFF & disconnect Accelerator Pedal connector.

• Turn the Ignition ON & measure voltage between terminal 2 &
terminal 3 of the APP1 (from the APP1 connector side.)
• It should be 5 ± 0.3 V
• Is it?
•
Yes No
Turn Ignition OFF
Measure the continuity between Measure the continuity between

terminal K09 in ECU and Terminal 4 K45 & 2 ( Voltage)
of connector K30 and 3 ( ground)
Continuity is OK? (resistance below Repair the damaged line/
1 Ω) connection
Clear code
Verify that the complaint has been
eliminated.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0123
2.2 P-0122
Yes No
Reconnect. Before reconnection Repair the damaged line/

check that the pins are not bent or connection
oxidation has not taken place.
Clear the codes Clear code
Does the problem persist? Verify that the complaint has been
eliminated.
Yes No
Check the APP 1 resistance in both
the state 0% & 100%
Is it within the specifications
Yes No
Clear the code. Replace the Accelerator pedal
Module
Verify that the complaint has been eliminated.

Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM P-0223
2.2 P-0222
BS III P-1220
Automotive Sector P-1221
Accelerator Pedal (APP2)
Description: The Accelerator pedal module (APM) mounts in place of

accelerator pedal and is connected to the ECU by wires. The APM sensor
is a variable resistor (potentiometer) whose resistance changes
according to the pedal position. ECU applies a reference voltage to the
APM sensor and then measures the voltage that is present on the APM
sensor signal circuit. The ECU uses the APM sensor signal for further
calculation of fuelling & other engine operational parameters.
DTC Diagnostic item

P-1220 Plausibility with APP1 violated
P-1221 Accelerator Pedal signal not plausible with brake

Proper Performance
Sensor output voltage has continued to • Open or shorted
between 0 to 2.5V, with varying accelerator Accelerator pedal
pedal position. module circuits, loose
or wrong connections.
• With the fully pressed Accelerator • Accelerator pedal
pedal module, the sensor output module failed or
voltage has continued to be 2.5V or 0 maladjusted.
for 4 sec.
Reaction
• The engine speed not varying with
changing accelerator pedal position.
(Constant 1200 rpm)
• The system lamp is continuously on.

Nov. 07
C-39 MAN-00029 P-0223
922MHKR011107EN-DM P-0222
2.2
BS III P-1220
P-1221
Automotive Sector
ECU
K45 K09 K30 K46 K31 K08
Gr-B
G-R
R-W Sb
P W-R
4-O/P 1 6-O/P 5-GND

2 3-GND
Vcc Vcc
APP1 APP2

Nov. 07
MAN-00029
922MHKR011107EN-DM P-0223
C-39
2.2 P-0222
BS III P-1220

Nov. 07
MAN-00029
922MHKR011107EN-DM
P-0223
C-39 P-0222
Automotive Sector 2.2 P-1220
BS III P-1221
Test Procedure APP2 –

3. Verify that either P0223/P0222/P1220 / or P1221 is present.
• Turn Ignition switches OFF & disconnect Accelerator pedal connector.

• It should be 2.5 ± 0.15 V

• Is it?
Yes No
Turn Ignition OFF

Measure the continuity between Measure the continuity between
terminal K31 in ECU and Terminal 6 K46 & 1 ( Voltage)
of connector. K08 and 5 ( ground)
Continuity is OK? (resistance below Repair the damaged line/
1 Ω) connection.
Clear code
eliminated.
Yes No

check that the pins are not bent or connection.
Nov. 07
MAN-00029
C-39922MHKR011107EN-DM P-0223
2.2 P-0222
BS III P-1220
Clear the codes. Clear code.
Does the problem persist? Verify that the complaint has been
eliminated.
Yes No
Check the APP 2 resistance in both
the state 0% & 100%
Is it within the specifications
Yes No
Replace the Accelerator pedal
Module
Clear code.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-1604
2.2 P-1605
P-1607
Boost Pressure Actuator

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-1604
2.2 P-1605
Automotive Sector
BS III P-1606
P-1607
Fault path for BPA (Boost pressure actuator/ modulator) power stage
Description - In normal operation and during an actuator test, the PWM

power stage of ECU is tested for short circuit to battery voltage, short
circuit to ground, open circuit and excess temperature. Once the errors
are confirmed, the power stage is switched off.
The BPA in turn controls the Variable vanes operation through vacuum.
Hint:
Short circuit to battery and excess temperature errors can be detected
only when the power stage is switched on.
Short circuit to ground and no load errors can be detected only when
the power stage is switched off.
DTC Diagnostic item

P-1604 Short circuit Battery
P-1605 Short circuit Ground
P-1606 No Load
Proper Performance Possible Causes
The ECU monitors the Boost pressure
actuator ( modulator) during the normal • Short circuit to battery
operation as well as during actuator test) or ground.
Malfunction; out-of-range • Excess temperature
• With the fully pressed Accelerator • No load.
pedal module, the sensor output
voltage has continued to be 2.5V or 0
for 4 sec.
Reaction
• Torque will be reduced
• EGR is switched off.
• System Check lamp is ON

Nov. 07
MAN-00029
C-39
922MHKR011107EN-DM P-1604
2.2 P-1605
BS III P-1606
A15
ECU

Nov. 07
MAN-00029
922MHKR011107EN-DM
P-1604
C-39 P-1605
2.2 P-1606

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-1604
2.2 P-1605
P-1607
The BPA can give errors due to the following causes:
1. Error present in modulator and reported by ECU.

2. There is vacuum leak in the system. Thus when the x amount of
boost but the actual amount is y. The BPA will supply more
vacuum to the VGT so that the vanes open further and boost is
increased. If however the VGT movement is not proportional to
the demand, then after a limit, the complaint will be registered
as an error.
3. If the boost pressure is not proportional to the expected
performance as the VGT is not able to respond to the changes then
the ECU will register is as an error of the BPA.
We suggest that the diagnostic procedure has to be 1 2 3
Test Procedure BPA

3. Verify that either P1604/P1605/P1606/P1607 is present.
For Defect Codes P 1605 & P1606 –
• Turn Ignition switches OFF & disconnect BPA connector.

• Is it?
Check the continuity from BPA to A15
Is it OK ?
Yes No
Nov. 07
MAN-00029
922MHKR011107EN-DM
P-1604
C-39 P-1605
BS III
P-1607
Measure the continuity from Battery Repair the damaged line/

to BPA connection
Clear code
eliminated.
Yes No
Reconnect. Before reconnection Check the vacuum lines ( in

check that the pins are not bent or particular the line from the BPA to
oxidation has not taken place. the actuator- check for looseness.
Or hardening due to aging.
Clear the codes.
Does the problem persist?
Yes No
Change the BPA with a known good
one
Clear the code
Reconnect. Before reconnection
check that the pins are not bent or
Clear the codes.
Does the problem persist?

Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM P-1604
2.2 P-1605
BS III P-1606
Yes No
Replace the VGT Replace the Accelerator pedal
Module
Clear code.
For Defect Codes P 1604 & P1607 -

• Turn Ignition switches ON & connect BPA connector.
• Turn the Ignition ON & measure voltage coming to the BPA it should
5 V.
• Is it?
Is it OK ?
Yes No
Check the voltage at A15. is it 5 V? Check the grounding from battery to

BPA. Repair or Replace the wire,
clear the codes. & confirm.
No
Check for shorting to ground from Check the vacuum lines ( in

BPA to A15. particular the line from the BPA to
the actuator- check for looseness Or
hardening due to aging.
Replace the wires.
Clear the codes and confirm.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-235
2.2 P-236
BS III P-1236
Automotive Sector
Boost Pressure Sensor
Description: The boost pressure signal is monitored. This signal is used

as a feedback for the control of the VGT and also for the EGR.
The boost pressure sensor is mounted on the outlet of the intercooler.
DTC Diagnostic item

P-235 Boost pressure sensor- Voltage above upper limit
P-236 Boost pressure sensor- Voltage below lower limit
P-1236 Boost pressure sensor not plausible with atmospheric
pressure sensor.

The ECU monitors the Boost pressure • Short circuit to battery
or ground.
Malfunction; out-of-range • No load.
• Monitors the pressure build up or • Defective sensor
decrease.
• Also monitors the plausibility with the
atmospheric pressure sensor
Reaction
• Engine torque is limited.
• Air mass – default values taken

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-235
2.2 P-236
Automotive Sector
BS III P-1236
ECU
A13 A23 A40
P
Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-235
2.2 P-236
The BPS can give errors due to the following causes:
There is vacuum leak in the system.

1. If the boost pressure is not proportional to the expected
performance as the VGT is not able to respond to the changes then
the ECU will register is as an error of the BPA.
Test Procedure BPA

3. Verify that either P235/P236/P1236 is present.

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
C-39 P-235
2.2 P-236
BS III P-1236
• Turn Ignition switches OFF & disconnect BPA connector.

• Is it?
Check the continuity from BPS to A13 to 1, A23- 2; A40-3
Is it OK ?
Yes No

check that the pins are not bent or connection
oxidation has not taken place
Clear the codes. Clear code
Does the problem persist Verify that the complaint has been
eliminated.
Yes No
Change the BPS with a known good

Reconnect. Before reconnection
check that the pins are not bent or
oxidation has not taken place
Clear the code

Nov. 07
C-39 MAN-00029 P-0340
922MHKR011107EN-DM
2.2 P-0341
BS III
Automotive Sector
Camshaft Speed Sensor

Nov. 07
MAN-00029
922MHKR011107EN-DM P-0340
C-39
2.2 P-0341
BS III
Automotive Sector
Camshaft speed sensor
DTC Diagnostic item

P-0340 No camshaft signal
P-0341 Wrong camshaft signal
Description
The Hall effect camshaft position sensor senses the Top dead center
(TDC) point of the # 1 cylinder in the compression stroke. Which allows
the ECU to determine when to start the injection.

Normal Operation
• When the engine is running, the • Open or shorted
Camshaft Position sensor outputs a camshaft position
pulse signal. sensor circuit,
• The ECU checks whether the pulse loose or wrong
signal is input. connection.
• Camshaft Position
Malfunction sensor malfunction.
• Normal signal pattern has not been
input for cylinder identification from
the camshaft position sensor signal for 4
sec. (Engine should be cranked to check
this error).
Reaction
• Engine will not start
• System lamp will be continuously on.

