Bolero Pikup FB .

Diagnostic Manual
MAN-00448
DIAGNOSTIC MANUAL
EMS - EDC17C55 BOLERO PIK-UP / EXTRA
LONG
Revision — 1
AUG- 2017
Published by — Service Engineering
Technical Hub
Diagnostic Manual MAN-00448
EMS - EDC17C55
BOLERO PIK-UP / EXTRA LONG AUG- 2017/Rev 1
Table of Contents
1 HOW TO USE THIS MANUAL .................................................................................................... 9

2 RECOMMENDED TROUBLE SHOOTING PROCESS ......................................................... 10
3 WARRANTY & OTHER INFORMATION ................................................................................. 11
4 EMS OVERVIEW ......................................................................................................................... 12
5 EMS ECU CONNECTORS PIN DETAILS ............................................................................... 13
6 EMS ECU WIRING DIAGRAM (PIKUP EXTRA LONG) ....................................................... 17
6.1 EMS ECU WIRING DIAGRAM (PIKUP) ............................................................................. 20
7 STANDARD TEST PROCEDURE ............................................................................................ 22

8 IQA/IMA CODE PROGRAMMING ............................................................................................ 26
9 NO COMMUNICATION BETWEEN ECU AND DIAGNOSTIC / FLASHING
TOOL ......................................................................................................................................... 27
9.1 CIRCUIT SCHEMATIC ....................................................................................................... 27
9.2 CONNECTOR VIEWS AND INFORMATION ..................................................................... 28
9.3 DIAGNOSTIC PROCEDURE ............................................................................................. 28
10 DTC BASED DIAGNOSIS.......................................................................................................... 33

10.1 P1128 — COOLANT TEMPERATURE SENSOR ABSOLUTE TEST NON
PLAUSIBLE ERROR ......................................................................................................... 34
10.2 P1126 — COOLANT TEMPERATURE SENSOR DYNAMIC TEST NON

PLAUSIBLE ERROR ......................................................................................................... 36
10.3 P0118 — SRC FOR COOLANT TEMPERATURE SENSOR ABOVE MAX

LIMIT ................................................................................................................................... 38
10.4 P0117 — SRC COOLANT TEMPERATURE SENSOR BELOW MINIMUM

LIMIT ................................................................................................................................... 42
10.5 P062F — ECU EEPROM ERROR .................................................................................. 46

10.6 P162F — ECU EEPROM ERROR .................................................................................. 48
10.7 P1630 — ECU EEPROM ERROR ................................................................................... 50
10.8 P062B — ECU MONITORING ERROR FOR INJECTOR CUT OFF DEMAND ............ 54
10.9 P0403 — EGR VALVE OPEN LOAD ERROR (PIKUP).................................................. 56
10.10 P0403 — EGR VALVE OPEN LOAD ERROR (PIKUP EXTRA LONG) ......................... 59
10.11 P1403 — EGR VALVE OVER TEMPERATURE ERROR ............................................... 63
10.12 P0406 — EGR VALVE SHORT TO BATTERY ERROR (PIKUP)................................... 65
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of 3
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2017 Mahindra & Mahindra Ltd.
EMS - EDC17C55
10.13 P0406 — EGR VALVE SHORT TO BATTERY ERROR (PIKUP EXTRA

LONG)................................................................................................................................. 68
10.14 P0405 — EGR VALVE SHORT TO GROUND ERROR (PIKUP) ................................... 71

10.15 P0405 — EGR VALVE SHORT TO GROUND ERROR (PIKUP EXTRA
LONG)................................................................................................................................. 74
10.16 P2228 — SRC FOR ENVIRONMENTAL PRESSURE SENSOR BELOW MIN

LIMIT .................................................................................................................................. 78
10.17 P2229 — SIG RANGE CHECK FOR ENVIRONMENTAL PRESSURE SENSOR

ABOVE MAX LIMIT ........................................................................................................... 80
10.18 P0340 — CAMSHAFT SENSOR NO SIGNAL ERROR ................................................. 82

10.19 P0341 — CAMSHAFT SENSOR SIGNAL ERROR ....................................................... 88
10.20 P1341 — CAMSHAFT SENSOR SIGNAL OFFSET ERROR ....................................... 91
10.21 P0336 — CRANKSHAFT SENSOR SIGNAL ERROR .................................................. 94
10.22 P0335 — CRANKSHAFT SENSOR NO SIGNAL ERROR ............................................ 99
10.23 P0183 — SRC FOR FUEL TEMPERATURE SENSOR ABOVE MAXIMUM
LIMIT ................................................................................................................................103
10.24 P0182 — SIGNAL RANGE CHECK FOR FUEL TEMPERATURE SENSOR

BELOW MINIMUM LIMIT .................................................................................................108
10.25 P268C — CYLINDER 1 INJECTOR ADJUSTMENT CODE INCORRECT

ERROR ............................................................................................................................. 112
10.26 P268E — CYLINDER 2 INJECTOR ADJUSTMENT CODE INCORRECT

ERROR. ............................................................................................................................ 114
10.27 P268F — CYLINDER 3 INJECTOR ADJUSTMENT CODE INCORRECT

ERROR ............................................................................................................................. 116
10.28 P268D — CYLINDER 4 INJECTOR ADJUSTMENT CODE INCORRECT

ERROR ............................................................................................................................. 118
10.29 P0201 — CYLINDER 1 INJECTOR OPEN LOAD ERROR .........................................120

10.33 P0261 — CYLINDER 1 INJECTOR SHORT CIRCUIT ERROR...................................132
10.34 P0267 — CYLINDER 2 INJECTOR SHORT CIRCUIT ERROR...................................135
10.35 P0270 — CYLINDER 3 INJECTOR SHORT CIRCUIT ERROR ..................................138
10.36 P0264 — CYLINDER 4 INJECTOR SHORT CIRCUIT ERROR ..................................141
10.37 P2146 — SHORT CIRCUIT IN BANK 0 ........................................................................144
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document, are
4 prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd., will
amount to unauthorized use and shall be liable for penalty/prosecution© 2017 Mahindra & Mahindra Ltd.
EMS - EDC17C55
10.38 P0001 — METERING UNIT OPEN LOAD ERROR .....................................................152

10.39 P1620 — METERING UNIT DEVICE DRIVER OVER TEMPERATURE
ERROR .............................................................................................................................156
10.40 P0004 — METERING UNIT OUTPUT SHORT CIRCUIT TO BATTERY

ERROR .............................................................................................................................158
10.41 P0003 — METERING UNIT OUTPUT SHORT CIRCUIT TO GROUND

ERROR .............................................................................................................................161
10.42 P1652 — MIL NO LOAD ERROR (PIKUP)...................................................................164

10.43 P1652 — MIL NO LOAD ERROR (PIKUP EXTRA LONG) ..........................................169
10.44 P1653 — MIL OVER TEMPERATURE ERROR (PIKUP) ............................................173
10.45 P1653 — MIL OVER TEMPERATURE ERROR ( PIKUP EXTRA LONG) ...................178
10.46 P1650 — MIL SHORT CIRCUIT TO BATTERY ERROR (PIKUP) ...............................182
10.47 P1650 — MIL SHORT CIRCUIT TO BATTERY ERROR (PIKUP EXTRA
LONG)...............................................................................................................................186
10.48 P1651 — MIL SHORT CIRCUIT TO GROUND ERROR (PIKUP) ...............................189

10.49 P1651 — MIL SHORT CIRCUIT TO GROUND ERROR (PIKUP EXTRA
LONG) ..............................................................................................................................193
10.50 P0238 — SRC HIGH FOR CHARGED AIR COOLER PRESSURE (DOWN
STREAM) .........................................................................................................................196
10.51 P0237 — SRC LOW FOR CHARGED AIR COOLER PRESSURE (DOWN
STREAM) .........................................................................................................................201
10.52 P0627 — PSP OPEN LOAD ERROR ...........................................................................205

10.53 P1611 — PSP OVER TEMPERATURE ERROR .........................................................209
10.54 P0629 — PSP SHORT TO BATTERY ERROR ............................................................ 211
10.55 P0628 — PSP SHORT TO GROUND ERROR .............................................................215
10.56 P0193 — SRC FOR RAIL PRESSURE SENSOR ABOVE MAXIMUM LIMIT .............218
10.57 P0192 — SRC FOR RAIL PRESSURE SENSOR BELOW MINIMUM LIMIT..............222
10.58 P0191 — RAIL PRESSURE OFFSET VALUE ABOVE MAXIMUM LIMIT ..................225
10.59 P1191 — RAIL PRESSURE OFFSET VALUE ABOVE MINIMUM LIMIT ....................227
10.60 P2123 — SRC FOR APP PEDAL SENSOR 1 ABOVE MAXIMUM LIMIT...................229
10.61 P2128 — SRC FOR APP PEDAL SENSOR 2 ABOVE MAXIMUM LIMIT...................234
10.62 P2138 — PLAUSIBILITY ERROR BETWEEN APP SIGNAL 1 AND SIGNAL
2 ........................................................................................................................................239
10.63 P1138 — ACC PEDAL PLAUSIBLE CHECK WITH THE BRAKE .............................245
EMS - EDC17C55
10.64 P0563 — SRC FOR BATTERY SENSOR SIGNAL ABOVE MAXIMUM

LIMIT .................................................................................................................................253
10.65 P0501 — VEHICLE SPEED SENSOR PLAUSIBILITY ERROR..................................255

10.66 P0641 — SENSOR SUPPLY VOLTAGE1 MONITORING ERROR .............................270
10.67 P0651 — SENSOR SUPPLY VOLTAGE 2 MONITORING ERROR ............................276
10.68 P0697 — SENSOR SUPPLY VOLTAGE 3 MONITORING ERROR .............................280
10.69 P1B87 — RAIL PRESSURE POSITIVE GOVERNOR DEVIATION ERROR IN
METERING UNIT..............................................................................................................283
10.70 P1C87 — MAXIMUM POSITIVE DEVIATION OF RAIL PRESSURE EXCEEDED

CONCERNING SET FLOW OF FUEL IN METERING UNIT MODE ...............................287
10.71 P1B88 — RAIL PRESSURE NEGATIVE GOVERNOR DEVIATION ERROR IN

METERING UNIT MODE ..................................................................................................291
10.72 P1D87 — RAIL PRESSURE BELOW MINIMUM LIMIT ERROR IN METERING

UNIT MODE ......................................................................................................................296
10.73 P1C88 — RAIL PRESSURE ABOVE MAXIMUM LIMIT ERROR IN METERING

UNIT MODE ......................................................................................................................300
10.74 P068A — MAIN RELAY EARLY OPENING ERROR ..................................................305

10.75 P068B — MAIN RELAY EARLY STRUCK ERROR .................................................... 311
10.76 P0069 — PLAUSIBILITY DEFECT BETWEEN CACDSP AND ENVP .......................317
10.77 P0504 — BRAKE SIGNAL PLAUSIBILITY ERROR ...................................................319
10.78 U0073 — CAN BUS OFF ERROR ................................................................................324
10.79 P0704 — CLUTCH NON PLAUSIBLE ERROR ..........................................................330
10.80 P172A — CLUTCH 90% SWITCH PLAUSIBLE ERROR (SHORT TO
BATTERY) .......................................................................................................................335
10.81 P171A — CLUTCH 90% SWITCH PLAUSIBLE ERROR(SHORT TO

GROUND) ........................................................................................................................338
10.82 P2269 — WATER PRESENCE IN FUEL ERROR ........................................................341

10.83 P2265 — WATER IN FUEL SENSOR FAULTY ............................................................345
10.84 P226A — WATER IN FUEL LAMP OPEN LOAD ERROR (PIKUP) ............................350
10.85 P226A — WATER IN FUEL LAMP OPEN LOAD ERROR ( PIKUP EXTRA
LONG)...............................................................................................................................355
10.86 P126A — WATER IN FUEL LAMP OVER TEMPERATURE ERROR

(PIKUP) .............................................................................................................................359
10.87 P126A — WATER IN FUEL LAMP OVER TEMPERATURE ERROR (PIKUP

EXTRA LONG) .................................................................................................................364
EMS - EDC17C55
10.88 P126B — WATER IN FUEL LAMP SHORT TO BATTERY ERROR (PIKUP) .............368
10.89 P126B — WATER IN FUEL LAMP SHORT TO BATTERY ERROR (PIKUP EXTRA
LONG)...............................................................................................................................372
10.90 P126C — WATER IN FUEL LAMP SHORT TO GROUND ERROR (PIKUP)..............375

10.91 P126C — WATER IN FUEL LAMP SHORT TO GROUND ERROR (PIKUP EXTRA
LONG)...............................................................................................................................379
10.92 P1631 — ECU MONITORING: START OF INJECTION PLAUSIBILITY

ERROR .............................................................................................................................382
10.93 P1632 — ECU MONITORING: ZFC NON PLAUSIBILITY ERROR ............................383

10.94 P1636 — ECU MONITORING: OVERRUN MONITORING ERROR............................384
10.95 P1633 — ECU MONITORING: POI 2 QTY ERROR .....................................................385
10.96 P170F — STARTER RELAY OPEN LOAD ..................................................................387
10.97 P170C — OVER TEMPERATURE ERROR ON ECU POWER STAGE FOR
STARTER .........................................................................................................................390
10.98 P170D — STARTER RELAY SHORT CIRCUIT TO BATTERY ERROR ....................392

10.99 P170E — STARTER RELAY SHORT CIRCUIT TO GROUND ERROR ......................394
10.100 P1AE9 — START STOP LAMP OPEN LOAD ERROR ...............................................396
10.101 P1AEC — START/STOP LAMP OVER TEMPERATURE ERROR .............................400
10.102 P1AEB — START - STOP LAMP SHORT CIRCUIT TO BATTERY ERROR ..............401
10.103 P1AEA — START STOP LAMP SHORT TO GROUND ERROR ................................405
10.104 P1656 — SVS NO LOAD ERROR (PIKUP)..................................................................409
10.105 P1656 — SVS NO LOAD ERROR (PIKUP EXTRA LONG) .........................................414
10.106 P1657 — SVS OVER TEMPERATURE ERROR (PIKUP) ...........................................418
10.107 P1657 — SVS OVER TEMPERATURE ERROR ( PIKUP EXTRA LONG) ..................423
10.108 P1655 — SVS SHORT CIRCUIT TO BATTERY ERROR (PIKUP) ..............................427
10.109 P1655 — SVS (CHECK ENGINE LAMP) SHORT CIRCUIT TO BATTERY ERROR
(PIKUP EXTRA LONG) ....................................................................................................431
10.110 P1654 — SVS (CHECK ENGINE LAMP) SHORT CIRCUIT TO GROUND ERROR
(PIKUP) ............................................................................................................................434
10.111 P1654 — SVS (CHECK ENGINE LAMP) SHORT CIRCUIT TO GROUND ERROR
(PIKUP EXTRA LONG) ...................................................................................................438
10.112 P160A — COOLANT TEMPERATURE OUTPUT NO LOAD (PIKUP) ........................441
10.113 P160A — COOLANT TEMPERATURE OUTPUT NO LOAD (PIKUP EXTRA

LONG)...............................................................................................................................446
EMS - EDC17C55
10.114 P160B — COOLANT TEMPERATURE OUTPUT EXCESS TEMP(PIKUP) ...............451
10.115 P160B — COOLANT TEMPERATURE OUTPUT EXCESS TEMP (PIKUP EXTRA

LONG)...............................................................................................................................456
10.116 P1608 — COOLANT TEMPERATURE OUTPUT SHORT CIRCUIT TO BATTERY

(PIKUP) .............................................................................................................................461
10.117 P1608 — COOLANT TEMPERATURE OUTPUT SHORT CIRCUIT TO BATTERY

(PIKUP EXTRA LONG) ....................................................................................................465
10.118 P1609 — COOLANT TEMPERATURE OUTPUT SHORT CIRCUIT TO GROUND

(PIKUP) ............................................................................................................................468
10.119 P1609 — COOLANT TEMPERATURE OUTPUT SHORT CIRCUIT TO GROUND

(PIKUP EXTRA LONG) ...................................................................................................472
10.120 P1641 — SOFTWARE RESET ERROR .......................................................................475
10.121 P1707 — T50 SIGNAL ERROR ....................................................................................476
10.122 P0071 — SIGNAL RANGE CHECK FOR BATTERY SENSOR SIGNAL ABOVE
MAXIMUM LIMIT ..............................................................................................................477
10.123 P1406 — SRC FOR EGR FEEDBACK SENSOR ABOVE MAXIMUM LIMIT .............479
10.124 P1405 — SRC FOR EGR FEEDBACK SENSOR BELOW MINIMUM LIMIT ..............483
10.125 P007D — SRC FOR INTERCOOLER DOWNSTREAM TEMPERATURE SENSOR

ABOVE MAXIMUM LIMIT ................................................................................................487
10.126 P007C — SRC FOR INTERCOOLER DOWNSTREAM TEMPERATURE SENSOR

BELOW MINIMUM LIMIT .................................................................................................490
10.127 P1900 — ECU MONITORING: ADC NTP ERROR ......................................................493
10.128 P1628 — ECU MONITORING: SHUT OFF PATH UNDER VOLTAGE

ERROR .............................................................................................................................495
10.129 P060D — CONTINUOS TORQUE MONITORING .......................................................496
11 SYMPTOM BASED DIAGNOSIS - WITH NO DTC CODES...............................................497

11.1 REASON FOR TORQUE LIMITATION .............................................................................499
11.2 SYNCHRONIZATION STATE ...........................................................................................500
EMS - EDC17C55
1 HOW TO USE THIS MANUAL

If a registered DTC is noted from diagnostic tool, then go to DTC BASED DIAGNOSIS, then
click on the DTC. The codes are hyperlinked to the respective troubleshooting procedures.
The following is the structure of the EMS Diagnostic Manual
• DTC and a brief description of the system
• DTC Information & Causes
– Normal operation of the system
– DTC detecting conditions
– DTC reaction on vehicle and tell tale lamp status
– Healing Condition
– Probable causes of Failure
• Circuit Schematic
• Connector location
• Connector face views and information
• DTC Checking Procedure
• Diagnostic Procedure (chart)
Always use the EMS Diagnostic Manual along with the vehicle’s applicable Wiring Manual
(MAN - 00482 and MAN - 00290).
DRIVING CYCLE — Ignition ON and OFF with the engine running. Vehicle speed can be
0 kmph.
EMS - EDC17C55
2 RECOMMENDED TROUBLE SHOOTING PROCESS
Customer complaint ⇨ Record/Understand Customer Verbatim

• What happened?
• When did it happen?
• Were any specific events recorded/observed before
the complaint?
• Does it happen all the time?
• Does it happen only in certain conditions?
⇩
Verify the complaint and perform visual checks
⇩
Search for published quick solution in TEKnet.
⇩
Follow DTC based diagnosis
⇩
Follow Symptom based diagnosis (If available)
⇩
Contact TEKliner with TAR
(Technical Assistance Request)
EMS - EDC17C55
3 WARRANTY & OTHER INFORMATION

All failures/complaints encountered in EMS ECU and other system components should be
reported through Service Complaint Report (SCR). Replacement of any of the EMS ECU and
other system components requires approval of the TEKline. Ensure that a TAR is raised in the
TEKnet website for approval, attaching the SCR. While raising a warranty claim, the TAR no
should be quoted on the warranty claim.
Only a trained and certified CoTEK can raise a TAR (in TEKnet website)
EMS - EDC17C55
4 EMS OVERVIEW
The EMS ECU uses the following Sensors and Actuators to govern all the Engine parameters
for optimized Engine performance
SENSORS AND SWITCHES
1. Engine Coolant Temperature Sensor

2. Ambient Air Pressure Sensor
3. Camshaft Position Sensor
4. Crankshaft Speed Sensor
5. Boost Pressure Sensor
6. Rail Pressure Sensor
7. Accelerator Pedal Module
8. Vehicle Speed Sensor
9. Brake Switch
10. Clutch Sensor
11. Gear neutral Switch
12. Boost Temperature Sensor
13. EGR feedback sensor
ACTUATORS
1. EGR Actuator
2. Injectors
3. Fuel Metering Unit
EMS - EDC17C55
5 EMS ECU CONNECTORS PIN DETAILS
ECU FUNCTION CONNECTED TO CONNECTOR NO

CONNEC- PIN NO
TOR PIN NO
BATTERY —
1 GROUND E2
NEGATIVE
BATTERY —
2 GROUND E2
NEGATIVE
INJECTOR
3 POWER E21 1
CYLINDER 4
INJECTOR
3 POWER E18 1
CYLINDER 1
4 SUPPLY ECU FUSE E13 2
INJECTOR
5 POWER E20 2
CYLINDER 3
INJECTOR
5 POWER E19 1
CYLINDER 2
6 SUPPLY ECU FUSE E13 2
INJECTOR
7 SIGNAL E21 2
CYLINDER 4
8 — — — —
9 — — — —
10 POWER CLUTCH SENSOR B30 1
COOLANT
11 GROUND TEMPERATURE E26 2
SENSOR
WATER IN FUEL /
12 POWER FUEL TEMP. E24 4
SENSOR
13 — — — —
14 — — — —
15 POWER EGR MODULATOR E10 1
16 POWER VSS E14 1
17 — — — —
18 POWER APP1 B21 2
WATER IN FUEL /
19 SIGNAL FUEL TEMP. E24 2
SENSOR
EMS - EDC17C55

CONNEC- PIN NO
TOR PIN NO
20 — — — —
21 — — — —
22 SIGNAL VSS E14 3
23 SIGNAL 90% CLUTCH SENSOR B30 5
REDUNDANT
24 SIGNAL B22 4
BRAKE SWITCH
25 — — — —
26 SIGNAL SPEEDOMETER B1 5
27 — — — —
28 — — — —
INJECTOR
29 SIGNAL E20 2
CYLINDER 3
CRANK SHAFT
30 GROUND E23 3
SENSOR
31 — — — —
RAIL PRESSURE
32 POWER E12 3
SENSOR
COOLANT
33 SIGNAL TEMPERATURE E26 1
SENSOR
WATER IN FUEL /
34 GROUND FUEL TEMP. E24 1
SENSOR
AIR MASS
35 POWER E8 3
SENSOR
36 — — — —
37 SIGNAL EGR MODULATOR E10 3
38 — — — —
39 — — — —
40 POWER APP2 B21 1
41 SIGNAL 10% CLUTCH SENSOR B30 2
42 CRANK SUPPLY ING SWITCH B4 1
43 — — — —
CAM SHAFT
44 GROUND E30 2
SENSOR
EMS - EDC17C55

CONNEC- PIN NO
TOR PIN NO
CAM SHAFT
45 POWER E30 3
SENSOR
CAM SHAFT
46 SIGNAL E30 1
SENSOR
47 — — — —
INSTRUMENT
48 SIGNAL B1 9
CLUSTER
VACUUM
49 SIGNAL EC4 1
MODULATOR
50 GROUND ECU MAIN RELAY E35 2
INJECTOR
51 SIGNAL E19 2
CYLINDER 2
CRANK SHAFT
52 SIGNAL E23 1
SENSOR
53 — — — —
RAIL PRESSURE
54 SIGNAL E12 2
SENSOR
55 GROUND VSS E14 2
AIR MASS
56 SIGNAL E8 4
SENSOR
57 — — — —
58 GROUND EGR MODULATOR E10 2
59 — — — —
60 SIGNAL APP2 B21 6
61 SIGNAL APP1L B21 4
62 — — — —
63 — — — —
64 — — — —
65 CAN LOW DLC B34 14
66 CAN HIGH DLC B34 6
67 GROUND STARTER RELAY E36 1
INSTRUMENT
68 SIGNAL B1 13
CLUSTER
PRE SUPPLY
69 GROUND B9 2
PUMP RELAY
EMS - EDC17C55

CONNEC- PIN NO
TOR PIN NO
INSTRUMENT
70 SIGNAL B1 7
CLUSTER
71 SUPPLY ECU FUSE B23 30
72 — — — —
INJECTOR
73 SIGNAL E18 2
CYLINDER 1
CRANK SHAFT
74 POWER E23 2
SENSOR
75 — — — —
RAIL PRESSURE
76 GROUND E12 1
SENSOR
77 — — — —
AIR MASS
78 GROUND E8 1
SENSOR
79 — — — —
MAIN BRAKE
80 SIGNAL B22 2
SWITCH
81 — — — —
82 GROUND AP2 B21 5
83 GROUND APP1 B21 3
84 — — — —
85 — — — —
86 — — — —
AIR MASS
87 SIGNAL E8 2
SENSOR
88 — — — —
FUEL METERING
89 SIGNAL E9 1
UNIT
INSTRUMENT
90 SIGNAL B1 15
CLUSTER
91 — — — —
92 — — — —
93 — — — —
94 — — — —
EMS - EDC17C55
6 EMS ECU WIRING DIAGRAM (PIKUP EXTRA LONG)
VEHICLE
IC-2 M 2
IC-2 F 2
LOAD FUSE
E4 6 6 6
60A
B Y Y Y B32 2
TERM 30 15a 15 50
POS
IC-3 M
IC-3 F
OFF
ACC
IC-2 M 1 IGN
9
9
IC-3 M 13
IC-3 F 13
START
IC-2 F 1 E32 E32 1.5 POS 30 15a 15 50
1.5 15 A
C2 C2 TERM
W 4 14 R/W 4 1 B4 1 0.75
L
P/B
1.5
FUEL FEED
PUMP
BATTERY
+ E5 14 IC-2 M
COOLANT TEMP
14 IC-2 F
GAUGE
12V
DAIGNOSTIC 1 MIL LAMP

WATER IN STARTER
4 6 LAMP FUEL SOLENOID 36 IC-2 F
87 B9
L
30A
30
FEED PUMP 36 IC-2 M
E2 - E3 E4 A RELAY
B1 7 9 15 13
1.5
86
E13 4 85
B
B9 2 4 1 E22
GR/R
CLUSTER
G/P
Y/G
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
LAMP
1.5
IC-2 M 25
IC-2 F 25
30 86 B
10
87 85 E13 E13 E13 0.75
0.75
2.5
2.5
10A IC-3 F 3 19 IC-2 M 33 21
L
32
L
2.5
R G/B
B
7 1 IC-3 M 3 19 IC-2 F 33 21 32
E13 8
STARTER
E36 2 4
1.5
RELAY
B
30 87
FUEL TEMP AND
20A
WATER IN FUEL 85 86
SENSOR
E36 1 3 0.5
V/R
0.5
E13 2
2.5
L
G/B
B
0.5
GR/R
SIG
G/P
0.5
0.5
0.5
Y/G
I/P GND SUP
B/R
0.5
E24 3 IC-3 F
4 1 2 3
3 IC-3 M
0.75
GR/B
V/R
0.5
0.5
R/L
0.5
L
2.5
B
0.5
R
P/L
0.5
G/R
0.5
2.5
R/W
6 4 50 12 34 19 69 70 48 90 68 67 42
SIG
GND
SIG
I/P
SIG SIG SIG SIG RLY COIL CRANK

RLY GND
SUP
SUP
GND SUP
EMS ECU EDC17C55 - 1.20
GND
SIG
GND GND I/P 5V GND SIG I/P GND SIG I/P 5V GND SIG
E1 2 26 10 23 41 15 37 58 16 22 55 33 11
O/G
0.5
IC-2 M 34
W/Y
SB
0.5
L/W
0.5
0.5
IC-2 F 34
O/G
0.5
O/BR
0.5
R/G
0.5
BR/R
0.5
R/O
0.5
Y/R
0.5
G/R
0.5
L/R
0.5
W/O
0.5
IC-2 M 4 20 11 IC-1 M
IC-2 F 4 20 11 IC-1 F
B1 5
W/Y
L/W
0.5
SB
0.5
0.5
SPEEDOMETER
1 5 4 2 1 3 2 E10
B30 1 3 2 E14 E26 1 2
I/P SIG GND
CLUTCH SENSOR
0.5
B
IC-2 M 27
IC-2 F 27
VEHICLE
EGR MODULATOR COOLANT
2.5 SPEED
2.5 2.5 TEMP
B B SENSOR
B SENSOR
EMS - EDC17C55
VEHICLE LOAD FUSE (BMF)
2
2
B 6 6 5 5
60 A
Y Y
IC - 4M
IC - 4F
E-4 Y Y
B32 2
TERM 30 15a 15 50
POS
OFF
30 A
ACC
A E4 IGNITION
START
POS
V
V
30 15a 15 50
4
4
TERM
4 8
E35 B32 1
30 86
ECU MAIN
IC-2 M 23
BRAKE SWITCH
IC-2 F 23
RELAY
+ E1
87 86
2.5 11 5 1.5
6 2 E35 R
15A
G
1.5
E13
G
E13
VACCUM
IC-2 M 25
IC-2 F 25
1 1
MODULATOR
REDUNDANT BRAKE
E13 G G
R
E2 E13
4
E3 2.5 0.75 0.75 0.75 B22 3
SWITCH
15 A B22 1
R 7 1 G/B G/B G/B MAIN BRAKE
FUEL SWITCH
2.5
EC4 2 1
R
METERING B22 2 B22 4
0.5
G
FUEL
2.5
E13 8
Y
G/B
0.5
BR
0.5
SB/R
0.5
METER 11 IC-5 F
0.5
P/L
UNIT
11 IC-5 M
20 A
IC-1 F 7
IC-1 M 7 8 IC-1 F
0.5
E13 2
G
8 IC-1 M
B23 5
R/W 2.5
12 IC-5 M
BR
0.5
2.5
2 1 E9 12 IC-5 F
13 IC-2 F REFER
13 IC-2 M
STOP
0.75
SB/R
G/B
LAMP
5A
0.5
2.
2.5
CKT
B
R/W
Y/W
0.75
BR
0.5
5
0.5
B
15
B23 1 2 6 4 50 89 G/B 49 80 24
SIG
GND
GND
SIG
I/P I/P RLY COIL
SIG
SIG
GND
0.75

R
SUP
GND
CAN CAN SUP
SIG
SIG
5V
HI LOW
66 65 71 35 56 78 87
0.5
0.5
Y
0.5
Y/L
0.75
W/Y
Y/L
IC-1 M 10 9 0.5
IC-1 F 10 9
BR/W
0.5
O/L
0.5
0.5
0.5
IC-2 M 24
G
Y
0.5 0.5 IC-2 F 24

Y G 3 4 1 2 E8
0.5
Y
0.5
0.5
G
Y
0.75
W/Y
0.5
B34 6 14 B29 2 5
G
AIR MASS SENSOR

0.5 16 DIAGNOSTIC IMMOBILIZER
R B34
0.5 0.5
B34 5 4 B29 1 8
W/Y W/Y
TERMINATING
1 B65 B1 3
RESISTOR
1.5
W/Y
2 TO CLUSTER
0.5
B
4
B23 30
0.5
Y
ECU
15 A
SUPPLY
B23 40
0.5
Y
0.5
B
2.5
IC-2 M 27
V
IC-2 F 27
0.5 2.5 0.5 0.5

IC-4 M 1
R B B B
IC-4 F 1
2.5
6 6 V
B B
EMS - EDC17C55
INJECTOR FIRING ORDER

1 3 4 2
ACCELERATOR PEDAL
MODULE (APM1) CYL.1 CYL.4 CYL.3 CYL.2
SIG SUP SIG SUP SIG SUP SIG SUP
E18 2 1 E21 2 1 E20 2 1 E19 2 1

6
1.5
B21 1 5 2 3 4
G
1.5
1.5
1.5
1.5
Y
1.5
L
1.5
P
R
G
1.5
V
BR/B
O/W
R/B
R/Y
W/R
0.5
0.5
0.5
0.5
0.5
0.5
P
1.5
1.5
1.5
1.5
1.5
R
P
Y
L
1 2 3 4 5 6 IC-1 F
1 2 3 4 5 6 IC-1 M
BR/B
O/W
W/R
R/B
R/Y
0.5
0.5
0.5
0.5
0.5
0.5
40 82 60 18 83 61 73 3 7 29 5 51
SIGNAL
GROUND
SIGNAL
SUPPLY
SIGNAL
SIGNAL
SUPPLY_5V
GROUND
SUPPLY_5V
SIGNAL
SUPPLY
SIGNAL
SUPPLY_5V
SUPPLY_5V
GROUND
GROUND
SIGNAL
GROUND
SIGNAL
SIGNAL
SUPPLY
45 44 46 52 74 30 32 54 76
0.75
R/B
B/Y
P/B
0.5
0.5
W/O
0.75
L/G
0.5
0.5
Y
0.75
L/Y
0.5
0.5
SB
G
1 2 3 E23
3 1 2 E30
3 2 1 E12
SIG SUP GND
SUP SIG GND
5V SUP SIG GND
5V
CAM SHAFT SENSOR CRANK SHAFT SENSOR

(TWO CORE SHIELDED CABLE) (TWISTED PAIR CABLE) RAIL PRESSURE SENSOR
EMS - EDC17C55
6.1 EMS ECU WIRING DIAGRAM (PIKUP)
EMS - EDC17C55
EMS - EDC17C55
7 STANDARD TEST PROCEDURE
TESTING OF VOLTAGE POTENTIAL
• Connect the ground lead of a voltmeter to a known good ground or battery ground
• Connect the other lead of voltmeter to selected test point. The vehicle ignition may need to
be turned ON to check voltage.
EMS - EDC17C55
TESTING FOR CONTINUITY (RESISTANCE)

• Disconnect the power supply (battery, ignition switch OFF)
• Set the Multimeter Mode selector to measure resistance
• Connect one lead of the multimeter to one side of the circuit being tested
• Connect the other lead to the other end of the circuit being tested. Low or no resistance
means good continuity
TESTING FOR A SHORT TO GROUND

• Disconnect the power supply (battery, ignition switch OFF)
• Set the Multimeter Mode selector to measure resistance, select resistance range
appropriately
• Connect one lead of the Multimeter to one side of the circuit being tested
• Connect the other lead to battery ground
• Starting at the fuse block, move / shake the wiring harness about six to eight inches apart
and look at the Multimeter display.
• If the Multimeter registers resistance value / audible beep, then there is a short to ground in
that area of the wiring harness.
TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS