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
C-39 P-0340
2.2 P-0341
BS III
Sensor R-L ECU

3 A 11
Vs
Vs
2 R-G
A50
Signal
1 G A20
GND.
Vs= Supply voltage- 5V

Nov. 07
MAN-00029
P-0340
C-39 922MHKR011107EN-DM
P-0341
2.2
BS III
Automotive Sector
Codes: P-0340, P-0341

3. Verify that either P0340 or P0341 are present.
• Switch off the Ignition.

• Disconnect the camshaft sensor connector.
• Turn ON the Ignition.
• Measure the voltage between the pins in the camshaft connector -
Pin No. 3 &1.
• It should be 5 ± 0.3 Volts
• Is it?

Nov. 07
MAN-00029
922MHKR011107EN-DM
P-0340
C-39
P-0341
2.2
Automotive Sector BS III
Yes No
Turn the Ignition OFF Repair the wires A 11 to Pin No.3 &A
20 to Pin No. 1.
Disconnect ECU connector A. Clear the error codes & verify.
Measure the continuity of Ground
(between sensor pin no 1 & ECU
terminal A20) in the camshaft phase
sensor harness.
Is it OK?
Yes No
Measure the continuity of signal Repair the connection.

sensor harness.
Is it OK? Clear the error codes & verify
Yes No
Check for physical damage to pins Repair the connection.
or oxidation.
Also check if the connectors are Clear the error codes & verify.
moving backwards when inserted.
Is it OK?
Yes No
Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
Replace the camshaft phase sensor. Repair the connection.

Clear the error codes & verify. Clear the error codes & verify.

Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM P-0335
2.2 P-0336
BS III
Automotive Sector
Crankshaft sensor
Phase Sensor Mounting on Camshaft
Single Mass Flywheel
Speed Sensor Mounting on Crankshaft

Nov. 07
C-39 MAN-00029 P-0335
922MHKR011107EN-DM P-0336
2.2
BS III
Automotive Sector
Crankshaft Sensor
Description - In order that the ECU can control the engine at all the
position of the crankshaft must be known so that the cylinder in
compression and the timing of the next fuel injection can be
calculated. The CKP is an inductive pulse generator, which scans
protrusions on the flywheel. Two teeth are missing, and this gap is
situated at 90° before TDC.
DTC Diagnostic item

P-0335 No crankshaft signal
P-0336 Wrong crankshaft signal

Background
• When the engine is running, the • Open, shorted or
Crankshaft Position sensor outputs a wrong connection
pulse signal. crankshaft position
• The ECU checks whether the pulse sensor circuit.
signal is input while the engine is • Failed or damaged
cranking. crankshaft position
sensor.
Normal Operating condition
• Engine is being cranked.
Malfunction
• Normal signal pattern has not been
input for cylinder identification from
the crankshaft position sensor signal
for 4 sec.
• No synchronization between crankshaft
& camshaft signal.
Reaction
• System lamp continuously on.
• Engine will not start.
• If engine is running & this fault occurs,
engine will stop immediately.

Nov. 07
MAN-00029 P-0335
C-39 922MHKR011107EN-DM
2.2 P-0336
BS III
Automotive Sector
ISS (Incremental speed sensor/ Crankshaft speed sensor)
Sensor ECU
N S Y
1 A 27
Positive
2 A 12
Negative
Shield
3
B-R A 21

Nov. 07
MAN-00029 P-0335
C-39 922MHKR011107EN-DM
2.2 P-0336
BS III
Automotive Sector
Test Procedure ISS

3. Verify that either P0335 or P0336 are present. Please verify while
cranking the engine.
• Turn the Ignition switch OFF.

• Disconnect the crankshaft position sensor connector and also the
connector at ECU.
• Measure the continuity between the sensor terminal 1 and ECU
terminal A 27.
• Is it OK?
Yes No
Measure all terminals for short to Repair the wires.

Ground.
Is it OK ? Clear code & verify the CKP sensor

is within normal parameters.
Yes No
Check if the sensor is damaged. If Repair the connection.

so change sensor with a known good
component.
Clear code & verify the CKP sensor is within normal parameters.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39
P-0103
2.2
P-0102
Air Flow

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0103
2.2 P-0102
Air Flow
Description -
Mass air flow rate is measured by detection of heat transfer from a hot
film probe because the change of the mass air flow rate causes change
in the amount of heat being transferred from the hot film probe surface
to the air flow. The airflow sensor generates a pulse so it repeatedly
opens and closes between the 5V voltage supplied from the engine
control module. This results in the change of the temperature of the hot
film probe and in the change of resistance.
DTC Diagnostic item

P-0103 Voltage above upper Limit
P-0102 Voltage below lower Limit

Normal Operation
• The HFM sensor outputs a voltage, • Open or shorted HFM
which corresponds to the intake airflow. sensor circuit, loose or
• The ECU checks whether this voltage is wrong connections.
within a specified range. • Failed HFM sensor.
Normal Operating Requirements
• Ignition switch: ON
• Malfunction lamp: OFF after 2 Sec
• Battery voltage is 8V-16V or more.
Malfunction
• The sensor output voltage has continued
to be 5V or higher.
to be 0.5V or lower.
Reactions:
• System lamp will continuously blink.
Engine will continue to run with default air
flow (depending on Speed & Fuelling)

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0103
2.2 P-0102
Automotive Sector
BS III
Bat+ 12V

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
P-0103
C-39 P-0102
2.2
BS III
Test Procedure HFM


Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector C-39 P-0103

Turn the ignition OFF 2.2 P-0102
Disconnect HFM sensor.BS III
Turn the Ignition ON
Measure the voltage at the
connector between terminal 3 & 4.
It should be 5 ± 0.3 Volts
Is it
Yes No
Check the output voltage ( with Check fuses

engine running)
Signal voltage within the range Check continuity between the A29
& 4 ( voltage)
Check continuity between A44 & 3 (

Ground)
Is it? Repair the open wire.
Clear codes and verify that the HFM
signal ratio is within limit.
Yes No
Switch off the Ignition

Check the connectors if the pins are Check the continuity between the
bent or having oxidation. A42 & 5 ( Signal)
Clear codes & verify if the codes Rectify
are eliminated.
Clear codes and verify that the HFM
signal ratio is within limit.
Nov. 07
MAN-00029 P-0103
C-39
922MHKR011107EN-DM
P-0102
2.2
BS III
Automotive Sector
No
Check the resistance of the HFM sensor ( between 5 & 3) it should be

between 5.119 to 5.892 KOhms
If not OK. Replace the HFM sensor.
Clear codes & verify that the error has been removed.

Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM P-0113
2.2 P-0112
BS III
Automotive Sector
Air Temperature

Nov. 07
MAN-00029
922MHKR011107EN-DM P-0113
C-39 P-0112
2.2
Air Temperature
DTC Diagnostic item

P-0113 Voltage above upper limit.
Description: The function acquires the raw voltage of the induction air
temperature. The raw value is linearised and monitored for compliance
with the signal range.
The sensor is mounted in HFM.

Normal Operation
• The HFM temperature sensor outputs a • Open or shorted HFM
voltage, which corresponds to the temperature sensor
temperature of intake airflow. circuit, loose or wrong
• The ECU checks whether this voltage is connections.
within a specified range.
• Failed HFM
Normal Operating Requirements temperature sensor.
• Battery voltage is 8V –16 V.
Malfunction
to be 5V or higher.
to be 0.2 V or lower.
Reactions
• Engine will run with default air temp of
20 Degrees Centigrade
• System lamp status for this error is off.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0113
2.2 P-0112
Automotive Sector
BS III
ECU
V-B V cl 4
A29 2
A42 G
Air flow o/p 5
G-B 3
A44
Ground
R/G 1
Temperature
A37
O/P
Ignition
switch
Bat+ 12V
10 Amp

Nov. 07
MAN-00029
922MHKR011107EN-DM
P-0113
C-39
P-0112
Automotive Sector 2.2
BS III
Test Procedure AFTSCD –
Codes: P0112, P0113

Turn the ignition OFF

Disconnect HFM sensor Connector.
Turn the Ignition ON
Measure the voltage between the
Terminal 3 & 4 of HFM Sensor
Connector.
Nov. 07
MAN-00029
922MHKR011107EN-DM
P-0113
C-39
P-0112
It should be 5 ± 0.3 Volts BS III
Is it
Yes No
Check fuses
Check continuity between the A29
& 4 ( voltage)
Check continuity between A44 & 3

( Ground)
Repair the open wire.
Clear codes and verify that error
has been eliminated.
Measure the continuity between A44 & 3 (ground)

• Is it?
Yes No
Check the continuity between the Rectify

A37 & 1 ( output signal)
Clear codes & verify.
Yes No
Replace the HFM sensor Rectify


Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0193
Automotive Sector
2.2 P-0192
BS III
Rail Pressure Sensor
DTC Diagnostic item

P-0193 Voltage above upper limit.

Normal operation • Open, shorted or
• When ignition is ON rail pressure sensor wrong connection of
getting supply from ECU. rail pressure sensor
• ECU reads the rail pressure in terms of circuit.
voltage. • Rail pressure sensor
• Engine is starting properly. failed.
• Building pressure in rail.
Malfunction
• Rail pressure output voltage is below
Reaction
• When ignition is ON system lamp is glowing.
Engine is not starting & error is set in ECU
Error memory.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0193
Automotive Sector
2.2 P-0192
BS III
ECU
A28 A43 A08
O-B R O
3 2 1
V cc V out GND
Rail Pressure Sensor

Nov. 07
MAN-00029 P-0193
C-39
922MHKR011107EN-DM P-0192
2.2
BS III
Automotive Sector

3. Verify that either P-0193 or P-0192 is present.
• Switch off the Ignition

• Disconnect the rail pressure sensor connector.
• Turn ON the Ignition.
• Measure the voltage between the supply and the ground of the Rail
pressure sensor (Pin no 1 & 3 of the RPS connector).
• It should be 5 ± 0.3 Volts
• Is it?

Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM
2.2 P-0193
BS III P-0192
Automotive Sector
Yes No
Check the continuity between the Repair the wire.