• Switch OFF the ignition and disconnect the battery.
• Referring the wiring diagrams, disconnect or isolate all items on the suspected fused
circuits.
• Replace the blown fuse.
• Supply power to the fuse by turning ON the ignition switch or re-connecting the battery as
applicable.
EMS - EDC17C55
• Start connecting or energizing the components in the fuse circuit one at a time. When the
fuse blows, the circuit with the short to ground has been identified.
TESTING FOR A VOLTAGE DROP

• Set the Multimeter Mode selector to measure voltage, select voltage range appropriately
• Connect positive lead of voltmeter to side of the circuit closest to battery positive terminal.
• Connect other lead of voltmeter to the other side of switch / component / circuit.
• The voltmeter will show the difference in voltage between the two points.
INTERMITTENT AND POOR CONNECTION

Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is
also possible for a sticking component or relay to cause a problem. First ask the customer for
details about the driving conditions, weather conditions, frequency of occurrence and trouble
symptoms and then try to recreate the trouble symptoms. Before replacing a component or
wiring assembly, check the following items.
• Connectors / inter—connector are fully locked
• Check for water traces in the fuse or relay box / connectors
• Any spread terminals or pin back out
• Terminals in the wiring assembly are fully seated into the connector/component and locked
into position
• Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an
intermittent problems
• Damaged connector/component casing exposing the item to dirt or moisture
• Wire insulation that has rubbed through, causing a short to ground
• Some or all of the wiring strands broken inside of the insulation
• Wiring broken inside of the insulation
Carry out the following checks with the connectors and components to confirm whether the
trouble symptom occurs.
EMS - EDC17C55
• Gently shake the connector up, down and to the left and right
• Gently shake the wiring harness up, down and to the left and right.
• Gently shake the fuse / relay board, etc. by hand.
• Gently shake the wiring harness at the location of hanging and other moving parts
EMS - EDC17C55
8 IQA/IMA CODE PROGRAMMING

An ECU controlled Engine needs precise metering of fuel. Due to manufacturing tolerances,
each injector deviates slighty from its idealized behavior. Thus each injector has a correction
factor, which is engraved on top of it, in the form of a 7-character alphanumeric code , out of
which the last character "W" is a dummy value. This is known as an IQA code/IMA code. For
optimal performance of the engine, the ECU needs to know the IQA code/IMA code of each
injector. This information is programmed into the ECU when the vehicle is manufactured.
However, if you need to replace an injector (s), then the IQA code/IMA code for that new
injector has to be updated in the ECU. The cylinder number starts from the timing side of the
Engine.
As a first step, you need to select the cylinder number of the injector being replaced. After the
cylinder number is selected by clicking on the check-button next to the number, the IQA code/
IMA code should be entered in the box provided.
Even though on the injector, 7 character alphanumeric code is engraved , while writing
the IQA code only the first 6 digits need to be entered.
• Click the button to the right of the text box. If the Injector code is valid and accepted by the
ECU, a message is displayed, indicating that the operation is performed successfully.
• A message “Invalid IQA code” will be displayed , if an incorrect IQA/IMA code is keyed in.
IQA codes are case sensitive
• Programming IQA codes is an extremely important activity. In order to ensure that the
correct code has been entered and that it has been entered in the correct cylinder, SMART
tester allows you to verify the codes that you have entered.
• Select an injector, and click the button below the ”Verify” line in figure. The IQA codes
present in the ECU will be read back and displayed in the text box before this button. It is
recommended that you carry out the verification activity whenever you change an IQA code
Please ensure to program IQA/IMA codes when you replace an Injector, ECU or Engine
The following are the fonts of the alphanumeric characters of the IQA/IMA code, as etched on
the injectors.
1. 0123456789
2. ABCDEFGHIJKLM
3. NOPQRSTUVWXYZ
EMS - EDC17C55
9 NO COMMUNICATION BETWEEN ECU AND DIAGNOSTIC /

FLASHING TOOL
9.1 CIRCUIT SCHEMATIC
B32 2
30 15a 15 50
OFF
ACC
IGN
START
E4 B IMMOBOLIZER
1 B32
VEHICLE
60A
LOAD
FUSE
2.5
V
1 G1
BATTERY
3 2 B29
12V
40 B23
ECU
0.50
0.50
15A
G
SUPPLY
G2
40 B23
CAN-H CAN-L
W/Y
1.5
G
0.50
16 14 B34
16 9
B34
DIAGNOSTIC
CONNECTOR
0.50
0.50
Y
G
8 1
6 5 4 C104
B 0.50 B 0.50
Y 0.50 W 1.0
B 4.00
1 C6
G9
B 2.00
CAN-H
B 6.00
G15
G
0.50
Y
0.50 CAN-H CAN-L
0.50
C7 G 0.50
Y
34 17
G 0.50 Y 0.50
65 66 E1
CAN-L CAN-H B35 1 2 B35
E1
EMS ECU
G1 4 120 ohm
TERMINATING
RESISTOR
EMS - EDC17C55
9.2 CONNECTOR VIEWS AND INFORMATION
CONNECTOR
CONNECTOR DESCRIPTION PIN NO FUNCTION
NO
6 BATTERY SUPPLY
4 BATTERY SUPPLY
71 IGNITION SUPPLY
E1 EMS ECU
65 CAN LOW
66 CAN HIGH
1&2 GROUND
16 SUPPLY
5 GROUND
PB34 DLC 4 GROUND
14 CAN LOW
6 CAN HI
1 CAN HI
B35 TERMINATING RESISTOR 2 CAN LOW
4 GROUND
9.3 DIAGNOSTIC PROCEDURE

STEP A– TRY TO ESTABLISH CONNECTION
PRE CONDITION
• Check condition of Garuda Cables
• Check LED status of Garuda interface
• Ignition ON
TEST PROCEDURE
• Connect i-SMART with any other ECU on the same vehicle
• Connect i-SMART with any other vehicle
ACCEPTANCE CRITERIA
• Communicated with ECU
ACTION TO BE TAKEN
EMS - EDC17C55
OK NOT OK
• Replace the below defective parts one by

one
1. Cable —i-SMART to Garuda
• GO TO STEP B
2. Cable —i-SMART to Vehicle
3. Garuda interface tool
• Establish connection
STEP B– CHECK CONDITION OF ECU / DLC FUSE AND RELAY
PRE CONDITION
• Ignition OFF
• Check and ensure battery voltage 12 to 16 V
TEST PROCEDURE
• Check function of ECU relay E35
• Check condition of fuses , F16– 5A, F7– 15A, F2–20A
ACCEPTANCE CRITERIA
• Fuses and relays are good
ACTION TO BE TAKEN
OK NOT OK
• Replace defective fuse / relay

• GO TO STEP C
STEP C– CHECK OPEN CIRCUIT OF DLC CAN WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check resistance between pin 6 & 14 of DLC (B35)
ACCEPTANCE CRITERIA
• Resistance = 60 Ω
ACTION TO BE TAKEN
EMS - EDC17C55
OK NOT OK
• Examine open circuit of DLC CAN wire

• GO TO STEP D
STEP D– CHECK OPEN CIRCUIT OF DLC GROUND WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check resistance between pin 5 ( B34) and ground G15
• Check resistance between pin 4( B34) and ground G9
ACCEPTANCE CRITERIA
• Resistance < 1Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine open circuit of DLC ground wire

• GO TO STEP E
STEP E– CHECK OPEN CIRCUIT OF DLC SUPPLY WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check voltage between pin 16 ( B34) and ground
ACCEPTANCE CRITERIA
• Voltage = Battery volt
ACTION TO BE TAKEN
OK NOT OK
• Examine open circuit of DLC supply wire

• GO TO STEP F
EMS - EDC17C55
STEP F– CHECK RESISTANCE OF ECU CAN CIRCUIT
PRE CONDITION
• Ignition OFF
• Terminating resistor connector (B35) DISCONNECTED
TEST PROCEDURE
• Check resistance between pin 6 & 14 of DLC (B35)
ACCEPTANCE CRITERIA
• Resistance = 120±5 Ω
ACTION TO BE TAKEN
OK NOT OK
• Replace EMS ECU with new one

• GO TO STEP G
STEP G– CHECK CONDITION OF ECU GROUND AND CONNECTOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check condition of ECU housing / connector for break
• Check the EMS ECU ground E2 fastened on a painted surface or corrosion
• Check condition of earth bolts on the battery terminal
ACCEPTANCE CRITERIA
• ECU housing / connector are good
• E2 earth bolt is good
• Earth bolt on the battery is good
ACTION TO BE TAKEN
OK NOT OK
• Replace / repair defective parts

• GO TO STEP H
EMS - EDC17C55
STEP H– CHECK OPEN CIRCUIT OF ECU SUPPLY WIRES
PRE CONDITION
• Ignition OFF
• Battery negative terminal DISCONNECTED
• EMS ECU connector (E44) DISCONNECTED
• Fuses F16–5A,F7– 15A, F2–20A and ECU Relay are REMOVED
TEST PROCEDURE
• Check resistance between pin 6 of C4 and Fuse F2
• Check resistance between pin 50 of C4 and pin 2 of E35 (ECU MAIN RELAY)
• Check resistance between pin 16 of DLC (B34) and Fuse F16
ACCEPTANCE CRITERIA
• Resistance < 1 Ω
ACTION TO BE TAKEN
OK NOT OK
• If problem is still exists, start procedure • Replace / repair the wiring harness
from STEP A • Establish connection
EMS - EDC17C55
10 DTC BASED DIAGNOSIS
EMS - EDC17C55
P1128
10.1 P1128 — COOLANT TEMPERATURE SENSOR ABSOLUTE TEST NON

PLAUSIBLE ERROR
10.1.1 COOLANT TEMPERATURE SENSOR
The CTS sensor is a variable resistor whose resistance changes as temperature of engine
coolant flowing past the sensor changes (NTC resistor) When the coolant temperature is low,
the sensor resistance is high; when the coolant temperature is high, the sensor resistance is
low. The ECU checks CTS voltage and uses the information to help for a smooth engine
operation.
DTC INFORMATION PROBABLE CAUSES OF FAILURE

NORMAL OPERATION
• Ignition ON
• The coolant temperature rises to a specified
temperature within a specific time period
when the Engine is in running condition.
DTC DETECTING CONDITIONS
• Ignition ON
• EMS ECU supply voltage 8 to 16 V • Defective temperature sensor.
• The coolant temperature do not rise enough • Thermostat stuck in open condition.
within a specific time period. • Thermostat removed.
• The coolant temperature do not reach a
warmed-up fuel control temperature within a
specific time period.
DTC REACTIONS
• No lamp Indication.
HEALING CONDITION
• Ignition Off/On
10.1.1.1 DTC CHECKING PROCEDURE
• Turn the ignition ON and Initialise i-SMART tool

• Record the DTC and clear
• Turn ignition OFF then ON
• Proceed to DIAGNOSTIC PROCEDURE if P1128 is present
• If not present, then check for any intermittent problem
EMS - EDC17C55
P1128
10.1.1.2 INTERMITTENT PROBLEMS
Check the following for intermittent problems

• Poor mating of the connector halves/damage of connector locking
• Terminals not fully seated in the connector body
• Damage of harness and terminals
• Connector pin separation from wire
• Corrosion on pin contact points
10.1.1.3 DIAGNOSTIC PROCEDURE
STEP A – CHECK FOR PROPER FITTMENT OF THERMOSTAT

• Ignition ON
• Check and ensure the coolant temperature sensor is functioning properly.
• Ignition OFF
• Check for the proper fittment of thermostat in thermostat housing. If OK go to STEP B
• If NO fix the thermostat in its correct position.
• Clear the DTC and verify.
STEP B – REPLACE THERMOSTAT
• Remove the thermostat and check whether thermostat is stuck in open position.
• Replace the thermostat with a new one.
EMS - EDC17C55
P1126
10.2 P1126 — COOLANT TEMPERATURE SENSOR DYNAMIC TEST NON

PLAUSIBLE ERROR
operation.

NORMAL OPERATION
• Ignition ON
• The coolant temperature rises to a specified
temperature within a specific time period
when the Engine is in running condition.
• Ignition ON
• EMS ECU supply voltage 8 to 16 V • Defective temperature sensor.
• The coolant temperature do not rise enough • Thermostat stuck in open condition.
within a specific time period. • Thermostat removed.
• The coolant temperature do not reach a
warmed-up fuel control temperature within a
specific time period.
DTC REACTIONS
• No lamp Indication.
HEALING CONDITION
• Ignition Off/On

EMS - EDC17C55
P1126

STEP A – CHECK FOR PROPER FITTMENT OF THERMOSTAT

• Ignition ON
• Check and ensure the coolant temperature sensor is functioning properly.
• Ignition OFF
• Check for the proper fittment of thermostat in thermostat Housing. If OK go to STEP B
• If NO fix the thermostat in its correct position.
STEP B – REPLACE THERMOSTAT
• Remove the thermostat and check whether thermostat is stuck in open position.
• Replace the thermostat with a new one.
EMS - EDC17C55
P0118
10.3 P0118 — SRC FOR COOLANT TEMPERATURE SENSOR ABOVE MAX

LIMIT
operation.

NORMAL OPERATION
• Ignition ON
• The measured output voltage value of the
coolant circuit temperature sensor is within
the range.
• Open coolant temperature sensor wires
• Ignition ON
• Short to battery of coolant temperature
• EMS ECU supply voltage 8 to 16 V wires
• The measured output voltage of the coolant • Faulty coolant temperature sensor
temperature sensor is higher than the
maximum range. • Malfunctioning EMS ECU
DTC REACTIONS
• MIL lamp continuously ON
• Coolant temperature value set as 110 °C
HEALING CONDITION
• Ignition Off/On
10.3.1.1 CIRCUIT SCHEMATIC
EMS COOLANT
ECU TEMPERATURE
SENSOR
11 0.5 2 GND
GND
G/R
33 SIG
SIG
0.5 1
W/O
E1 E26
EMS - EDC17C55
P0118
10.3.1.1.2 CONNECTOR VIEWS AND INFORMATION
E1 - EMS ECU E26 - COOLANT TEM P SENSOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F024_E26
CONNECTOR
CONNECTOR NO PIN NO FUNCTION
DESCRIPTION
33 SIGNAL
EMS ECU E1
11 GROUND
COOLANT 1 SIGNAL
TEMPERATURE E26
SENSOR 2 GROUND
10.3.1.1.3 DTC CHECKING PROCEDURE

• If not present, then check for any intermittent problems
10.3.1.1.4 INTERMITTENT PROBLEMS

EMS - EDC17C55
P0118
10.3.1.1.5 DIAGNOSTIC PROCEDURE
STEP A – CHECK VOLTAGE BETWEEN COOLANT TEMPERATURE SENSOR SIGNAL

WIRE AND GROUND
PRE CONDITION
• Ignition OFF
• Coolant Temperature Sensor wiring harness connector ( E26) DISCONNECTED
• Ignition ON
TEST PROCEDURE
• Check the voltage between pin 1 of E26 and battery ground
ACCEPTANCE CRITERIA
• Voltage = 5 ± 0.25 V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP C • GO TO STEP B
STEP B – CHECK FOR OPEN CIRCUIT OF COOLANT TEMPERATURE SENSOR SIGNAL

WIRE
PRE CONDITION
• Ignition OFF
• Coolant temperature sensor wiring harness connector (E26 ) DISCONNECTED
• EMS ECU wiring harness connector (E1) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 33 of E1 and pin 1 of E26
ACCEPTANCE CRITERIA
• Resistance < 1Ω
ACTION TO BE TAKEN
OK NOT OK
• Suspect the EMS ECU Malfunction • Examine the open circuit in Coolant
temperature sensor signal wire
• Replace the EMS ECU with a new one
• Check and verify for any new DTC’s • Replace the wiring harness
• Clear the DTC and verify
EMS - EDC17C55
P0118
STEP C – CHECK FOR OPEN CIRCUIT OF COOLANT TEMPERATURE SENSOR

GROUND WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • Examine the open circuit in Coolant

temperature sensor ground wire
• Replace the wiring harness
STEP D – CHECK FOR OPEN CIRCUIT INSIDE COOLANT TEMPERATURE SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 1 and pin 2 of the Coolant Temperature sensor
ACCEPTANCE CRITERIA
• Resistance = 2.2 KΩ — 2.7 KΩ at 20°C
ACTION TO BE TAKEN
OK NOT OK
• Suspect EMS ECU Malfunction • Examine the open circuit in Coolant

temperature sensor
• Replace EMS ECU with a new one.
• Replace the sensor with a new one
• Check and verify for any new DTC’s
Clear the DTC and verify
EMS - EDC17C55
P0117
10.4 P0117 — SRC COOLANT TEMPERATURE SENSOR BELOW

MINIMUM LIMIT
operation.

NORMAL OPERATION
• Ignition ON
coolant circuit temperature sensor is within
the range.
• Ignition ON • Short to battery of coolant temperature
• EMS ECU supply voltage 8 to 16 V wires
• The measured output voltage of the coolant • Faulty coolant temperature sensor
temperature sensor is lower than the • Malfunctioning EMS ECU
maximum range.
DTC REACTIONS
• Coolant temperature value set as 110 °C
HEALING CONDITION
• Ignition Off/On
EMS COOLANT
ECU TEMPERATURE
SENSOR
11 0.5 2 GND
GND
G/R
33 SIG
SIG
0.5 1
W/O
E1 E26
EMS - EDC17C55
P0117
E1 - EMS ECU E26 - COOLANT TEM P SENSOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F024_E26
CONNECTOR CONNECTOR
PIN NO FUNCTION
DESCRIPTION NO
33 SIGNAL
EMS ECU E1
11 GROUND
COOLANT 1 SIGNAL
TEMPERATURE E26
SENSOR 2 GROUND


EMS - EDC17C55
P0117
STEP A – CHECK VOLTAGE OF COOLANT TEMPERATURE SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Coolant Temperature Sensor wiring harness connector ( E26) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5 ± 0.25V
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP C • GO TO STEP B
STEP B – CHECK FOR SHORT TO GROUND OF COOLANT TEMPERATURE SENSOR

SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check resistance between pin 1 of E26 and battery ground.
ACCEPTANCE CRITERIA
• Resistance = ∞ Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine the short to ground in Coolant

temperature sensor signal wire
• GO TO STEP C • Replace wiring harness
EMS - EDC17C55
P0117
STEP C – CHECK FOR INTERNAL SHORT IN COOLANT TEMPERATURE SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 1 and pin 2 of the Coolant Temperature sensor wires
(E26)
ACCEPTANCE CRITERIA
• Resistance = 2.2 KΩ — 2.7 KΩ at 20°C
ACTION TO BE TAKEN
OK NOT OK
• Examine the internal failure in Coolant

• Suspect EMS ECU Malfunction
temperature sensor
EMS - EDC17C55
P062F
10.5 P062F — ECU EEPROM ERROR

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

NORMAL OPERATION
• Ignition ON
• EEPROM can be flashed, read & written
• Ignition ON
• EMS ECU supply voltage 8 to 16 V
• The block cannot be written more than 3 • Malfunctioning EMS ECU
times from the EEPROM
DTC REACTIONS
• Engine check lamp continuously ON.
• EMS ECU Switches OFF
HEALING CONDITION
• Fault absent for 3 driving cycles

• Turn ignition OFF
• Wait for 2 minutes and turn Ignition ON
• Proceed to DIAGNOSTIC PROCEDURE if P062F is present
• If not present, then check for any intermittent problem.

EMS - EDC17C55
P062F
• Suspect EMS ECU EEPROM failure

EMS - EDC17C55
P162F
10.6 P162F — ECU EEPROM ERROR


NORMAL OPERATION
• Ignition ON
• Ignition ON
• The block cannot be read more than 3 times • Malfunctioning EMS ECU
from the EEPROM
DTC REACTIONS
HEALING CONDITION


EMS - EDC17C55
P162F

EMS - EDC17C55
P1630
10.7 P1630 — ECU EEPROM ERROR


NORMAL OPERATION
• Ignition ON
• Ignition ON
from the EEPROM
DTC REACTIONS
HEALING CONDITION
• Ignition OFF / ON.


EMS - EDC17C55
P1630

EMS - EDC17C55
P1619
10.7.2 P1619 — ECU CHIP ERROR
10.7.2.1 EPROM ERROR

NORMAL OPERATION
• Ignition ON
• Ignition ON
from the EEPROM
DTC REACTIONS
HEALING CONDITION

• Proceed to DIAGNOSTIC PROCEDURE if P1619 is present.
10.7.2.1.1.2 INTERMITTENT PROBLEMS

EMS - EDC17C55
P1619
10.7.2.1.1.3 DIAGNOSTIC PROCEDURE
• Suspect ECU CHIP ERROR failure

EMS - EDC17C55
P062B
10.8 P062B — ECU MONITORING ERROR FOR INJECTOR CUT OFF

DEMAND
10.8.1 MONITORING COMMUNICATION: ICO MONITORING
Engine speed is continuously monitored by EMS ECU. Whenever the engine speed goes
above the maximum threshold , injection driver stages gets disconnected in EMS ECU.

NORMAL OPERATION
• Ignition ON
• The engine speed is less than or equal to
the maximum engine speed in injection cut
off monitoring.
• Ignition ON
• Malfunctioning EMS ECU
• The engine speed exceeds the threshold
speed in Injection cut off monitoring and
injection driver stage gets disconnected.
DTC REACTIONS
HEALING CONDITION

• Proceed to DIAGNOSTIC PROCEDURE if P062B is present.

• Connector pin separation from wire, Corrosion on pin contact points
EMS - EDC17C55
P062B
• Suspect ECU CHIP ERROR failure

EMS - EDC17C55
P0403
10.9 P0403 — EGR VALVE OPEN LOAD ERROR (PIKUP)

10.9.1 EGR MODULATOR
EGR modulator controls the EGR valve . EMS ECU converts the air control output into duty
cycle and outputs a PWM signal to EGR modulator.

NORMAL OPERATION
• Ignition ON
• No error detected in EGR control circuit
during self check
• Engine runs as per the EGR mapping
• Ignition ON • EGR modulator control wire open
• EMS ECU supply voltage 8 - 16 V • Faulty EGR modulator
• Open circuit in EGR control circuit. • Malfunctioning EMS ECU
DTC REACTIONS
• MIL lamp continuously ON after the DTC
registers 3 driving cycles
• EGR Switches OFF
HEALING CONDITION
• Self Healing
EMS EGR
ECU MODULATOR
E1
B23
SIG
0.5 GND
58 Y/R 2
0.5 SIG
GND
37 O/BR 3
0.5 I/P
I/P
15 R/O 1
EMS - EDC17C55
P0403
E1 - EMS ECU B23 - VACCUM MODUL ATOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
P1A01F001_E1 P1A03F003_B23
CONNECTOR CONNEC-
PIN NO FUNCTION
DESCRIPTION TOR NO
EMS ECU E1 49 SIGNAL
1 SIGNAL
EGR MODULATOR B23
2 SUPPLY

• Perform 3 Driving Cycles

STEP A – CHECK THE VOLTAGE OF EGR MODULATOR SUPPLY WIRE
EMS - EDC17C55
P0403
PRE CONDITION
• Ignition OFF
• Check and confirm the proper function of 15 A fuse in ECU fuse box.
• EGR Modulator wiring harness connector DISCONNECTED (B 23 )
• Ignition ON
TEST PROCEDURE
• Check the voltage between pin 2 of B 23 and battery ground
ACCEPTANCE CRITERIA
• Voltage = Vehicle battery Voltage
ACTION TO BE TAKEN
OK NOT OK
• Examine the open / short to ground of

EGR modulator power supply wire from
main relay.
• GO TO STEP B
STEP B – CHECK FOR OPEN CIRCUIT OF EGR MODULATOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• EGR Modulator wiring harness connector DISCONNECTED (B 23)
TEST PROCEDURE
• Check resistance between pin 1 of B 23 and pin 49 of E1
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of EGR

• Suspect EGR modulator internal failure
modulator signal wire.
• Replace EGR modulator with a new one.
• Check and verify for any new DTC’s.
EMS - EDC17C55
P0403
10.10 P0403 — EGR VALVE OPEN LOAD ERROR (PIKUP EXTRA LONG)

NORMAL OPERATION
• Ignition ON
during self check
• Ignition ON • EGR modulator control wire open
• EMS ECU supply voltage 8 - 16 V • Faulty EGR modulator
• Open circuit in EGR control circuit. • Malfunctioning EMS ECU
DTC REACTIONS
registers 3 driving cycles
HEALING CONDITION
• Self Healing
EMS - EDC17C55
P0403
E4
+ ECU FUSE (BMF)
A
30 A
E4
E3
V
4
V
4
E35 4 8
30 86
ECU MAIN
RELAY VACCUM
87 86
MODULATOR
E35
IC-2 M 25
6 2
IC-2 F 25
E13 E13
R
4
2.5 0.75 0.75 0.75

15 A
R G/B G/B G/B
7 1 EC4 2 1
0.5
G/B
0.5
G
P/L
0.5
11 IC-5 F
12 IC-5 M 11 IC-5 M
12 IC-5 F
0.5
G
0.5 13 IC-2 F
G/B 13 IC-2 M
50 49
SIG
RLY COIL
GND
E1 - EMS ECU EC4 - VACCUM MODUL ATOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
P1A01F001_E1 P1A03F003_EC4
CONNECTOR CONNEC-
PIN NO FUNCTION
DESCRIPTION TOR NO
1 SIGNAL
EGR MODULATOR EC 4
2 SUPPLY
EMS - EDC17C55
P0403

• Perform 3 Driving Cycles

STEP A – CHECK THE VOLTAGE OF EGR MODULATOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Check and confirm the proper function of 15 A fuse in ECU fuse box.
• EGR Modulator wiring harness connector DISCONNECTED (EC 4)
• Ignition ON
TEST PROCEDURE
• Check the voltage between pin 2 of EC 4 and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open / short to ground of

EGR modulator power supply wire from
main relay.
• GO TO STEP B
EMS - EDC17C55
P0403
STEP B – CHECK FOR OPEN CIRCUIT OF EGR MODULATOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• EGR Modulator wiring harness connector DISCONNECTED (EC 4)
TEST PROCEDURE
• Check resistance between pin 1 of EC 4 and pin 49 of E1
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of EGR

modulator signal wire.
• Replace EGR modulator with a new one.
EMS - EDC17C55
P1403
10.11 P1403 — EGR VALVE OVER TEMPERATURE ERROR

EGR actuator controls the EGR valve. EMS ECU converts the air control output into duty cycle
and outputs a PWM signal to EGR actuator

NORMAL OPERATION
• Ignition ON
• No error detected in EGR actuator control
circuit during self check
• Ignition ON
• EMS ECU supply voltage 8 - 16 V • Defective EMS ECU
• Power stage overheating is detected
DTC REACTIONS
registers continuously in 3 driving cycles.
• EGR switches OFF.
HEALING CONDITION
• Self Healing

• Perform 3 driving cycles.
EMS - EDC17C55
P1403

• Check EGR actuator connector for loose connection.

• Replace EGR valve with a new one
• If the problem continuos replace EMS ECU with a new one
EMS - EDC17C55
P0406
10.12 P0406 — EGR VALVE SHORT TO BATTERY ERROR (PIKUP)


NORMAL OPERATION
• Ignition ON
• Ignition ON • Short to battery in EGR modulator control
wire
• Short to battery in EGR modulator control
circuit • Faulty EGR modulator.
DTC REACTIONS
HEALING CONDITION
• Self healing.
EMS - EDC17C55
P0406
EMS EGR
ECU MODULATOR
E1
B23
SIG
0.5 GND
58 Y/R 2
0.5 SIG
GND
37 O/BR 3
0.5 I/P
I/P
15 R/O 1
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
P1A01F001_E1 P1A03F003_B23
CONNECTOR
DESCRIPTION
1 SIGNAL
EGR MODULATOR B 23
2 SUPPLY
EMS - EDC17C55
P0406

• Perform 3 driving cycles

STEP A – CHECK VOLTAGE OF EGR MODULATOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• EGR modulator wiring harness connector (B 23) DISCONNECTED
• Ignition ON
TEST PROCEDURE
• Check the voltage between pin 1 of B 23 and battery ground.
ACCEPTANCE CRITERIA
• Voltage > 4V
ACTION TO BE TAKEN
OK NOT OK

• Examine the short circuit of EGR actuator
• Replace EGR actuator with a new one. control wire with battery positive
• If the DTC still exists, replace the EMS • Check and verify for any new DTC’s
ECU with a new one
EMS - EDC17C55
P0406
10.13 P0406 — EGR VALVE SHORT TO BATTERY ERROR (PIKUP EXTRA

LONG)

NORMAL OPERATION
• Ignition ON
• Ignition ON • Short to battery in EGR modulator control
wire
• Short to battery in EGR modulator control
circuit • Faulty EGR modulator.
DTC REACTIONS
HEALING CONDITION
• Self healing.
EMS - EDC17C55
P0406
E4
+ ECU FUSE (BMF)
A
30 A
E4
E3
V
4
V
4
E35 4 8
30 86
ECU MAIN
RELAY VACCUM
87 86
MODULATOR
E35
IC-2 M 25
6 2
IC-2 F 25
E13 E13
R
4
2.5 0.75 0.75 0.75

15 A
R G/B G/B G/B
7 1 EC4 2 1
0.5
G/B
0.5
G
P/L
0.5
11 IC-5 F
12 IC-5 M 11 IC-5 M
12 IC-5 F
0.5
G
0.5 13 IC-2 F
G/B 13 IC-2 M
50 49
SIG
RLY COIL
GND
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
P1A01F001_E1 P1A03F003_EC4
CONNECTOR
DESCRIPTION
1 SIGNAL
EGR MODULATOR EC 4
2 SUPPLY
EMS - EDC17C55
P0406


STEP A – CHECK VOLTAGE OF EGR MODULATOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• EGR modulator wiring harness connector (EC 4) DISCONNECTED
• Ignition ON
TEST PROCEDURE
• Check the voltage between pin 1 of EC 4 and battery ground.
ACCEPTANCE CRITERIA
• Voltage > 4V
ACTION TO BE TAKEN
OK NOT OK

• Examine the short circuit of EGR actuator
• Replace EGR actuator with a new one. control wire with battery positive
• If the DTC still exists, replace the EMS • Check and verify for any new DTC’s
ECU with a new one
EMS - EDC17C55
P0405
10.14 P0405 — EGR VALVE SHORT TO GROUND ERROR (PIKUP)


NORMAL OPERATION
• Ignition ON
during self check
• Ignition ON • EGR modulator control wire short to
ground.
• EMS ECU supply voltage 8 - 16 V
• Faulty EGR actuator
• Short to ground in EGR modulator control
circuit
DTC REACTIONS
HEALING CONDITION
• Self Healing
EMS EGR
ECU MODULATOR
E1
B23
SIG
0.5 GND
58 Y/R 2
0.5 SIG
GND
37 O/BR 3
0.5 I/P
I/P
15 R/O 1
EMS - EDC17C55
P0405
10.14.1.2 CONNECTOR VIEWS AND INFORMATION
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
P1A01F001_E1 P1A03F003_B23
CONNECTOR CONNECTOR
PIN NO FUNCTION
DESCRIPTION NO
1 SIGNAL
EGR MODULATOR B23
2 SUPPLY


STEP A – CHECK SHORT TO GROUND OF EGR MODULATOR SIGNAL WIRE
EMS - EDC17C55
P0405
PRE CONDITION
• Ignition OFF
• EGR modulator wiring harness connector (B 23) DISCONNECTED
• EMS ECU connector E1 DISCONNECTED
TEST PROCEDURE
• Check resistance between pin 1 of B23 and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Suspect EGR modulator internal failure • Examine the short circuit of EGR actuator
• Replace EGR modulator with a new one. control wire with ground
EMS - EDC17C55
P0405
10.15 P0405 — EGR VALVE SHORT TO GROUND ERROR (PIKUP EXTRA

LONG)

NORMAL OPERATION
• Ignition ON
during self check
• Ignition ON • EGR modulator control wire short to
ground.
• Faulty EGR actuator
• Short to ground in EGR modulator control
circuit
DTC REACTIONS
HEALING CONDITION
• Self Healing
EMS - EDC17C55
P0405
E4
+ ECU FUSE (BMF)
A
30 A
E4
E3
V
4
V
4
E35 4 8
30 86
ECU MAIN
RELAY VACCUM
87 86
MODULATOR
E35
IC-2 M 25
6 2
IC-2 F 25
E13 E13
R
4
2.5 0.75 0.75 0.75

15 A
R G/B G/B G/B
7 1 EC4 2 1
0.5
G/B
0.5
G
P/L
0.5
11 IC-5 F
12 IC-5 M 11 IC-5 M
12 IC-5 F
0.5
G
0.5 13 IC-2 F
G/B 13 IC-2 M
50 49
SIG
RLY COIL
GND
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
P1A01F001_E1 P1A03F003_EC4
CONNECTOR CONNECTOR
PIN NO FUNCTION
DESCRIPTION NO
1 SIGNAL
EGR MODULATOR EC 4
2 SUPPLY
EMS - EDC17C55
P0405


EMS - EDC17C55
P0405
STEP A – CHECK SHORT TO GROUND OF EGR MODULATOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• EGR modulator wiring harness connector (EC 4) DISCONNECTED
• EMS ECU connector E1 DISCONNECTED
TEST PROCEDURE
• Check resistance between pin 1 of EC4 and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Suspect EGR modulator internal failure • Examine the short circuit of EGR actuator
• Replace EGR modulator with a new one. control wire with ground
EMS - EDC17C55
P2228
10.16 P2228 — SRC FOR ENVIRONMENTAL PRESSURE SENSOR BELOW

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

NORMAL OPERATION
• Ignition ON
• EMS ECU receives an output voltage signal
from environment pressure sensor and is
within the range.
• Ignition ON
• EMS ECU supply voltage 8 - 16 V • Faulty Environment Pressure sensor (EMS
ECU)
• The output voltage signal received from the
environment pressure sensor is lower than
the minimum value.
DTC REACTIONS
HEALING CONDITION
• Self Healing

• Proceed to DIAGNOSTIC PROCEDURE if P2228 still present

• Poor mating of the ECU connector halves/damage of connector locking
EMS - EDC17C55
P2228
• Suspect ENVIRONMENTAL PRESSURE SENSOR internal failure.