ECU terminal A28 & pin no 3 of the
RPS.
Continuity between the ECU

terminal A43 & pin no 2 of the RPS.
Is it OK? Clear the error codes & verify.
Yes No
Connect the rail pressure sensor Repair the wire.

connector to sensor. (Check for pins contamination)
Switch ON the Ignition. Clear the error codes & verify.
Check the output of the RPS (
Should be in range of 500 to 700
mVolts.
Is it?
Yes No
Change the engine speed and check Rail pressure sensor has failed.
the corresponding increase in RPS
value.
( This can be done using the live Change the Rail assembly ( RPS is
data in the ‘Smart Tester’) not recommended to service
separately)
Is there a change in the RPS. Clear codes & verify
Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
Yes No
Clear codes & verify. Replace rail.


Nov. 07
P-1192
C-39 MAN-00029 P- 1193
2.2 922MHKR011107EN-DM
BS III
Automotive Sector
Rail Pressure Deviation
DTC Diagnostic item

P-1192 Maximum positive Rail pressure deviation exceeded
P-1193 Maximum positive Rail pressure deviation exceeded
concerning the set flow value

The ECU compares the rail pressure • Defective fuel tank
monitored through the RPS against the cap ( improper
expected pressure generated due to HPP ( breathing)
Based on MPROP position and the engine RPM • Fuel filter
and other parameters)
• Filter assembly
• Tank strainer choked.
• Injector stuck in open
• If the deviation is more then error is
condition
generated.
• M-Prop valve stuck
Reaction
• Engine will be switched OFF
• Engine can not be started

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-1192
P- 1193
2.2
BS III
Automotive Sector
Test Procedure Rail Pressure Deviation -

Nov. 07
MAN-00029
922MHKR011107EN-DM P-1192
C-39 P- 1193
2.2
BS III
Automotive Sector
3. Verify that either P1192/1193 is present.
Complaint < 2000 Kms.
after filter change
Yes No
Air lock-do Change Filter

OK
bleeding & bleed
Change Filter No
Not
assembly along
OK
with copper
washer Clean tank strainer
& fuel line
Do bleeding at rail in the 4th

OK
cylinder injector nut as well
as 2nd & 3rd
Change Not
OK Injector Check injector overflow
OK
Change Metering valve can be

OK HPP getting stuck
OK
Change Rail
Not
& sensor
OK OK
Hint:All Try bleeding after removal of the fuel tank cap.

copyrights reserved by
If that works, the
Confidential- Forcap is defective,
Internal Circulationchange
Only it. Page 71 of 177
Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 Not
2.2 connecting
K line: Diagnostic connector
Connect the ‘Smart Tester’ to the Diagnostic Connector.

Turn the Ignition ON.
Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
C-39 Not
Check for the connection2.2on the ‘Smart Tester’. connecting
Is it OK? BS III
No Yes
Remove the smart tester from the Diagnostic connector is OK.

connector.
Switch on the Ignition.
Check the voltage of the pin no 4/5
& 7 of the connector ( It should
show 12 Volts when Ignition is ON
and show 0 Volts when Ignition is
switched OFF.
Is it OK?
No Yes
Check connectivity between K25 Check the voltage between the

and diagnostic connector pin no 7. connector pins10 & pin 4/5. It
should show 12 V continuously.
If is not OK, then repair. If it is not showing , repair the
connection.
Check the voltage. Otherwise it indicates
less/poor/intermittent contact.
Is it OK. Repair
Yes No
Connect smart tester & confirm. Diagnostic hardware is faulty.

Change the hardware.
Nov. 07
MAN-00029
922MHKR011107EN-DM
P-0406
C-39 P-0405
2.2 P-0403
EGR power stage

Description
A pulse-width-modulated signal is output for the Exhaust Gas
Recirculation actuator control. Converting the air control output into
duty cycle carries this out. The possible defects are short circuit to
battery, ground & no load.
DTC Diagnostic item

P-0406 Short Circuit Battery
P-0405 Short Circuit Ground
P-0403 No Load
Background
• The ECU checks current flows in the EGR • Open or shorted
solenoid drive circuit when the solenoid EGR solenoid
is ON and OFF. circuit, loose or
Range of check, set conditions. wrong connection.
• When the EGR solenoid is turned OFF, no • EGR solenoid
surge voltage is detected. failed
Normal operation • EGR control
• When engine is running per the EGR vacuum is too low
mapping.
• System lamp off after 2 sec.
Malfunction
• EGR valve will remain open in case of short
circuit to ground fault & remain closed for
other fault conditions.
Reaction
• System lamp will blink in case of short
circuit to ground condition i.e.P0405.For all
other fault condition (related to EGR) lamp
will be OFF.
• Emission will affect.

Nov. 07
C-39 MAN-00029
922MHKR011107EN-DM P-0406
2.2
BS III P-0405
P-0403
Automotive Sector
*- Twisted pair
Codes: P-0406, P-405, P-403, P404

3. Verify that either P0406 or P0405 or P0403 or P0404 are present.
• Disconnect the EGR control solenoid valve connector.

• Turn Ignition ON
Nov. 07
C-39 MAN-00029
922MHKR011107EN-DM P-0406
2.2
BS III P-0405
P-0403
Automotive Sector
• Check the voltage between Ground & EGR control solenoid, valve
harness connector terminal. Battery voltage should be present.
• It should be 12 V when Ignition ON.
• Is it?
Yes No
Turn Ignition OFF. Verify that the 15 Amp fuse is OK (

same fuse is also used for brake &
clutch switch).
Disconnect the EGR control Repair open or short to Ground on
solenoid. wire between ECU control relay &
EGR control solenoid valve.
Disconnect the ECU connector. Clear codes & verify.
Check the continuity of the EGR
connector with ECU terminal A 60.
Is it OK?
Yes No
Are the connectors OK ( check for Rectify the wiring.

bent pins or oxidation).
Yes No
Replace EGR solenoid with known Rectify the wiring harness.

good components.
Clear codes & verify EGR solenoid is within limits.
If problem persist, replace EGR.
Note – The Modulator for EGR is Black in colour.
Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM P-1340
2.2
BS III
Automotive Sector
Error path of offset between camshaft and crankshaft
DTC Diagnostic item

P-1340 Offset between camshaft and crankshaft

Normal operation
• Engine is being cranked & started. • Mounting of phase
sensor, speed sensor
Malfunction or flywheel is loose.
• Normal signal pattern has not been • Manufacturing defect.
input for cylinder identification from • Sensors faulty or
the crankshaft position sensor signal damaged.
and camshaft position sensor signal for
4 sec.
• No synchronization between crankshaft
& camshaft signal.
Reaction
• Engine is not being cranked.
• System lamp will continuously ON.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-1340
BS III
Segment Speed Sensor (camshaft sensor)
Sensor R-L ECU

3 A 11
Vs
Vs
2 R-G
A50
Signal
1 G A20
GND.
C-39
2.2
BS III
Vs= Supply voltage- 5V

Nov. 07
MAN-00029
C-39922MHKR011107EN-DM P-1340
2.2
BS III
Automotive Sector
ISS (Incremental speed sensor/ Crankshaft speed sensor)
Sensor ECU
N S Y
1 A 27
Positive
2 A 12
Negative
Shield
3
B-R A 21

Nov. 07
C-39 MAN-00029 P-1340
922MHKR011107EN-DM
2.2
BS III
Automotive Sector
1. Connect the ‘Smart Tester’ to diagnostic connector

3. Verify that P1340 is present.
Turn the Ignition OFF.

Disconnect the camshaft & also the crankshaft sensors.
Yes No
Check the sensor mounting of crank Correct the mounting.

shaft speed sensor.
Check the wiring harness continuity Clear codes & verify that the signal
between the cam sensor to ECU & is within limit.
also the crankshaft speed sensor to
ECU.
Flywheel mounting is OK.
Check the phase sensor for any
nicks.
Yes No
Check for any manufacturing Correct the mounting.

defects.
Clear codes & verify that the signal Clear codes & verify that the signal
is within limit. is within limit.
If it is not in limit, change the
corresponding sensor.

Nov. 07
C-39 MAN-00029
922MHKR011107EN-DM
2.2
BS III
Automotive Sector
Fuel Temperature Sensor

Nov. 07
C-39 MAN-00029 P-0182
922MHKR011107EN-DM P-0183
2.2
BS III
Automotive Sector

Description –
Fuel temperature sensor acquires the raw value of the fuel

temperature. The raw value is linearised and monitored for compliance
with the signal range. The sensor is a NTC type
DTC Diagnostic item

P-0183 Voltage below lower limit

Background
• The fuel temperature sensor converts • Open or shorted
the engine fuel temperature to a voltage Engine fuel
and outputs it. temperature sensor
• The ECU checks whether the voltage is circuit, loose or
within a specified range. wrong connection
• Fuel temperature
Malfunction; out-of-range sensor failed.
• Sensor output voltage has continued to
be 5V or higher for 4 sec.
be 0.1V or lower for 4 sec.
Reaction
• System lamp will blink continuously.
• Engine will run with default fuel temp of
20 Deg C.

Nov. 07
MAN-00029
922MHKR011107EN-DM P-0182
C-39
P-0183
2.2
BS III
Automotive Sector
ECU
A 52 A 51
W G
1 2

Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM P-0182
2.2 P-0183
BS III
Automotive Sector
Test Procedure Fuel Temperature Sensor –
Codes: P-0182, P-0183

2. Turn the Ignition Switch ON.
• Turn the Ignition OFF.

• Disconnect the FTS connector.
Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM P-0182
2.2 P-0183
BS III
Automotive Sector
• Turn the Ignition ON and check the voltage between FTS’ signal
terminal 1 and ground.
• It should be 5 V ± 0.3 when Ignition ON
• Is it?
Yes No
Turn the Ignition OFF. Open or short between FTS signal

terminal 1 and ECU.
Measure continuity between A 52 of Repair as necessary.
ECU & connector terminal 1.
Measure continuity between A 51 of
ECU & connector terminal 2.
Is it OK ?
Yes No
Connect FTS connector. Open or short between FTS signal

terminal 1 and ECU.
Turn Ignition ON. Repair as necessary.
Check the voltage of FTS ( at A51 &
A52)
Is it as per specification ?
Yes No
Poor terminal contact due to Temporarily install a known good

oxidation , bent or misplaced FTS and check for proper operation.
Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0182
2.2 P-0183
terminal.
Repair as necessary. If problem is corrected, replace
FTS.
• Return vehicle to original condition. Clear all DTC.