• Replace EMS ECU with a new one
EMS - EDC17C55
P2229
10.17 P2229 — SIG RANGE CHECK FOR ENVIRONMENTAL PRESSURE

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

NORMAL OPERATION
• Ignition ON
from environment pressure sensor and is
within the range.
• Ignition ON
• EMS ECU supply voltage 8 - 16 V • Faulty Environment Pressure sensor (EMS
ECU)
environment pressure sensor is higher than
the minimum value.
DTC REACTIONS
HEALING CONDITION
• Self Healing
10.17.2 DTC CHECKING PROCEDURE

• Proceed to DIAGNOSTIC PROCEDURE if P2229 still present

EMS - EDC17C55
P2229
• Suspect ENVIRONMENTAL PRESSURE SENSOR internal failure.

EMS - EDC17C55
P0340
10.18 P0340 — CAMSHAFT SENSOR NO SIGNAL ERROR

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

NORMAL OPERATION
• Ignition ON
• During engine cranking, the output signal
received from Camshaft position sensor to
ECU is within the range
• Ignition ON
• Open/short cam shaft position sensor circuit
• Faulty cam shaft position sensor
• While engine cranking, no valid signal from
camshaft position sensor • Cam shaft mechanical failure.
DTC REACTIONS • Malfunctioning EMS ECU
• Engine check lamp continuously ON
• Engine will not start
• If this failure occurs when the engine is
running then engine will remain running.
HEALING CONDITION
• Ignition OFF/ON
EMS - EDC17C55
P0340
(TWISTED
EMS CRANK SHAFT
PAIR
ECU SENSOR
CABLE)
30 0.5 3
GND
GROUND
B/Y
74 0.5 2
SIG (-)
SIGNAL (-)
L/G
52 1
0.5
SIG(+)
SIGNAL (+)
L/Y
E1 E23
E1 - EMS ECU E30 - CAM SHAFT SENSOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3
P1A01F028_E30
P1A01F001_E1
CONNECTOR CONNECTOR
PIN NO FUNCTION
DESCRIPTION NO
45 POWER
44 GROUND
3 POWER
CAM SHAFT POSITION
E 30 1 SIGNAL
SENSOR
2 GROUND

EMS - EDC17C55
P0340
• Crank the Engine


STEP A – CHECK VOLTAGE OF CAM SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Camshaft position sensor wiring harness connector (E 30) DISCONNECTED
• Ignition ON
TEST PROCEDURE
• Check the voltage between pin 3 of E 30 and battery ground
ACCEPTANCE CRITERIA
• Voltage = 5 ± 0.25 V
ACTION TO BE TAKEN
OK NOT OK
• Examine the open /short circuit Camshaft

position sensor power wire to ground /
battery
• GO TO STEP B
STEP B – CHECK OPEN CIRCUIT OF CAM SHAFT SIGNAL WIRE
EMS - EDC17C55
P0340
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check resistance between pin 1 of E 30 and pin 46 of E1
ACCEPTANCE CRITERIA
• Resistance = < Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of Camshaft

position sensor signal wire
• GO TO STEP D • Replace the wiring harness
STEP D —CHECK SHORT TO GROUND OF CAM SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check resistance between pin 2 of E 30 and ground
ACCEPTANCE CRITERIA
• Resistance = ∞ Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of Camshaft

position sensor signal wire to ground
• GO TO STEP E • Replace the wiring harness
EMS - EDC17C55
P0340
STEP E — CHECK SHORT CIRCUIT BETWEEN POWER ,SIGNAL WIRES OF CAM SHAFT
SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check resistance between pin 3 and 1 of E 30
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of Camshaft

position sensor signal wire and power wire
• GO TO STEP F • Replace the wiring harness
STEP F — CHECK SHORT CIRCUIT BETWEEN SIGNAL AND GROUND WIRES OF CAM
SHAFT SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check resistance between pin 2 and 1 of E 30
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P0340
OK NOT OK
• Suspect Camshaft position sensor internal • Examine the short circuit of Camshaft
failure. position sensor signal wire to ground
• Replace the Camshaft position sensor with • Replace the wiring harness
a new one. • Clear the DTC and verify
• Clear and verify any new DTC’s
• If the DTC still exists, check for proper
fittment of Camshaft position sensor
mounting bolt.
• Check for any internal damage in cam
shaft trigger wheel.
EMS - EDC17C55
P0341
10.19 P0341 — CAMSHAFT SENSOR SIGNAL ERROR

10.19.1 CAM SHAFT SENSOR
Hall Effect Camshaft position sensor is mounted on the front timing cover and senses the Top
determine when to start the injection. The trigger is mounted in the front side of the Camshaft
sensor.

NORMAL OPERATION
• Ignition ON
• During engine cranking, the output signal
received from cam shaft sensor to ECU is
within the range
• Ignition ON • Increased air gap between cam shaft
position sensor and the trigger wheel.
• Cam shaft position sensor mounting
• While engine cranking disturbance noticed loosened
in Camshaft sensor position signal
• Increased cam shaft end play
DTC REACTIONS
• Faulty cam shaft position sensor
• Engine will not Start
running then engine will remain running.
HEALING CONDITION
• Ignition OFF then ON
(TWO CORE
EMS CAM SHAFT
SHIELDED
ECU SENSOR
CABLE)
46
0.75 1
SIG
SIGNAL
R/B
44
0.75 2
GND
GROUND
Y
45
0.75 3
POWER
POWER 5V
G
E1 E30
EMS - EDC17C55
P0341
E1 - EMS ECU E30 - CAM SHAFT SENSOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3
P1A01F028_E30
P1A01F001_E1
CONNECTOR CONNEC-
PIN NO FUNCTION
DESCRIPTION TOR NO
45 POWER
44 GROUND
3 POWER
CAM SHAFT POSITION
E 30 1 SIGNAL
SENSOR
2 GROUND

• Crank the Engine

EMS - EDC17C55
P0341
STEP A – CHECK FOR PROPER FITTMENT OF CAM PHASE SENSOR
PRE CONDITION
• Ignition OFF
• Camphase sensor wiring harness connector E 30 DISCONNECTED
TEST PROCEDURE
• Check for any damage on the cam phase sensor front face
ACCEPTANCE CRITERIA
• No damage on the cam phase sensor
ACTION TO BE TAKEN
OK NOT OK
• Suspect for any foreign particles presence.

• identify the cause and rectify.
• GO TO STEP B
• Replace the cam phase sensor with a new
one
STEP B – CHECK END PLAY OF CAM SHAFT WITHIN THE LIMITS
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check for end play in the Camshaft sensor.
ACCEPTANCE CRITERIA
• End play within the limits (Refer repair manual)
ACTION TO BE TAKEN
OK NOT OK
• Suspect the cam phase sensor internal • Identify the root cause of the cam shaft
failure end play and rectify
• Replace the cam phase sensor with a new • Clear the DTC and verify.
one
EMS - EDC17C55
P1341
10.20 P1341 — CAMSHAFT SENSOR SIGNAL OFFSET ERROR

10.20.1 Camshaft sensor
Hall Effect Camshaft position sensor is mounted on the front timing cover and senses the Top
determine when to start the injection. The trigger is mounted in the front side of the Camshaft
sensor.

NORMAL OPERATION
• Ignition ON
• During engine cranking , the EMS ECU
compares the crankshaft sensor signal and
cam shaft position sensor signal and the
deviation is within the range
• Ignition ON • Increased air gap between cam shaft
position sensor and the trigger wheel.
• Cam shaft position sensor mounting
• While engine cranking, the cam shaft loosened
position sensor and crankshaft speed sensor
are not synchronized. • Increased cam shaft end play
DTC REACTIONS • Faulty cam shaft position sensor
• Engine will not Start
running then engine will keep on running.
HEALING CONDITION

• Crank the engine

EMS - EDC17C55
P1341

STEP A – CHECK FLYWHEEL, CAMSHAFT SENSOR AND CRANKSHAFT SENSOR

MOUNTING BOLTS FOR TIGHTNESS
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the flywheel mounting bolts for tightness
• Check the Camshaft sensor/crankshaft mounting bolts for tightness as per the torque
chart(refer repair manual)
ACCEPTANCE CRITERIA
• All bolts are tight as per torque chart (Refer repair manual)
ACTION TO BE TAKEN
OK NOT OK
• Tighten the bolts to the torque specified

• GO TO STEP B
STEP B – CHECK TRIGGER WHEEL FOR ANY DAMAGE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check for any damage on the trigger wheel teeth
• Check for proper mounting of trigger wheel mounting screws
ACCEPTANCE CRITERIA
• Is there any damage/ Screws loosened
ACTION TO BE TAKEN
EMS - EDC17C55
P1341
OK NOT OK
• If the screws are loosened , tighten to

torque
• If toner wheel damaged, replace it with a • GO TO STEP C
new one
STEP C– CHECK THE SPROCKETS AND CHAIN
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the sprockets and chain for any damage
ACCEPTANCE CRITERIA
• No damage in chain and sprockets
ACTION TO BE TAKEN
OK NOT OK
• Check for proper functioning of hydraulic • Replace the chain/sprocket assembly with
chain tensioner a new one
• If not functioning properly , replace with a • Clear the DTC and verify
new one
EMS - EDC17C55
P0336
10.21 P0336 — CRANKSHAFT SENSOR SIGNAL ERROR

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

NORMAL OPERATION
• Ignition ON
• During engine cranking and running, the
EMS ECU receives the output signal from the
crankshaft speed sensor and is within the
specified range
• Open crankshaft speed sensor circuit
• Sensor mounting loosened
• Ignition ON
• Increased air gap between crankshaft
• EMS ECU supply voltage 8 - 16 V speed sensor and the trigger wheel
• While engine cranking/running, disturbance • Fly wheel damaged/mounting loosened
noticed in crankshaft speed signal
• EMI noise
DTC REACTIONS
• Engine will not start / Engine stops
HEALING CONDITION
• Ignition Off/On
(TWISTED
EMS CRANK SHAFT
PAIR
ECU SENSOR
CABLE)
30 0.5 3
GND
GROUND
B/Y
74 0.5 2
SIG (-)
SIGNAL (-)
L/G
52 1
0.5
SIG(+)
SIGNAL (+)
L/Y
E1 E23
EMS - EDC17C55
P0336
E1 - EMS ECU E23 - CRANK SHAFT SENSOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2 3
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F021_E23
P1A01F001_E1
CONNECTOR CONNECTOR
PIN NO FUNCTION
DESCRIPTION NO
74 SIGNAL (-)
EMS ECU E1 52 SIGNAL (+)
30 GROUND
1 SIGNAL (+)
CRANK SHAFT
E 23 2 SIGNAL (-)
POSITION SENSOR
3 GROUND


EMS - EDC17C55
P0336
STEP A – CHECK OPEN CIRCUIT OF CRANK SHAFT SPEED SENSOR SIGNAL WIRES
PRE CONDITION
• Ignition OFF
• Crankshaft speed sensor wiring harness connector (E 23) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 2 of E 23 and pin 74 of E1
• Check the resistance between pin 1of E 23 and pin 52 of E1
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of crank shaft

speed sensor signal wire
• GO TO STEP B • Replace the wiring harness
STEP B – CHECK LOOSE CONNECTIONS IN CRANKSHAFT SPEED SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check and correct if any loose connections noticed in the crankshaft speed sensor wiring
harness connector
• Check for proper fitment of the crank shaft speed sensor mounting bolt
ACCEPTANCE CRITERIA
• Fitment and connections are proper
ACTION TO BE TAKEN
EMS - EDC17C55
P0336
OK NOT OK
• Fix the bolt properly and tighten it to the

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

• Replace the crankshaft speed sensor with
• GO TO STEP D a new one
STEP D– CHECK FOR ANY DAMAGE / LOOSENED SCREWS
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check for any damage on the flywheel
ACCEPTANCE CRITERIA
• Fly wheel and mounting bolts are good
ACTION TO BE TAKEN
EMS - EDC17C55
P0336
OK NOT OK
• If the screws are loosened, tighten to

torque
• GO TO STEP E • If the toner wheel damaged, replace it with
a new one
STEP E– CHECK THE SENSOR WIRE IS CLOSER TO THE STARTER MOTOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check for the crankshaft speed sensor wire is closer is closer to the starter motor
ACCEPTANCE CRITERIA
• The wire is not closer to the starter motor
ACTION TO BE TAKEN
OK NOT OK
• Suspect crankshaft speed sensor internal

• Route the wires correctly failure
• (Refer wiring manual for proper routing) • Replace crankshaft speed sensor with a
• Clear the DTC and verify with a new one
EMS - EDC17C55
P0335
10.22 P0335 — CRANKSHAFT SENSOR NO SIGNAL ERROR

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

NORMAL OPERATION
• Ignition ON
• During engine cranking and running, the
EMS ECU receives the output signal from the
crankshaft speed sensor and is within the
specified range
• Ignition ON • Sensor mounting loosened
• EMS ECU supply voltage 8 - 16 V • Open/short crankshaft speed sensor circuit
• While engine cranking/running, no • Faulty crankshaft speed sensor
crankshaft speed signal received by the EMS
ECU
DTC REACTIONS
• Engine will not start / Engine stops.
HEALING CONDITION
• Ignition Off / On.
(TWISTED
EMS CRANK SHAFT
PAIR
ECU SENSOR
CABLE)
30 0.5 3
GND
GROUND
B/Y
74 0.5 2
SIG (-)
SIGNAL (-)
L/G
52 1
0.5
SIG(+)
SIGNAL (+)
L/Y
E1 E23
EMS - EDC17C55
P0335
E1 - EMS ECU E23 - CRANK SHAFT SENSOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2 3
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F021_E23
P1A01F001_E1
CONNECTOR CONNECTOR
PIN NO FUNCTION
DESCRIPTION NO
74 SIGNAL (-)
EMS ECU E1 52 SIGNAL (+)
30 GROUND
1 SIGNAL (+)
CRANK SHAFT
E 23 2 SIGNAL (-)
POSITION SENSOR
3 GROUND

• Turn ignition OFF then ON and crank the engine

EMS - EDC17C55
P0335
STEP A – CHECK PROPER FITMENT OF SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check and correct if any loose connections noticed in the crankshaft speed sensor wiring
harness connector
• Check for proper fitment of the crank shaft speed sensor mounting bolt
ACCEPTANCE CRITERIA
• Fitment and connection are good
ACTION TO BE TAKEN
OK NOT OK
• Fix the bolt properly and tighten it to the

• GO TO STEP B torque specified
STEP B – CHECK SHORT CIRCUIT BETWEEN SENSOR SIGNAL WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 1 and pin 2 of E 23
ACCEPTANCE CRITERIA
• Resistance = ∞Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit between the

crankshaft speed sensor signal wires
• GO TO STEP C • Repair/Replace the wiring harness
• Clear DTC and verify
EMS - EDC17C55
P0335
STEP C – CHECK OPEN CIRCUIT OF SENSOR SIGNAL WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of crankshaft

speed sensor signal wires
STEP D– CHECK INTERNAL FAILURE OF CRANKSHAFT SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 1 and pin 2 of Crankshaft speed sensor
ACCEPTANCE CRITERIA
• Resistance value= 890 ±25Ω
ACTION TO BE TAKEN
OK NOT OK
• Suspect EMS ECU malfunction • Suspect internal failure of crankshaft

• Replace EMS ECU with a new one. speed sensor
• Check and verify for any new DTC’s • Replace the crank shaft speed sensor
EMS - EDC17C55
P0183
10.23 P0183 — SRC FOR FUEL TEMPERATURE SENSOR ABOVE

MAXIMUM LIMIT
10.23.1 FUEL TEMPERATURE SENSOR
The fuel temperature sensor is a variable resistor whose resistance changes as temperature
of fuel flowing past the sensor changes (NTC resistor). When the fuel temperature is low, the
sensor resistance is high; when the fuel temperature is high, the sensor resistance is low.

NORMAL OPERATION
• Ignition ON
fuel temperature sensor is within the range
• Open fuel temperature wiring harness
• Ignition ON
• Short to battery of fuel temperature wiring
• EMS ECU supply voltage 8 to 16 V harness
• The measured output voltage of the fuel • Faulty fuel temperature sensor
temperature sensor is above the maximum
range • Faulty EMS ECU
DTC REACTIONS
• Nil
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P0183
+ E5
BATTERY
12V
-
30A
E2
E4 A
E35 4 8
30 86 FUEL TEMP AND
WATER IN FUEL
SENSOR
87 85
2.5 E13 E13 0.75
E35 6 2 10A
R 7 1 G/B
8
G/B
SIG SUP
0.5
SIG GND
4 1 2 3
P/L
0.5
0.5 G/R
R/L 0.5
0.5
R
E1 50 12 34 19
RLY GND SIG GND SIG
TEMP WATER IN FUEL
EMS ECU
E1 - EMS ECU E24 - WATER IN FUEL
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 4 3 2 1
P1A01F001_E1 P1A01F022_E24
EMS - EDC17C55
P0183
CONNECTOR
DESCRIPTION
12 SIGNAL — FUEL
TEMPERATURE
EMS ECU E1
34 GROUND
19 SIGNAL —WATER IN FUEL
4 SIGNAL —FUEL
TEMPERATURE
FUEL TEMPERATURE 1 GROUND
E24
SENSOR
3 SUPPLY


STEP A – CHECK VOLTAGE IN FUEL TEMPERATURE SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Fuel temperature sensor wiring harness connector (E24) DISCONNECTED
• Ignition ON
TEST PROCEDURE
EMS - EDC17C55
P0183
ACCEPTANCE CRITERIA
• Voltage = 5 ± 0.25 V
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit Fuel temperature

sensor signal wire to battery
STEP B– CHECK OPEN CIRCUIT OF FUEL TEMPERATURE SENSOR GROUND WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU wiring harness connector (E1)DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of Fuel

STEP E– CHECK INTERNAL FAILURE OF FUEL TEMPERATURE SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 1 and pin 4 of fuel temperature sensor
EMS - EDC17C55
P0183
ACCEPTANCE CRITERIA
• Resistance = 2.2kΩ — 2.7 kΩ at 20°C
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of Fuel

• Examine the EMS ECU malfunction
• Replace the EMS ECU
EMS - EDC17C55
P0182
10.24 P0182 — SIGNAL RANGE CHECK FOR FUEL TEMPERATURE

SENSOR BELOW MINIMUM LIMIT
10.24.1 FUEL TEMPERATURE SENSOR
The fuel temperature sensor is a variable resistor whose resistance changes as the
temperature of the fuel flowing past the sensor changes (NTC resistor). When the fuel
temperature is low, the sensor resistance is high; when the fuel temperature is high, the
sensor resistance is low.

NORMAL OPERATION
• Ignition ON
fuel temperature sensor is within the range
• Ignition ON
• EMS ECU supply voltage 8 to 16 V • Short to ground of fuel temperature sensor
wire
• The measured output voltage of the fuel
temperature sensor is Below the minimum • Faulty fuel temperature sensor
range • Faulty EMS ECU
DTC REACTIONS
• Engine will run with a default fuel
temperature of 20 °C.
• MIL lamp ON
HEALING CONDITION
• Ignition Off/On
EMS - EDC17C55
P0182
+ E5
BATTERY
12V
-
30A
E2
E4 A
E35 4 8
30 86 FUEL TEMP AND
WATER IN FUEL
SENSOR
87 85
2.5 E13 E13 0.75
E35 6 2 10A
R 7 1 G/B
8
G/B
SIG SUP
0.5
SIG GND
4 1 2 3
P/L
0.5
0.5 G/R
R/L 0.5
0.5
R
E1 50 12 34 19
RLY GND SIG GND SIG
TEMP WATER IN FUEL
EMS ECU
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 4 3 2 1
P1A01F001_E1 P1A01F022_E24
EMS - EDC17C55
P0182
CONNECTOR
DESCRIPTION
12 SIGNAL —FUEL
TEMPERATURE
EMS ECU E1
34 GROUND
4 SIGNAL — FUEL
TEMPERATURE
FUEL TEMPERATURE 1 GROUND
E24
SENSOR
3 SUPPLY


STEP A – CHECK SHORT TO BATTERY OF FUEL TEMPERATURE SENSOR SIGNAL

WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
EMS - EDC17C55
P0182
• Check the resistance between pin 4 of E24 and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit fuel temperature

sensor wire to ground
STEP B– CHECK INTERNAL SHORT IN FUEL TEMPERATURE SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 4 and pin 1 of fuel temperature sensor
ACCEPTANCE CRITERIA
• Resistance = 2.2 < 2.7 KΩ at 20°C
ACTION TO BE TAKEN
OK NOT OK
• Suspect internal short in fuel temperature

• Suspect EMS ECU malfunction. sensor
• Replace EMS ECU with a new one • Replace the fuel temperature sensor with
• Check and verify for any new DTC’s a new one
EMS - EDC17C55
P268C
10.25 P268C — CYLINDER 1 INJECTOR ADJUSTMENT CODE

INCORRECT ERROR
10.25.1 INJECTOR IQA MONITORING
IQA monitoring monitors the missing or faulty programming of individual IQA values and
registers an error if it is missing or faulty.

NORMAL OPERATION
• Ignition ON
• ECU monitors the checksum of cylinder 1
IQA code and is within the range
• Ignition ON
• No cylinder 1 IQA code read by EEPROM • Cylinder 1 IQA code not written
• The checksum of cylinder 1 IQA code is not • Cylinder 1 IQA code wrongly written
correct • Faulty EMS ECU
DTC REACTIONS
• Cylinder 1 injector adjustment will not
happen
HEALING CONDITION
• Ignition Off/On

• Proceed to DIAGNOSTIC PROCEDURE if P268C is present

EMS - EDC17C55
P268C
STEP A – CHECK THE IQA CODE
PRE CONDITION
• Ignition ON
TEST PROCEDURE
• Using iSmart , check whether the 1st cylinder 6 digit IQA code is written properly
ACCEPTANCE CRITERIA
• IQA code written correctly
ACTION TO BE TAKEN
OK NOT OK
• Suspect EMS ECU malfunction

• Write the correct IQA code
EMS - EDC17C55
P268E
10.26 P268E — CYLINDER 2 INJECTOR ADJUSTMENT CODE

INCORRECT ERROR.
registers an error if it is missing or faulty. The injectors are with 6 digit IQA code

NORMAL OPERATION
• Ignition ON
• Ignition ON
DTC REACTIONS
happen
HEALING CONDITION
• Ignition Off/On

• Proceed to DIAGNOSTIC PROCEDURE if P268E is present

EMS - EDC17C55
P268E
PRE CONDITION
• Ignition ON
TEST PROCEDURE
• Using iSmart , check whether the 2nd cylinder 6 digit IQA code is written properly
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

EMS - EDC17C55
P268F
10.27 P268F — CYLINDER 3 INJECTOR ADJUSTMENT CODE

INCORRECT ERROR

NORMAL OPERATION
• Ignition ON
• Ignition ON
DTC REACTIONS
happen
HEALING CONDITION
• Ignition Off/On


EMS - EDC17C55
P268F
PRE CONDITION
• Ignition ON
TEST PROCEDURE
• Using iSmart , check whether the 3rd cylinder 6 digit IQA code is written properly
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

EMS - EDC17C55
P268D
10.28 P268D — CYLINDER 4 INJECTOR ADJUSTMENT CODE

INCORRECT ERROR

NORMAL OPERATION
• Ignition ON
• Ignition ON
DTC REACTIONS
happen
HEALING CONDITION
• Ignition Off/On

• Proceed to DIAGNOSTIC PROCEDURE if P268D is present

EMS - EDC17C55
P268D
PRE CONDITION
• Ignition ON
TEST PROCEDURE
• Using iSmart , check whether the 4th cylinder 6 digit IQA code is written properly
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

EMS - EDC17C55
P0201
10.29 P0201 — CYLINDER 1 INJECTOR OPEN LOAD ERROR

10.29.1 INJECTORS
The injector are solenoid actuated and controlled by EMS ECU. Both high and low side of the
injectors are controlled by EMS ECU. The EMS ECU measures the voltage drop through fixed
resistors and controls it.

NORMAL OPERATION
• Ignition ON
• The PWM control signals of the injector 1 is
monitored and is within the range.
• Ignition ON
• Open in injector 1 circuit
• Faulty injector 1
• A open load is detected in injector 1 circuit
• Faulty EMS ECU
DTC REACTIONS
• Injection in cylinder 1 will not happen
• Engine vibrate
HEALING CONDITION
• Ignition Off/On
1
CYLINDER 4
1.5
SUP
Y EMS
ECU
2 1.5 1.5 7
SIG
SIGNAL
E21 L L
1 1.5 1.5 3
CYLINDER 1
SUP
SUPPLY
Y Y
2 1.5 73
SIG
SIGNAL
E18 V
E1
EMS - EDC17C55
P0201
E1 - EMS ECU E18 - CYLINDER 1
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
P1A01F001_E1 P1A01F001_E18
CONNECTOR CONNECTOR
PIN NO FUNCTION
DESCRIPTION NO
3 HIGH SIDE INJECTOR 1
EMS ECU E1
73 LOW SIDE INJECTOR 1
INJECTOR 1 E18


STEP A – CHECK OPEN CIRCUIT OF INJECTOR 1 HIGH AND LOW SIDE WIRES
EMS - EDC17C55
P0201
PRE CONDITION
• Ignition OFF
• Injector 1 wiring harness connector (E18 )DISCONNECTED
TEST PROCEDURE
• Check resistance between pin 2 of E18 and pin 73 of E1
• Check resistance between pin 1 of E18 and pin 3 of E1
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of injector 1 high

and low side wires
• GO TO STEP B • Repair / Replace the wiring harness
STEP B – CHECK INTERNAL FAILURE OF INJECTOR 1
PRE CONDITION
• Ignition OFF
• Injector 1 wiring harness connector (E18)DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 1 and pin 2 of the injector 1
ACCEPTANCE CRITERIA
• Resistance = 0.255 ± 0.040 Ω
ACTION TO BE TAKEN
OK NOT OK
• Suspect EMS ECU malfunction. • Examine internal failure of the injector 1

• Replace EMS ECU with a new one. • Replace the injector 1 with a new one
• Check and verify for any new DTC’s • Clear DTC and verify
EMS - EDC17C55
P0203

10.30.1 INJECTORS

NORMAL OPERATION
• Ignition ON
• Ignition ON
• Faulty EMS ECU
DTC REACTIONS
• Engine vibrate
HEALING CONDITION
• Ignition Off/On

CYLINDER 2
1 1.5 EMS
SUP
G ECU
51
2 1.5 1.5
SIG
SIGNAL
E19 R R
CYLINDER 3
1 1.5 1.5 SUPPLY

SUP
G G
29
2 1.5 1.5
SIG
SIGNAL
E20 P P
E1
EMS - EDC17C55
P0203
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F017_E19
CONNECTOR
DESCRIPTION
EMS ECU E1
INJECTOR 2 E19


EMS - EDC17C55
P0203
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

and low side wire
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance = 0.255 ± 0.040 Ω
ACTION TO BE TAKEN
OK NOT OK
• Suspect EMS ECU malfunction.. • Examine internal failure of the injector 2

EMS - EDC17C55
P0204

10.31.1 INJECTORS

NORMAL OPERATION
• Ignition ON
• Ignition ON
• Faulty EMS ECU
DTC REACTIONS
• Engine Switches OFF
HEALING CONDITION
• Ignition Off/On

CYLINDER 2
1 1.5 EMS
SUP
G ECU
51
2 1.5 1.5
SIG
SIGNAL
E19 R R
CYLINDER 3
1 1.5 1.5 SUPPLY

SUP
G G
29
2 1.5 1.5
SIG
SIGNAL
E20 P P
E1
EMS - EDC17C55
P0204
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F018_E20
CONNECTOR CONNECTOR
PIN NO FUNCTION
DESCRIPTION NO
EMS ECU E1
INJECTOR 3 E 20


EMS - EDC17C55
P0204
PRE CONDITION
• Ignition OFF
• Injector 3 wiring harness connector (E 20)DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

and low side wire
• GO TO STEP B • Repair / Replace the wiring harness
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance = 0.255 ± 0.040 Ω
ACTION TO BE TAKEN
OK NOT OK
• Suspect EMS ECU malfunction. • Examine internal failure of the injector 3

EMS - EDC17C55
P0202

10.32.1 INJECTORS

NORMAL OPERATION
• Ignition ON
• Ignition ON
• Faulty EMS ECU
DTC REACTIONS
• Engine switches Off
HEALING CONDITION
• Ignition Off/On
1
CYLINDER 4
1.5
SUP
Y EMS
ECU
2 1.5 1.5 7
SIG
SIGNAL
E21 L L
1 1.5 1.5 3
CYLINDER 1
SUP
SUPPLY
Y Y
2 1.5 73
SIG
SIGNAL
E18 V
E1
EMS - EDC17C55
P0202
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F019_E21
CONNECTOR
DESCRIPTION
POWER HIGH SIDE
3
INJECTOR 4
EMS ECU E1
POWER LOW SIDE
7
INJECTOR 4
POWER HIGH SIDE
1
INJECTOR 4
INJECTOR 4 E21
POWER LOW SIDE
2
INJECTOR 4


EMS - EDC17C55
P0202
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

and low side wires
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance = 0.255 ± 0.040 Ω
ACTION TO BE TAKEN
OK NOT OK
• Suspect EMS ECU malfunction • Examine internal failure of the injector 4

EMS - EDC17C55
P0261
10.33 P0261 — CYLINDER 1 INJECTOR SHORT CIRCUIT ERROR

10.33.1 INJECTORS
resistors and controls it

NORMAL OPERATION
• Ignition ON
• The PWM control signal of the injector 1 is
monitored and is within the range
• Ignition ON
• EMS ECU supply voltage 8 - 16 V • Short between injector 1 low and high side
• Short between injector 1 low side and high • Faulty Injector 1
side • Faulty EMS ECU
DTC REACTIONS
• No Injection in cylinder 1
HEALING CONDITION
• Ignition Off/On
1
CYLINDER 4
1.5
SUP
Y EMS
ECU
2 1.5 1.5 7
SIG
SIGNAL
E21 L L
1 1.5 1.5 3
CYLINDER 1
SUP
SUPPLY
Y Y
2 1.5 73
SIG
SIGNAL
E18 V
E1
EMS - EDC17C55
P0261
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
P1A01F001_E1 P1A01F001_E18
CONNECTOR
DESCRIPTION
73 INJECTOR 1 LOW SIDE
(SIGNAL)
EMS ECU E1
3 INJECTOR 1 HIGH SIDE
(SUPPLY)
1 HIGH SIDE (SUPPLY)

INJECTOR 1 E18
2 LOW SIDE (SIGNAL)


EMS - EDC17C55
P0261
STEP A – CHECK SHORT CIRCUIT BETWEEN INJECTOR 1 HIGH AND LOW SIDE WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 1 and 2 of E1
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine short circuit of injector 1 high and

low side wires
STEP B – CHECK INTERNAL OPEN CIRCUIT OF INJECTOR 1
PRE CONDITION
• Ignition OFF
• Injector wiring harness connector (E18)DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance = 0.255 ± 0.040 Ω
ACTION TO BE TAKEN
OK NOT OK

• Replace EMS ECU with a new one • Replace the injector 1 with a new one
• Check and verify for any new DTC’s • Clear the DTC and verify
EMS - EDC17C55
P0267

10.34.1 INJECTORS

NORMAL OPERATION
• Ignition ON
• Ignition ON
DTC REACTIONS
• No Injection in cylinder 2.
HEALING CONDITION
• Ignition Off/On

CYLINDER 2
1 1.5 EMS
SUP
G ECU
51
2 1.5 1.5
SIG
SIGNAL
E19 R R
CYLINDER 3
1 1.5 1.5 SUPPLY

SUP
G G
29
2 1.5 1.5
SIG
SIGNAL
E20 P P
E1
EMS - EDC17C55
P0267
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F017_E19
CONNECTOR
DESCRIPTION
3 POWER HIGH SIDE
INJECTOR 2
EMS ECU E1
7 POWER LOW SIDE
INJECTOR 2
1 POWER HIGH SIDE
INJECTOR 2
INJECTOR 2 E19
2 POWER LOW SIDE
INJECTOR 2


EMS - EDC17C55
P0267
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 1 and pin 2 of E19
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

low side wires
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance = 0.255 ± 0.040 Ω
ACTION TO BE TAKEN
OK NOT OK
• Suspect EMS ECU malfunction • Suspect internal failure of the injector 2

EMS - EDC17C55
P0270

10.35.1 INJECTORS

NORMAL OPERATION
• Ignition ON
• Ignition ON
DTC REACTIONS
• Injection in cylinder 3 will not happen.
• Engine will vibrate
HEALING CONDITION
• Ignition Off/On

CYLINDER 2
1 1.5 EMS
SUP
G ECU
51
2 1.5 1.5
SIG
SIGNAL
E19 R R
CYLINDER 3
1 1.5 1.5 SUPPLY

SUP
G G
29
2 1.5 1.5
SIG
SIGNAL
E20 P P
E1
EMS - EDC17C55
P0270
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F018_E20
CONNECTOR
DESCRIPTION
5 POWER HIGH SIDE
INJECTOR 3
EMS ECU E1
29 POWER LOW SIDE
INJECTOR 3
1 POWER HIGH SIDE
INJECTOR 3
INJECTOR 3 E 20
2 POWER LOW SIDE
INJECTOR 3


EMS - EDC17C55
P0270
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance ∞ Ω
ACTION TO BE TAKEN
OK NOT OK

low side wires
PRE CONDITION
• Ignition OFF
• Injector wiring harness connector (E 20)DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 1 and pin 2 of the injector E 20
ACCEPTANCE CRITERIA
• Resistance = 0.255 ± 0.040 Ω
ACTION TO BE TAKEN
OK NOT OK

EMS - EDC17C55
P0264

10.36.1 INJECTORS

NORMAL OPERATION
• Ignition ON
• Ignition ON
DTC REACTIONS
• Injection in cylinder 4 will not happen.
HEALING CONDITION
• Ignition Off/On

CYLINDER 2
1 1.5 EMS
SUP
G ECU
51
2 1.5 1.5
SIG
SIGNAL
E19 R R
CYLINDER 3
1 1.5 1.5 SUPPLY

SUP
G G
29
2 1.5 1.5
SIG
SIGNAL
E20 P P
E1
EMS - EDC17C55
P0264
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F019_E21
CONNECTOR
DESCRIPTION
3 POWER HIGH SIDE
INJECTOR 4
EMS ECU E1
7 POWER LOW SIDE
INJECTOR 4
1 POWER HIGH SIDE
INJECTOR 4
INJECTOR 4 E 21
2 POWER LOW SIDE
INJECTOR 4


EMS - EDC17C55
P0264
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

low side wires
PRE CONDITION
• Ignition OFF
• Injector wiring harness connector (E 21)DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 1 and pin 2 of the injector 4 (E 21)
ACCEPTANCE CRITERIA
• Resistance = 0.255 ± 0.040 Ω
ACTION TO BE TAKEN
OK NOT OK

EMS - EDC17C55
P2146
10.37 P2146 — SHORT CIRCUIT IN BANK 0

10.37.1 INJECTORS

NORMAL OPERATION
• Ignition ON
• The injector bank is checked while
initialization and running and found normal.
• Ignition ON • Short in injector bank
• EMS ECU supply voltage 8 - 16 V • Faulty Injectors
• Short in injector bank • Faulty EMS ECU
DTC REACTIONS
• Engine shuts OFF
HEALING CONDITION
• Ignition Off/On
EMS - EDC17C55
P2146
CYLINDER 4
1.5
SUP
Y EMS
ECU
2 1.5 1.5 7
SIG
SIGNAL
E21 L L
1 1.5 1.5 3
CYLINDER 1
SUP SUPPLY
Y Y
2 1.5 73
SIG
SIGNAL
E18 V
E1
CYLINDER 2
1 1.5 EMS
SUP
G ECU
51
2 1.5 1.5
SIG
SIGNAL
E19 R R
CYLINDER 3
1 1.5 1.5 SUPPLY

SUP
G G
29
21.5 1.5
SIG
SIGNAL
E20 P P
E1
EMS - EDC17C55
P2146
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
P1A01F001_E1 P1A01F001_E18
E19 - CYLINDER 2 E20 - CYLINDER 3
1 2 1 2
P1A01F017_E19 P1A01F018_E20
E21 - CYLINDER 4
1 2
P1A01F019_E21
EMS - EDC17C55
P2146
CONNECTOR CONNECTOR
PIN NO FUNCTION
DESCRIPTION NO
POWER HIGH SIDE

3
INJECTOR 1
POWER LOW SIDE

73
INJECTOR 1
POWER HIGH SIDE

5
INJECTOR 2
POWER LOW SIDE

51
INJECTOR 2
EMS ECU E1
POWER HIGH SIDE
5
INJECTOR 3
POWER LOW SIDE

29
INJECTOR 3
POWER HIGH SIDE

3
INJECTOR 4
POWER LOW SIDE

7
INJECTOR 4
POWER HIGH SIDE

1
INJECTOR 1
INJECTOR 1 E18
POWER LOW SIDE
2
INJECTOR 1
POWER HIGH SIDE

1
INJECTOR 2
INJECTOR 2 E19
POWER LOW SIDE
2
INJECTOR 2
POWER HIGH SIDE

1
INJECTOR 3
INJECTOR 3 E20
POWER LOW SIDE
2
INJECTOR 3
POWER HIGH SIDE

1
INJECTOR 4
INJECTOR 4 E21
POWER LOW SIDE
2
INJECTOR 4
EMS - EDC17C55
P2146


STEP A—CHECK SHORT CIRCUIT TO GROUND OF INJECTOR HIGH SIDE WIRES
PRE CONDITION
• Ignition OFF
• Injector 1,2,3 and 4 wiring harness connector (E18, E19, E 20, E 21) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 1 of E 20 and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine short circuit of injector high side

wire to ground
EMS - EDC17C55
P2146
STEP B— CHECK SHORT TO GROUND OF INJECTOR LOW SIDE WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine short circuit of injector low side

wires to ground
• STEP C • Replace the wiring harness
STEP C— CHECK SHORT TO BATTERY OF INJECTOR HIGH SIDE WIRES
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
• Check the voltage between pin 2 of E18 and ground
• Check the voltage between pin 2 of E 20 and ground
• Check the voltage between pin 2 of E 21 and ground
ACCEPTANCE CRITERIA
• Voltage = 0 V
EMS - EDC17C55
P2146
ACTION TO BE TAKEN
OK NOT OK

wires to positive
STEP D— CHECK SHORT TO BATTERY OF INJECTOR LOW SIDE WIRES
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK

wires to ground
STEP E— CHECK SHORT CIRCUIT OF INJECTORS SOLENOID
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
EMS - EDC17C55
P2146

• Check the resistance between pin 2 and 1 of E 20
ACCEPTANCE CRITERIA
• Resistance = 0.255 ± 0.040 Ω
ACTION TO BE TAKEN
OK NOT OK
• Suspect EMS ECU malfunction • Examine short circuit of injectors solenoid

• Replace the wiring harness • Replace the injector with a new one
• Clear the DTC and verify • Clear the DTC and verify
EMS - EDC17C55
P0001
10.38 P0001 — METERING UNIT OPEN LOAD ERROR

10.38.1 FUEL METERING UNIT ( FUEL CONTROL UNIT)
Fuel metering unit ( Fuel Control Unit)(also called Fuel Control Unit-FCU) is located in the inlet
side of the High Pressure Pump and controls the fuel flow to Fuel Pump. EMS ECU regulates
the Fuel metering unit ( Fuel Control Unit) based on the rail pressure set point and the actual
value.

NORMAL OPERATION
• Ignition ON
• No malfunction detected by EMS ECU in
the Fuel metering unit ( Fuel Control Unit)
circuit
• Open in Fuel metering unit ( Fuel Control
• Ignition ON Unit) circuit
• EMS ECU supply voltage 8 to 16 V • Faulty Fuel metering unit ( Fuel Control
• A open load detected in Fuel metering unit ( Unit)
Fuel Control Unit) circuit • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Ignition Off/On
EMS - EDC17C55
P0001
E4
+
ECU FUSE
(BMF)
30 A
A E4
V
4
V
E3
4
E35 4 8
30 86
ECU MAIN
RELAY
87 86
E35 6 2
E13 E13 FUEL
R
4
2.5 0.75
15 A METER
R 7 1 G/B
FUEL UNIT
METERING
P/L
0.5
E9 1
2
0.75
G/B
E1 50 89
SIG
RLY COIL
GND
EMS
ECU
E1 - EMS ECU E9 - FUEL METRING UNIT
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F008_E9
CONNECTOR
NO
EMS ECU E1 89 CONTROL SIGNAL
1 CONTROL SIGNAL
Fuel metering unit ( Fuel Control Unit) E9
2 SUPPLY
EMS - EDC17C55
P0001

• Run the vehicle for 3 driving cycles
• If not present, then check for any intermittent problems

STEP A – CHECK VOLTAGE IN FUEL METERING UNIT ( FUEL CONTROL UNIT) SUPPLY
WIRE
PRE CONDITION
• Ignition OFF
• Check and confirm the proper function of 15A fuse in ECU fuse Box
• Fuel metering unit ( Fuel Control Unit) wiring harness connector (E9) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = Vehicle battery
ACTION TO BE TAKEN
OK NOT OK
• Examine the open/short to ground of Fuel

metering unit ( Fuel Control Unit) supply
wire
• GO TO STEP B
EMS - EDC17C55
P0001
STEP B– CHECK OPEN CIRCUIT OF FUEL METERING UNIT ( FUEL CONTROL UNIT)
CONTROL WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU wiring harness connector(E1) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine Fuel metering unit ( Fuel Control • Examine the open circuit of Fuel metering
Unit) internal failure unit ( Fuel Control Unit) control wire
• Replace fuel control unit / metering unit • Replace the wiring harness
with a new one • Clear the DTC and verify
EMS - EDC17C55
P1620
10.39 P1620 — METERING UNIT DEVICE DRIVER OVER TEMPERATURE

ERROR
Fuel metering unit ( Fuel Control Unit) is located in the inlet side of the High Pressure Pump
and controls the fuel flow to Fuel Pump. EMS ECU regulates the Fuel metering unit ( Fuel
Control Unit) based on the rail pressure set point and the actual value.

NORMAL OPERATION
• Ignition ON
circuit
• Ignition ON
• EMS ECU supply voltage 8 - 16 V • Faulty EMS ECU
• Overheating detected in EMS ECU power
stage
DTC REACTIONS
• Engine Check lamp continuously ON
HEALING CONDITION
• Fault absent

10.39.3 INTERMITTENT PROBLEMS

EMS - EDC17C55
P1620
10.39.4 DIAGNOSTIC PROCEDURE
• Check metering unit connector for proper fitting

• If the DTC still exists, replace the EMS ECU with a new one
• Check for any new DTC’s
EMS - EDC17C55
P0004
10.40 P0004 — METERING UNIT OUTPUT SHORT CIRCUIT TO BATTERY

ERROR
Fuel metering unit ( Fuel Control Unit) is located in the inlet side of the High Pressure Pump
and controls the fuel flow to Fuel Pump. EMS ECU regulates the Fuel metering unit ( Fuel
Control Unit) based on the rail pressure set point and the actual value.

NORMAL OPERATION
• Ignition ON
circuit
• Short to battery in Fuel metering unit ( Fuel
• Ignition ON Control Unit) control circuit
• EMS ECU supply voltage 8 to 16 V • Faulty Fuel metering unit ( Fuel Control
• Short to battery detected in Fuel metering Unit)
unit ( Fuel Control Unit) control circuit • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Ignition Off/On
EMS - EDC17C55
P0004
E4
+
ECU FUSE
(BMF)
30 A
A E4
V
4
V
E3
4
E35 4 8
30 86
ECU MAIN
RELAY
87 86
E35 6 2
E13 E13 FUEL
R
4
2.5 0.75
15 A METER
R 7 1 G/B
FUEL UNIT
METERING
P/L
0.5
E9 1
2
0.75
G/B
E1 50 89
SIG
RLY COIL
GND
EMS
ECU
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F008_E9
CONNECTOR
NO
1 CONTROL SIGNAL
2 SUPPLY
EMS - EDC17C55
P0004


STEP A – CHECK SHORT TO BATTERY OF FUEL METERING UNIT ( FUEL CONTROL

UNIT) CONTROL WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
• Check voltage between pin 1 and battery negative
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of Fuel metering

• Suspect Fuel metering unit ( Fuel Control
unit ( Fuel Control Unit) control wire with
Unit) internal failure
battery positive
• Replace fuel control unit with a new one
EMS - EDC17C55
P0003
10.41 P0003 — METERING UNIT OUTPUT SHORT CIRCUIT TO GROUND

ERROR
The component driver for the metering unit regulates the opening and closing of the metering
unit based on the rail pressure set point and the actual value. Metering unit controls the fuel
flow to the high pressure pump.

NORMAL OPERATION
• Ignition ON
circuit
• Ignition ON • Short to ground in Fuel metering unit ( Fuel
Control Unit) control wire
• Fuel metering unit ( Fuel Control Unit) faulty
• Short to ground detected in metering unit
control circuit. • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Ignition Off/On
EMS - EDC17C55
P0003
E4
+
ECU FUSE
(BMF)
30 A
A E4
V
4
V
E3
4
E35 4 8
30 86
ECU MAIN
RELAY
87 86
E35 6 2
E13 E13 FUEL
R
4
2.5 0.75
15 A METER
R 7 1 G/B
FUEL UNIT
METERING
P/L
0.5
E9 1
2
0.75
G/B
E1 50 89
SIG
RLY COIL
GND
EMS
ECU
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F008_E9
CONNEC-
TOR NO
1 CONTROL SIGNAL
2 SUPPLY
EMS - EDC17C55
P0003


STEP A – CHECK SHORT TO BATTERY GROUND OF FUEL METERING UNIT ( FUEL

CONTROL UNIT) CONTROL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of Fuel metering • Suspect the Fuel metering unit ( Fuel
unit ( Fuel Control Unit) control wire with Control Unit) internal failure
battery ground • Replace the Fuel metering unit ( Fuel
• Replace the wiring harness Control Unit) with a new one
• Clear the DTC and verify • Check and verify for any new DTC’s
EMS - EDC17C55
P1652
10.42 P1652 — MIL NO LOAD ERROR (PIKUP)

10.42.1 MIL LAMP
MIL lamp will illuminate whenever the emission related faults are detect in the EMS ECU

NORMAL OPERATION
• Ignition ON
• MIL lamp will ON for 02 seconds and will
get switched OFF if no error is set in the
ECU. • Open circuit of MIL lamp
DTC DETECTING CONDITIONS • Short to battery / ground
• Ignition ON • Faulty wiring harness
• The MIL lamp does not glow/ON • Faulty EMS ECU
DTC REACTIONS
• No MIL lamp in the cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1652
10.42.2 CIRCUIT SCHEMATIC
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
E13 0.5
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1652
10.42.3 CONNECTOR VIEWS AND INFORMATION
E1 - EMS ECU B1 - CLUSTER
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNECTOR CONNECTOR
PIN NO FUNCTION
DESCRIPTION NO
INSTRUMENT CLUSTER
(10P) B1 07 SIGNAL
• Turn ON ignition and initialise i-SMART tool

• Record DTC and clear
• Turn OFF ignition, then turn ON
• Proceed to DIAGNOSTIC PROCEDURE, if P1652 is present

• Poor mating of the connector halves/damage of connector lock
EMS - EDC17C55
P1652
STEP A – CHECK OPEN CIRCUIT OF MIL SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Instrument cluster connector (B1) DISCONNECTED
TEST PROCEDURE
• Check resistance between pin 07 of B1 and pin 90 of E1
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of MIL signal wire

STEP B– CHECK SHORT CIRCUIT TO GROUND OF MIL SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of MIL signal wire

with ground
• GO TO STEP C • Replace the wiring harness
EMS - EDC17C55
P1652
STEP C– CHECK SHORT CIRCUIT TO BATTERY OF MIL SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check voltage between pin 07 of B1 and ground
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK

with battery supply
STEP D– CHECK MIL LAMP
PRE CONDITION
• Ignition ON
• Coolant temperature sensor connector (E26) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
• MIL glow
ACTION TO BE TAKEN
OK NOT OK
• Check the instrument cluster /ECU • Replace the Instrument cluster with new
connector for damage or Oxidation one
• Clear the DTC and verify • If problem is still present , replace EMS
ECU
EMS - EDC17C55
P1652
10.43 P1652 — MIL NO LOAD ERROR (PIKUP EXTRA LONG)

10.43.1 MIL LAMP

NORMAL OPERATION
• Ignition ON
• The MIL lamp does not glow • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Fault absent

IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP

ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1652
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNECTOR CONNECTOR
PIN NO FUNCTION
DESCRIPTION NO
INSTRUMENT CLUSTER
(32P) B1 15 SIGNAL


EMS - EDC17C55
P1652
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

with ground
EMS - EDC17C55
P1652
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check voltage between pin 15 of B1 and battery negative
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK

with battery supply
STEP D– CHECK MIL LAMP
PRE CONDITION
• Ignition ON
TEST PROCEDURE
• Coolant temperature sensor connector (E26) DISCONNECTED
ACCEPTANCE CRITERIA
• MIL glow
ACTION TO BE TAKEN
OK NOT OK
• Check the instrument cluster /ECU • Replace the Instrument cluster with new
connector for damage or Oxidation one
• Clear the DTC and verify • If problem is still present , replace EMS
ECU
EMS - EDC17C55
P1653
10.44 P1653 — MIL OVER TEMPERATURE ERROR (PIKUP)

10.44.1 MIL LAMP

NORMAL OPERATION
• Ignition ON
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1653
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
0.5
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1653
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNEC-
TOR NO
INSTRUMENT CLUSTER (10P) B1 07 SIGNAL


EMS - EDC17C55
P1653
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

with ground
EMS - EDC17C55
P1653
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Check the instrument cluster /ECU • Examine the short circuit of MIL signal wire
connector for damage or Oxidation with battery supply
• Clear the DTC and verify • Replace the wiring harness
EMS - EDC17C55
P1653
10.45 P1653 — MIL OVER TEMPERATURE ERROR ( PIKUP EXTRA LONG)

10.45.1 MIL LAMP

NORMAL OPERATION
• Ignition ON
DTC REACTIONS
HEALING CONDITION
• Fault absent

IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP

ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1653
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNECTOR CONNECTOR
PIN NO FUNCTION
DESCRIPTION NO
INSTRUMENT CLUSTER
(32P) B1 15 SIGNAL


EMS - EDC17C55
P1653
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

with ground
EMS - EDC17C55
P1653
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
EMS - EDC17C55
P1650
10.46 P1650 — MIL SHORT CIRCUIT TO BATTERY ERROR (PIKUP)

10.46.1 MIL LAMP

NORMAL OPERATION
• Ignition ON
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1650
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
E13 0.5
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1650
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNECTOR
NO
INSTRUMENT CLUSTER
(10P) B1 07 SIGNAL


EMS - EDC17C55
P1650
STEP A– CHECK SHORT CIRCUIT TO BATTERY OF MIL SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
EMS - EDC17C55
P1650
10.47 P1650 — MIL SHORT CIRCUIT TO BATTERY ERROR (PIKUP EXTRA

LONG)
10.47.1 MIL LAMP

NORMAL OPERATION
• Ignition ON
DTC REACTIONS
HEALING CONDITION
• Fault absent

IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP

ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1650
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNEC-
TOR NO


EMS - EDC17C55
P1650
STEP A– CHECK SHORT CIRCUIT TO BATTERY OF MIL SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check voltage between pin 15 of B1 and battery p
ACCEPTANCE CRITERIA
• Voltage = V batt
ACTION TO BE TAKEN
OK NOT OK
EMS - EDC17C55
P1651
10.48 P1651 — MIL SHORT CIRCUIT TO GROUND ERROR (PIKUP)

10.48.1 MIL LAMP

NORMAL OPERATION
• Ignition ON
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1651
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
0.5
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1651
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNECTOR
NO
INSTRUMENT CLUSTER
(10P) B1 07 SIGNAL


EMS - EDC17C55
P1651
STEP A– CHECK SHORT CIRCUIT TO GROUND OF MIL SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
connector for damage or Oxidation with ground
EMS - EDC17C55
P1651
10.49 P1651 — MIL SHORT CIRCUIT TO GROUND ERROR (PIKUP EXTRA

LONG)
10.49.1 MIL LAMP

NORMAL OPERATION
• Ignition ON
DTC REACTIONS
HEALING CONDITION
• Fault absent

IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP

ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1651
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNECTOR
NO
INSTRUMENT CLUSTER
(32P) B1 15 SIGNAL


EMS - EDC17C55
P1651
STEP A– CHECK SHORT CIRCUIT TO GROUND OF MIL SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
connector for damage or Oxidation with ground
EMS - EDC17C55
P0238
10.50 P0238 — SRC HIGH FOR CHARGED AIR COOLER PRESSURE

(DOWN STREAM)
10.50.1 Air Mass Sensor (Boost Pressure Sensor)
The Air Mass Sensor (Boost Pressure Sensor) is mounted on the Intake manifold. The boost
pressure signal is continuously monitored by EMS ECU. This signal is used as a feedback for
the control of EGR.

NORMAL OPERATION
• Ignition ON
from Air Mass Sensor (Boost Pressure
Sensor) and is within the range
• Short in Air Mass Sensor (Boost Pressure
DTC DETECTING CONDITIONS Sensor) signal and supply wire
• Ignition ON • Short to battery in Air Mass Sensor (Boost
• EMS ECU supply voltage 8 to 16 V Pressure Sensor) circuit
• The output voltage signal received from the • Open in Air Mass Sensor (Boost Pressure
Air Mass Sensor (Boost Pressure Sensor) is Sensor) signal and ground wire
above the maximum limit • Faulty Air Mass Sensor (Boost Pressure
DTC REACTIONS Sensor)
• MIL lamp continuously ON • Faulty EMS ECU
• EGR switches off
• Default boost pressure values taken
HEALING CONDITION
• Ignition Off/On
EMS - EDC17C55
P0238
AIR
EMS
MASS
ECU
87 SENSOR
0.5 2 SIG
SIG
Y/L
78
GND
0.5 1 GND
BR/W
56 4 SIG
SIG
0.5
Y/L
35 3
SUP 0.5
5V
E1 O/L E8
SUP 5V
E1 - EMS ECU E8 - AIR MASS SENSOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4
P1A01F001_E1 P1A01F007_E8
CONNECTOR
NO
35 POWER
78 GROUND
EMS ECU E1
56 SIGNAL-AIR MASS
87 SIGNAL-AIR TEMP.
1 GROUND
Air Mass Sensor (Boost Pressure 2 SIGNAL-AIR TEMP.
Sensor) E8
3 POWER
4 SIGNAL-AIR MASS
EMS - EDC17C55
P0238


STEP A – CHECK SHORT CIRCUIT TO BATTERY OF AIR MASS SENSOR (BOOST

PRESSURE SENSOR) SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Air Mass Sensor (Boost Pressure Sensor) wiring harness connector (E8)
DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage > 5.25 V
ACTION TO BE TAKEN
EMS - EDC17C55
P0238
OK NOT OK
• Examine the short circuit of Air Mass

Sensor (Boost Pressure Sensor) supply
wire with battery positive
• GO TO STEP B • Clear the DTC and verify
• If the DTC still exists, replace the EMS
ECU with a new one
STEP B – CHECK SHORT CIRCUIT BETWEEN POWER AND SIGNAL WIRES OF AIR
MASS SENSOR (BOOST PRESSURE SENSOR)
PRE CONDITION
• Ignition OFF
DISCONNECTED
• EMS ECU wiring harness connector (C 8) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of Air Mass

Sensor (Boost Pressure Sensor) supply and
signal wires
• GO TO STEP C
EMS - EDC17C55
P0238
STEP C – CHECK OPEN CIRCUIT OF AIR MASS SENSOR (BOOST PRESSURE SENSOR)
SIGNAL AND GROUND WIRE
PRE CONDITION
• Ignition OFF
DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine Air Mass Sensor (Boost Pressure • Examine the open circuit of Air Mass
Sensor) internal failure Sensor (Boost Pressure Sensor) signal wire
• Replace Air Mass Sensor (Boost Pressure and/or ground wire
Sensor) with a new one • Replace the wiring harness
• Clear and verify for any new DTC’s • Clear the DTC and verify
EMS - EDC17C55
P0237
10.51 P0237 — SRC LOW FOR CHARGED AIR COOLER PRESSURE

(DOWN STREAM)
10.51.1 AIR MASS SENSOR (BOOST PRESSURE SENSOR)
The Air Mass Sensor (Boost Pressure Sensor) is mounted on the Intake manifold. The boost
pressure signal is continuously monitored by EMS ECU. This signal is used as a feedback for
the control of EGR.

NORMAL OPERATION
• Ignition ON
from Air Mass Sensor (Boost Pressure
Sensor) and is within the range.
• Short to ground of Air Mass Sensor (Boost
• Ignition ON Pressure Sensor) supply wire
• EMS ECU supply voltage 8 to 16 V • Open in Air Mass Sensor (Boost Pressure
• The output voltage signal received from the Sensor) supply wire
Air Mass Sensor (Boost Pressure Sensor) is • Faulty Air Mass Sensor (Boost Pressure
below the minimum limit Sensor)
DTC REACTIONS • Faulty EMS ECU
• EGR switches off
• Default boost pressure values taken
HEALING CONDITION
• Ignition Off/On
AIR
EMS
MASS
ECU
87 SENSOR
0.5 2 SIG
SIG
Y/L
78
GND
0.5 1 GND
BR/W
56 4 SIG
SIG
0.5
Y/L
35 3
SUP 0.5
5V
E1 O/L E8
SUP 5V
EMS - EDC17C55
P0237
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4
P1A01F001_E1 P1A01F007_E8
CONNECTOR
NO
35 POWER
78 GROUND
EMS ECU E1
56 SIGNAL-AIR MASS
87 SIGNAL-AIR TEMP.
1 GROUND
Air Mass Sensor (Boost Pressure 2 SIGNAL-AIR TEMP.
Sensor) E8
3 POWER
4 SIGNAL-AIR MASS


EMS - EDC17C55
P0237
STEP A – CHECK SHORT TO GROUND OF AIR MASS SENSOR (BOOST PRESSURE

SENSOR) POWER AND SIGNAL WIRE
PRE CONDITION
• Ignition OFF
DISCONNECTED
• EMS ECU harness connector (E1) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of sensor power/

signal wires
STEP B – OPEN CIRCUIT OF BOOST PRESSURE SIGNAL WIRE
PRE CONDITION
• Ignition OFF
DISCONNECTED
• EMS ECU harness connector (E1) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P0237
OK NOT OK
• Examine the open circuit of pressure

signal wire
STEP C – CHECK OPEN CIRCUIT OF AIR MASS SENSOR (BOOST PRESSURE SENSOR)
POWER WIRE
PRE CONDITION
• Ignition OFF
DISCONNECTED
• EMS ECU wiring harness connector (E1)DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance < 1 Ω
ACTION TO BE TAKEN
OK NOT OK
• Replace Air Mass Sensor (Boost Pressure • Examine the open circuit of Air Mass
Sensor) Sensor (Boost Pressure Sensor) power wire
• If problem is still exists, replace EMS ECU • Replace the wiring harness
with a new one • Clear the DTC and verify
EMS - EDC17C55
P0627
10.52 P0627 — PSP OPEN LOAD ERROR

10.52.1 FUEL FEED PUMP
The Fuel feed pump (Intank pump)is located inside the fuel tank. Intank pump is controlled by
Fuel pump relay which inturn is controlled by EMS ECU It supplies fuel to Fuel metering unit (
Fuel Control Unit). From the metering unit, the fuel then enters the Fuel Pump, where it gets
compressed and supplied through the high pressure pipes into the common rail and to the
injectors.

NORMAL OPERATION
• Ignition ON
• EMS ECU switches ON the Fuel feed pump
once it receives ignition input
the Fuel feed pump relay control circuit
• Open in Fuel feed pump relay control circuit
• Ignition ON
• Faulty Fuel feed pump relay
• Faulty EMS ECU
• A open load is detected in Fuel feed pump
relay control circuit
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P0627
IC-2 M 1
VEHICLE
IC-2 F 1
LOAD FUSE
IC-3 M 13
IC-3 F 13
E4 1.5 E32 E32 C2 C2
60A
6 15 A 1.5
B Y W 4 14 P/B
4 1
FUEL FEED
PUMP
R/W
1.5
14 IC-2 M
1.5
B
E5 14 IC-2 F
BATTERY 6
4
12V FEED B9
30A
30 87
PUMP
1.5
E3 E4 A
B
RELAY 85 86
B9 2 4
E35 4 8
IC-2 M
IC-2 F
30 86
ECU
RELAY
IC-3 F 3
87 85 IC-3 M 3
2 6 E35 E13 E13
2.5
0.75
B
10A
G/B
25
25
7 1
1.5
CLUSTER
B
LAMP
V/R
0.5
2.5
B
3 IC-3 F
3 IC-3 M
V/R
0.5
P/L
0.5
2.5
R/W
50 69
RLY GND SIG
EMS ECU
E1 - EMS ECU B9 - RELAY
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A00F031_B9
CONNEC-
TOR NO
2 CONTROL SIGNAL
FUEL PUMP RELAY B9
4 SUPPLY

EMS - EDC17C55
P0627


STEP A – CHECK FUNCTIONALITY OF FUEL FEED PUMP RELAY
PRE CONDITION
• Ignition OFF
• Ensure the Fuel feed pump relay is fixed properly in the connector (B9)
• Remove the Fuel feed pump relay
TEST PROCEDURE
• Check the functioning of relay by providing 12V to terminal 86 and ground to terminal 85
ACCEPTANCE CRITERIA
• Clicking sound heard
ACTION TO BE TAKEN
OK NOT OK
• Replace the Fuel feed pump relay with a

• GO TO STEP B new one
EMS - EDC17C55
P0627
STEP B – CHECK OPEN CIRCUIT OF FEED PUMP RELAY SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Check the proper functioning of 15 A fuse
• Ignition ON
TEST PROCEDURE
• Check the voltage between pin 4 of B9 and battery ground
ACCEPTANCE CRITERIA
• voltage = Vehicle battery Voltage
ACTION TO BE TAKEN
OK NOT OK
• Examine the open/short circuit of Fuel feed

pump relay supply wire
STEP C – CHECK OPEN CIRCUIT OF FEED PUMP RELAY CONTROL WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU Wiring harness connector (E1) DISCONNECTED
• Remove the Fuel feed pump relay (B9)
TEST PROCEDURE
• Check the resistance between pin 2 of B9 and pin 69 of E1
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of Fuel feed

• Replace EMS ECU with a new one. pump relay control wire
EMS - EDC17C55
P1611
10.53 P1611 — PSP OVER TEMPERATURE ERROR

pressurized and supplied through the high pressure pipes into the common rail and to the
injectors.

NORMAL OPERATION
• Ignition ON
the Fuel feed pump circuit
• Ignition ON
• Faulty EMS ECU
• Overheating detected in EMS ECU power
stage
DTC REACTIONS
HEALING CONDITION
• Fault absent


EMS - EDC17C55
P1611
• Check PSP connector for loose contact

EMS - EDC17C55
P0629
10.54 P0629 — PSP SHORT TO BATTERY ERROR

injectors.

NORMAL OPERATION
• Ignition ON
• Ignition ON
• Faulty EMS ECU
• Short circuit to battery is detected in fuel
feed pump control circuit
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P0629
IC-2 M 1
VEHICLE
IC-2 F 1
LOAD FUSE
IC-3 M 13
IC-3 F 13
E4 1.5 E32 E32 C2 C2
60A
6 15 A 1.5
B Y W 4 14 P/B
4 1
FUEL FEED
PUMP
R/W
1.5
14 IC-2 M
1.5
B
E5 14 IC-2 F
BATTERY 6
4
12V FEED B9
30A
30 87
PUMP
1.5
E3 E4 A
B
RELAY 85 86
B9 2 4
E35 4 8
IC-2 M
IC-2 F
30 86
ECU
RELAY
IC-3 F 3
87 85 IC-3 M 3
2 6 E35 E13 E13
2.5
0.75
B
10A
G/B
25
25
7 1
1.5
CLUSTER
B
LAMP
V/R
0.5
2.5
B
3 IC-3 F
3 IC-3 M
V/R
0.5
P/L
0.5
2.5
R/W
50 69
RLY GND SIG
EMS ECU
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A00F031_B9
CONNEC-
TOR NO
B9 2 CONTROL SIGNAL
FUEL PUMP RELAY
B9 4 SUPPLY

EMS - EDC17C55
P0629


STEP A – CHECK FUNCTIONALITY OF FUEL FEED PUMP RELAY
PRE CONDITION
• Ignition OFF
• Ensure the Fuel feed pump relay is fixed properly in the connector (B9)
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace the Fuel feed pump relay with a

• GO TO STEP B new one
EMS - EDC17C55
P0629
STEP B– CHECK SHORT CIRCUIT TO BATTERY OF FEED PUMP RELAY CONTROL

WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU Wiring harness connector (E1) DISCONNECTED
• Remove the Fuel feed pump relay (B9)
• Ignition ON
TEST PROCEDURE
• Check voltage between pin 69 of E1 and battery ground
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Replace the Fuel feed pump relay with a • Examine the short circuit of Fuel feed
new one pump relay control wire
• Replace EMS ECU with a new one. • Replace the wiring harness
EMS - EDC17C55
P0628
10.55 P0628 — PSP SHORT TO GROUND ERROR

injectors.