• Verify by driving vehicle with “Smart Tester” connected and monitor
for error codes.

Nov. 07
MAN-00029 P-1252
C-39 922MHKR011107EN-DM P-1253
2.2 P-1250
BS III P-1251
Automotive Sector
Metering unit pump -Power stage
DTC Diagnostic item

P-1252 Short Circuit to Battery
P-1253 Short Circuit to Ground
P-1250 No Load

Normal operation
• When ignition is ON pump is getting supply • Open, shorted or
from ECU. wrong connection of
• Engine is starting properly. pump circuit.
Malfunction
• When ignition is ON pump is not getting
PWM signal from ECU.
Reaction
• Engine is not starting & error is recorded in
ECU error memory.
• Fuel output is not available from pump.
• System lamp will remain ON.

Nov. 07
C-39 MAN-00029 P-1252
922MHKR011107EN-DM P-1253
2.2
BS III P-1250
P-1251
Automotive Sector
High Pressure Pump (with fuel metering unit)
ECU
A19 A 49
W
Y
2 1
Twisted pair wires

Nov. 07
C-39 MAN-00029 P-1252
922MHKR011107EN-DM P-1253
2.2
BS III P-1250
P-1251
Automotive Sector

3. Verify that either P-1252 or P-1253 or P-1250 or P-1251 is present.
• Check the connections to the pump.

• Check that the connections are connected correctly; and that it is
not connected in reverse way.
• Disconnect the pump and ECU connectors.
• Check the continuity between the ECU terminal A19 and pump
terminal 2.
• Check the continuity between the ACY terminal A49 with pump
terminal 1.
Nov. 07
MAN-00029
922MHKR011107EN-DM
P-1252
P-1253
C-39 P-1250
• Is it OK? BS III
Yes No
Check the continuity of ECU Check for terminal contamination.

connector terminal A49 and A19 Repair the connection.
with Battery +ve and Ground.
Is it OK? Clear codes and verify that the
error has been eliminated.
No Yes
Error observed due to loose/ There is a possibility of short circuit

intermittent connection. of battery to ground.
Ensure that the connections are Repair the connections.
proper.
Clear codes and verify the error. Clear codes & verify.
The Error Code P 1251 can also be generated if there is leakage in

the HPP adaptor.

Nov. 07
MAN-00029
C-39922MHKR011107EN-DM P121A
2.2 P121B
BS III
Automotive Sector
Main relay
DTC Diagnostic item

P-121A Main relay does not open in time
P-121B Main relay opens too early

Normal operation
• While cranking engine will start properly. • Open, shorted or
wrong connection of
Malfunction main relay.
• Supply will not come to ECU input. • Main relay fuse is
blown.
Reaction • Relay is not working
• No communication with smart tester.
• System check lamp will be on.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P121A
2.2 P121B
Automotive Sector
BS III
Engine not cranking – ‘Smart Tester’ not responding.

Check battery voltage. It should be greater than 8 Volts.
Check the 30 Amp fuse.

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
C-39 P121A
3. Verify that either P121A
2.2or P121B is present. P121B
BS III
• Ensure that the main relay is inserted properly in the connector

• Remove relay.
• Check the relay externally.
• Give 12 Volts to terminal 86 and Ground the terminal 85.
• A clicking sound should be heard.
• If the sound is not heard, replace the relay.
• Check if 12 Volts is available at terminal 30, 86 & 85.
• With respect to ground, terminal 87 should show 0 Volts.
• Is it OK?
Yes No
Switch ON the Ignition. Check the wiring harness.

Measure the voltage at terminal K72 Repair the main relay connections (
of ECU or terminal 85 of the relay. check the 30 Amp fuse)
Is it showing 0 Volts ? Clear codes & verify that the main
relay is working properly.
Yes No
Measure the voltage at ECU Check that the terminal K 28 of ECU

terminal K05/K01. Or at terminal 87 is showing 12 Volts. If not repair the
of the relay. connection.
It should show 12 Volts.
Yes No

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
Clear codes and verify that the Replace the relay with a known
main relay is working properly. good component.
Clear codes and verify that the
main relay is working properly.

Nov. 07
MAN-00029 P-0577
C-39 922MHKR011107EN-DM P-0576
2.2 P-0575
BS III
Automotive Sector
Cruise Control
DTC Diagnostic item

P-0577 SRC MAX error for analog signal
P-0576 SRC MIN error for analog signal
P-0575 Plausibility error for analog signal

Normal operation
• When vehicle is running, no clutch & brake • Open, shorted or
is pressed, by pressing cruise control wrong connection
switch vehicle will go into cruise mode. of cruise control
• Pressing resume key; vehicle will set the circuit.
previous set speed. • Brake or clutch
• Pressing set + or Set - vehicle speed can be error is set into
adjusted. ECU.
• Pressing OFF switch, vehicle will come out • Switches are not
of cruise mode. responding or
• It will be operational in 2nd /3rd /4th & 5th faulty.
Gear. • Engine RPM less
• Clutch signal & brake switch signal are ok. than 1200.
• Engine RPM is > 1200
Malfunction
• By pressing any of the cruise control
switch vehicle will not go into cruise
mode.
• Vehicle will not respond to set +, Set -,
OFF or resume switch when vehicle is in
cruise mode.

Nov. 07
MAN-00029
922MHKR011107EN-DM
P-0577
Automotive Sector C-39 P-0576
2.2 P-0575
BS III
ECU
K35 K32 K80 K17 K58
W-B
V P-B Br Br-B
Redundant
brake
switch
On/off
On/Off
Set
Set--
Set +
Set +
Main Clutch
Coast/Resume
brake
switch
15A
Coast / Reset
15A
Cruise Battery Battery

control
activator

Nov. 07
MAN-00029
922MHKR011107EN-DM

C-39
P-0576
2.2
P-0575
BS III

Nov. 07
MAN-00029 P-0577
C-39922MHKR011107EN-DM P-0576
2.2 P-0575
BS III
Automotive Sector
Connect the ‘Smart Tester’ to diagnostic connector.

2. Verify that either P0577 or P0576 or P0575 is present.
• Turn the Ignition OFF/ON to measure the Voltages.

• Check the resistances across all the switches when they are activated
Parameter Resistance Voltage

No key pressed 4.323 K Ώ 4.35 V
ON/OFF 150 Ώ 0.9823 V
Coast/Reset 1.63 K Ώ 3.61 V
Set + 810 Ώ 2.845 V
Set - 420 K Ώ 2.035 V
Do the switch show the above value?
Yes No
Switch ON the Ignition. Switches are faulty.

Check if there is any error of the Replace the switch with a new good
brake & clutch switch set. Clear part.
them.
Is there any other error present? Clear codes & verify.
Yes No

Nov. 07
MAN-00029
C-39922MHKR011107EN-DM
2.2 P-0577
BS III P-0576
Diagnose the error & clear it. Check the connection of ECU
terminals K 35 & K32 and the cruise
control switch connections.
Clear codes & verify that the cruise control is functioning properly.
Is it OK?
Yes No
Check for any short or intermittent Repair the connections.

connections.
Repair it. Clear codes & verify that the cruise
control is working properly.
Clear codes & verify that the cruise
control is working properly.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0563
2.2 P-0562
Battery

Nov. 07
MAN-00029
922MHKR011107EN-DM P-0563
C-39
P-0562
2.2
Battery
Description:
The system voltage has to guarantee to perform diagnosis functions. The
Electronic Control Unit (ECU) monitors battery voltage. If this code is
set, the System Lamp is off.
DTC Diagnostic item


Detecting Condition
• Battery voltage <8 V • Charging system not
Enable Condition working.
- No main relay failure • Wiring harness to
ECU faulty.
• Battery voltage > 16V
Enable Condition
- No main relay failure
Test Procedure Battery –

• Check charging system.
• Check charging system (including battery) for proper operation.
• Refer the charging system section in the Electrical.
• Charging system OK. ( Voltage during cranking should be at least 9
volts)
Yes No
Check the ECU, problem procedure. Repair or replace.

Nov. 07
C-39
2.2 MAN-00029 P-1792
922MHKR011107EN-DM
BS III P-1791
Automotive Sector
Brake Switch
Description:
The function acquires and processes the information via the brake
contact and the redundant brake contact. The status message of the
brake position is the output.
DTC Diagnostic item
P-1792 Brake signal is defective
P-1791 Brake signals not plausible

Principle
• The brake switch outputs a voltage, • Open, shorted, loose
which corresponds to the brake or wrong connections
position. of brake switch Wiring.
• The ECU checks whether this voltage is • Brake switch damage
within a specified range (0 or 12V). or faulty
• Brake switch failed or
Normal Operation maladjusted.
• Ignition switch: ON .
• System lamp: OFF after 2 Sec
• Battery voltage is 8V –16V.
Malfunction
• The sensor output voltage has
continued to be 0V in spite of brake
pedal being pressed/not pressed
continued to 12V in spite of brake
pedal being pressed/not pressed
• Main or redundant switch is not
working.
Reaction
• System lamp will be off.
Cruise control will not work.

Nov. 07
MAN-00029
922MHKR011107EN-DM P-1792
C-39
2.2 P-1791
BS III
Automotive Sector

Nov. 07
MAN-00029 P-1792
C-39
922MHKR011107EN-DM P-1791
2.2
BS III
Automotive Sector
Test Procedure Brake switch --
Codes: P-01792, P-1791

2. Turn Ignition Switch ON
Disconnect the brake switch connector.
• Turn Ignition ON and check the supply voltage to brake switch two
point connector.
• It should be 12 V when Ignition ON
• Is it?
Yes No
Turn the Ignition OFF. Check the 15 Amp fuse after the
main relay.
Connect the brake switch Check the supply to K01 & K05.
connector. (Fuses of K01 & K05)
Check the voltage at K80 of ECU Repair connections as necessary.
input pin when the brake is in
released position.
When the brake pedal is pressed

then it should be checked at K17.
It should be 12 V. Clear codes & verify.
Is it?
Yes No

Nov. 07
MAN-00029
922MHKR011107EN-DM P-1792
C-39
P-1791
2.2
Replace the brake switch with Turn Ignition OFF

known good component.
Check for error. Remove brake switch connection &
check continuity between terminal
K17 & K80 to brake switch
connector.
Clear the error memory. Is it OK?
No Yes
Repair the connection as necessary. Replace the brake switch with

known good component
Clear the error and verify.