NORMAL OPERATION
• Ignition ON
• Ignition ON • Short to ground in Fuel feed pump control
• EMS ECU supply voltage 8 - 16 V wire
• Short to ground is detected in fuel feed • Faulty Fuel feed pump

pump control circuit • Faulty EMS ECU
DTC REACTIONS
• Fuel pump continuously ON
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P0628
IC-2 M 1
VEHICLE
IC-2 F 1
LOAD FUSE
IC-3 M 13
IC-3 F 13
E4 1.5 E32 E32 C2 C2
60A
6 15 A 1.5
B Y W 4 14 P/B
4 1
FUEL FEED
PUMP
R/W
1.5
14 IC-2 M
1.5
B
E5 14 IC-2 F
BATTERY 6
4
12V FEED B9
30A
30 87
PUMP
1.5
E3 E4 A
B
RELAY 85 86
B9 2 4
E35 4 8
IC-2 M
IC-2 F
30 86
ECU
RELAY
IC-3 F 3
87 85 IC-3 M 3
2 6 E35 E13 E13
2.5
0.75
B
10A
G/B
25
25
7 1
1.5
CLUSTER
B
LAMP
V/R
0.5
2.5
B
3 IC-3 F
3 IC-3 M
V/R
0.5
P/L
0.5
2.5
R/W
50 69
RLY GND SIG
EMS ECU
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A00F031_B9
CONNEC-
TOR NO
FUEL PUMP RELAY B9 2 CONTROL SIGNAL

EMS - EDC17C55
P0628


STEP A – CHECK SHORT CIRCUIT TO GROUND OF FUEL PUMP RELAY CONTROL

WIRE
PRE CONDITION
• Ignition OFF
• Remove the Fuel pump relay
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance =∞Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of fuel pump

• Replace EMS ECU with a new one. relay control signal wire with ground
EMS - EDC17C55
P0193
10.56 P0193 — SRC FOR RAIL PRESSURE SENSOR ABOVE MAXIMUM

LIMIT
10.56.1 RAIL PRESSURE SENSOR
The rail pressure sensor is mounted on the common rail and is used to measure the rail
pressure. The EMS ECU determine the optimum fuel injection quantity at specific engine
condition based on rail pressure sensor

NORMAL OPERATION
• Ignition ON
from rail pressure sensor and is within the
range.
DTC DETECTING CONDITIONS • Short to battery in rail pressure sensor
circuit
• Ignition ON
• Short in rail pressure sensor signal and
• EMS ECU supply voltage 8 to 16 V supply wire
• The output voltage signal received from the • Open in rail pressure sensor ground circuit
rail pressure sensor is above the maximum
limit. • Faulty rail pressure sensor
DTC REACTIONS • Faulty EMS ECU
HEALING CONDITION
• Ignition Off/On
EMS RAIL PRESSURE

ECU SENSOR
E12
76
0.5
GND
GROUND
P/B 1
54
0.5
SIG
SIGNAL
W/O 2
32
0.5
SUP
SUPPLY_5V
SB
5V
E1 3
EMS - EDC17C55
P0193
E1 - EMS ECU E12 - RAIL PRESSURE SENSOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3
P1A01F001_E1 P1A01F011_E12
CONNEC-
TOR NO
32 POWER
EMS ECU E1 76 GROUND
54 SIGNAL
3 POWER
RAIL PRESSURE SENSOR E12 1 GROUND
2 SIGNAL


EMS - EDC17C55
P0193
STEP A – CHECK VOLTAGE OF RAIL PRESSURE SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Rail pressure sensor wiring harness connector (E12) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5±0.25 V
ACTION TO BE TAKEN
OK NOT OK
• Examine the open/short to battery of Rail

pressure sensor power wire
STEP B – CHECK SHORT CIRCUIT BETWEEN POWER AND SIGNAL WIRE OF RAIL
PRESSURE SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of rail pressure

sensor power and signal wires
EMS - EDC17C55
P0193
STEP C– CHECK OPEN CIRCUIT OF RAIL PRESSURE SENSOR SIGNAL AND GROUND
WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine rail pressure sensor internal • Examine the open circuit of rail pressure
failure sensor supply and signal wires
• Replace rail pressure sensor with a new • Replace the wiring harness
one
EMS - EDC17C55
P0192
10.57 P0192 — SRC FOR RAIL PRESSURE SENSOR BELOW MINIMUM

LIMIT
pressure. The EMS ECU determines the optimum fuel injection quantity at specific engine
condition based on rail pressure sensor.

NORMAL OPERATION
• Ignition ON
from rail pressure sensor and is within the
range.
• Ignition ON • `Short circuit in rail pressure sensor signal
• EMS ECU supply voltage 8 to 16 V and ground
• The output voltage signal received from the • Faulty rail pressure sensor
rail pressure sensor is below the minimum • Faulty EMS ECU
limit.
DTC REACTIONS
HEALING CONDITION
EMS RAIL PRESSURE

ECU SENSOR
E12
76
0.5
GND
GROUND
P/B 1
54
0.5
SIG
SIGNAL
W/O 2
32
0.5
SUP
SUPPLY_5V
SB
5V
E1 3
EMS - EDC17C55
P0192
E1 - EMS ECU E12 - RAIL PRESSURE SENSOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3
P1A01F001_E1 P1A01F011_E12
CONNEC-
TOR NO
32 POWER
54 SIGNAL
3 POWER
RAIL PRESSURE SENSOR E12 1 GROUND
2 SIGNAL


EMS - EDC17C55
P0192
STEP A – CHECK SHORT TO GROUND 0F RAIL PRESSURE SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Rail pressure sensor wiring harness connector ( E12) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Suspect rail pressure sensor internal • Examine the short circuit of rail pressure
failure sensor supply wire with ground
• Replace rail pressure sensor with a new • Replace the wiring harness
one. • Clear the DTC and verify
EMS - EDC17C55
P0191
10.58 P0191 — RAIL PRESSURE OFFSET VALUE ABOVE MAXIMUM LIMIT


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


EMS - EDC17C55
P0191
STEP A – CHECK THE FUEL RETURN LINE

• Ignition OFF
• Check and rectify if any kinks/blockage noticed in the fuel return line
• If the DTC still exits replace the rail pressure sensor with a new one.
EMS - EDC17C55
P1191
10.59 P1191 — RAIL PRESSURE OFFSET VALUE ABOVE MINIMUM LIMIT


NORMAL OPERATION
• Ignition ON
• During after run the EMS ECU monitors the
raw value of the rail pressure and is within
the limits.
• Ignition ON
• EMS ECU supply voltage 8 - 16 V • Faulty rail pressure sensor
• The raw value of the rail pressure sensor is
below the minimum set point during after run
DTC REACTIONS
• Torque limitations in net ignition cycle
HEALING CONDITION


EMS - EDC17C55
P1191
STEP A – CHECK RAIL PRESSURE SENSOR

• Examine Rail pressure sensor
• Replace the rail pressure sensor with a new one
EMS - EDC17C55
P2123
10.60 P2123 — SRC FOR APP PEDAL SENSOR 1 ABOVE MAXIMUM LIMIT
10.60.1 ACCELERATOR PEDAL PLAUSIBILITY
The Accelerator pedal module (APM) is mounted in the accelerator pedal and is connected to
the ECU by wires. The module consists of two potentiometers. EMS ECU receives the signals
from both the potentiometers and compares them for plausibility . If the difference between
both the signals goes beyond the maximum range then it is taken as a failure.

NORMAL OPERATION
• Ignition ON
from the accelerator pedal module sensor 1
and is within the specified range
• Short /open in accelerator pedal module
• Ignition ON sensors 1 circuit
• The output voltage signal received from the • Faulty accelerator pedal module
accelerator pedal module sensor 1 is above
the maximum limit. • Faulty EMS ECU
DTC REACTIONS
• Torque Limitation
HEALING CONDITION
• Ignition off / on
EMS - EDC17C55
P2123
ACCELERATOR
EMS
6 IC-1 M
PEDAL
6 IC-1 F
MODULE ECU
SIGNAL 4 0.5 0.5 61
SIGNAL
W/R W/R
GROUND
3 0.5 0.5 83
GROUND
BR/B BR/B
5
5
2 0.5 0.5 18
SUPPLY_5V
R/Y R/Y
4
4
SUPPLY_5V
SIGNAL
6 0.5 0.5 60
SIGNAL
3
P P
3
GROUND
0.5 0.5 82
5
GROUND
O/W O/W
2
2
1 0.5 0.5 40
SUPPLY_5V SUPPLY_5V
R/B R/B
1
1
B21 E1
E1 - EMS ECU B21 - ACC PEDA L SENSOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
1 2 3 4 5 6
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A00F013_B21
EMS - EDC17C55
P2123
CONNEC-
TOR NO
18 POWER
83 GROUND
2 POWER
APP1 B21 4 SIGNAL
3 GROUND


STEP A – CHECK VOLTAGE IN APP1 SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Accelerator pedal wiring harness connector (B21) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage > 5.25V
EMS - EDC17C55
P2123
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of APP 1 power

• Repair/Replace the wiring harness
ECU with a new one
STEP B – CHECK SHORT CIRCUIT BETWEEN SIGNAL AND SUPPLY WIRES OF APP1
PRE CONDITION
• Ignition OFF
• EMS ECU (E1) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 2 and 4 of B21
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of APP1 power

and signal wires
STEP C– CHECK OPEN CIRCUIT OF APP1 SIGNAL AND GROUND WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
EMS - EDC17C55
P2123
ACCEPTANCE CRITERIA
• Resistance < 1Ω?
ACTION TO BE TAKEN
OK NOT OK
• Examine accelerator pedal sensor 1 • Examine the open circuit of accelerator

internal failure pedal sensor 1 signal wire and/or ground
• Replace accelerator pedal with a new one wire
EMS - EDC17C55
P2128
10.61 P2128 — SRC FOR APP PEDAL SENSOR 2 ABOVE MAXIMUM LIMIT
the ECU by wires. The module consists of two potentiometers. EMS ECU receives the signals
from both the potentiometers and compares them for plausibility . If the difference between
both the signals goes beyond the maximum range then it is taken as a failures

NORMAL OPERATION
• Ignition ON
from the accelerator pedal module sensor 2
and is within the specified range
• Ignition ON • Short /open in accelerator pedal module
sensors 2 circuit
accelerator pedal module sensor 2 is above • Faulty accelerator pedal module
the maximum limit. • Faulty EMS ECU
DTC REACTIONS
• Torque Limitation
HEALING CONDITION
• Fault absent continuously for 3 driving
cycles
EMS - EDC17C55
P2128
ACCELERATOR
EMS
6 IC-1 M
PEDAL
6 IC-1 F
MODULE ECU
SIGNAL 4 0.5 0.5 61
SIGNAL
W/R W/R
GROUND
3 0.5 0.5 83
GROUND
BR/B BR/B
5
5
2 0.5 0.5 18
SUPPLY_5V
R/Y R/Y
4
4
SUPPLY_5V
SIGNAL
6 0.5 0.5 60
3 SIGNAL
P P
3
GROUND
0.5 0.5 82
5
GROUND
O/W O/W
2
2
1 0.5 0.5 40
SUPPLY_5V SUPPLY_5V
R/B R/B
1
1
B21 E1
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
1 2 3 4 5 6
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A00F013_B21
EMS - EDC17C55
P2128
CONNECTOR
NO
40 POWER
82 GROUND
1 POWER
APP2 B21 6 SIGNAL
5 GROUND


STEP A – CHECK VOLTAGE IN APP2 SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage > 5.25V
EMS - EDC17C55
P2128
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of APP2 supply

ECU with a new one
STEP B – CHECK SHORT CIRCUIT BETWEEN SIGNAL AND POWER WIRES OF APP 2
PRE CONDITION
• Ignition OFF
• Accelerator pedal wiring harness connector (E 21) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of APP 2 signal

and power wires
STEP C– CHECK OPEN CIRCUIT OF APP2 SIGNAL AND GROUND WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
EMS - EDC17C55
P2128
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine APP2 internal failure • Examine the open circuit of APP2 signal
wire and/or ground wire
• Replace accelerator pedal with a new one
EMS - EDC17C55
P2138
10.62 P2138 — PLAUSIBILITY ERROR BETWEEN APP SIGNAL 1 AND

SIGNAL 2
the ECU by wires. The function checks both the acceleration pedal signals for plausibility and
makes the test result. The ECU also checks the ratio of both the signals. If the difference
between both the signals goes beyond the maximum range then it is taken as a failure.

NORMAL OPERATION
• Ignition ON
• EMS ECU compares both APP 1 and APP
2 signals and the difference is within the
maximum range
• Ignition ON • Short /open in accelerator pedal module
• EMS ECU supply voltage 8 - 16 V sensors circuit
• The difference between APP1 and APP2 • Faulty accelerator pedal module
signals is more than the maximum range • Faulty EMS ECU
DTC REACTIONS
• Engine rpm limited to 1200 .Vehicle in limp
home mode
HEALING CONDITION
• Ignition Off/On
EMS - EDC17C55
P2138
ACCELERATOR
EMS
6 IC-1 M
PEDAL
6 IC-1 F
MODULE ECU
SIGNAL 4 0.5 0.5 61
SIGNAL
W/R W/R
GROUND
3 0.5 0.5 83
GROUND
BR/B BR/B
5
5
2 0.5 0.5 18
SUPPLY_5V
R/Y R/Y
4
4
SUPPLY_5V
SIGNAL
6 0.5 0.5 60
SIGNAL
3
P P
3
GROUND
0.5 0.5 82
5
GROUND
O/W O/W
2
2
1 0.5 0.5 40
SUPPLY_5V SUPPLY_5V
R/B R/B
1
1
B21 E1
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
1 2 3 4 5 6
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A00F013_B21
EMS - EDC17C55
P2138
CONNECTOR
NO
18 POWER
61 SIGNAL
83 GROUND
EMS ECU E1
40 POWER
60 SIGNAL
83 GROUND
2 POWER
APP1 B21 4 SIGNAL
3 GROUND
1 POWER
APP2 B21 6 SIGNAL
5 GROUND


EMS - EDC17C55
P2138
STEP A – CHECK VOLTAGE IN APP 1 POWER WIRE
PRE CONDITION
• Ignition OFF
• Accelerator Pedal module wiring harness connector (B21) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5±0.25V
ACTION TO BE TAKEN
OK NOT OK
• Examine the short to battery of APP 1

power wire
STEP B – CHECK OPEN CIRCUIT OF APP 1 SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU wiring harness connector(E1) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance >1Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of APP 1 signal

wire
EMS - EDC17C55
P2138
STEP C — CHECK VOLTAGE IN APP 2 POWER WIRE
PRE CONDITION
• Ignition OFF
• Accelerator Pedal module wiring harness connector (B21) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5±0.25V
ACTION TO BE TAKEN
OK NOT OK
• Examine the short to battery of APP 2

power wire
STEP D – CHECK OPEN CIRCUIT OF APP 2 SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU wiring harness connector ( E1) CONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of APP 2 signal

wire
EMS - EDC17C55
P2138
STEP E – CHECK SHORT CIRCUIT TO GROUND OF APP 1 SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU wiring harness connector ( E1) CONNECTED
TEST PROCEDURE
• Check the resistance between pin 4 and battery ground
ACCEPTANCE CRITERIA
• Resistance = ∞Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of APP1 signal

wire with battery
• GO TO STEP F • Replace the wiring harness
STEP F – CHECK SHORT CIRCUIT TO GROUND OF AAP 2 SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 6 and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of APP 2 signal

• Examine APP internal failure
wire with battery
• Replace APP with a new one
EMS - EDC17C55
P1138
10.63 P1138 — ACC PEDAL PLAUSIBLE CHECK WITH THE BRAKE

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

NORMAL OPERATION
• Ignition ON
• No plausibility between accelerator pedal
and brake input
• Ignition ON
• IMetering unit (MPROP) er mounting of
• EMS ECU supply voltage 8 to 16 V accelerator pedal
• Accelerator pedal and brake inputs are • IMetering unit (MPROP) er adjustment of
available at EMS ECU simultaneously brake switch
• Plausibility between accelerator pedal and • Sticky accelerator pedal
brake input
DTC REACTIONS
• Vehicle goes to limp home mode (i. e
Engine RPM restricted to 1200)
HEALING CONDITION
• Ignition Off/On


EMS - EDC17C55
P1138
• Perform brake switch setting

• Check for proper mounting of accelerator pedal assembly
• Check for any short to battery in the accelerator pedal signal wires
• Check for any short to battery in brake switch circuit
• Check for sticky accelerator pedal assembly. Replace if required
EMS - EDC17C55
P0562
10.63.2 P0562 — SRC FOR BATTERY SENSOR SIGNAL BELOW MINIMUM LIMIT
10.63.2.1 BATTERY
The Electronic Control Unit continuously monitors the battery voltage for its proper functioning.
The normal operating voltage for ECU is 8- 16 V.

NORMAL OPERATION
• Ignition ON
• EMS ECU receives a supply voltage of 8–
16 V.
• Ignition ON • Faulty battery
• The supply voltage to EMS ECU is less • Faulty charging system
than 8 V for few seconds. • Malfunctioning EMS ECU
DTC REACTIONS
• Engine Check lamp will be continuously ON
• EMS ECU switches OFF
HEALING CONDITION
• Ignition Off/On
EMS - EDC17C55
P0562
10.63.2.1.2 CIRCUIT SCHEMATIC
2
2
B 6 6 5 5
60 A
Y Y
IC - 4M
IC - 4F
E-4 Y Y
B32 2
TERM 30 15a 15 50
POS
OFF
30 A
ACC
A E4 IGNITION
START
POS
V
V
30 15a 15 50
4
4
TERM
4 8
E35 B32 1
30 86
ECU MAIN
IC-2 M 23
BRAKE SWITCH
IC-2 F 23
RELAY
+ E1
87 86
2.5 11 5 1.5
6 2 E35 R
15A
G
1.5
E13
G
E13
VACCUM
IC-2 M 25
IC-2 F 25
1 1
MODULATOR
REDUNDANT BRAKE
E13 G G
R
E2 E13
4
E3 2.5 0.75 0.75 0.75 B22 3
SWITCH
15 A B22 1
FUEL
1 SWITCH
2.5
EC4 2
R
0.5
G
FUEL
2.5
E13 8
Y
G/B
0.5
BR
0.5
SB/R
0.5
METER 11 IC-5 F
0.5
P/L
UNIT
11 IC-5 M IC-1 F
20 A
7
IC-1 M 7 8 IC-1 F
0.5
E13 2
G
8 IC-1 M
B23 5
R/W 2.5
12 IC-5 M
BR
0.5
2.5
2 1 E9 12 IC-5 F
13 IC-2 F REFER
13 IC-2 M
STOP
0.75
SB/R
G/B
LAMP
5A
0.5
2.
2.5
CKT
B
R/W
Y/W
0.75
BR
0.5
5
0.5
B
15
B23 1 2 6 4 50 89 G/B 49 80 24
SIG
GND
GND
SIG
I/P I/P RLY COIL SIG
SIG
GND
0.75

R
SUP
GND
CAN CAN
SUP
SIG
SIG
5V
HI LOW
66 65 71 35 56 78 87
0.5
0.5
Y
0.5
Y/L
0.75
W/Y
Y/L
0.5
IC-1 M 10 9
IC-1 F 10 9
BR/W
0.5
O/L
0.5
0.5
0.5
IC-2 M 24
G
Y
0.5 0.5 IC-2 F 24

Y G 3 4 1 2 E8
0.5
Y
0.5
0.5
G
Y
0.75
W/Y
0.5
B34 6 14 B29 2 5
G
AIR MASS SENSOR

R B34
0.5 0.5
B34 5 4 B29 1 8
W/Y W/Y
TERMINATING
1 B65 B1 3
RESISTOR
1.5
W/Y
2 TO CLUSTER
0.5
B
4
B23 30
0.5
Y
ECU
15 A
SUPPLY
B23 40
0.5
Y
0.5
B
2.5
IC-2 M 27
V
IC-2 F 27
0.5 2.5 0.5 0.5

IC-4 M 1
R B B B
IC-4 F 1
2.5
6 6 V
B B
EMS - EDC17C55
P0562
E1 - EMS ECU
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNECTOR
NO
71 SUPPLY
EMS ECU E1 1 GROUND
2 GROUND


EMS - EDC17C55
P0562
STEP A – CHECK VOLTAGE IN BATTERY
PRE CONDITION
• Ignition ON
TEST PROCEDURE
• Check the voltage between battery positive and battery negative terminals.
ACCEPTANCE CRITERIA
• Voltage – 11 to 14.5 V
ACTION TO BE TAKEN
OK NOT OK
• Examine the charging circuit

• Check and confirm the proper functioning
• GO TO STEP B of charging system circuit (Alternator &
Battery)
STEP B – CHECK VOLTAGE IN PIN 71 OF EMS ECU CONNECTOR
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = Battery voltage
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP E • GO TO STEP C
EMS - EDC17C55
P0562
STEP C – CHECK OPEN CIRCUIT OF EMS ECU IGNITION SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Ignition switch wiring harness connector (B 32) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 71 of E1 and pin 15 of B 32
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of EMS ECU

supply wire from ignition switch
STEP D – CHECK SHORT CIRCUIT OF EMS ECU IGNITION SUPPLY WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of EMS ECU

• Examine the battery positive and negative supply wire from ignition switch to ground
cable for any loose connection
EMS - EDC17C55
P0562
STEP E– CHECK OPEN CIRCUIT OF EMS ECU GROUND WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Suspect the EMS ECU malfunction • Examine the open circuit of EMS ECU
• Replace EMS ECU with a new one. ground wires
• Repair/replace the wiring harness
EMS - EDC17C55
P0563
10.64 P0563 — SRC FOR BATTERY SENSOR SIGNAL ABOVE MAXIMUM

LIMIT
10.64.1 BATTERY
EMS ECU continuously monitors the battery voltage . The normal operating voltage for EMS
ECU is 8 –16 V. If the voltage is lesser or greater than the range , then error gets registered.

NORMAL OPERATION
• Ignition ON
• EMS ECU receives a supply voltage of 8 –16 V.
• Ignition ON • Faulty charging system
• The supply voltage to EMS ECU is more than • Malfunctioning EMS ECU
16V for few seconds
DTC REACTIONS
HEALING CONDITION
• Fault absent


EMS - EDC17C55
P0563
STEP A– CHECK BATTERY VOLTAGE
PRE CONDITION
• Ignition ON
• Engine running at high idle
TEST PROCEDURE
• Check the voltage between battery positive and battery negative terminals
ACCEPTANCE CRITERIA
• Voltage >16 V
ACTION TO BE TAKEN
OK NOT OK

of charging system
EMS - EDC17C55
P0501
10.65 P0501 — VEHICLE SPEED SENSOR PLAUSIBILITY ERROR

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

NORMAL OPERATION
• Ignition ON
• When the vehicle is driven , VSS outputs a
pulse signal to the EMS ECU and is within
the range
• Ignition ON
• Clutch is engaged and gear not in neutral • Short /open in Vehicle speed sensor
but the VSS sensor output remains same for • Faulty Vehicle Speed sensor
more than calibrated time
DTC REACTIONS
• All the load dependent functions e. g. FBC,
ZFC are switched off
• Vehicle may feel jerky while driving
• Engine check continuously ON
HEALING CONDITION
• Ignition Off/On
VEHICLE
EMS SPEED
ECU SENSOR
55 2
0.5 GND
GND
BR/R
22 3 SIG
SIG
0.5
L/R
16 0.5 1
I/P 5V
R/G E14
I/P 5V
E1
EMS - EDC17C55
P0501
E1 - EMS ECU E14 - VEHICLE SPEED SENSOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3
P1A01F001_E1 P1A01F012_E14
CONNEC-
TOR NO
16 SUPPLY
55 GROUND
1 SUPPLY
VEHICLE SPEED SENSOR E14 3 SIGNAL
2 GROUND


EMS - EDC17C55
P0501
STEP A – CHECK VOLTAGE IN VEHICLE SPEED SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• VSS wiring harness connector (E14) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 4.75 — 5.25V
ACTION TO BE TAKEN
OK NOT OK
• Examine the open/short to battery of VSS

power wire
STEP B – CHECK OPEN CIRCUIT OF VEHICLE SPEED SENSOR SIGNAL WIRE AND
GROUND WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P0501
OK NOT OK
• Examine the open circuit of the VSS signal

wire and ground wire to EMS ECU
STEP C – CHECK SHORT CIRCUIT TO GROUND OF VEHICLE SPEED SENSOR SIGNAL

WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of the VSS signal

and ground wires
• Examine the short circuit of the VSS signal
• GO TO STEP D and power wires
STEP D – CHECK SHORT CIRCUIT BETWEEN SIGNAL AND POWER WIRES OF

VEHICLE SPEED SENSOR
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
EMS - EDC17C55
P0501
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Suspect faulty VSS • Examine the short circuit of the VSS signal
and power wires
• Replace VSS with a new one
• If problem is still present, replace EMS • Examine the short circuit of the VSS signal
ECU and power wires
EMS - EDC17C55
P0500
10.65.3 P0500 — VEHICLE SPEED OUTPUT OPEN LOAD ERROR

NORMAL OPERATION
• Ignition ON
the range
• Ignition ON
• EMS ECU supply voltage 8 - 16 V • Open circuit in VSS circuit
• VSS sensor output not available • Faulty Vehicle Speed sensor
DTC REACTIONS
HEALING CONDITION
• Ignition Off/On
VEHICLE
EMS SPEED
ECU SENSOR
55 2
0.5 GND
GND
BR/R
22 3 SIG
SIG
0.5
L/R
16 0.5 1
I/P 5V
R/G E14
I/P 5V
E1
EMS - EDC17C55
P0500
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3
P1A01F001_E1 P1A01F012_E14
CONNEC-
TOR NO
16 POWER
55 GROUND
1 POWER
2 GROUND


EMS - EDC17C55
P0500
STEP A– CHECK OPEN CIRCUIT OF VEHICLE SPEED SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• VSS wiring harness (E14) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of VSS signal

wire from EMS ECU
STEP B– CHECK OPEN CIRCUIT OF VEHICLE SPEED SENSOR GROUND WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P0500
OK NOT OK
• Suspect faulty VSS • Examine the open circuit of the VSS signal
• Replace VSS with a new one
• If problem is still present, replace EMS • Replace the wiring harness
ECU • Clear the DTC and verify
EMS - EDC17C55
P0503
10.65.5 P0503 —VEHICLE SPEED OUTPUT SHORT TO BATTERY ERROR

NORMAL OPERATION
• Ignition ON
the range
• Ignition ON
• EMS ECU supply voltage 8 - 16 V • Short to battery in VSS circuit
DTC REACTIONS
HEALING CONDITION
• Ignition Off/On
VEHICLE
EMS SPEED
ECU SENSOR
55 2
0.5 GND
GND
BR/R
22 3 SIG
SIG
0.5
L/R
16 0.5 1
I/P 5V
R/G E14
I/P 5V
E1
EMS - EDC17C55
P0503
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3
P1A01F001_E1 P1A01F012_E14
CONNEC-
TOR NO
16 SUPPLY
55 GROUND
1 SUPPLY
2 GROUND


EMS - EDC17C55
P0503
STEP A – CHECK SHORT TO BATTERY OF VEHICLE SPEED SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the voltage between pin 22 of E1 and Battery negative
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of the VSS signal

STEP B – CHECK OPEN CIRCUIT OF VEHICLE SPEED SENSOR GROUND WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace VSS with a new one • Examine the open circuit of the VSS
• If problem is still present, replace EMS ground wire to EMS ECU
ECU • Replace the wiring harness
EMS - EDC17C55
P0502
10.65.7 P0502 —VEHICLE SPEED OUTPUT SHORT TO GROUND ERROR

NORMAL OPERATION
• Ignition ON
the range
• Ignition ON
• EMS ECU supply voltage 8 - 16 V • Short to ground in VSS circuit
DTC REACTIONS
HEALING CONDITION
• Ignition Off/On
VEHICLE
EMS SPEED
ECU SENSOR
55 2
0.5 GND
GND
BR/R
22 3 SIG
SIG
0.5
L/R
16 0.5 1
I/P 5V
R/G E14
I/P 5V
E1
EMS - EDC17C55
P0502
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3
P1A01F001_E1 P1A01F012_E14
CON-
CONNECTOR DESCRIPTION NECTOR PIN NO FUNCTION
NO
16 SUPPLY
55 GROUND
1 SUPPLY
2 GROUND


EMS - EDC17C55
P0502
STEP A – CHECK SHORT TO GROUND OF VEHICLE SPEED SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 22 of E1 and ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short to ground of the VSS

signal wire
STEP B – CHECK OPEN CIRCUIT OF VEHICLE SPEED SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance < Ω
ACTION TO BE TAKEN
OK NOT OK
• Replace VSS with a new one • Examine the open circuit of the VSS signal
• If problem is still present, replace EMS wire and ground
EMS - EDC17C55
P0641
10.66 P0641 — SENSOR SUPPLY VOLTAGE1 MONITORING ERROR

10.66.1 SENSOR SUPPLY VOLTAGE1 MONITORING
EMS ECU monitors the reference voltage of the Air Mass Sensor (Boost Pressure Sensor) ,
Rail pressure sensor, Clutch sensor, Vehicle speed sensor and Camshaft sensor and registers
a DTC if the voltage is not within the range

NORMAL OPERATION
• Ignition ON
• EMS ECU monitors the reference voltage of
the Air Mass Sensor (Boost Pressure
Sensor) ,Rail pressure sensor, Clutch sensor,
Vehicle speed sensor and Camshaft sensor
and are within the range
• Ignition ON • Short to ground /battery of supply wire of Air
Mass Sensor (Boost Pressure Sensor) , Rail
• EMS ECU supply voltage 8 to 16 V pressure sensor, Clutch sensor, Vehicle
• The sensor supply voltage of Air Mass speed sensor and Camshaft sensor
Sensor (Boost Pressure Sensor) , Rail • Faulty sensors (as listed above)
pressure sensor, Clutch sensor, Vehicle
speed sensor and Camshaft sensor are out
of the range
DTC REACTIONS
HEALING CONDITION
EMS - EDC17C55
P0641
AIR
EMS
MASS
ECU
87 SENSOR
0.5 2 SIG
SIG
Y/L
78
GND
0.5 1 GND
BR/W
56 4 SIG
SIG
0.5
Y/L
35 3
SUP 0.5
5V
E1 O/L E8
SUP 5V
EMS RAIL PRESSURE

ECU SENSOR
E12
76
0.5
GND
GROUND
P/B 1
54
0.5
SIG
SIGNAL
W/O 2
32
0.5
SUP
SUPPLY_5V
SB
5V
E1 3
VEHICLE
EMS SPEED
ECU SENSOR
55 2
0.5 GND
GND
BR/R
22 3 SIG
SIG
0.5
L/R
16 0.5 1
I/P 5V
R/G E14
I/P 5V
E1
EMS - EDC17C55
P0641
(TWO CORE
EMS CAM SHAFT
SHIELDED
ECU SENSOR
CABLE)
46
0.75 1
SIG
SIGNAL
R/B
44
0.75 2
GND
GROUND
Y
45
0.75 3
POWER
POWER 5V
G
E1 E30
IC-2 F 27
IC-2 M 27
E2 2.5 2.5 2.5 0.5

BATTERY
NEGATIVE B B B B
EMS CLUTCH
ECU SENSOR
11 IC-1 M
11 IC-1 F
2
E1
0.5 0.5 4
SIG
41 W/Y W/Y
0.5 0.5 5
GND
SB
4 20
4 20
23 SB
0.5 0.5 1
I/P 5V
10 L/W L/W
IC-2 M
IC-2 F
B30
EMS - EDC17C55
P0641
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4
P1A01F001_E1 P1A01F007_E8
E12 - RAIL PRESSURE SENSOR E14 - VEHICLE SPEED SENSOR
1 2 3 1 2 3
P1A01F011_E12 P1A01F012_E14
B30 - CLUTCH SENSOR E30 - CAM SHAFT SENSOR
1 2
3 4 5 6 1 2 3
P4A00F021_B30 P1A01F028_E30
EMS - EDC17C55
P0641
CONNECTOR
NO
CAMSHAFT SENSOR
45
POWER
VEHICLE SPEED
16
SENSOR POWER
RAIL PRESSURE
EMS ECU E1 32
SENSOR POWER
AIR MASS SENSOR
35
POWER
CLUTCH SENSOR
10
POWER
VEHICLE SPEED SENSOR E14 1 SUPPLY
RAIL PRESSURE SENSOR E12 3 SUPPLY
AIR MASS SENSOR E8 3 SUPPLY
CLUTCH SENSOR B30 1 SUPPLY
CAM SHAFT SENSOR E30 3 SUPPLY


EMS - EDC17C55
P0641
STEP A – CHECK SHORT TO GROUND OF SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Clutch sensor connector ( B30) DISCONNECTED
• VSS connector (E14) DISCONNECTED
• Rail pressure sensor connector(E12)DISCONNECTED
• Air Mass Sensor (Boost Pressure Sensor) connector(E8) DISCONNECTED
• Camshaft sensor connector (E30) DISCONNECTED
• Ignition ON
TEST PROCEDURE
• Check resistance between pin 1 of E14 and battery ground
ACCEPTANCE CRITERIA
• Resistance = ∞Ω
ACTION TO BE TAKEN
OK NOT OK
• Disconnect one sensor (for the sensors

listed above) wiring harness connector at a
time and switch ON the ignition
• Try to clear the DTC
• Examine the short circuit to ground /
• If the DTC is cleared, then suspect internal battery of the sensor supply wires
failure of the sensor for which the wiring
harness connector is disconnected • Replace the wiring harness
• Replace the sensor with a new one • Clear the DTC and verify
• If problem is still present replace EMS
ECU
EMS - EDC17C55
P0651
10.67 P0651 — SENSOR SUPPLY VOLTAGE 2 MONITORING ERROR

10.67.1 SENSOR SUPPLY VOLTAGE 2 MONITORING
EMS ECU monitors the supply voltage of Accelerator pedal position sensor 2 (APP2) and
registers a DTC if the voltage is not within the range

NORMAL OPERATION
• Ignition ON
Accelerator Pedal position sensor 2 (APP2)
and is within the range
• Ignition ON
• Short to ground/battery of APP2 supply wire
• Faulty APP2 (Accelerator Pedal)
• The sensor supply voltage of Accelerator
pedal position sensor 2 (APP2) is out of the
range
DTC REACTIONS
• Nil
HEALING CONDITION
EMS - EDC17C55
P0651
ACCELERATOR
EMS
6 IC-1 M
PEDAL
6 IC-1 F
MODULE ECU
SIGNAL 4 0.5 0.5 61
SIGNAL
W/R W/R
GROUND
3 0.5 0.5 83
GROUND
BR/B BR/B
5
5
2 0.5 0.5 18
SUPPLY_5V
R/Y R/Y
4
4
SUPPLY_5V
SIGNAL
6 0.5 0.5 60
SIGNAL
3
P P
3
GROUND
0.5 0.5 82
5
GROUND
O/W O/W
2
2
1 0.5 0.5 40
SUPPLY_5V SUPPLY_5V
R/B R/B
1
1
B21 E1
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
1 2 3 4 5 6
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A00F013_B21
EMS - EDC17C55
P0651
CONNEC-
TOR NO
40 POWER
82 GROUND
1 POWER
APP2 B21 6 SIGNAL
5 GROUND


STEP A – CHECK VOLTAGE OF APP 2 SENSOR POWER WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5.0 ±0.25 V
EMS - EDC17C55
P0651
ACTION TO BE TAKEN
OK NOT OK
• If the voltage is greater than 5.25V, check

for short to battery of the APP2 sensor
reference voltage wire
• Replace the accelerator pedal
• If it is less than 4.75, examine the short to
• Clear the DTC and verify ground of APP2 reference voltage wire
EMS - EDC17C55
P0697
10.68 P0697 — SENSOR SUPPLY VOLTAGE 3 MONITORING ERROR

EMS ECU monitors the supply voltage of Accelerator pedal position sensor 1 (APP1) and
registers a DTC if the voltage is not within the range

NORMAL OPERATION
• Ignition ON
Accelerator Pedal position sensor 1 (APP1)
and is within the range
• Ignition ON
• Short to ground/battery of APP1 supply wire
• Faulty APP1 (Accelerator Pedal)
• The sensor supply voltage of Accelerator
pedal position sensor 1 (APP1) is out of the
range
DTC REACTIONS
• Nil
HEALING CONDITION
ACCELERATOR
EMS
6 IC-1 M
PEDAL
6 IC-1 F
MODULE ECU
SIGNAL 4 0.5 0.5 61
SIGNAL
W/R W/R
GROUND
3 0.5 0.5 83
GROUND
BR/B BR/B
5
5
2 0.5 0.5 18
SUPPLY_5V
R/Y R/Y
4
4
SUPPLY_5V
SIGNAL
6 0.5 0.5 60
SIGNAL
3
P P
3
GROUND
0.5 0.5 82
5
GROUND
O/W O/W
2
2
1 0.5 0.5 40
SUPPLY_5V SUPPLY_5V
R/B R/B
1
1
B21 E1
EMS - EDC17C55
P0697
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
1 2 3 4 5 6
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A00F013_B21
CONNEC-
TOR NO
18 POWER
83 GROUND
2 POWER
APP1 B21 4 SIGNAL
3 GROUND


EMS - EDC17C55
P0697
STEP A – CHECK VOLTAGE OF APP 1 SENSOR POWER WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5.0 ±0.25 V
ACTION TO BE TAKEN
OK NOT OK
• If the voltage is greater than 5.25V, check

for short to battery of the APP 1 sensor
reference voltage wire
• Replace the accelerator pedal
• If it is less than 4.75, examine the short to
• Clear the DTC and verify ground of APP 1 reference voltage wire
EMS - EDC17C55
P1B87
10.69 P1B87 — RAIL PRESSURE POSITIVE GOVERNOR DEVIATION

ERROR IN METERING UNIT
10.69.1 RAIL PRESSURE MONITORING
EMS ECU compares the rail pressure monitored through the rail pressure sensor against the
expected pressure generated due to Fuel Pump

NORMAL OPERATION
• Ignition ON
• The ECU compares the rail pressure
monitored through the rail pressure sensor
against the expected pressure generated due
to Fuel Pump ( Based on Metering unit
(MPROP) position and the engine RPM and • Leak on fuel lines
coolant temperature )
• Defective fuel tank cap
• Defective fuel filter
• Ignition ON
• Fuel tank strainer chocked
• Injector struck in open condition
• The positive governor deviation is more
than the range • Metering unit (MPROP) valve struck
DTC REACTIONS
• Torque limitation
HEALING CONDITION
• Fault absent

• Proceed to DIAGNOSTIC PROCEDURE if P1B87 is present
EMS - EDC17C55
P1B87

STEP A – CHECK FOR THE FUEL FILTER CHANGE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check and verify the last fuel filter change kilometers
ACCEPTANCE CRITERIA
• Fuel filter changed as per the schedule kms
ACTION TO BE TAKEN
OK NOT OK
• Replace the fuel filter with a new one

• GO TO STEP B • Refer the intermittent problem inspection
procedure
STEP B – CHECK FOR ANY FUEL BLEEDING
PRE CONDITION
• Ignition OFF
• Check condition of Fuel tank cap for breather hole blockage
TEST PROCEDURE
• Carry out the fuel system bleeding at the injector side
• Start the engine
• Check and verify for the DTC
ACCEPTANCE CRITERIA
• DTC absent
EMS - EDC17C55
P1B87
ACTION TO BE TAKEN
OK NOT OK
• Diagnosis completed • GO TO STEP C
STEP C – REPLACE THE FUEL FILTER
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Replace the fuel filter with a new one.
ACCEPTANCE CRITERIA
• DTC absent
ACTION TO BE TAKEN
OK NOT OK
• Diagnosis completed • GO TO STEP D
STEP D – CLEAN THE FUEL STRAINER AND FUEL LINES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Clean the fuel strainer and fuel lines.
ACCEPTANCE CRITERIA
• DTC absent
ACTION TO BE TAKEN
OK NOT OK
• Diagnosis completed • GO TO STEP E
EMS - EDC17C55
P1B87
STEP E – CHECK FOR INJECTORS OVERFLOW
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check for injectors overflow
ACCEPTANCE CRITERIA
• Overflow within the limit
ACTION TO BE TAKEN
OK NOT OK
• Replace the Fuel control unit • Replace the faulty injector with a new one
• Check and verify for the DTC. • Check and verify for the DTC.
• If the DTC still exists, replace the rail
pressure sensor with a new one.
EMS - EDC17C55
P1C87
10.70 P1C87 — MAXIMUM POSITIVE DEVIATION OF RAIL PRESSURE

EXCEEDED CONCERNING SET FLOW OF FUEL IN METERING UNIT MODE

NORMAL OPERATION
• Ignition ON
(MPROP) position and the engine RPM and
coolant temperature ) • Leak on fuel lines
DTC DETECTING CONDITIONS • Defective fuel tank cap
• Ignition ON • Defective fuel filter
• EMS ECU supply voltage 8 - 16 V • Fuel tank strainer choked
• The positive governor deviation is more • Injector struck in open condition
than the range and the high pressure pump • Metering unit (M prop) valve struck
delivery is more than the limit
DTC REACTIONS
HEALING CONDITION
• Fault absent

• Proceed to DIAGNOSTIC PROCEDURE if P1C87 is present
EMS - EDC17C55
P1C87

STEP A – CHECK FOR THE FUEL FILTER CHANGE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Fuel filter changed as per the schedule kms
ACTION TO BE TAKEN
OK NOT OK

• GO TO STEP B • Refer the intermittent problem inspection
procedure
STEP B – CHECK FOR ANY FUEL BLEEDING
PRE CONDITION
• Ignition OFF
• Check condition of Fuel tank cap for breather hole blockage
TEST PROCEDURE
ACCEPTANCE CRITERIA
• DTC absent
EMS - EDC17C55
P1C87
ACTION TO BE TAKEN
OK NOT OK
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Replace the fuel filter with a new one.
ACCEPTANCE CRITERIA
• DTC absent
ACTION TO BE TAKEN
OK NOT OK
• Diagnosis completed • GO TO STEP D
STEP D – CLEAN THE FUEL STRAINER AND FUEL LINES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Clean the fuel strainer and fuel line
ACCEPTANCE CRITERIA
• DTC absent
ACTION TO BE TAKEN
OK NOT OK
EMS - EDC17C55
P1C87
STEP E – CHECK FOR INJECTORS OVERFLOW
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Overflow within the limit
ACTION TO BE TAKEN
OK NOT OK
• Replace the Fuel control unit • Replace the faulty injector with a new one
• If the DTC still exists, replace the fuel • Check and verify for the DTC.
pump with a new one.
• Check and verify for the DTC.
EMS - EDC17C55
P1B88
10.71 P1B88 — RAIL PRESSURE NEGATIVE GOVERNOR DEVIATION

ERROR IN METERING UNIT MODE

NORMAL OPERATION
• Ignition ON
to Fuel Pump ( Based on Metering unit/
• Fuel return pipe squeezed /Blocked
• Ignition ON
• Malfunction of metering unit (fuel control
• EMS ECU supply voltage 8 - 16 V unit)
• The negative governor deviation is less
than the range and the set point for fuel flow
through metering unit is lesser than the limit
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1B88
E4
+
ECU FUSE
(BMF)
30 A
A E4
V
4
V
E3
4
E35 4 8
30 86
ECU MAIN
RELAY
87 86
E35 6 2
E13 E13 FUEL
R
4
2.5 0.75
15 A METER
R 7 1 G/B
FUEL UNIT
METERING
P/L
0.5
E9 1
2
0.75
G/B
E1 50 89
SIG
RLY COIL
GND
EMS
ECU
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F008_E9
CONNEC-
TOR NO
1 CONTROL SIGNAL
2 SUPPLY
EMS - EDC17C55
P1B88

• Proceed to DIAGNOSTIC PROCEDURE if P1B88 is present

STEP A – CHECK FUEL RETURN PIPE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check condition of fuel return pipe for block
ACCEPTANCE CRITERIA
• No squeeze /block
ACTION TO BE TAKEN
OK NOT OK
• Examine fuel return pipe for block

• GO TO STEP B • Replace the fuel return pipe.
EMS - EDC17C55
P1B88
STEP B – CHECK VOLTAGE IN FUEL METERING UNIT ( FUEL CONTROL UNIT) SUPPLY
WIRE
PRE CONDITION
• Ignition OFF
• Check and confirm the proper function of 15 A fuse in Engine room fuse box
• Fuel metering unit ( Fuel Control Unit) wiring harness connector (E 9) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = Vehicle Battery Voltage
ACTION TO BE TAKEN
OK NOT OK

metering unit ( Fuel Control Unit) supply
wire from main relay
• GO TO STEP C
STEP C– CHECK OPEN CIRCUIT OF FUEL METERING UNIT ( FUEL CONTROL UNIT)
CONTROL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P1B88
OK NOT OK
• Replace fuel pump with a new one • Replace the wiring harness
EMS - EDC17C55
P1D87
10.72 P1D87 — RAIL PRESSURE BELOW MINIMUM LIMIT ERROR IN

METERING UNIT MODE

NORMAL OPERATION
• Ignition ON
monitored thought the rail pressure sensor
• Clogged Fuel filter, leakage in fuel lines
• Leakage in high pressure pipes, injector
• Ignition ON stuck in open position, worn Fuel Pump, worn
• EMS ECU supply voltage 8 - 16 V injectors
• Rail pressure falls below the limiting value
DTC REACTIONS
HEALING CONDITION
• Fault absent

• Proceed to DIAGNOSTIC PROCEDURE if P1D87 is present

EMS - EDC17C55
P1D87
STEP A – CHECK THE CONDITION OF FUEL FILTER
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Fuel filter replace as per the schedule kms
ACTION TO BE TAKEN
OK NOT OK

• GO TO STEP B
STEP B – CHECK THE FUEL SYSTEM
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• check and verify for the DTC
ACCEPTANCE CRITERIA
• DTC absent
ACTION TO BE TAKEN
OK NOT OK
EMS - EDC17C55
P1D87
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• DTC still Present
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP D • Diagnosis completed
STEP D – CHECK THE FUEL STRAINER AND FUEL LINE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Clean the fuel strainer and fuel lines
ACCEPTANCE CRITERIA
• DTC absent
ACTION TO BE TAKEN
OK NOT OK
STEP E – CHECK THE INJECTORS
PRE CONDITION
• Ignition ON
TEST PROCEDURE
EMS - EDC17C55
P1D87
ACCEPTANCE CRITERIA
• Overflow with in the limits
ACTION TO BE TAKEN
OK NOT OK
• Examine Metering unit (Fuel control Unit)

malfunction
• Replace Metering unit (Fuel control Unit) • Replace the faulty injector with a new one
• If the DTC still exists, replace the Fuel • Check and verify for the DTC
Pump with a new one
EMS - EDC17C55
P1C88
10.73 P1C88 — RAIL PRESSURE ABOVE MAXIMUM LIMIT ERROR IN

METERING UNIT MODE

NORMAL OPERATION
• Ignition ON
DTC DETECTING CONDITIONS • Metering unit struck
• Ignition ON • Fuel return pipe squeezed /blocked
• EMS ECU supply voltage 8 - 16 V • Malfunction of Metering unit
• Rail pressure exceeds above the limiting
value
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1C88
E4
+
ECU FUSE
(BMF)
30 A
A E4
V
4
V
E3
4
E35 4 8
30 86
ECU MAIN
RELAY
87 86
E35 6 2
R E13 E13 FUEL
4 2.5 0.75
15 A METER
R 7 1 G/B
FUEL UNIT
METERING
P/L
0.5
E9 1
2
0.75
G/B
E1 50 89
SIG
RLY COIL
GND
EMS
ECU
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1 P1A01F008_E9
CONNEC-
TOR NO
1 CONTROL SIGNAL
2 SUPPLY
EMS - EDC17C55
P1C88

• Proceed to DIAGNOSTIC PROCEDURE if P1C88 is present

STEP A – CHECK FUEL RETURN PIPE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check condition of fuel return pipe for blockage
ACCEPTANCE CRITERIA
• No squeeze/block
ACTION TO BE TAKEN
OK NOT OK
• Examine fuel return pipe for blockage

• GO TO STEP B • Replace the fuel return pipe.
EMS - EDC17C55
P1C88
STEP B– CHECK THE VOLTAGE IN FUEL METERING UNIT ( FUEL CONTROL UNIT)
SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Check and confirm the proper function of 15 A fuse in ECU fuse box
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

metering unit ( Fuel Control Unit) power
supply wire from main relay
• GO TO STEP C
STEP C – CHECK OPEN CIRCUIT OF FUEL METERING UNIT ( FUEL CONTROL UNIT)
CONTROL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P1C88
OK NOT OK
• Replace fuel metering unit with a new one • Replace the wiring harness
EMS - EDC17C55
P068A
10.74 P068A — MAIN RELAY EARLY OPENING ERROR

10.74.1 MAIN RELAY
Main relay is located in the engine compartment fuse box . It controls the battery supply
voltage to EMS ECU and many other actuators. Main relay is energized by EMS ECU after
getting the ignition input. Main relay will remain energized for 15 seconds after ignition OFF

NORMAL OPERATION
• Ignition ON
• EMS ECU checks the main relay actuation
time during initialization and is within the
range
• ECU checks the main relay during
operation and no sticky operation noticed
DTC DETECTING CONDITIONS • Open / short wiring harness
• Ignition ON • Loose wiring harness connectors
• EMS ECU supply voltage 8 - 16 V • Sticky relay
• The main relay is not operating in the set

time
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P068A
2
2
B 6 6 5 5
60 A
Y Y
IC - 4M
IC - 4F
E-4 Y Y
B32 2
TERM 30 15a 15 50
POS
OFF
30 A ACC
A E4 IGNITION
START
POS
V
V
30 15a 15 50
4
4
TERM
4 8
E35 B32 1
30 86
ECU MAIN
IC-2 M 23
BRAKE SWITCH
IC-2 F 23
RELAY
+ E1
87 86
2.5 11 5 1.5
6 2 E35 R
15A
G
1.5
E13
G
E13
VACCUM
IC-2 M 25
IC-2 F 25
1 1
MODULATOR
REDUNDANT BRAKE
E13 G G
R
E2 E13
4
E3 2.5 0.75 0.75 0.75 B22 3
SWITCH
15 A B22 1
FUEL
1 SWITCH
2.5
EC4 2
R
0.5
G
FUEL
2.5
E13 8
Y
G/B
0.5
BR
0.5
SB/R
0.5
METER 11 IC-5 F
0.5
P/L
UNIT
11 IC-5 M IC-1 F
20 A
7
IC-1 M 7 8 IC-1 F
0.5
E13 2
G
8 IC-1 M
B23 5
R/W 2.5
12 IC-5 M
BR
0.5
2.5
2 1 E9 12 IC-5 F
13 IC-2 F REFER
13 IC-2 M
STOP
0.75
SB/R
G/B
LAMP
5A
0.5
2.
2.5
CKT
B
R/W
Y/W
0.75
BR
0.5
5
0.5
B
15
B23 1 2 6 4 50 89 G/B 49 80 24
SIG
GND
GND
SIG
I/P I/P RLY COIL
SIG
SIG
GND
0.75

R
SUP
GND
CAN CAN
SUP
SIG
SIG
5V
HI LOW
66 65 71 35 56 78 87
0.5
0.5
Y
0.5
Y/L
0.75
W/Y
Y/L
0.5
IC-1 M 10 9
IC-1 F 10 9
BR/W
0.5
O/L
0.5
0.5
0.5
IC-2 M 24
G
Y
0.5 0.5 IC-2 F 24

Y G 3 4 1 2 E8
0.5
Y
0.5
0.5
G
Y
0.75
W/Y
0.5
B34 6 14 B29 2 5
G
AIR MASS SENSOR

R B34
0.5 0.5
B34 5 4 B29 1 8
W/Y W/Y
TERMINATING
1 B65 B1 3
RESISTOR
1.5
W/Y
2 TO CLUSTER
0.5
B
4
B23 30
0.5
Y
ECU
15 A
SUPPLY
B23 40
0.5
Y
0.5
B
2.5
IC-2 M 27
V
IC-2 F 27
0.5 2.5 0.5 0.5

IC-4 M 1
R B B B
IC-4 F 1
2.5
6 6 V
B B
EMS - EDC17C55
P068A
E1 - EMS ECU
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNECTOR
NO
6 POWER SUPPLY 1
4 POWER SUPPLY 2
EMS ECU E1
50 SIGNAL
71 IGNITION SUPPLY

• Proceed to DIAGNOSTIC PROCEDURE if P068A is present

EMS - EDC17C55
P068A
STEP A – CHECK FUNCTIONING OF MAIN RELAY
PRE CONDITION
• Ignition OFF
• Before proceeding further, ensure the main relay is fixed properly in the connector (E35)
• Remove the main relay
TEST PROCEDURE
• Check the functioning of relay by providing 12 V to terminal 86 and ground to terminal 85
ACCEPTANCE CRITERIA
• Clicking sound audible
ACTION TO BE TAKEN
OK NOT OK
• Replace the main relay with a new one

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

WIRING CIRCUIT
PRE CONDITION
• Ignition OFF
• Ensure the 30A fuse (E4) is functioning properly
TEST PROCEDURE
• Check the voltage at pin 30 of E35 and battery ground
ACCEPTANCE CRITERIA
• Voltage = Vehicle battery voltage
ACTION TO BE TAKEN
OK NOT OK
• Examine the short/open circuit in battery

power supply to main relay
EMS - EDC17C55
P068A
STEP C– CHECK SHORT CIRCUIT IN MAIN RELAY TO EMS ECU WIRING CIRCUIT
PRE CONDITION
• Ignition OFF
• Battery Disconnected
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit in main relay to

EMS ECU wiring circuit
• GO TO STEP D • Replace the wiring harness with a new one
STEP D – CHECK OPEN CIRCUIT IN MAIN RELAY TO EMS ECU WIRING CIRCUIT
PRE CONDITION
• Ignition OFF
• Ensure fusE10A ECU supply fuse is functionally properly.
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P068A
OK NOT OK
• Examine the open circuit in main relay to

• GO TO STEP E • Replace the wiring harness with a new one
STEP E – CHECK OPEN CIRCUIT IN MAIN RELAY TO EMS ECU IGNITION SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU wiring harness connector DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open / short circuit to ground

• Suspect EMS ECU malfunction.
of EMS ECU ignition supply wire.
• Replace the wiring harness with a new one
EMS - EDC17C55
P068B
10.75 P068B — MAIN RELAY EARLY STRUCK ERROR

10.75.1 MAIN RELAY
Main relay is located in the engine compartment fuse box . It controls the battery supply
voltage to EMS ECU and many other actuators. Main relay is energized by EMS ECU after
getting the ignition input. Main relay will remain energized for 15 seconds after ignition OFF

NORMAL OPERATION
• Ignition ON
• EMS ECU checks the main relay actuation
time during initialization and is within the
range
• ECU checks the main relay during
operation and no sticky operation noticed
DTC DETECTING CONDITIONS • Open / short wiring harness
• Ignition ON • Loosen wiring harness connectors
• EMS ECU supply voltage 8 - 16 V • Sticky relay
• The main relay is not operating in the set

time
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P068B
2
2
B 6 6 5 5
60 A
Y Y
IC - 4M
IC - 4F
E-4 Y Y
B32 2
TERM 30 15a 15 50
POS
OFF
30 A ACC
A E4 IGNITION
START
POS
V
V
30 15a 15 50
4
4
TERM
4 8
E35 B32 1
30 86
ECU MAIN
IC-2 M 23
BRAKE SWITCH
IC-2 F 23
RELAY
+ E1
87 86
2.5 11 5 1.5
6 2 E35 R
15A
G
1.5
E13
G
E13
VACCUM
IC-2 M 25
IC-2 F 25
1 1
MODULATOR
REDUNDANT BRAKE
E13 G G
R
E2 E13
4
E3 2.5 0.75 0.75 0.75 B22 3
SWITCH
15 A B22 1
FUEL
1 SWITCH
2.5
EC4 2
R
0.5
G
FUEL
2.5
E13 8
Y
G/B
0.5
BR
0.5
SB/R
0.5
METER 11 IC-5 F
0.5
P/L
UNIT
11 IC-5 M IC-1 F
20 A
7
IC-1 M 7 8 IC-1 F
0.5
E13 2
G
8 IC-1 M
B23 5
R/W 2.5
12 IC-5 M
BR
0.5
2.5
2 1 E9 12 IC-5 F
13 IC-2 F REFER
13 IC-2 M
STOP
0.75
SB/R
G/B
LAMP
5A
0.5
2.
2.5
CKT
B
R/W
Y/W
0.75
BR
0.5
5
0.5
B
15
B23 1 2 6 4 50 89 G/B 49 80 24
SIG
GND
GND
SIG
I/P I/P RLY COIL
SIG
SIG
GND
0.75

R
SUP
GND
CAN CAN
SUP
SIG
SIG
5V
HI LOW
66 65 71 35 56 78 87
0.5
0.5
Y
0.5
Y/L
0.75
W/Y
Y/L
0.5
IC-1 M 10 9
IC-1 F 10 9
BR/W
0.5
O/L
0.5
0.5
0.5
IC-2 M 24
G
Y
0.5 0.5 IC-2 F 24

Y G 3 4 1 2 E8
0.5
Y
0.5
0.5
G
Y
0.75
W/Y
0.5
B34 6 14 B29 2 5
G
AIR MASS SENSOR

R B34
0.5 0.5
B34 5 4 B29 1 8
W/Y W/Y
TERMINATING
1 B65 B1 3
RESISTOR
1.5
W/Y
2 TO CLUSTER
0.5
B
4
B23 30
0.5
Y
ECU
15 A
SUPPLY
B23 40
0.5
Y
0.5
B
2.5
IC-2 M 27
V
IC-2 F 27
0.5 2.5 0.5 0.5

IC-4 M 1
R B B B
IC-4 F 1
2.5
6 6 V
B B
EMS - EDC17C55
P068B
E1 - EMS ECU
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNECTOR
NO
6 POWER SUPPLY 1
4 POWER SUPPLY 2
EMS ECU E1
50 SIGNAL
71 IGNITION SUPPLY

• Proceed to DIAGNOSTIC PROCEDURE if P068B is present

EMS - EDC17C55
P068B
STEP A – CHECK FUNCTIONING OF MAIN RELAY
PRE CONDITION
• Ignition OFF
• Before proceeding further, ensure the main relay is fixed properly in the connector (E35)
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Clicking sound audible
ACTION TO BE TAKEN
OK NOT OK
• Replace the main relay with a new one

• GO TO STEP B
STEP B – CHECK OPEN CIRCUIT IN BATTERY POSITIVE TO MAIN RELAY WIRING

CIRCUIT
PRE CONDITION
• Ignition OFF
• Ensure the 30A fuse (E4) is functioning properly
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short/open circuit in battery

power supply to main relay
EMS - EDC17C55
P068B
STEP C– CHECK SHORT CIRCUIT IN MAIN RELAY TO EMS ECU WIRING CIRCUIT
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit in main relay to

• GO TO STEP D • Replace the wiring harness with a new one
STEP D – CHECK OPEN CIRCUIT IN MAIN RELAY TO EMS ECU WIRING CIRCUIT
PRE CONDITION
• Ignition OFF
• Check condition of fuse 10 A ECU .
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P068B
OK NOT OK
• Examine the open circuit in main relay to

• GO TO STEP E • Replace the wiring harness with a new one
STEP E – CHECK OPEN CIRCUIT IN MAIN RELAY TO EMS ECU IGNITION SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU wiring harness connector DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open / short circuit to ground

• Suspect EMS ECU malfunction.
of EMS ECU ignition supply wire.
• Replace the wiring harness with a new one
EMS - EDC17C55
P0069
10.76 P0069 — PLAUSIBILITY DEFECT BETWEEN CACDSP AND ENVP

10.76.1 MONITORING COMMUNICATION — PRESSURE SENSOR
Engine speed is continuously monitored by EMS ECU. Whenever the engine speed goes
above the maximum threshold, injection driver stages gets disconnected in EMS ECU

NORMAL OPERATION
• Ignition ON
• When engine running , the difference in
absolute value of atmospheric pressure and
boost pressure is with in the limit
• Ignition ON • Sensor supply monitoring error
• EMS ECU supply voltage 8 - 16 V • Environment pressure sensor malfunction
• When engine running, the difference in (EMS ECU)
absolute value of atmospheric pressure value
and boost pressure is out of range.
DTC REACTIONS
HEALING CONDITION
• Ignition Off then On


EMS - EDC17C55
P0069
• If this DTC occurs along with P0641 , then refer the diagnostic procedure to clear P0641 .
This DTC will get cleared along with P0641
• If this DTC occurs without P0641 , then suspect Environment pressure sensor (Inside EMS
ECU) malfunction . Replace EMS ECU and verify
EMS - EDC17C55
P0504
10.77 P0504 — BRAKE SIGNAL PLAUSIBILITY ERROR

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

NORMAL OPERATION
• Ignition ON
• The brake switch outputs a voltage which
corresponds to the brake position and is
within the range.
• Main brake signal is ON and redundant
signal is OFF and vice versa.
• Ignition ON • Open / short wiring harness
• EMS ECU supply voltage 8 - 16 V • Brake switch adjustment
• The brake switch output remains same in • Faulty brake switch
spite of brake pressed or not pressed
• The main and redundant switch status
remains same
DTC REACTIONS
• Accelerator plausibility error detection
stopped.
HEALING CONDITION
• Ignition Off/On
EMS - EDC17C55
P0504
E4
+ ECU FUSE (BMF)

30 A
A E4
Y
E2
6
V
4
V
4
E35 4 8
30 86
ECU MAIN
RELAY
87 86
E35 BRAKE
IC-2 M
6 2
IC-2 F 23
SWITCH
R
4
2.5 11 5 1.5
15A
23
1.5
R E13 G
G
E13
1 1
MAIN BRAKE
REDUNDANT
B22 1 G G
SWITCH
P/L
0.5
SWITCH
BRAKE
B22 3
B22 2
BR B22 4
0.5
SB/R
0.5
IC-1 F 7
IC-1 M 7
8 IC-1 F
BR
0.5
8 IC-1 M
SB/R
0.5
BR
0.5
E1 50 80 24
SIG
SIG
EMS ECU
E1 - EMS ECU B22 - BRAKE SWITCH
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4 1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
3 4
P1A01F001_E1 P1A00F014_B22
EMS - EDC17C55
P0504
CONNEC-
TOR NO
80 MAIN SIGNAL
EMS ECU E1
24 REDUNDANT SIGNAL
1 SUPPLY
2 MAIN SIGNAL
BRAKE SWITCH B22
3 SUPPLY
4 REDUNDANT SIGNAL


STEP A – CHECK FOR OPEN CIRCUIT IN BRAKE SWITCH SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Ensure that the brake switch is adjusted properly (refer repair manual for procedure)
• Ensure proper functioning of 15A fuse in Engine Compartment Fuse Box
• Brake switch connector (B22) DISCONNECTED
• Ignition ON
TEST PROCEDURE
EMS - EDC17C55
P0504
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open /short circuit in brake

switch supply wires
STEP B – CHECK OPEN CIRCUIT OF BRAKE SWITCH SIGNAL WIRES
PRE CONDITION
• Ignition OFF
• Brake switch wiring harness connector (B22) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit in brake switch

signal wires to EMS ECU
STEP C– CHECK SHORT CIRCUIT TO GROUND OF BRAKE SWITCH SIGNAL WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 4 of B22 and battery ground
EMS - EDC17C55
P0504
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit in brake switch

signal wires to ground
STEP D – CHECK INTERNAL SHORT IN BRAKE SWITCH
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 4 and pin 2 of brake switch connector (B22)
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit between brake • Examine faulty brake switch
switch signal wires
• Replace the brake switch with a new one
• Replace the brake switch with a new one
• Check for any DTC
EMS - EDC17C55
U0073
10.78 U0073 — CAN BUS OFF ERROR

10.78.1 CAN BUS OFF
CAN communication is a multiplex communication system. This enables the system to

transmit and receive large quantities of data at high speed by connecting ECU's with two
communication lines (CAN-H and CAN-L). ECU's on the CAN network transmit and receive
signals using the CAN High and CAN Low lines.

NORMAL OPERATION
• Ignition ON
• ECU's on the CAN network transmit and
receive signals using the CAN High and CAN
Low lines • CAN High and CAN Low short
DTC DETECTING CONDITIONS • CAN High short to ground
• Ignition ON • CAN HIGH or CAN Low short to Battery
• No communication in CAN • ECU's internal short
DTC REACTIONS
• Immobilizer tell tale will blink
HEALING CONDITION
• Fault absent
EMS - EDC17C55
U0073
B32 2
30 15a 15 50
OFF
ACC
IGN
START
E4 B IMMOBOLIZER
1 B32
VEHICLE
60A
LOAD
FUSE
2.5
V
1 G1
BATTERY
3 2 B29
12V
40 B23
ECU
0.50
0.50
15A
G
SUPPLY
G2
40 B23
CAN-H CAN-L
W/Y
1.5
G
0.50
16 14 B34
16 9
B34
DIAGNOSTIC
CONNECTOR
0.50
0.50
Y
G
8 1
6 5 4 C104
B 0.50 B 0.50
Y 0.50 W 1.0
B 4.00
1 C6
G9
B 2.00
CAN-H
B 6.00
G15
G
0.50
Y
0.50 CAN-H CAN-L
0.50
C7 G 0.50
Y
34 17
G 0.50 Y 0.50
65 66 E1
CAN-L CAN-H B35 1 2 B35
E1
EMS ECU
G1 4 120 ohm
TERMINATING
RESISTOR
EMS - EDC17C55
U0073

• Proceed to DIAGNOSTIC PROCEDURE if U0073 is present

STEP 1– CHECK CAN WIRES ARE OK
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 14 and pin 6 of the DLC connector
ACCEPTANCE CRITERIA
• Resistance = 60±5 Ω
ACTION TO BE TAKEN
OK NOT OK
• GO TO STEP 7 • GO TO STEP 2
STEP 2– CHECK INTERNAL SHORT CIRCUIT IN TERMINATING RESISTOR
PRE CONDITION
• Ignition OFF
• Terminating resistor wiring harness connector (B35) DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 1 and 2 of terminating resistor (B35)
EMS - EDC17C55
U0073
ACCEPTANCE CRITERIA
• Resistance = 120±5 Ω
ACTION TO BE TAKEN
OK NOT OK
• Suspect internal short in Terminal resistor

• Replace the Terminal resistor with a new
• GO TO STEP 3 one
• Check and confirm that ECU’s are able to
communicate with the diagnostic tool
STEP 3– CHECK INTERNAL SHORT CIRCUIT IN CAN LOW AND CAN HIGH OF EMS ECU
PRE CONDITION
• Ignition OFF
• Terminating resistor connector (B35) DISCONNECTED
• Immobilizer connector (B29) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance = 120 ± 5 Ω
ACTION TO BE TAKEN
OK NOT OK
• Suspect internal short in EMS ECU

• GO TO STEP 4
STEP 4– CHECK INTERNAL SHORT CIRCUIT IN CAN LOW AND CAN HIGH OF
IMMOBILIZER
PRE CONDITION
• Ignition OFF
• IMMOBILIZER wiring harness connector (B29) DISCONNECTED
TEST PROCEDURE
EMS - EDC17C55
U0073
ACCEPTANCE CRITERIA
• Resistance = 60 ± 5 Ω
ACTION TO BE TAKEN
OK NOT OK
• Suspect internal short in IMMOBILIZER

• Replace the IMMOBILIZER with a new • Reconnect the Immobilizer
one
• GO TO STEP 5
STEP 5– CHECK SHORT CIRCUIT TO BATTERY OF CAN LOW AND HIGH WIRES
PRE CONDITION
• Ignition OFF
• Battery negative terminal DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of CAN LOW and

HIGH with battery positive wire
• GO TO STEP 6 • Replace the wiring harness
STEP 6 – CHECK SHORT TO GROUND IN CAN HIGH AND LOW WIRES
PRE CONDITION
• Ignition OFF
• Battery Positive and Negative terminal DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 6 of the DLC connector and battery ground
EMS - EDC17C55
U0073
• Check the resistance between pin 14 of the DLC connector and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of CAN HIGH

• Clear and verify the DTC
and LOW with ground wire
• Check for intermittent issue
• If problem is still exists, follow the
procedure STEP 1
EMS - EDC17C55
P0704
10.79 P0704 — CLUTCH NON PLAUSIBLE ERROR

10.79.1 CLUTCH SENSOR
The clutch pedal sensor is a hall effect sensor encompassing two hall chips mounted on fixed
part of the clutch pedal and a magnet mounted on the moving shank of the clutch pedal. The
clutch sensor sends both 10% and 90% signal to EMS ECU based on the clutch pedal
position.