Nov. 07
MAN-00029
922MHKR011107EN-DM P-0704
C-39
2.2
Clutch Switch –
DTC Diagnostic item

P-0704 Clutch signal is not plausible
Description
The clutch signal is acquired as a hardware signal. The signal is checked
for plausibility using gear information. Error is detected, if there is a
valid gear change without the clutch being pressed during the time that
elapsed since the last gear change.

Normal Operation
• The clutch switch outputs a voltage, • Open, shorted, loose
which corresponds to the clutch or wrong connections
position. of brake switch Wiring.
• The ECU checks whether this voltage is • Clutch switch failed or
within a specified range (0 or 12V). maladjusted.
• Clutch switch damage
Normal Operating Requirements: or faulty.
Malfunction
continued to be 0V in spite of clutch
pedal being pressed/not pressed.
continued to 12V in spite of clutch
pedal being pressed/not pressed.
Reaction:
• System lamp will be off.
• Cruise control will not work.

Nov. 07
C-39 MAN-00029 P-0704
922MHKR011107EN-DM
2.2
BS III
Automotive Sector
15 Amp
4 Br-B
K58
4
R G
Clutch switch ECU

(normally closed)

Nov. 07
MAN-00029 P-0704
922MHKR011107EN-DM
Automotive Sector

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39
BS III
Test Procedure Clutch switch –

3. Verify that error P 0704 is present.
Verify that no error related to vehicle speed (vehicle speed sensor

related) is present. If present, first attend to those complaints then
verify if the error P 0704 is present and then proceed.
Disconnect clutch switch connector.
Turn the ignition ON.
Check supply voltage to clutch switch on connector.
It should be 12 V, when Ignition is ON. Is it?
Yes No
Turn Ignition OFF. Check the 15 Amp fuse after the

main relay ( this fuse also controls
EGR & Brake switch).
Connect the clutch switch Check the supply to K01 & K05.
connector.
Check the voltage at K 58 of the Repair the connections as
ECU pin, when the clutch is in necessary.
released condition.
It should be 12 V. Clear codes & verify.
Is it ?
Yes No

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39
2.2 P-0704
Clear the codes & verify. Turn Ignition OFF.
If the problem persist, replace with Remove clutch switch connection &
a known good clutch switch. check continuity between terminal
K58 with clutch switch connector.
Clear the codes & verify. Is it OK?
No Yes
Repair the connection as necessary. Replace the clutch switch with

known good component.
Clear the error memory & verify

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0118
2.2 P-0117
Coolant Temperature Sensor

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0118
2.2 P-0117

Description: The Water temperature sensor (WTF) is located in the
coolant pipe of the cylinder head. The WTF 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 WTF
voltage and uses the information to help smoothen the engine
operation.
DTC Diagnostic item

Background
• The engine coolant temperature sensor • Open or shorted
converts the engine coolant temperature Engine Coolant
to a voltage and outputs it. Temperature
• The ECU checks whether the voltage is sensor circuit, or
within a specified range. In addition, it loose or wrong
checks that the engine coolant connection
temperature (signal) does not drop while • Engine Coolant
the engine is warming up. Temperature
sensor failed.
be 5V or higher for 4 sec.
be 0.1V or lower for 4 sec.
Reaction:
• System lamp will be on.
Engine will continue to run with water
temperature of 120 deg C.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0118
2.2 P-0117
ECU
A 58 A41
G-R
W-R
2
1

Nov. 07
MAN-00029 P-0118
922MHKR011107EN-DM
C-39 P-0117
2.2
BS III
Automotive Sector
Test Procedure Coolant Temperature Sensor --
Codes: P-0118, P-0117,

• Verify DTC P0118 or P0117 are present.

• Turn the Ignition OFF
• Disconnect the CTS connector.
• Turn Ignition ON and check the voltage between ‘CTS’ signal terminal
1 and ground.
• It should be 5 V when Ignition ON
• Is it?

Nov. 07
C-39MAN-00029 P-0118
922MHKR011107EN-DM
2.2 P-0117
BS III
Automotive Sector
Yes No
Turn the Ignition OFF Open or short between CTS signal

terminal 1 and ECU
Measure continuity between A 58 of Repair as necessary.
ECU & connector terminal 1
Measure continuity between A 41 of
ECU & connector terminal 2
Is it OK
Yes No
Connect CTS connector Open or short between CTS signal

terminal 1 and ECU
Turn Ignition ON Repair as necessary.
Check the voltage of CTS
Is it as per specification
Yes No
Poor terminal contact due to Temporarily install a known good

oxidation, bent or misplaced CTS and check for proper operation.
terminal
Repair as necessary If problem is corrected, replace
CTS.
• Return vehicle to original condition. Clear all DTC.

• Verify by driving vehicle with “Insight” connected and monitor for
error codes.
Nov. 07
MAN-00029 P-2558
C-39 922MHKR011107EN-DM
2.2 P-1126
BS III
Automotive Sector
Coolant temperature sensor absolute & dynamic test
Description - When the engine is switched ON then the ECU detects the
temperature. After that when the engine runs then the temperature
output on a time frame is detected and compared against
predetermined slope.
DTC Diagnostic item

P-2558 Minimum Temperature not reached within time limit.
P-1126 Minimum temperature or temperature raise no reached
within time limit

Proper Performance
The coolant temperature rises to a specified • Defective temperature
temperature within a specific time period. sensor.
It also compares the rate of rise with a • Thermostat stuck in

defined rate of rise open condition
• Thermostat removed.
The coolant temperature do not rise enough
within a specific time period,
• The coolant temperature do not reach a
warmed-up fuel control temperature within
a specific time period.
Reaction
System check lamp : OFF

Nov. 07
MAN-00029
922MHKR011107EN-DM
P-2558
P-1126
Automotive Sector
Test Procedure -
Remove the connector of

the temperature sensor
Not Ok
Replace the
temperature sensor
Fit a new good

thermostat
Check if the
thermostat present Not
Present
Present
Check if thermostat
opening is OK
Not Ok Replace OK
Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM P-165E
2.2 P-165F
BS III P-1660
Coolant overheat Lamp - power stage
DTC Diagnostic item

P-165E Short Circuit to Battery
P-165F Short Circuit to Battery
P-1660 No Load

Normal operation
• When ignition is ON coolant overheat
lamp will be ON & OFF after 2 sec. • Open short circuit to
• When coolant temperature crosses the battery or ground.
set value lamp will glow. • Wrong connection for
coolant overheats
Malfunction lamp circuit.
• Coolant overheat lamp will not respond,
during the lamp test.
• Show wrong display.

Nov. 07
MAN-00029
922MHKR011107EN-DM
P-165E
C-39 P-165F
2.2 P-1660
BS III
P-165E
C-39 P-165F
2.2 P-1660
BS III P-1661

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
2. Verify that either P1660 or P1661 or P165E or P165F is present.

• Check the connection to the coolant overheat lamp.
• Go to the Actuator Test # ACT 1. If the lamp is working as per the
command then the lamp & connections are OK.
• If not working then:-
• Check the continuity between ECU terminal K94 with overheat lamp.
• Is it OK?
Yes No
Switch ON the Ignition Repair the connection

Check if the supply is coming to the Clear codes and verify that the
overheat lamp overheat lamp is working correctly.
Is it OK
Yes No
Lamp failure. Repair the connection.

Change the lamp Check the 15 Amp fuse ( cluster
lamp fuse)
Clear codes and verify that the coolant overheat lamp is working properly

Nov. 07
P-0108
C-39 MAN-00029
922MHKR011107EN-DM P-0107
2.2
BS III
Automotive Sector
Atmospheric pressure sensor
DTC Diagnostic item


Normal Operation
• The atmospheric pressure sensor • Failed atmospheric
outputs a voltage, which corresponds to pressure sensor.
atmospheric pressure.
Normal Operation
• Battery voltage is 8V to 12V.
• No error reported in error memory.
Malfunction
to be 5V or higher.
to be 0V or lower.
Reaction
• System lamp will blink.
• Engine will run with default
atmospheric Pressure of 800hPa

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0108
2.2 P-0107
Automotive Sector
BS III

3. Verify that either P0108 or P0107 is present.
• Check the battery voltage.

• Clear the error codes.
• Verify if the error has been cleared.
Yes No
Repeat the clear error, for 3 times.

Replace the ECU

Nov. 07
MAN-00029 P-1623
C-39 922MHKR011107EN-DM P-1625
2.2 P-161F
BS III P-1621
Automotive Sector
Injector Energising time

Description: Controller not able to control power stage
DTC Diagnostic item
P1623 Below lower limit of enegising time- Injector # 1
P161F Below lower limit of enegising time- Injector # 3
Reaction: The System Check lamp will be Off.
Vehicle speed may drop.

Test Procedure –
1. Pl. confirm IMA (IQA) codes are flashed.

2. Confirm no fuel leakage in low & high pressure circuit.( including the
injector backflow test)
3. Check the continuity for the high & low sides.
4. Confirm battery voltage is above 10V.
5. Ensure fuel filter is not clogged. (Service interval followed as per
schedule)
6. Check with swapping Injector.
7. If still error persists change the injector.

Nov. 07
C-39 MAN-00029 P-162A
922MHKR011107EN-DM
2.2
BS III
Automotive Sector
Communication Monitoring
Description: Communication between controller and power stage inside

the ECU is not OK
DTC Diagnostic item

P-162A Communication error of CJ940
Reaction: The System Check lamp will be continuously ON.
Test Procedure:
1. Switch ON Ignition
2. Using smart tester, clear the ECU faults.
3. Switch OFF Ignition key and wait for 2 minutes.
4. Switch ON Ignition.
5. Using smart tester check whether any of the above mentioned fault is
present.
6. If fault is still present, switch OFF ignition.
7. Replace the ECU with a new one and repeat steps 4 & 5.
8. If fault is not present in the new ECU, then the old ECU is defective
and has to be sent back to M&M.

Nov. 07
C-39MAN-00029 P-1659
922MHKR011107EN-DM
2.2
BS III
Automotive Sector
Controller and TPU Monitoring
Description: Controller and Time processing unit out of sync.
DTC Diagnostic item

P-1659 Deviation between TPU and system time
Test Procedure:
1. Switch ON Ignition
2. Using smart tester, clear the ECU faults.
present.

Nov. 07
MAN-00029 P-1638
C-39 922MHKR011107EN-DM
2.2
BS III
Automotive Sector
ECU Monitoring
Description: Monitoring module inside ECU reports a defect.
DTC Diagnostic item

P-1638 Set, if error-counter of Watchdog or controller are not
plausible or the system must shut down
Engine will shut down.
Test Procedure:
2. Using ‘Smart Tester’, clear the ECU faults.
present.

Nov. 07
MAN-00029 P-162B
C-39 922MHKR011107EN-DM
2.2 P-162C
BS III
Automotive Sector
EEPROM Monitoring
Description: EEPROM storage device inside ECU is not OK
DTC Diagnostic item

P-162B EEPROM: error during last read operation
P-162C EEPROM: error during last write operation
P-162D EEPROM: default value used
Test Procedure:
present.

Nov. 07
P-160C
MAN-00029
922MHKR011107EN-DM P-160D
C-39
P-160E
2.2
BS III
Automotive Sector
Error path for the Tachometer signal
DTC Diagnostic item

P-160C Short Circuit to Battery
P-160D Short Circuit to Ground
P-160E No Load

Normal operation
• When ignition is ON system lamp will be • Open, shorted or
switch OFF after 2sec. wrong connection of
• When engine is running it will show tachometer circuit.
corresponding engine speed on dash
panel.
Malfunction
• When engine is running it wouldn't show
corresponding engine speed on dash
panel.
Reaction
• No impact on vehicle performance.
Only engine speed indication on dash
panel can not be seen.
• Cruise control will not work.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-160C
2.2 P-160D
Automotive Sector BS III P-160E

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector C-39 P-160C

2.2 P-160D
BS III P-160E
Test Procedure Tachometer signal

3. Verify that either P160C or P160D or P160E is present.
• Turn the Ignition OFF.

• Disconnect the tachometer connector from the cluster connections.
• Check the continuity between the ECU connector terminal K48 and
cluster tachometer connections.
• Is it OK?
Yes No
Check if any other error is set for Repair the connections.

speed sensor and check for short
circuit.
Check for short with battery or Clear codes & verify that signal is as
Ground per the limit.
Is it?
Yes No
Correct the error and check for Repair cluster connections, or they
tachometer error is not available. are not connected properly.
Clear codes & verify signal is as per the limit.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P1608
2.2 P1609
Automotive Sector P160A
BS III
P160B
Error path of coolant temperature output
Description
The component driver for the coolant temperature outputs the variable
as a PWM signal to the power stage. (Output on the cluster) In normal
operation, the PWM power stage is tested for short circuit to battery, to
ground, open circuit and excess temperature.
DTC Diagnostic item

P-1608 Short circuit to battery
P-1609 Short circuit to ground
P-160A No load
P-160B Excess temperature

Normal Operation • Open or shorted
• The coolant temperature output voltage, Engine Coolant
which is given to the cluster from ECU as Temperature
an output. output sensor
• The ECU checks whether this voltage is circuit, or loose or
within a specified range (0 or 5V). wrong connection.
Normal Operating Conditions

• System lamp: OFF after 2 Sec
Malfunction
• No indication of water temperature on
the instrument cluster.

Nov. 07
C-39 MAN-00029 P1608
922MHKR011107EN-DM P1609
2.2
BS III P160A
P160B
Automotive Sector
Test Procedure Coolant temperature output --

3. Verify that the either of the error codes P1608 or P1609 or P160A or
P160B is present.

Nov. 07
MAN-00029 P1608
C-39 922MHKR011107EN-DM P1609
2.2
P160A
BS III
P160B
Automotive Sector
• Remove the cluster connections of the coolant temperature

indicator.
• Check the continuity between coolant temperature output connector
with K29 of the ECU.
• Is it OK?
Yes No
Check the cluster lamp fuse Open or short between coolant

temperature output & ECU K29
Check the temperature value in Repair as necessary.
smart tester. Compare it with
physical measurements.
Check the output at K29 when

Ignition is ON.
Is it OK? Clear the error & verify.
Yes No
Replace the instrument cluster. Clear codes & verify.

Verify DTC with coolant
temperature output.

Nov. 07
C-39 MAN-00029 P-1530
922MHKR011107EN-DM P-1531
2.2
BS III P-1532
P-1533
Automotive Sector
Fault path of air condition power stage
Description –
The A/C compressor routes the A/C compressor control signal to the
digital power stage output. The power stage is monitored. An error such
as short circuit, open circuit or excess temperature, occurring at the
power stage is reported.
The function routes the control signal for the A/C compressor to the
power stage.
DTC Diagnostic item

P-1530 Short circuit to battery
P-1531 Short circuit to ground
P-1532 No load
P-1533 Excess temperature
DTC detection condition Probable cause for

malfunction
Normal Operation • No AC gas available.
• AC relay is OFF when the AC switch & blower • AC relay is not working.
switch is OFF. • Open or shorted AC
• The ECU checks whether AC switch is ON then it circuits, loose or wrong
will try to switch ON the AC relay provided connections.
blower is ON. • Compressor is not
• When AC relay is energized then it will switch working
ON the AC compressor. • ECU AC circuit faulty.
Normal Operation
• Engine is ON
• System lamp: OFF after 2Sec
• AC switch & blower switches are ON.
Malfunction
• ECU not recognizing 12V when AC switch is ON.
• ECU output to AC relay has continued to 0.5V or
more.
Reaction
• System lamp will blink continuously.
• AC will not work.

Nov. 07
C-39 MAN-00029 P-1530
922MHKR011107EN-DM
2.2 P-1531
BS III P-1532
P-1533
Automotive Sector
2. Verify that either P1530 or P1531 or P1532 or P1533 are present.
• Check that all the AC connections are fitted.

• Check the AC charging.
• Check that the AC & compressor relay both are functioning properly
• Is it OK?
Yes No
Turn the Ignition OFF. If needed change the relay & repair
the connections.
Measure continuity between K54 Clear codes & verify.
and AC switch & AC relay.
Measure continuity between K 70 &
ECU relay.
Is it OK ?
Yes No

Nov. 07
MAN-00029 P-1530
C-39 922MHKR011107EN-DM
P-1531
2.2 P-1532
BS III P-1533
Automotive Sector
Switch ON the Ignition. Check the fuses ( 15 Amp AC fuse)

Switch ON the AC switch. If required , replace it.
Check the voltage between the ECU Repair the connections.
terminal K54 & Ground.
Also check the voltage between K70

& ground.
At K70- Gnd. It should be 0 Volts when in Clear codes & verify that AC is
OFF condition and 12 Volts when in ON working properly.
condition.
Switch on the blower.
Check the voltage between K 70 &
ground.
It should show 0 Voltage.
Is it OK ?
Yes No
Check AC compressor connections & Repair the connections as per the

supply. circuit diagram.
Clear codes & verify AC is working. Clear codes & verify AC is working
properly.

Nov. 07
MAN-00029 P-1210
C-39 922MHKR011107EN-DM P-1211
2.2 P-1212
BS III P-1213
P-1215
Injector power stage- chip specific errors P-1216
P-1217
Description:
Injector power stage inside ECU defective
DTC Diagnostic item

P-1210 Chip-specific errors : CY33X internal reset / clock loss /
under voltage
P-1211 Chip-specific errors: CY33X is unlocked / CY33X init error
P-1212 Chip-specific errors:CY33X is in Test mode
P-1213 Chip-specific errors: CY33X SPI communication error
/checksum/read back
P-1214 Chip-specific errors ->CY33X internal parity error
P-1215 Chip-specific errors ->CY33X internal program flow error
P-1216 Chip-specific errors ->CY33X check of inv. YSEL during ON
failed
P-1217 Chip-specific errors ->CY33X ON timeout for at least 1
cylinder
Engine stops.
Test Procedure –
2. Using ‘Smart Tester’ clear the ECU faults.
5. Using diagnostic tester check whether any of the above mentioned
fault is present.
Nov. 07
C-39 MAN-00029 P-1664
922MHKR011107EN-DM
2.2
BS III
Automotive Sector
Monitoring module communication Monitoring
Description: Communication failure with monitoring module.
DTC Diagnostic item

P-1664 The fault path contains the supervision of the SPI-Handler
Set, if SPI-communication failed
Test Procedure –
present.

Nov. 07
MAN-00029
922MHKR011107EN-DM
P-1641
C-39 P-1642
2.2 P-1643
Power Stage Monitoring

Description: Controller not able to control power stage
DTC Diagnostic item
P-1641 Test of redundant shut off paths during initialization: Watch
dog switch off path defect
P-1642 Test of redundant shut off paths during initialization:
Voltage monitoring upper limit shut off path defect
P-1643 Test of redundant shut off paths during initialization:
Voltage monitoring lower limit shut off path defect

Test Procedure –
present.

Nov. 07
C-39 MAN-00029 P-1631
922MHKR011107EN-DM P-1632
2.2
BS III
Automotive Sector
Power stage voltage Monitoring
Description: Over / Under voltage to power stage detected
DTC Diagnostic item

P-1631 (Hardware) CJ940 upper limit: internal supply voltage upper
limit
P-1632 (Hardware) CJ940 lower limit: internal supply voltage lower
limit
Test Procedure –
present.

Nov. 07
C-39 P-1644
MAN-00029
2.2 922MHKR011107EN-DM P-1645
BS III
Automotive Sector
Sensor supply monitoring 1
DTC Diagnostic item


Normal Operation
The ECU monitors the supply voltage to
camshaft phase sensor, and accelerator pedal
( APP1)
Malfunction
The voltages are beyond the range.
Reactions
System lamp status for this error is ON.