NORMAL OPERATION
• Ignition ON
• Clutch pedal sensor outputs a signal which
corresponds to the clutch pedal position and
is within the range
• Clutch signals are received every time a
gear change is detected
• Open / short Clutch sensor wiring harness
• Clutch pedal sensor adjustment
• Ignition ON
• Faulty clutch sensor
• Gear change detected without clutch signal
DTC REACTIONS
• ESS will not function
HEALING CONDITION
• Ignition Off/On

IC-2 F 27
IC-2 M 27
E2 2.5 2.5 2.5 0.5

BATTERY
NEGATIVE B B B B
EMS CLUTCH
ECU SENSOR
11 IC-1 M
11 IC-1 F
2
E1
0.5 0.5 4
SIG
41 W/Y W/Y
0.5 0.5 5
GND
SB
4 20
4 20
23 SB
0.5 0.5 1
I/P 5V
10 L/W L/W
IC-2 M
IC-2 F
B30
EMS - EDC17C55
P0704
E1 - EMS ECU B30 - CLUTCH SENSOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
1 2
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
3 4 5 6
P1A01F001_E1 P4A00F021_B30
CONNEC-
TOR NO
10 POWER SUPPLY
EMS ECU E1 23 10 % CLUTCH SIGNAL
41 90 % CLUTCH SIGNAL
1 SUPPLY
CLUTCH SENSOR B30
2 GROUND


EMS - EDC17C55
P0704
STEP A – CHECK VOLTAGE IN CLUTCH SENSOR
PRE CONDITION
• Ignition OFF
• Ensure that the clutch sensor is adjusted properly (refer repair manual for procedure)
• Clutch sensor wiring harness connector (B30) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5 ±0.25 V
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit in Clutch sensor

supply wire
• If the DTC still exists, suspect EMS ECU
STEP B – CHECK OPEN CIRCUIT IN CLUTCH SENSOR SIGNAL WIRES
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P0704
OK NOT OK
• Examine the open circuit in Clutch sensor

signal wire to EMS ECU
STEP C – CHECK SHORT CIRCUIT TO GROUND IN CLUTCH SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Clutch sensor wiring harness connector DISCONNECTED (B30)
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Resistance ∞ Ω
ACTION TO BE TAKEN
OK NOT OK

signal wires to ground
STEP D – CHECK OPEN CIRCUIT IN CLUTCH SENSOR GROUND WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU wiring harness connector (B30) DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P0704
OK NOT OK
• Examine the open circuit in Clutch sensor

• Examine faulty clutch sensor
ground wire
• Replace the clutch sensor with a new one
EMS - EDC17C55
P172A
10.80 P172A — CLUTCH 90% SWITCH PLAUSIBLE ERROR (SHORT TO

BATTERY)
part of the clutch pedal and a magnet mounted on the moving shank of the clutch pedal

NORMAL OPERATION
• Ignition ON
• Whenever clutch 90% signal is received by
EMS ECU , there is a change in clutch status
which is received through 10% signal
• Ignition ON • Short to battery in 90% signal wire
• EMS ECU supply voltage 8 to 16 V • Clutch pedal sensor adjustment
• Clutch 90% signal is received by EMS ECU • Faulty clutch sensor
continuously without change in clutch status
received through 10% signal
DTC REACTIONS
• Start stop function will not work
HEALING CONDITION
• Ignition Off/On

IC-2 F 27
IC-2 M 27
E2 2.5 2.5 2.5 0.5

BATTERY
NEGATIVE B B B B
EMS CLUTCH
ECU SENSOR
11 IC-1 M
11 IC-1 F
2
E1
0.5 0.5 4
SIG
41 W/Y W/Y
0.5 0.5 5
GND
SB
4 20
4 20
23 SB
0.5 0.5 1
I/P 5V
10 L/W L/W
IC-2 M
IC-2 F
B30
EMS - EDC17C55
P172A
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
1 2
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
3 4 5 6
P1A01F001_E1 P4A00F021_B30
CONNECTOR
NO
90 % CLUTCH
EMS ECU E1 41
SIGNAL
90 % CLUTCH
CLUTCH SENSOR B30 4
SIGNAL


EMS - EDC17C55
P172A
STEP A – CHECK VOLTAGE IN CLUTCH SENSOR 90% SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Ensure that the clutch sensor is adjusted properly (refer repair manual for procedure)
• Ignition ON
TEST PROCEDURE
• Check the voltage between pin 4 (90% signal) of B30 and battery ground
ACCEPTANCE CRITERIA
• Voltage > 0.5V
ACTION TO BE TAKEN
OK NOT OK

90% signal wire to battery
• Examine clutch sensor malfunction
• Replace the clutch sensor
• If the DTC still exists, suspect EMS ECU
EMS - EDC17C55
P171A
10.81 P171A — CLUTCH 90% SWITCH PLAUSIBLE ERROR(SHORT TO

GROUND)
part of the clutch pedal and a magnet mounted on the moving shank of the clutch pedal.
Clutch sensor sends both 10% and 90% signal to the EMS ECU based on the clutch pedal
position.

NORMAL OPERATION
• Ignition ON
• Whenever clutch 10% signal is received by
EMS ECU , there is a change in clutch status
which is received through 90% signal
• Ignition ON
• EMS ECU supply voltage 8 to 16 V • Short to battery in 90% signal wire
• Clutch 10% signal is received by EMS ECU • Faulty clutch sensor
continuously without change in clutch status
received through 90% signal
DTC REACTIONS
• Clutch plausibility error occurs
HEALING CONDITION
• Ignition Off/On

IC-2 F 27
IC-2 M 27
E2 2.5 2.5 2.5 0.5

BATTERY
NEGATIVE B B B B
EMS CLUTCH
ECU SENSOR
11 IC-1 M
11 IC-1 F
2
E1
0.5 0.5 4
SIG
41 W/Y W/Y
0.5 0.5 5
GND
SB
4 20
4 20
23 SB
0.5 0.5 1
I/P 5V
10 L/W L/W
IC-2 M
IC-2 F
B30
EMS - EDC17C55
P171A
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
1 2
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
3 4 5 6
P1A01F001_E1 P4A00F021_B30
CONNEC-
TOR NO
EMS ECU E1 41 90 % CLUTCH SIGNAL
CLUTCH SENSOR B30 4 90 % CLUTCH SIGNAL


STEP A – CHECK SHORT TO GROUND IN CLUTCH SENSOR 90% SIGNAL WIRE
EMS - EDC17C55
P171A
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 4 (90% signal) of B30 and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the short to ground in 90% clutch

sensor signal wire
STEP B – CHECK OPEN CIRCUIT IN CLUTCH SENSOR 90% SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU wiring harness connector DISCONNECTED (E1)
TEST PROCEDURE
• Check the resistance between pin 41 (90% signal) of E1 and pin 5 of the clutch sensor
wiring harness connector
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit in 90% clutch

• Replace the clutch sensor sensor signal wire
EMS - EDC17C55
P2269
10.82 P2269 — WATER PRESENCE IN FUEL ERROR

10.82.1 WATER IN FUEL
Water in fuel sensor works on the principle of difference of conductivity through water and
diesel. The water in fuel signal is provided to EMS ECU to indicate the presence of water in
fuel . It works on the difference of electric conductivity by 2 electrodes

NORMAL OPERATION
• Ignition ON
• No water present in fuel . The indication lamp on
cluster will come ON after ignition ON and goes OFF
in 2 seconds
• Ignition ON
• Water accumulation on fuel filter
• EMS ECU supply voltage 8 - 16 V bottom bowl
• Water present in the fuel
DTC REACTIONS
• Water in fuel warning / tell tale lamp ON
• Torque limitation
HEALING CONDITION
• Ignition Off/On
EMS - EDC17C55
P2269
+ E5
BATTERY
12V
-
30A
E2
E4 A
E35 4 8
30 86 FUEL TEMP AND
WATER IN FUEL
SENSOR
87 85
2.5 E13 E13 0.75
E35 6 2 10A
R 7 1 G/B
8
G/B
SIG SUP
0.5
SIG GND
4 1 2 3
P/L
0.5
0.5 G/R
R/L 0.5
0.5
R
E1 50 12 34 19
RLY GND SIG GND SIG
TEMP WATER IN FUEL
EMS ECU
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 4 3 2 1
P1A01F001_E1 P1A01F022_E24
EMS - EDC17C55
P2269
CONNECTOR DESCRIPTION CONNECTOR NO PIN NO FUNCTION

19 SIGNAL (WATER)
12 SIGNAL (TEMP)
2 SIGNAL (WATER)
1 GROUND
WATER IN FUEL SENSOR E24
4 SIGNAL (TEMP)
3 SUPPLY


STEP A – DRAIN THE WATER FROM FUEL FILTER
PRE CONDITION
• Ignition OFF
• Drain the water from fuel filter
• Ignition ON
TEST PROCEDURE
• Start the engine and check for DTC
ACCEPTANCE CRITERIA
• DTC absent
EMS - EDC17C55
P2269
ACTION TO BE TAKEN
OK NOT OK
• Diagnosis completed GO TO STEP B
STEP B – CHECK SHORT TO BATTERY IN WATER IN FUEL SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Water in fuel sensor wiring harness connector (E24) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Examine water in fuel sensor malfunction • Examine the short to battery in water in
fuel sensor signal wire
EMS - EDC17C55
P2265
10.83 P2265 — WATER IN FUEL SENSOR FAULTY

10.83.1 WATER IN FUEL SENSOR
The water in fuel signal indicates the presence of water in fuel .It is fitted on the bottom of the
fuel filter and gives the water in fuel signal EMS ECU to indicate the presence of water in fuel.
It works on the difference of electric conductivity by 2 electrodes.

NORMAL OPERATION
• Ignition ON
• EMS ECU receives the signal from water in
fuel sensor and is with in the range
• Ignition ON
• EMS ECU supply voltage 8 to 16 V • Open/ short in water in fuel circuit
• No signal from water in fuel sensor to EMS • Faulty water in fuel sensor
ECU
DTC REACTIONS
• Engine Check lamp Continuously ON
• Torque limitations.
HEALING CONDITION
• Ignition Off/On
EMS - EDC17C55
P2265
+ E5
BATTERY
12V
-
30A
E2
E4 A
E35 4 8
30 86 FUEL TEMP AND
WATER IN FUEL
SENSOR
87 85
2.5 E13 E13 0.75
E35 6 2 10A
R 7 1 G/B
8
G/B
SIG SUP
0.5
SIG GND
4 1 2 3
P/L
0.5
0.5 G/R
R/L 0.5
0.5
R
E1 50 12 34 19
RLY GND SIG GND SIG
TEMP WATER IN FUEL
EMS ECU
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 4 3 2 1
P1A01F001_E1 P1A01F022_E24
EMS - EDC17C55
P2265
CONNECTOR
NO
19 SIGNAL (WATER)
12 SIGNAL (TEMP)
2 SIGNAL (WATER)
1 GROUND
WATER IN FUEL SENSOR E24
4 SIGNAL (TEMP)
3 SUPPLY


STEP A – CHECK FOR OPEN CIRCUIT IN WATER IN FUEL SENSOR SUPPLY WIRE
PRE CONDITION
• Ignition OFF
• Check and ensure the proper functioning of 10 A fuse.
• Water in fuel sensor wiring harness connected (E24)DISCONNECTED
• Ignition ON
TEST PROCEDURE
• Check the voltage between pin 3 of the water in fuel sensor wiring harness connector and
battery ground
EMS - EDC17C55
P2265
ACCEPTANCE CRITERIA
• Voltage = Vehicle battery voltage
ACTION TO BE TAKEN
OK NOT OK
• Examine the open /short circuit in water in

fuel sensor power supply wire
STEP B – CHECK OPEN CIRCUIT IN WATER IN FUEL SENSOR GROUND WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit in water in fuel

sensor signal wire
STEP C – CHECK OPEN CIRCUIT IN WATER IN FUEL SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
EMS - EDC17C55
P2265
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit in water in fuel

sensor signal wire
STEP D – CHECK SHORT CIRCUIT IN WATER IN FUEL SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Suspect water in fuel sensor malfunction • Examine the short circuit in water in fuel
• Replace the sensor with a new one sensor signal wire
EMS - EDC17C55
P226A
10.84 P226A — WATER IN FUEL LAMP OPEN LOAD ERROR (PIKUP)

10.84.1 WATER IN FUEL LAMP
The water in fuel signal indicates the presence of water in fuel. It is fitted on the fuel filter and
gives the water in fuel signal EMS ECU to indicate the presence of water in fuel.

NORMAL OPERATION
• Ignition ON
• Water in fuel waning lamp will ON for 02
seconds and will get switched OFF if no error
is set in the ECU.
• Open circuit of water in fuel warning lamp
• Short to battery / ground
• Ignition ON
• Faulty wiring harness
• The water in fuel warning lamp does not
glow • Faulty EMS ECU
DTC REACTIONS
• Water in fuel warning lamp in the cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P226A
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
E13 0.5
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P226A
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNEC-
TOR NO

• Proceed to DIAGNOSTIC PROCEDURE, if P226A is present

EMS - EDC17C55
P226A
STEP A – CHECK OPEN CIRCUIT OF WATER IN FUEL LAMP SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of water in fuel

lamp signal wire
STEP B– CHECK SHORT CIRCUIT TO GROUND OF WATER IN FUEL LAMP SIGNAL

WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P226A
OK NOT OK
• GO TO STEP C • Examine the short circuit of water in fuel

lamp signal wire with ground
STEP C– CHECK SHORT CIRCUIT TO BATTERY OF WATER IN FUEL LAMP SIGNAL

WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Replace the Instrument cluster with new • Examine the short circuit of water in fuel
one lamp signal wire with battery supply
• If problem is still present , replace EMS • Replace the wiring harness
ECU
EMS - EDC17C55
P226A
10.85 P226A — WATER IN FUEL LAMP OPEN LOAD ERROR ( PIKUP

EXTRA LONG)

NORMAL OPERATION
• Ignition ON
• Water in fuel warning lamp will ON for 02
is set in the ECU. • Open circuit of water in fuel lamp
• The water in fuel lamp does not glow/ON • Faulty EMS ECU
DTC REACTIONS
• Water in fuel lamp in cluster
HEALING CONDITION
• Fault absent

IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP

ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P226A
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNEC-
TOR NO
INSTRUMENT CLUSTER ( 32P) B1 13 SIGNAL


EMS - EDC17C55
P226A
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

lamp signal wire

WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P226A
OK NOT OK
• GO TO STEP C • Examine the short circuit of water in fuel


WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0V
ACTION TO BE TAKEN
OK NOT OK
ECU
EMS - EDC17C55
P126A

(PIKUP)

NORMAL OPERATION
• Ignition ON
• Water in fuel warning lamp will ON for 02
is set in the ECU.
• Open circuit of water in fuel warning lamp
• Ignition ON
• The water in fuel warning lamp does not
glow/ON • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P126A
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
0.5
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P126A
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNEC-
TOR NO


EMS - EDC17C55
P126A
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

lamp signal wire

WIRE
PRE CONDITION
• Ignition OFF
• Instrument cluster connector (B1)DISCONNECTED
• EMS ECU connector (E1 DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P126A
OK NOT OK
• Examine the short circuit of water in fuel


WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
one signal wire with battery supply
ECU
EMS - EDC17C55
P126A

(PIKUP EXTRA LONG)

NORMAL OPERATION
• Ignition ON
• Water in fuel lamp will ON for 02 seconds
and will get switched OFF if no error is set in
the ECU. • Open circuit of water in fuel sensor lamp
DTC REACTIONS
• No Water in fuel warning lamp in the cluster
HEALING CONDITION
• Fault absent

IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP

ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P126A
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNEC-
TOR NO


EMS - EDC17C55
P126A
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

lamp signal wire

WIRE
PRE CONDITION
• Ignition OFF
• Instrument cluster connector (B1)DISCONNECTED
• EMS ECU connector (E1 DISCONNECTED
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P126A
OK NOT OK
• Examine the short circuit of water in fuel


WIRE
PRE CONDITION
• Ignition OFF
• EMS ECU connector (B1) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
ECU
EMS - EDC17C55
P126B
10.88 P126B — WATER IN FUEL LAMP SHORT TO BATTERY ERROR

(PIKUP)

NORMAL OPERATION
• Ignition ON
the ECU. • Open circuit of water in fuel warning lamp
DTC REACTIONS
• No Water in fuel warning lamp in the cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P126B
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
E13 0.5
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P126B
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNEC-
TOR NO

• Proceed to DIAGNOSTIC PROCEDURE, if P126B is present

EMS - EDC17C55
P126B
STEP A– CHECK SHORT CIRCUIT TO BATTERY OF WATER IN FUEL LAMP SIGNAL

WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Replace the Instrument cluster with new • Examine the short circuit of WIF signal
one wire with battery supply
ECU
EMS - EDC17C55
P126B
10.89 P126B — WATER IN FUEL LAMP SHORT TO BATTERY ERROR

(PIKUP EXTRA LONG)

NORMAL OPERATION
• Ignition ON
the ECU. • Open circuit of water in fuel lamp
DTC REACTIONS
• No water in fuel waning lamp in the cluster
HEALING CONDITION
• Fault absent

IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP

ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P126B
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNEC-
TOR NO


EMS - EDC17C55
P126B
STEP A– CHECK SHORT CIRCUIT TO BATTERY OF WATER IN FUEL LAMP SIGNAL

WIRE
PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0V
ACTION TO BE TAKEN
OK NOT OK
ECU
EMS - EDC17C55
P126C
10.90 P126C — WATER IN FUEL LAMP SHORT TO GROUND ERROR

(PIKUP)

NORMAL OPERATION
• Ignition ON
• water in fuel lamp will ON for 02 seconds
the ECU. • Open circuit of water in fuel lamp
DTC REACTIONS
• No water in fuel warning lamp in the cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P126C
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
0.5
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P126C
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNEC-
TOR NO

• Proceed to DIAGNOSTIC PROCEDURE, if P126C is present

EMS - EDC17C55
P126C
STEP A– CHECK SHORT CIRCUIT TO GROUND OF WATER IN FUEL LAMP SIGNAL

WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
one signal wire with ground
ECU
EMS - EDC17C55
P126C
10.91 P126C — WATER IN FUEL LAMP SHORT TO GROUND ERROR

(PIKUP EXTRA LONG)

NORMAL OPERATION
• Ignition ON
• water in fuel lamp will ON for 02 seconds
the ECU. • Open circuit of water in fuel warning lamp
DTC REACTIONS
• No water in fuel warning lamp in the cluster
HEALING CONDITION
• Fault absent

IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP

ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P126C
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNEC-
TOR NO


EMS - EDC17C55
P126C
STEP A– CHECK SHORT CIRCUIT TO GROUND OF WATER IN FUEL LAMP SIGNAL

WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
one signal wire with ground
ECU
EMS - EDC17C55
P1631
10.92 P1631 — ECU MONITORING: START OF INJECTION PLAUSIBILITY

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

NORMAL OPERATION
• Ignition ON
• The start of the energizing time is monitored
• Ignition ON • EMI interference in injection signals ( look at
the starter motor cable & starter motor
condition.)
• If the start of the energizing time is outside
the plausible valid range then this error is
registered
DTC REACTIONS
• Engine will shuts OFF
HEALING CONDITION
• Check and rectify if any EMI interference in injection signals ( possible cause can be starter
motor cable or starter motor taking extra load )
• Clear the DTC and Turn Ignition ON/OFF
EMS - EDC17C55
P1632
10.93 P1632 — ECU MONITORING: ZFC NON PLAUSIBILITY ERROR

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

NORMAL OPERATION
• Ignition ON
• The maximum plausible energizing time of
the ZFC results, depending on the rail
pressure is compared with a predetermined
curve and is within the range
• The minimum energizing time is also
compared with a predetermined curve and is
within the range
• Ignition ON • Injector worn/ stuck
• EMS ECU supply voltage 8 to 16 V • Faulty EMS ECU
• The actual ZFC value is out of range of
value given in the curves
DTC REACTIONS
HEALING CONDITION
• Check for injector stuck or worn ( through fuel leak off test)
• Using i-SMART clear the DTC and Turn Ignition On/Off
• Clear the DTC and verify for 3 times
EMS - EDC17C55
P1636
10.94 P1636 — ECU MONITORING: OVERRUN MONITORING ERROR
DTC DESCRIPTION
ECU Monitoring: Overrun monitoring

P1636
error
ECU Monitoring: Torque limitation

P1624 error before shut off path test error
reaction

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

EMS - EDC17C55
P1633
10.95 P1633 — ECU MONITORING: POI 2 QTY ERROR
DTC DESCRIPTION
P1633 ECU Monitoring: PoI 2 qty error
P1634 ECU Monitoring: PoI 2 shut off error
P1635 ECU Monitoring: PoI 3 efficiency factor error
ECU Monitoring: Injection quantity correction

P1637
error
P061B ECU Monitoring: Torque comparison error
ECU Monitoring: Torque monitoring level 2

P163E
error
ECU Monitoring: Lead torque monitoring

P1639
level 2 error
ECU Monitoring: Set torque monitoring level

P163D
2 error

NORMAL OPERATION
• Ignition ON
• The voltage monitoring of the injector
energizing time is found normal
• Ignition ON
• EMS ECU supply voltage 8 to 16 V • Faulty EMS ECU
• The difference between the programmed
energizing time and the measured energizing
time exceeds the limit
DTC REACTIONS
• Engine Check lamp Continuously ON
HEALING CONDITION
• Ignition Off/On
Lamp Status — Engine Check lamp Continuously ON
EMS - EDC17C55
P1633
• Check for injector stuck or worn ( through fuel leak off test)
• Using i-SMART clear the DTC and Turn Ignition On/Off
EMS - EDC17C55
P170F
10.96 P170F — STARTER RELAY OPEN LOAD

10.96.1 STARTER RELAY
Starter relay is energized by EMS ECU during ignition start and start stop(ESS). Starter relay
controls the starter motor.

NORMAL OPERATION
• Ignition ON
the control circuit of starter relay
• Ignition ON
• Open circuit in starter relay control wire
• Faulty starter relay
• Open circuit is detected in the control circuit
of starter relay • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
E4 6 6 6
2 IC-2 M
2 IC-2 F
60 A
B Y Y Y
VEHICLE B32 2
+ E5 LOAD POS
TERM 30 15a 15 50
BATTERY
FUSE OFF
ACC
12V
2.5
R
IGN
START
POS 30 15a 15 50
TERM
0.75
-
L
STARTER
SOLENOID 36 IC-2 F
36 IC-2 M
1 E22
2.5
L
0.75
E36 2
L
4
STARTER 30 87
86
RELAY 85
E36 1 3 0.5
L
0.75
GR/B
0.5
67 42 E1
RLY COIL CRANK SUP
GND
EMS - EDC17C55
P170F


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

• GO TO STEP B
EMS - EDC17C55
P170F
STEP B– CHECK THE OPEN CIRCUIT OF STARTER RELAY CONTROL WIRE
PRE CONDITION
• Ignition ON
• Ensure battery voltage is available at seating of relay terminal 30
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 85 of the starter relay seating and pin 67 of E1
ACCEPTANCE CRITERIA
• Resistance <1Ω
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of starter relay

• Suspect EMS ECU with a new one
control wire from EMS ECU
EMS - EDC17C55
P170C
10.97 P170C — OVER TEMPERATURE ERROR ON ECU POWER STAGE

FOR STARTER
Starter relay is used to actuate the starter motor. Whenever T50 input is available at EMS
ECU, it energizes starter relay to engage the starter motor

NORMAL OPERATION
• Ignition ON
• No malfunction detected by EMS ECU in control
circuit of starter relay
DTC DETECTING CONDITIONS • Short to ground in starter relay control
• Ignition ON wire
• Overheating detected in power stage • Faulty EMS ECU
DTC REACTIONS
• Nil
HEALING CONDITION
• Fault absent


EMS - EDC17C55
P170C

EMS - EDC17C55
P170D
10.98 P170D — STARTER RELAY SHORT CIRCUIT TO BATTERY ERROR

Starter relay is energized by EMS ECU during ignition start and start stop (ESS) . Starter relay
controls the starter motor.

NORMAL OPERATION
• Ignition ON
• Ignition ON
• Short to battery in starter relay control wire
• Faulty starter relay
• Short to ground is detected in control circuit
of starter relay • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Ignition Off/On
E4 6 6 6
2 IC-2 M
2 IC-2 F
60 A
B Y Y Y
VEHICLE B32 2
+ E5 LOAD POS
TERM 30 15a 15 50
BATTERY
FUSE OFF
ACC
12V
2.5
R
IGN
START
POS 30 15a 15 50
TERM
0.75
-
L
STARTER
SOLENOID 36 IC-2 F
36 IC-2 M
1 E22
2.5
L
0.75
E36 2
L
4
STARTER 30 87
86
RELAY 85
E36 1 3 0.5
L
0.75
GR/B
0.5
67 42 E1
RLY COIL CRANK SUP
GND
EMS - EDC17C55
P170D


STEP A – CHECK THE FUNCTIONING OF RELAY
PRE CONDITION
• Ignition OFF
• Ensure the starter relay is fixed properly in the connector of the relay box
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Clicking sound is audible
ACTION TO BE TAKEN
OK NOT OK
• Examine the short to battery of starter • Replace the starter relay with a new one
relay control wire from EMS ECU • Clear the DTC and verify
EMS - EDC17C55
P170E
10.99 P170E — STARTER RELAY SHORT CIRCUIT TO GROUND ERROR

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

NORMAL OPERATION
• Ignition ON
the control circuit of starter relay
• Ignition ON
• Short to ground in starter relay control wire
• Faulty EMS ECU
• Short to ground is detected in the control
circuit of starter relay
DTC REACTIONS
• Starter relay is always energized
HEALING CONDITION
• Fault not present
E4 6 6 6
2 IC-2 M
2 IC-2 F
60 A
B Y Y Y
VEHICLE B32 2
+ E5 LOAD POS
TERM 30 15a 15 50
BATTERY
FUSE OFF
ACC
12V
2.5
R
IGN
START
POS 30 15a 15 50
TERM
0.75
-
L
STARTER
SOLENOID 36 IC-2 F
36 IC-2 M
1 E22
2.5
L
0.75
E36 2
L
4
STARTER 30 87
86
RELAY 85
E36 1 3 0.5
L
0.75
GR/B
0.5
67 42 E1
RLY COIL CRANK SUP
GND
EMS - EDC17C55
P170E

• Proceed to DIAGNOSTIC PROCEDURE if P170E is present

STEP B– CHECK STARTER RELAY CONTROL CIRCUIT SHORT TO GROUND
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the functioning of relay by providing 12V to terminal 85 and battery ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Suspect EMS ECU malfunction • Examine the short circuit of starter relay
• Replace EMS ECU with a new one. control signal wire with ground
EMS - EDC17C55
P1AE9
10.100 P1AE9 — START STOP LAMP OPEN LOAD ERROR

10.100.1 ENGINE START STOP LAMP (ESS)
ESS lamp will illuminate whenever the ESS switch is in active mode.

NORMAL OPERATION
• Ignition ON
• The ESS lamp will illuminate whenever the ESS
switch is pressed
• Short to ground in ESS lamp circuit
• Ignition ON
• Faulty ESS switch
• Short circuit battery detected in ESS lamp
signal to EMS • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1AE9
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP

ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1AE9
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNECTOR
NO
EMS ECU E1 28 ESS INPUT SIGNAL

• Proceed to DIAGNOSTIC PROCEDURE, if P1AE9 is present

EMS - EDC17C55
P1AE9
STEP A – CHECK OPEN CIRCUIT OF ESS LAMP SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• EMC ECU (E1) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace the Instrument cluster with a new • Examine the open circuit ESS lamp signal
one wire
• If problem still exits, replace EMS ECU • Replace the wiring harness
EMS - EDC17C55
P1AEC
10.101 P1AEC — START/STOP LAMP OVER TEMPERATURE ERROR

10.101.1 ESS LAMP
ESS lamp will be illuminate whenever the ESS switch is in active mode

NORMAL OPERATION
• Ignition ON
the ESS lamp circuit
• Ignition ON • Faulty EMS ECU
• Overheating detected in power stage
DTC REACTIONS
HEALING CONDITION
• Fault absent

• Proceed to DIAGNOSTIC PROCEDURE, if P1AEC is present


EMS - EDC17C55
P1AEB
10.102 P1AEB — START - STOP LAMP SHORT CIRCUIT TO BATTERY

ERROR

NORMAL OPERATION
• Ignition ON
switch is pressed
• Short to battery in ESS lamp circuit
• Ignition ON
• Short circuit battery detected in ESS lamp
signal to EMS • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1AEB
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP

ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1AEB
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNEC-
TOR NO

• Proceed to DIAGNOSTIC PROCEDURE, if P1AEB is present

EMS - EDC17C55
P1AEB
STEP A – CHECK SHORT TO BATTERY OF ESS LAMP SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Instrument cluster wiring harness connector (B1) DISCONNECTED
• EMC ECU wiring harness connector (E1) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• ESS Lamp failed • Examine the short to battery of ESS lamp

• Replace the ESS switch with a new one signal wire
EMS - EDC17C55
P1AEA
10.103 P1AEA — START STOP LAMP SHORT TO GROUND ERROR


NORMAL OPERATION
• Ignition ON
switch is pressed
• Short to ground in ESS lamp circuit
• Ignition ON
• Short circuit battery detected in ESS lamp signal
to EMS • Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1AEA
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP

ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1AEA
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNECTOR
NO

• Proceed to DIAGNOSTIC PROCEDURE, if P1AEA is present

EMS - EDC17C55
P1AEA
STEP A – CHECK SHORT TO GROUND OF ESS LAMP SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Instrument cluster wiring harness connector (B1) DISCONNECTED
• EMC ECU wiring harness connector (E1) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace the Cluster with a new one • Examine the short to ground of ESS lamp
• If problem is still exists , replace the EMS signal wire
• • Clear the DTC and verify
EMS - EDC17C55
P1656
10.104 P1656 — SVS NO LOAD ERROR (PIKUP)

10.104.1 SVS LAMP (ENGINE CHECK LAMP)
SVS lamp will illuminate whenever the emission related faults are detect in the EMS ECU

NORMAL OPERATION
• Ignition ON
• SVS lamp (Check Engine Lamp) will ON for
02 seconds and will get switched OFF if no
error is set in the ECU.
• Open circuit of SVS lamp (Check Engine
DTC DETECTING CONDITIONS Lamp)
• Ignition ON • Short to battery / ground
• The SVS lamp (Check Engine Lamp) does • Faulty wiring harness
not glow/ON
• Faulty EMS ECU
DTC REACTIONS
• No SVS lamp (Check Engine Lamp) in the
cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1656
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
0.5
E13 B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1656
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNECTOR
NO
INSTRUMENT CLUSTER (12 P) B2 07 SIGNAL


EMS - EDC17C55
P1656
STEP A – CHECK OPEN CIRCUIT OF SVS LAMP (CHECK ENGINE LAMP) SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of SVS lamp

(Check Engine Lamp) signal wire
STEP B– CHECK SHORT CIRCUIT TO GROUND OF SVS LAMP (CHECK ENGINE LAMP )
SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P1656
OK NOT OK
• Examine the short circuit of SVS lamp

(Check Engine Lamp) signal wire with
ground
• GO TO STEP C
STEP C– CHECK SHORT CIRCUIT TO BATTERY OF SVS LAMP (CHECK ENGINE LAMP)
SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Check the instrument cluster /ECU • Examine the short circuit of SVS almp
connector for damage or Oxidation (Check Engine Lamp) signal wire with
• Replace Instrument cluster, if problem is battery supply
exists, replace EMS WCU • Replace the wiring harness
EMS - EDC17C55
P1656
10.105 P1656 — SVS NO LOAD ERROR (PIKUP EXTRA LONG)

10.105.1 SVS LAMP (CHECK ENGINE LAMP)
SVS lamp (Check Engine Lamp) will illuminate whenever the emission related faults are detect
in the EMS ECU

NORMAL OPERATION
• Ignition ON
• Open circuit of SVS lamp (Check Engine
DTC DETECTING CONDITIONS Lamp)
• Ignition ON • SVS Short to battery / ground
not glow/ON
• Faulty EMS ECU
DTC REACTIONS
cluster
HEALING CONDITION
• Fault absent

IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP

ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1656
E1 - EMS ECU
B1 - CLUSTER
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P4A00F001_B1
P1A01F001_E1
CONNEC-
TOR NO
CHECK ENGINE —
EMS ECU E1 48
SIGNAL
INSTRUMENT CLUSTER (32P) CHECK ENGINE —

B1 09
SIGNAL


STEP A – CHECK OPEN CIRCUIT OF SVS LAMP ( CHECK ENGINE LAMP) SIGNAL WIRE
EMS - EDC17C55
P1656
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

STEP B– CHECK SHORT CIRCUIT TO GROUND OF SVS LAMP (CHECK ENGINE LAMP)
SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

ground
• GO TO STEP C
EMS - EDC17C55
P1656
SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Check the instrument cluster /ECU • Examine the short circuit of SVS lamp
EMS - EDC17C55
P1657
10.106 P1657 — SVS OVER TEMPERATURE ERROR (PIKUP)

in the EMS ECU

NORMAL OPERATION
• Ignition ON
not glow/ON
DTC REACTIONS
cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1657
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
E13 0.5
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1657
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNEC-
TOR NO
CHECK ENGINE —
EMS ECU E1 48
SIGNAL
INSTRUMENT CLUSTER (12 P) CHECK ENGINE —

B2 07
SIGNAL


EMS - EDC17C55
P1657
STEP A – CHECK OPEN CIRCUIT OF SVS LAMP (CHECK ENGINE LAMP) SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P1657
OK NOT OK

ground
• GO TO STEP C
SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Replace Instrument Cluster, if problem is battery supply
still exists, replace EMS ECU • Replace the wiring harness
EMS - EDC17C55
P1657
10.107 P1657 — SVS OVER TEMPERATURE ERROR ( PIKUP EXTRA