Nov. 07
MAN-00029 P-1644
C-39 922MHKR011107EN-DM P-1645
2.2
BS III
Automotive Sector

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-1644
2.2 P-1645

2. Verify that either P-1644 or P-1645 is present.
• This is related to the cam shaft sensor supply & also APP1 supply
voltage.
• Check the connection of the cam shaft sensor supply & accelerator
pedal connector.
• Is it OK?
Yes No
Remove the sensor connections of Repair the connection.

the camshaft sensor & the
Accelerator pedal.
Clear the error. Clear codes and verify.
If the error heals then the problem
may be due to poor connection.
Does it heal?
No Yes
Clear the codes & verify. Check the continuity between the
ECU connector A11 and the
camshaft terminal 3.
&
Between ECU connector K 45 and
Accelerator pedal Terminal 2.
Repair the connection.

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
If the error is still present, then the Reconnect everything.
ECU is suspect.
Replace ECU with a known good Clear codes and check cam phase
one. sensor and Accelerator pedal are
Clear codes & verify. working properly.

Nov. 07
C-39 MAN-00029 P-1646
2.2 922MHKR011107EN-DM P-1647
BS III
Automotive Sector
Sensor supply monitoring 2
DTC Diagnostic item


Normal Operation
The ECU monitors the supply voltage to Rail
pressure sensor, HFM and accelerator pedal
(APP 2)
Malfunction
The voltages are beyond the range.
Reactions
System lamp status for this error is ON.

Nov. 07
C-39 MAN-00029 P-1646
2.2 922MHKR011107EN-DM P-1647
BS III
Automotive Sector

Nov. 07
C-39 MAN-00029 P-1646
2.2 922MHKR011107EN-DM P-1647
BS III
Automotive Sector
1.Connect the ‘Smart Tester’ to diagnostic connector.

2.Turn Ignition Switch ON.
3.Verify that either P-1646 or P-1647 is present.
• This is related to the rail pressure sensor, HFM and APP2 supply
voltage.
• Check the connection of the rail pressure sensor, HFM & accelerator
pedal connector.
• Is it OK?
Yes No
Remove the sensor connections of Repair the connection

the Rail pressure sensor , HFM & the
Accelerator pedal
Clear the error Clear codes and verify.
If the error heals then the problem
may be due to poor connection.
Does it heal?
No Yes
Clear the codes & verify. Check the continuity between the
ECU connector A 29 and the HFM
terminal 4.
Check the continuity between the
Rail pressure connector terminal 3
and terminal A14 of the ECU
Check the continuity of between
terminal 1 of the Accelerator pedal
(APP2) and K 46 of the ECU.
Repair the connection.

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
If the error is still present, then the Reconnect everything.
ECU is suspect.
Replace ECU with a known good Clear codes and verify.
one.

Nov. 07
MAN-00029 P-1654
C-39 922MHKR011107EN-DM P-1655
2.2 P-1656
BS III P-1657
Automotive Sector
System lamp -Power Stage fault status
DTC Diagnostic item

P-1656 No Load

Normal Operation
• When Ignition is switched ON the system • Open, shorted or
lamp will glow ON for 2 sec. wrong connection of
• It will switch OFF if no error is set. system lamp circuit.
Malfunction
• When ignition is switched ON the system
lamp does not glow ON.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-1654
2.2 P-1655
BS III P-1656
Automotive Sector
P-1657

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-1654
2.2 P-1655
P-1657
3. Verify that either P1654 or P1655 or P1666 or P1667 is present.
Go to the Actuator Test # ACT 2. If the system check lamp works with
the actuator test then the system check lamp, wiring & ECU are OK.
If not working then:

• Disconnect the camshaft sensor connector.
• The connections to the system lamp.
• Check the continuity between the ECU terminal K71 with system
lamp
• Is it OK?
Yes No
Turn the Ignition OFF Check the fuse.

Disconnect ECU connector A Repair the wire.
Measure the continuity of Ground Clear the error codes & verify
sensor harness.
Is it OK?
Yes No
Lamp failure Repair the connection.

Replace lamp Clear codes and verify that the
system lamp is working properly.
Clear codes and verify that the
system lamp is working properly.
Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM P-1658
2.2
BS III
Automotive Sector
Terminal 15 (Ignition)- contains plausibility error [Sig] of T15
DTC Diagnostic item

P-1658 No Terminal T15 signals detected

Normal operation
• When ignition is ON relay coil will get • Open, shorted or
energized. wrong connection of
• Engine being started. T15 circuit.
Malfunction
• When ignition is ON supply is not coming to
ECU.
• Main relay coil will not get energized.

Nov. 07
C-39 MAN-00029 P-1658
2.2922MHKR011107EN-DM
BS III
Automotive Sector
2. Verify that P-1658 is present.
• Check that the main relay is getting energized.

• To check that the relay is getting energized, hear for the clicking
sound from the main relay when the Ignition is switched ON.
• Is it OK ?
Yes No
Turn the Ignition OFF. Follow the Main relay fault finding
procedure.
Measure the continuity of the wire Clear the error codes & verify.
between the K28 terminal of the
ECU and the Ignition switch
(Terminal 15).
Is it OK?
Yes No
Check for loose or intermittent Repair the connection.

connection.
Repair the connection Clear the codes and verify that the
vehicle is working perfectly.
Clear the codes and verify that the
vehicle is working perfectly.

Nov. 07
C-39 MAN-00029 P-0503
922MHKR011107EN-DM P-0500
2.2
BS III P-0501
Automotive Sector
Vehicle speed sensing
DTC Diagnostic item

P-0503 Exceeding of the maximum vehicle speed
P-0500 HW signal for vehicle speed not valid
P-0501 Vehicle speed not plausible with injection mass and
engine speed

Normal Operation
• The vehicle speed sensor outputs a • Failed vehicle speed
pulse signal while the vehicle is driven. sensor.
• The ECU checks whether the pulse • Open shorted
signal is present. vehicle-speed sensor
circuit, loose or
wrong connection.
Malfunction
• Sensor output voltage has not changed
(No pulse signal) for 4 sec.

Nov. 07
C-39 MAN-00029 P-0503
922MHKR011107EN-DM P-0500
2.2
BS III P-0501
Automotive Sector

3. Verify that either P0503 or P0500 or P0501 is present.
• Drive the vehicle.

• Does the speedometer show the correct value? (Compare the values
of speedometer with the value visible in the “‘Smart Tester’”- use
the live data tab in ‘Smart Tester’.)
• Is it OK?
Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM P-0503
2.2 P-0500
BS III P-0501
Automotive Sector
Yes No
Turn the Ignition OFF. Repair the cable ( from the pin no 1
to pin no 5 of the instrument cluster
socket- C24).
Inspect the interface between the Clear the error codes & verify.
VSS and the speedometer gear in
the Gearbox.
Is it OK?
Yes No
Disconnect VSS Repair the interface between he

speedometer & the VSS
Disconnect ECU connector Clear codes & verify that VSS signal
is within limit.
Measure the continuity between the
ECU terminal K75 and sensor
terminal 3
Is it OK?
Yes No
Check the open circuit between the Repair the wire between VSS
sensor Ground & positive supply connector & ECU terminal
Is it OK Clear codes & verify that VSS signal
is within limit.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-0503
2.2 P-0500
Yes No
Verify that the ECU connections are Repair short circuit to Ground or
OK another circuit in wire between VSS
harness connector
If OK replace VSS with a known Clear codes and verify that the VSS
good VSS signal is within range.
Clear codes and verify that the VSS
signal is within range.
If problem persist- replace ECU

Nov. 07
C-39 MAN-00029 P-1887
922MHKR011107EN-DM P-1888
2.2
BS III P-1889
P-1890
Automotive Sector
Glow control relay actuator (If Applicable)
DTC Diagnostic item

P-1888 Short Circuit to Ground
P-1889 No Load
P-1890 Excess temperature

Normal operation • Open, shorted or
• When ignition is ON after 2 seconds the wrong connection
system lamp will switch OFF. of glow circuit.
• When Ignition is ON glow relay will switch • Fuse is blown.
ON & switch OFF after 10 sec. (If temp. is • Relay is not
lesser than 0 Degree Centigrade) working.
• Glow relay will get energized as per the
logic in the ECU.
Malfunction
• When ignition is ON system lamp will be
ON.
• Relay will not get energized as per ECU
logic.

Nov. 07
C-39 MAN-00029 P-1887
922MHKR011107EN-DM P-1888
2.2
BS III P-1889
P-1890
Automotive Sector

Nov. 07
MAN-00029
922MHKR011107EN-DM P-1887
C-39 P-1888
2.2 P-1889
Test Procedure –
1.Connect the ‘Smart Sensor’ to diagnostic connector.

2.Turn Ignition Switch ON
3.Verify that either P-1888 or P-1889 or P-1890 or P1887 is present.
• Check the 15 Amp fuses. If defective, replace.
• Check when the Ignition ON the Glow lamp is ON (Check lamp check:
the system lamp & the overheat lamp should come On for 2 seconds
and then go off)
• If not On then check lamp & replace.
• Check the insertion of glow plug & glow relays.
• Is it OK?
Yes No
Check the contuinity between the Repair the terminal of the glow
ECU terminal K 93 and terminal 85 plug & relay.
of the relay.
When the supply is ON the supply is Clear codes & verify that the glow
coming to terminal 86 & 30 of the plugs are working properly.
relay.
Check the 60 Amp fuse, if faulty,
replace fuse.
Yes No
Check as per the glow plug logic Repair the connection.

that the glow plug’s are working.
( the glow plug light will glow ON
for 15 seconds)
Check the relay is energizing. Clear codes & verify.
Is it OK ?

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 P-1887
2.2 P-1888
BS III P-1889
Yes No
Loose or intermittent connections. Relay is defective.

Repair connection. Change the relay.
Clear codes and verify that it is working properly.

Nov. 07
MAN-00029
922MHKR011107EN-DM
Automotive Sector
Immobiliesr Error Codes
Code Error description Vehicle Behavior

Error
Immobilizer Immobilizer The vehicle will not start and if
Signal Error control: indicates the driver tries for more than
that the received three times then the vehicle will
P1812 pattern and the get completely locked.
transmitted
pattern is not
correct
SRC High Vehicle will not start, even the
Communication
P1828 Error starter motor will not get
wire may open
activated
SRC Low Communication Vehicle will not start, even the
P1829 Error wire may be starter motor will not get
short activated
Signal is in Wrong The vehicle will not start and if
the error communication, the driver tries for more than
zone - Code three times then the vehicle will
received get completely locked.
P182A from CDL
may not be
correct
- Theft made
attempt.
Signal is in ECU is Locked Vehicle will not start
Immobilize Completely (ECU
zone Locked due to
P182B continuous
occurrence of 3
immobilizer
errors)
Please note that to enable/disable the immobilizer- you have to use the
Immobilizer tool. The diagnostic tool can not be used for it.
Nov. 07
MAN-00029
C-39
922MHKR011107EN-DM
2.2
BS III
Automotive Sector
Actuator Tests
Home screen for the Actuator test

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 ACT # 1
2.2
BS III
Automotive Sector
ACT # 1 - System Lamp
Test condition: Ignition ON
Actuate: Click on the System Lamp ON.
Expected Result: The system lamp in the cluster will come ON
Click on the release to release the lamp

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 ACT # 1
2.2

Nov. 07
MAN-00029
922MHKR011107EN-DM
ACT # 2
C-39
BS III
ACT # 2– Coolant Overheat Lamp Test
Test condition: Engine Running
Actuate: Click the switch ON.
Expected Result: The coolant overheat lamp at the end of the

temperature scale will light up.
It will remain ON for 20 seconds or until is Released

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39
2.2 ACT # 3
Automotive Sector
BS III
ACT # 3– Air Conditioning Actuator
Test condition: Engine at Idle or With Ignition ON
Actuate
Expected result: The air condition actuator will become ON, you can
hear the compressor engage
Note: This actuator does not get released automatically. You have to
manually release

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 ACT # 4
2.2
ACT #4– EGR Actuator
Test condition:
Engine Running at Idle

Note the quantity of the injection and the air mass.
Action: Put EGR quantity >80%. In the Enter duty cycle. Actuate
Expected result: The actual duty cycle will change.
The air mass quantity and the injection quantity should change. The
value are very small Air mass by around 4 and fuel quantity change of
around 0.47.
Note: If not released manually, the system will automatically release

the entered duty cycle after 30 seconds

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 ACT # 5
BS III
ACT #5– Boost Pressure Actuator ( BPA) Test
Test Condition: Engine running – at idle
Enter duty cycle – between 0 to 100%. Click on Test
Expected result : There is a change in Engine RPM and also the air mass
quantity changes. The engine noise change is also clearly audible
Disabled Actuator Test:
¾ Rail Pressure set Point

¾ Metering Unit Actuator
¾ Glow Lamp & Glow relay

Nov. 07
C-39 MAN-00029 SBD #1
2.2 922MHKR011107EN-DM
BS III
Automotive Sector
Symptom Based Diagngosis – SBD # 1
Complaint - Engine not starting

Error codes - No error codes.
Check for error codes while cranking
No Error Error code

present
Check the Battery Voltage.

Not OK Follow the procedure
It should be minimum 9
volts for the code displayed
Replace the battery and OK

OK check charging system
Not
OK
Check the Not Change starter

cranking RPM ( > OK
180)
OK
Check the Synchronization status and

the state of the starting system

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 SBD #1
2.2
BS III
Automotive Sector
First look at the label- while

cranking.
Remains in 0
State of starting system while
cranking
0 Wait for engine speed
1 Ignore engine speed
2 f i
Not sensing engine RPM, check

Remains in 1 gap, sensor, connector
while
cranking
The engine is not getting

synchronized. Look at the code
in the synchronization status.
Engine can be
started
Check the injector back

If Synchronization flow as per Test-
status jumping from Injectors- replace if
3 to 48 & back. required
Based on the code

Engine not
description, take
starting
corrective action.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 SBD #1
2.2
BS III
Automotive Sector
Synchronisation state
Code Description
0 INIT: Basic initialization of state machine

1 RECOVER: Resetting the counters
2 TIMEOUT: Engine stops or error case in which all engine speed

sensors of system are defective
3 INTERIMS: Additional asynchronous interrupts which is generated

when engine position is detected based on the time condition of
system.
4 WAIT_INC: Plausibility test is done on the events of the redundant

sensor system w/o the mail sensor system delivering events.
Interrupts are generated with min. system freq.
5 PHASE_FREQ_CHK: Plausibility test is done on the events of the

redundant sensor system w/o the mail sensor system delivering
events. Interrupts are generated with max. system freq.
8 PHASE_PLAUS_CHK: Plausibility test is done on the events of the

redundant sensor system w/o the main system delivering events.
16 POLLING: The overall system behaves frq. Synchronous & waits for
further events to determine the phases.
32 WAIT_PHASE: Waits for the unique positioning by the phase

system.
33 VERIFY A unique positioning of the system has occurred. A

plausibility test is run on all sensor systems wrt each other in their
status & angle info.
34 RESYNC_OVERFLOW: No unique position was found

35 RESYNC_OFFSET
Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 SBD #1
2.2
BS III
Automotive Sector
48
64 POST: The system wait until there is a complete engine stop.
128 VERIFY_BACKUP
129 BACK UP
130 START_BACKUP
131 WAIT_BACKUP: Engine has decelerated. Metering unit no longer be

activated.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 SBD #2
2.2
BS III
Automotive Sector
Symptom Based Diagngosis – SBD # 2. Injector Back leak
Applicable to
Scorpio CRDe 2.2
DTC code
• None
( Will happen when injectors stuck close)
• P1193/P1192
( Will happen when injectors are stuck open)
Engine Status
• Can not be started
State of Starting System Synchronization status Code

Code
• 1 • Jumps from 3 to 48
Tools required for Doing the test

• 4 Test tubes with graduations, (capacity 30 to 75 ml)
• 4 no rubber tube of 310 mm ( Recommend part number
9350042680 - Engine–Tube Connection Injection Pump)

Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM SBD #2
2.2
BS III
Automotive Sector
Caution - The ID of the tube is important; hence please use this part
number.
Blow air around the injectors to remove the dust.
Remove injector overflow connector holder clips from all

the four injectors.
Remove injector overflow connections from all the four

injectors.
Do not remove overflow tube connection from the fuel
return line ‘T’ joint
Insert injector overflow pipe firmly in Each Injector.
Over flow
pipe
inserted
in the
injector.

Nov. 07
MAN-00029
922MHKR011107EN-DM
C-39 SBD #2
2.2
BS III
Automotive Sector
Insert the pipes open end in to the test tubes as shown in photograph).
Start Engine.
Idle for 1 minute
Stop the engine
Ignore first reading. Empty

the test tubes & reconnect.
If any test tube

gets filled during
the test, “STOP”
the test and
Replace that
cylinder injector. If the fuel quantity in any
test tube is more than 20 ml,
If collected fuel quantity is then the corresponding
injector(s) is defective.
“5 to 20” ml, all injectors
are “OK”.
Start engine &
repeat test for
exactly one
minute.
Nov. 07
MAN-00029
C-39 922MHKR011107EN-DM SBD #2
2.2
BS III
Automotive Sector
The root cause for the injectors stuck open or close is the presence of
water in the fuel or poor fuel quality.
Investigate & advice the customer accordingly to avoid repeat failure.
In case of water – please advise the customer how to drain water when
the indicator comes ON.
If it is suspected due to poor fuel quality- please advise accordingly.

Nov. 07

SCORPIO VLX DIAGNOSTIC MANUAL mHAWK Rev1

Uploaded by

Document Information

Original Title

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

SCORPIO VLX DIAGNOSTIC MANUAL mHAWK Rev1

Uploaded by

Copyright:

Available Formats

SCORPIO Vlx

DIAGNOSTIC MANUAL - mHAWK

2. BRIEF ENGINE SPECIFICATIONS 3

3. GUIDELINES FOR TROUBLE-SHOOTING 4

4. DTC CODES – HYPERLINKED INDEX 10

5. DTC BASED DIAGNOSTICS 21

ACCELERATOR PEDAL – CIRCUIT 1 21

6. ACTUATOR TESTS 163

7. SYMPTOM BASED DIAGNOSTICS 170

All copyrights reserved by

BRIEF SPECIFICATIONS (m-HAWK ENGINE)

Type 4-cylinder, 4-stroke, Turbo-charged, Inter-cooled, Direct

Max Power 120 hp @ 4000 rpm

Max Torque 29.5 Kg-m @ 1800 – 2800 rpm

Emission Bharat Stage 3

Turbocharger – Variable Geometry Turbocharger (VGT) , controlled by engine

Valve Mechanism – Double overhead camshaft (DOHC), operating 4-valves per

Exhaust System – Closed-coupled oxidation catalyst.

During the fault diagnosis, under no circumstance, the traditional

If any arc welding has to be done then it is essential that besides

The trouble-shooting manual is done in a manner that all the trouble

All copyrights reserved by

Preliminary trouble shooting (common for all trouble codes)

• Ensure that the connectors are tightened properly to the sensors.

• Ensure battery voltage is between 8 to 16 Volts. It should not go

• Communication to the diagnostic tester will not be established in

6. If no errors are registered with ignition on, (In diagnostic tester)

All copyrights reserved by

1. Vehicle speed sensor.

At this point of time it will be worthwhile to note that if an error has

Refer to the circuit diagrams. It has to be remembered that

All copyrights reserved by

• Check for the connector’ conditions. Many times continuity is not

• Engine will go to limp home in following condition:

All copyrights reserved by

All copyrights reserved by

• Before changing any components, ensure that the error is cleared at

• Trouble shooting methods related to Turbocharger (Noise, loss of pick

All copyrights reserved by

Index of DTC codes

Group Code Label Page No

All copyrights reserved by

All copyrights reserved by

All copyrights reserved by

Group Code Label Page No

All copyrights reserved by

Group Code Label Page No

All copyrights reserved by

All copyrights reserved by

All copyrights reserved by

Group Code Label Page No

All copyrights reserved by

Group Code Label Page No

All copyrights reserved by

Group Code Label Page No

All copyrights reserved by

Group Code Label Page No

All copyrights reserved by

Accelerator Pedal Module 1

All copyrights reserved by

Accelerator Pedal Module 1

DTC Diagnostic item

DTC detection condition Probable cause