LONG)
in the EMS ECU

NORMAL OPERATION
• Ignition ON
• SVS check lamp (Check Engine Lamp) will
ON for 02 seconds and will get switched OFF
if no error is set in the ECU.
not glow/ON
DTC REACTIONS
cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1657
IC-3 M 9
IC-3 F 9
BATTERY B1 24
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP
ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNEC-
TOR NO
CHECK ENGINE —
EMS ECU E1 48
SIGNAL

B1 09
SIGNAL
EMS - EDC17C55
P1657


STEP A – CHECK OPEN CIRCUIT OF SVS LAMP (CHECK ENGINE LAMP ) SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

SIGNAL WIRE
EMS - EDC17C55
P1657
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

ground
• GO TO STEP C
SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
EMS - EDC17C55
P1655
10.108 P1655 — SVS SHORT CIRCUIT TO BATTERY ERROR (PIKUP)

in the EMS ECU

NORMAL OPERATION
• Ignition ON
• Ignition ON
• The SVS lamp (Check Engine Lamp) does
not glow/ON • Faulty EMS ECU
DTC REACTIONS
cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1655
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
0.5
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1655
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNEC-
TOR NO
CHECK ENGINE —
EMS ECU E1 48
SIGNAL

B2 07
SIGNAL


STEP A– CHECK SHORT CIRCUIT TO BATTERY OF SVS LAMP (CHECK ENGINE LAMP)
SIGNAL WIRE
EMS - EDC17C55
P1655
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
battery supply
• Replace Instrument Cluster, if problem is
EMS - EDC17C55
P1655
10.109 P1655 — SVS (CHECK ENGINE LAMP) SHORT CIRCUIT TO

BATTERY ERROR (PIKUP EXTRA LONG)
10.109.1 SVS lamp (Check Engine Lamp)
in the EMS ECU

NORMAL OPERATION
• Ignition ON
• Short to battery
• Ignition ON
DTC REACTIONS
cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1655
IC-3 M 9
IC-3 F 9
BATTERY B1 24
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP
ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNECTOR
NO
CHECK ENGINE —
EMS ECU E1 48
SIGNAL

B1 09
SIGNAL
EMS - EDC17C55
P1655


STEP A– CHECK SHORT CIRCUIT TO BATTERY OF SVS LAMP (CHECK ENGINE LAMP)
SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
battery supply
EMS - EDC17C55
P1654

GROUND ERROR (PIKUP)
in the EMS ECU

NORMAL OPERATION
• Ignition ON
• Short to ground
• Ignition ON
not glow • Faulty EMS ECU
DTC REACTIONS
cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1654
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
E13 0.5
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1654
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNEC-
TOR NO
CHECK ENGINE —
EMS ECU E1 48
SIGNAL

B2 07
SIGNAL


EMS - EDC17C55
P1654
STEP A– CHECK SHORT CIRCUIT TO GROUND OF SVS LAMP (CHECK ENGINE LAMP)
SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace Instrument Cluster, if problem is ground
EMS - EDC17C55
P1654

GROUND ERROR (PIKUP EXTRA LONG)
10.111.1 SVS lamp (Check Engine Lamp)
in the EMS ECU

NORMAL OPERATION
• Ignition ON
• Short to ground
• Ignition ON
DTC REACTIONS
cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1654
IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP
ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNEC-
TOR NO
CHECK ENGINE —
EMS ECU E1 48
SIGNAL

B1 9
SIGNAL
EMS - EDC17C55
P1654


STEP A– CHECK SHORT CIRCUIT TO GROUND OF SVS LAMP (CHECK ENGINE LAMP)
SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Check the instrument cluster /ECU • Examine the short circuit of SVS almp
ground
EMS - EDC17C55
P160A
10.112 P160A — COOLANT TEMPERATURE OUTPUT NO LOAD (PIKUP)

10.112.1 ENGINE HIGH TEMPERATURE WARNING LAMP
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
open circuit.

NORMAL OPERATION
• Ignition ON
• The coolant temperature output voltage,
which is given to the cluster from ECU as an
output. The ECU checks whether this voltage
is within a specified range (0 or 5V).
DTC DETECTING CONDITIONS • Open circuit of Engine high temperature
warning lamp
• Ignition ON
• ECU detect DTC when open circuit in
coolant temperature signal • Faulty EMS ECU
DTC REACTIONS
• No Engine high temperature warning lamp
in the cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P160A
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
0.5
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P160A
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNECTOR
NO
HIGH TEMPERATURE
EMS ECU E1 70
—SIGNAL
INSTRUMENT CLUSTER (10 P) HIGH TEMPERATURE

B1 5
—SIGNAL


EMS - EDC17C55
P160A
STEP A – CHECK OPEN CIRCUIT OF ENGINE HIGH TEMPERATURE WARNING LAMP

SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of Engine high

temperature warning lamp signal wire
STEP B– CHECK SHORT CIRCUIT TO GROUND OF ENGINE HIGH TEMPERATURE

WARNING LAMP SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P160A
OK NOT OK
• Examine the short circuit of Engine high

temperature warning lamp signal wire with
ground
• GO TO STEP C
STEP C– CHECK SHORT CIRCUIT TO BATTERY OF ENGINE HIGH TEMPERATURE

PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Check the instrument cluster /ECU • Examine the short circuit of Engine high
connector for damage or Oxidation temperature warning lamp signal wire with
EMS - EDC17C55
P160A
10.113 P160A — COOLANT TEMPERATURE OUTPUT NO LOAD (PIKUP

EXTRA LONG)
open circuit.

NORMAL OPERATION
• Ignition ON
DTC DETECTING CONDITIONS • Open circuit of Engine high temperature
warning lamp
• Ignition ON
• EMS ECU detect open circuit in Engine high
temperature warning lamp • Faulty EMS ECU
DTC REACTIONS
in the cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P160A
IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP
ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNECTOR
NO
HIGH TEMPERATURE
EMS ECU E1 70
—SIGNAL

B1 07
—SIGNAL
EMS - EDC17C55
P160A



SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

EMS - EDC17C55
P160A

PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

ground
• GO TO STEP C

PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
EMS - EDC17C55
P160A
OK NOT OK
battery supply
• Replace Instrument cluster, if problem is
exists, replace EMS ECU • Replace the wiring harness
EMS - EDC17C55
P160B
10.114 P160B — COOLANT TEMPERATURE OUTPUT EXCESS TEMP

(PIKUP)
excess temperature

NORMAL OPERATION
• Ignition ON
is within a specified range (0 or 5V)..
• Loose contact of Engine high temperature
DTC DETECTING CONDITIONS warning lamp signal wire
• Ignition ON • Short to battery / ground
• The coolant temperature output voltage, • Faulty wiring harness
output. The ECU checks whether this voltage • Faulty EMS ECU
is within a specified range (0 or 5 V).
DTC REACTIONS
• Over heat detect in power stage
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P160B
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
0.5
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P160B
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNEC-
TOR NO
ENGINE TEMPERATURE
EMS ECU E1 70
—SIGNAL
INSTRUMENT CLUSTER (10 P) ENGINE TEMPERATURE

B1 05
—SIGNAL


EMS - EDC17C55
P160B

SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK


PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P160B
OK NOT OK

ground
• GO TO STEP C

PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
EMS - EDC17C55
P160B
10.115 P160B — COOLANT TEMPERATURE OUTPUT EXCESS TEMP

(PIKUP EXTRA LONG)
excess temperature

NORMAL OPERATION
• Ignition ON
is within a specified range (0 or 5V).. • Loose contact of Engine high temperature
warning lamp signal wire
• Ignition ON
• Over heat detect in power stage
• Faulty EMS ECU
DTC REACTIONS
in the cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P160B
IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP
ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNECTOR
NO
HIGH TEMPERATURE
EMS ECU E1 70
—SIGNAL

B1 07
—SIGNAL
EMS - EDC17C55
P160B



SIGNAL WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

EMS - EDC17C55
P160B

PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK

ground
• GO TO STEP C

PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
EMS - EDC17C55
P160B
OK NOT OK
battery supply
EMS - EDC17C55
P1608
10.116 P1608 — COOLANT TEMPERATURE OUTPUT SHORT CIRCUIT TO

BATTERY (PIKUP)
short circuit to battery.

NORMAL OPERATION
• Ignition ON
• Coolant output Short to battery
• Ignition ON
• Faulty Instrument Cluster
• EMS ECU detect short circuit to battery in
Engine high temperature warning lamp signal • Faulty EMS ECU
DTC REACTIONS
in the cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1608
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
0.5
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1608
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNECTOR
NO
HIGH TEMPERATURE —
EMS ECU E1 70
SIGNAL
INSTRUMENT CLUSTER (10 P) HIGH TEMPERATURE —

B1 05
SIGNAL


EMS - EDC17C55
P1608
STEP A– CHECK SHORT CIRCUIT TO BATTERY OF ENGINE HIGH TEMPERATURE

PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
EMS - EDC17C55
P1608

BATTERY (PIKUP EXTRA LONG)
short circuit to battery.

NORMAL OPERATION
• Ignition ON
• Coolant temperature output Short to battery
• Ignition ON
• ECU detect short to battery in Engine high
temperature warning lamp signal • Faulty EMS ECU
DTC REACTIONS
in the cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1608
IC-3 M 9
IC-3 F 9
BATTERY B1 24
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP
ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNEC-
TOR NO
EMS ECU E1 70
SIGNAL
INSTRUMENT CLUSTER (32 P) ENGINE TEMPERATURE

B1 07
—SIGNAL
EMS - EDC17C55
P1608


STEP A– CHECK SHORT CIRCUIT TO BATTERY OF ENGINE HIGH TEMPERATURE

PRE CONDITION
• Ignition OFF
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
EMS - EDC17C55
P1609

GROUND (PIKUP)
short circuit to ground.

NORMAL OPERATION
• Ignition ON
is within a specified range (0 or 5V). • Coolant temperature output Short to ground
DTC DETECTING CONDITIONS • Faulty Instrument Cluster
• ECU detects short to ground in Engine high • Faulty EMS ECU
temperature warning lamp signal
DTC REACTIONS
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1609
IC-3 M
IC-3 F
9
9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
WATER IN DAIG
MIL LAMP FUEL LAMP
30A
B1 5 7 9 B2 7
E3 E4 A E13 4
Y/G
0.5
GR/R
G/P
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85 33
8 2 19 IC-2 M 21 32
33
19 IC-2 F 21 32
0.5
Y/G
GR/R
G/P
0.5
E13 0.5
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 90 68 48
SIG SIG SIG SIG
RLY GND
SUP
SUP
EMS - EDC17C55
P1609
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 10 9 8 7 6 5 4 3 2 1
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
P1A01F001_E1
CONNEC-
TOR NO
EMS ECU E1 70
SIGNAL

B1 05
SIGNAL


EMS - EDC17C55
P1609
STEP A– CHECK SHORT CIRCUIT TO GROUND OF ENGINE HIGH TEMPERATURE

PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace Instrument Cluster, if problem is ground
EMS - EDC17C55
P1609

GROUND (PIKUP EXTRA LONG)
short circuit to ground.

NORMAL OPERATION
• Ignition ON
• Coolant output Short to ground
• Ignition ON
• ECU detects short to ground in Engine high
temperature warning lamp • Faulty EMS ECU
DTC REACTIONS
in the cluster
HEALING CONDITION
• Fault absent
EMS - EDC17C55
P1609
IC-3 M 9
IC-3 F 9
B1 24
BATTERY
+ E5
COOLANT TEMP
GAUGE
12V
DAIG 1 MIL LAMP
ESS WATER IN
FUEL
LAMP INDICATION
L
30A
B1 7 9 15 3 13
E3 E4 A E13 4
GR/R
G/P
G/P
Y/G
0.5
0.5
0.5
B/R
0.5
0.5
15A
E35 4 8
30 86
E13 10
87 85
8 2 19 IC-2 M 33 21 21 32
19 IC-2 F 33 21 21 32
GR/R
G/P
0.5
G/P
0.5
0.5
0.5
Y/G
E13
B/R
0.5
20A
E13
P/L
0.5
E1 6 4 50 70 48 90 28 68
SIG SIG SIG SIG SIG
RLY GND
SUP
SUP
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
3 4
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
P4A00F001_B1
P1A01F001_E1
CONNEC-
TOR NO
EMS ECU E1 70
SIGNAL

B1 07
SIGNAL
EMS - EDC17C55
P1609


STEP A– CHECK SHORT CIRCUIT TO GROUND OF ENGINE HIGH TEMPERATURE

PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
ground
EMS - EDC17C55
P1641
10.120 P1641 — SOFTWARE RESET ERROR

10.120.1 SOFTWARE RESET ERROR
EMS ECU monitors the supply voltage and registers a DTC if the voltage is less than range

NORMAL OPERATION
• Ignition ON
• The monitored supply voltage monitored to
EMS ECU is with in the range of 8-16 V
• Charging circuit malfunction
• Short to ground in EMS ECU power supply
• Ignition ON wire
• The EMS ECU supply voltage is less than 5 • Loose EMS ECU ground
V and a software reset happens
• Faulty EMS ECU
DTC REACTIONS
• Engine shuts OFF.
HEALING CONDITION
• Ignition Off/On

• Check the battery voltage and ensure it is within the range (11-14V). If voltage is less, check
for charging circuit malfunction
• Check for loose EMS ECU ground connection
• Check for short to ground in EMS ECU power supply
EMS - EDC17C55
P1707
10.121 P1707 — T50 SIGNAL ERROR

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

NORMAL OPERATION
• Ignition ON
• The T50 input (crank) is monitored by EMS
ECU is with in the allowable duration
• Short to battery in T50 input to EMS ECU
• Ignition switch malfunction
• Ignition ON
• The key hold Continuously in the cranking
• The T50 input is available at EMS ECU position
continuously for 7 seconds
• Faulty EMS ECU
DTC REACTIONS
HEALING CONDITION
• Ignition Off/On
• Check the battery for short to battery in T50 input to EMS ECU
• Check for ignition switch malfunction
• Check for mechanical failure in engine which results in lengthy continuous cranking
EMS - EDC17C55
P0071
10.122 P0071 — SIGNAL RANGE CHECK FOR BATTERY SENSOR

SIGNAL ABOVE MAXIMUM LIMIT
EMS ECU continuously monitors the battery voltage . The normal operating voltage for EMS
ECU is 8 –16 V. If the voltage is lesser or greater than the range , then error gets registered.

NORMAL OPERATION
• Ignition ON
• EMS ECU receives a supply voltage of 8 –
16 V.
• Ignition ON
• The supply voltage to EMS ECU is more
than 16.8 V for few seconds • Faulty Charging System
DTC REACTIONS
• EMS ECU switches OFF
HEALING CONDITION
• Ignition Off/On


EMS - EDC17C55
P0071
STEP A– CHECK BATTERY VOLTAGE
PRE CONDITION
• Ignition ON
• Engine running at high idle
TEST PROCEDURE
• Check the voltage between battery positive and battery negative terminals
ACCEPTANCE CRITERIA
• Voltage 12 to 14.5 V
ACTION TO BE TAKEN
OK NOT OK

of charging system
EMS - EDC17C55
P1406
10.123 P1406 — SRC FOR EGR FEEDBACK SENSOR ABOVE MAXIMUM

LIMIT
10.123.1 EGR FEEDBACK SENSOR
The EGR valve actuation is controlled by EMS ECU through EGR modulator .EGR feedback
valve senses the actual % opening of the EGR valve and sends to EMS ECU

NORMAL OPERATION
• Ignition ON
• The measured output signal of EGR
feedback sensor is within the range.
• Ignition ON • Open EGR feedback sensor ground wire
• The measured output signal of EGR • EGR feedback sensor supply and signal
feedback sensor is above the maximum wire short
range.
• Faulty EGR feedback sensor
DTC REACTIONS
• MIL lamp will be continuously ON after 3
driving cycles.
HEALING CONDITION
• Ignition Off/On
EMS ECU
POWER SIG GND
15 37 58
O/BR
0.5
Y/R
0.5
R/O
0.5
1 3 2
E10
EGR
POSITION
SENSOR
EMS - EDC17C55
P1406
E1 - EMS ECU E10 - EGR MODULATOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
3 2 1
P1A01F001_E10
P1A01F001_E1
CONNECTOR
NO
15 POWER
58 GROUND
1 POWER
EGR MODULATOR E10 3 SIGNAL
2 GROUND

• Perform 3 driving Cycles

EMS - EDC17C55
P1406
STEP A – CHECK SHORT TO BATTERY OF EGR FEEDBACK SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• EGR feedback sensor wiring harness connector (E10) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Examine the short circuit of EGR feedback

sensor signal with battery positive
STEP B– CHECK SHORT CIRCUIT BETWEEN POWER AND SIGNAL WIRES
PRE CONDITION
• Ignition OFF
• EGR feedback sensor wiring harness connector DISCONNECTED (E10)
TEST PROCEDURE
• Check the resistance between pin 1 & 3 of E10
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
EMS - EDC17C55
P1406
OK NOT OK
• Suspect EGR feedback sensor • Examine the short circuit of EGR feedback
malfunction sensor signal and power wires.
• Replace EGR feedback sensor with a new • Replace the wiring harness
one. • Clear the DTC and verify
EMS - EDC17C55
P1405
10.124 P1405 — SRC FOR EGR FEEDBACK SENSOR BELOW MINIMUM

LIMIT
10.124.1 EGR FEEDBACK SENSOR
The EGR valve actuation is controlled by EMS ECU through EGR modulator .EGR feedback
valve senses the actual % opening of the EGR valve and sends to EMS ECU

NORMAL OPERATION
• Ignition ON
• The measured output signal of EGR
feedback sensor is within the range.
DTC DETECTING CONDITIONS • Open EGR feedback sensor supply wire
• Ignition ON • Open EGR feedback sensor signal wire
• The measured output signal of EGR • EGR feedback sensor signal wire short to
feedback sensor is below the minimum ground
range.
• Faulty EGR feedback sensor
DTC REACTIONS
• Faulty EMS ECU
• MIL lamp will be continuously ON after 3
driving cycles.
HEALING CONDITION
• Ignition Off/On
EMS ECU
POWER SIG GND
15 37 58
O/BR
0.5
Y/R
0.5
R/O
0.5
1 3 2
E10
EGR
POSITION
SENSOR
EMS - EDC17C55
P1405
E1 - EMS ECU E10 - EGR MODULATOR
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
3 2 1
P1A01F001_E10
P1A01F001_E1
CONNEC-
TOR NO
15 POWER
58 GROUND
1 POWER
EGR MODULATOR E10 3 SIGNAL
2 GROUND

• Turn ignition ON
• Initialise the diagnostic tool
• Turn ignition OFF and ON.
• Perform 3 driving Cycles
EMS - EDC17C55
P1405

STEP A – CHECK OPEN CIRCUIT OF EGR POWER WIRE
PRE CONDITION
• Ignition OFF
• EGR feedback sensor wiring harness connector (E10) DISCONNECTED
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 5 ± 0.25 V
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of EGR feedback

sensor power wire
STEP B – CHECK OPEN CIRCUIT OF EGR FEEDBACK WIRE
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
ACCEPTANCE CRITERIA
EMS - EDC17C55
P1405
ACTION TO BE TAKEN
OK NOT OK
• Examine the open circuit of EGR feedback

wire
STEP C – CHECK SHORT CIRCUIT BETWEEN SIGNAL / GROUND WIRE OF EGR

FEEDBACK
PRE CONDITION
• Ignition OFF
TEST PROCEDURE
• Check the resistance between pin 3 and ground
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Replace EGR • Examine the short circuit of EGR feedback

• If problem still exists, replace EMS ECU sensor ground and signal wires
with a new one. • Replace the wiring harness
EMS - EDC17C55
P007D
10.125 P007D — SRC FOR INTERCOOLER DOWNSTREAM

TEMPERATURE SENSOR ABOVE MAXIMUM LIMIT
10.125.1 AIR MASS (BOOST PRESSURE)TEMPERATURE SENSOR
Air mass temperature sensor is an integral part of Air mass pressure sensor and is used to
measure the intercooler downstream temperature.

NORMAL OPERATION
• Ignition ON
Air mass temperature sensor (Boost
Pressure Sensor) is within the range
• Air mass temperature sensor (Boost
• Ignition ON pressure) sensor wires
• EMS ECU supply voltage 8-16 V • Short to battery of Air mass temperature
• The measured output voltage of the Air wires
mass temperature sensor is higher than the • Faulty Air Mass Sensor (Boost Pressure
maximum range Sensor)
DTC REACTIONS • Malfunctioning EMS ECU
• MIL lamp continuously ON after 3 driving
cycles
• Air mass temperature sensor (Boost
pressure) value taken for calculations
HEALING CONDITION
• Ignition Off/On
AIR
EMS
MASS
ECU
87 SENSOR
0.5 2 SIG
SIG
Y/L
78
GND
0.5 1 GND
BR/W
56 4 SIG
SIG
0.5
Y/L
35 3
SUP 0.5
5V
E1 O/L E8
SUP 5V
EMS - EDC17C55
P007D
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4
P1A01F001_E1 P1A01F007_E8
CONNEC-
TOR NO
AIR MASS SENSOR (Boost Pressure
Sensor) E8 2 SIGNAL


EMS - EDC17C55
P007D
STEP A – CHECK SHORT TO BATTERY OF AIR MASS (BOOST PRESSURE)

TEMPERATURE SENSOR SIGNAL WIRE
PRE CONDITION
• Ignition OFF
• Air Mass Sensor (Boost Pressure Sensor) wiring harness connected DISCONNECTED
(E8)
• Ignition ON
TEST PROCEDURE
ACCEPTANCE CRITERIA
• Voltage = 0 V
ACTION TO BE TAKEN
OK NOT OK
• Suspect internal failure of Air Mass Sensor • Examine the short circuit of Air mass
(Boost Pressure Sensor). temperature signal wire with battery positive
• Replace boost pressure sensor • Replace the wiring harness
EMS - EDC17C55
P007C
10.126 P007C — SRC FOR INTERCOOLER DOWNSTREAM

TEMPERATURE SENSOR BELOW MINIMUM LIMIT
10.126.1 AIR MASS (BOOST PRESSURE ) TEMPERATURE SENSOR
Air temperature sensor is an integral part of Air Mass Sensor (Boost Pressure Sensor) and is
used to measure the intercooler downstream temperature

NORMAL OPERATION
• Ignition ON
Air Mass Sensor (Boost Pressure Sensor) is
within the range
• Ignition ON
• Short Air Mass Sensor (Boost Pressure
• EMS ECU supply voltage 8-16 V Sensor) wiring harness
• The measured output voltage of the Air • Faulty Air Mass Sensor (Boost Pressure
Mass Sensor (Boost Pressure Sensor) is Sensor)
lower than the minimum range
DTC REACTIONS
• MIL lamp continuously ON after 3 driving
cycles
• Default Air temperature value taken for
calculations
HEALING CONDITION
• Ignition Off/On
AIR
EMS
MASS
ECU
87 SENSOR
0.5 2 SIG
SIG
Y/L
78
GND
0.5 1 GND
BR/W
56 4 SIG
SIG
0.5
Y/L
35 3
SUP 0.5
5V
E1 O/L E8
SUP 5V
EMS - EDC17C55
P007C
5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
1 2
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4
P1A01F001_E1 P1A01F007_E8
CONNECTOR
NO
Air Mass Sensor (Boost Pressure
Sensor) E8 2 SIGNAL

• Proceed to DIAGNOSTIC PROCEDURE if P007C is present

EMS - EDC17C55
P007C
STEP A– CHECK SHORT CIRCUIT OF AIR MASS (BOOST PRESSURE) TEMPERATURE

SENSOR SIGNAL WIRE TO GROUND
PRE CONDITION
• Ignition OFF
DISCONNECTED
TEST PROCEDURE
• Check the resistance between pin 2 of E8 and ground.
ACCEPTANCE CRITERIA
ACTION TO BE TAKEN
OK NOT OK
• Suspect internal failure of Air Mass Sensor • Examine the Short circuit of Air mass
(Boost Pressure Sensor). (Boost pressure) temperature signal wire to
• Replace boost pressure sensor with a new ground.
one • Replace the wiring harness
EMS - EDC17C55
P1900
10.127 P1900 — ECU MONITORING: ADC NTP ERROR
Monitored
DTC Description Malfunction
Component
The ADC ( Analog to

NTP error in ADC Digital Controller ) of
P1900 —
monitoring the micro controller is
monitored
ECU Monitoring: Test voltage of ADC Error in plausibility of

P163B monitoring the test voltage
ADC test error
ECU Monitoring: Error in plausibility of

Ratiometry correction
P163C Voltage ratio error in ratiometry correction
monitored
ADC
Error in plausibility of
ECU Monitoring:
Function controller function controller
P1621 Query response
monitored and monitoring
communication error
module
ECU Monitoring: SPI SPI communication Interrupted SPI

P1622
communication error monitored communication
Multiple error in
ECU Monitoring: ROM memory
P0605 complete ROM test
ROM memory error monitored during post drive
Too less bytes

ECU Monitoring: MM response to CPU received by MM from
P1623
CPU error is monitored CPU as response
ECU Monitoring:
MM response time is Error in MM response
P1625 Response time error
monitored time
in ECU
ECU Monitoring:
SPI communication Error detected in SPI
P1626 Shut off path test SPI
monitored communication
communication error
LAMP STATUS — Engine check lamp continuously ON

DTC REACTION — Engine will not start
EMS - EDC17C55
P1900

• Turn ignition OFF/ON
• If DTC still exists replace the EMS ECU with a new one
EMS - EDC17C55
P1628
10.128 P1628 — ECU MONITORING: SHUT OFF PATH UNDER VOLTAGE

ERROR
Monitored
Component
ECU Monitoring: Shut off path test Error in shut off path
P1628 Shut off path under monitored for under test of the under
voltage error voltage voltage detection
ECU Monitoring: Shut off path check Error in shut off path
P1629 WDA not working check monitoring
monitored
Time out in calling Error in calling

ECU Monitoring:
P162A operative system operative system
Time out error
services services
ECU Monitoring:
Error during positive Error during positive
P162C Positive test failure
test is monitored test
error
ECU Monitoring: Error in time Error in time

P162D Time out error for monitoring of shut off monitoring of shut off
shut off path test path test path test
ECU Monitoring: Shut off path test Error in shut off path
P163A Over voltage monitored for over test of the over
monitoring error voltage voltage detection


EMS - EDC17C55
P060D
10.129 P060D — CONTINUOS TORQUE MONITORING
Monitored
Component
ECU Monitoring: Two voltage values Implausible

P060D Accelerator position of accelerator pedal accelerator pedal
error is monitored voltage
Offset between
calculated engine Non-permissible
ECU Monitoring: speed and engine offset between the
P061C Engine speed error speed with low engine speed of level
resolution is 2 and level 1
monitored
Rail pressure level 1

ECU Monitoring: Rail Error in the
an level 2 values are
P1638 pressure monitoring plausibility check of
monitored for
plausibility error rail pressure
plausibility
If the difference
between the
programmed
ECU Monitoring: Plausibility of energizing time and
P060A Energizing time injection quantities the measured
plausibility error monitored energizing time
exceeds a limit then
this error will be
registered


EMS - EDC17C55
11 SYMPTOM BASED DIAGNOSIS - WITH NO DTC CODES

Complaint — Engine not starting
Error codes — No error codes.
Caution:
• After dry run, switch the Ignition OFF for 1 min and switch it ON.
• Follow the above step for 3 to 5 times & then crank.
• If the engine is still not starting , loose filter bleeder screw and ensure no air in the fuel
system, Presence of Banjo with overflow valve must, otherwise engine will not start.
• No kink in the fuel leak off from Rail
• If all are found OK then :
• Open the "LIVE DATA" in EMS ECU .
• Check the "Service information for trouble in starting engine"
MAHINDRA>>>BOLERO PIKUP>>>BOLERO PIKUP>>>BOLERO PIKUP_EMS
• Note the value .

• Convert it into binary
• See the bit position of first occurrence of "1" from right and look against the bit position in
the table below
EMS - EDC17C55
P060D
Bit Implication
Conditions to be met Action to be taken
Position
• Check the fuel level in

fuel tank
The engine speed is • Check for any

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

less voltage
• Check any loose
The pressure built up in connections in starter
the rail is sufficient but motor
1 the engine speed is Cranking RPM less • Check the starter
below the minimum motor for any
threshold malfunction
• Check for Engine
partial seizure/hydraulic
lock
The pressure built up in

the rail is sufficient but
the engine speed is Check the sync status
Engine speed and Cam
above the minimum label under Start Live
2 phase sensor not
threshold but there is a data pocket and refer the
synchronised
problem with table given in next page.
synchronization of
engine
There is a shut off Check the value of

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

When there is a start
Starter engagement Check for any
4 attempt a check is made
status immobilizer related errors
whether the starter has
been released or not
EMS - EDC17C55
P060D
11.1 REASON FOR TORQUE LIMITATION

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

0 event of a system error
1 Limiting torque for differential protection
Limiting torque for engine mechanics

2 protection
3 Limiting torque for smoke limitation
Limiting torque due to quantity limitation in

4 the event of a system error
Limiting torque for protection against

5 overheating
Limiting torque for the propulsion in the event

6 of a system error
7 Maximum gearbox input torque
Limiting torque due to injection quantity

8
limitation from T3Lim
Limiting torque due to high pressure pump

9
unit
13 Limiting torque due to inner engine torque
14 Limiting torque for engine protection
EMS - EDC17C55
P060D
11.2 SYNCHRONIZATION STATE
CODE NUMBER CODE NAME CODE DESCRIPTION
Basic initialization of state

0 INIT
machine
1 RECOVER Resetting the counters
Engine stops or error case in

which all engine speed
2 TIME OUT
sensors of system are
defective
Additional asynchronous
interrupts which is generated
3 INTERIMS when engine position is
detected based on the time
condition of system.
Plausibility test is done on

the events of the redundant
sensor system w/o the mail
4 WAIT_INC sensor system delivering
events. Interrupts are
generated with min. system
frequency.

sensor system w/o the mail
5 PHASE_FREQ_CHK sensor system delivering
events. Interrupts are
generated with max. system
frequency.

8 PHASE_PLAUS_CHK
sensor system w/o the main
system delivering events.
The overall system behaves

frequent Synchronous &
16 POLLING waits for further events to
determine the phases.
Waits for the unique

32 WAIT_PHASE positioning by the phase
system.
A unique positioning of the

33 VERIFY system has occurred. A
EMS - EDC17C55
P060D
plausibility test is run on all

sensor systems write each
other in their status & angle
info.
RESYNC_OVERFLOW No unique position was

34
found
35 RESYNC_OFFSET —
The system wait until there is

64 POST a complete engine stop.
128 VERIFY_BACKUP —
129 BACK UP —
130 START_BACKUP —
Engine has decelerated.

131 WAIT_BACKUP Metering unit no longer be
activated.

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Diagnostic Manual

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

7 STANDARD TEST PROCEDURE ............................................................................................ 22

9.2 CONNECTOR VIEWS AND INFORMATION ..................................................................... 28

9.3 DIAGNOSTIC PROCEDURE ............................................................................................. 28

10 DTC BASED DIAGNOSIS.......................................................................................................... 33

10.2 P1126 — COOLANT TEMPERATURE SENSOR DYNAMIC TEST NON

10.3 P0118 — SRC FOR COOLANT TEMPERATURE SENSOR ABOVE MAX

10.4 P0117 — SRC COOLANT TEMPERATURE SENSOR BELOW MINIMUM

10.5 P062F — ECU EEPROM ERROR .................................................................................. 46

10.13 P0406 — EGR VALVE SHORT TO BATTERY ERROR (PIKUP EXTRA

10.14 P0405 — EGR VALVE SHORT TO GROUND ERROR (PIKUP) ................................... 71

10.16 P2228 — SRC FOR ENVIRONMENTAL PRESSURE SENSOR BELOW MIN

10.17 P2229 — SIG RANGE CHECK FOR ENVIRONMENTAL PRESSURE SENSOR

10.18 P0340 — CAMSHAFT SENSOR NO SIGNAL ERROR ................................................. 82

10.24 P0182 — SIGNAL RANGE CHECK FOR FUEL TEMPERATURE SENSOR

10.25 P268C — CYLINDER 1 INJECTOR ADJUSTMENT CODE INCORRECT

10.26 P268E — CYLINDER 2 INJECTOR ADJUSTMENT CODE INCORRECT

10.27 P268F — CYLINDER 3 INJECTOR ADJUSTMENT CODE INCORRECT

10.28 P268D — CYLINDER 4 INJECTOR ADJUSTMENT CODE INCORRECT

10.29 P0201 — CYLINDER 1 INJECTOR OPEN LOAD ERROR .........................................120

10.38 P0001 — METERING UNIT OPEN LOAD ERROR .....................................................152

10.40 P0004 — METERING UNIT OUTPUT SHORT CIRCUIT TO BATTERY

10.41 P0003 — METERING UNIT OUTPUT SHORT CIRCUIT TO GROUND

10.42 P1652 — MIL NO LOAD ERROR (PIKUP)...................................................................164

10.48 P1651 — MIL SHORT CIRCUIT TO GROUND ERROR (PIKUP) ...............................189

10.52 P0627 — PSP OPEN LOAD ERROR ...........................................................................205

10.64 P0563 — SRC FOR BATTERY SENSOR SIGNAL ABOVE MAXIMUM

10.65 P0501 — VEHICLE SPEED SENSOR PLAUSIBILITY ERROR..................................255

10.70 P1C87 — MAXIMUM POSITIVE DEVIATION OF RAIL PRESSURE EXCEEDED

10.71 P1B88 — RAIL PRESSURE NEGATIVE GOVERNOR DEVIATION ERROR IN

10.72 P1D87 — RAIL PRESSURE BELOW MINIMUM LIMIT ERROR IN METERING

10.73 P1C88 — RAIL PRESSURE ABOVE MAXIMUM LIMIT ERROR IN METERING

10.74 P068A — MAIN RELAY EARLY OPENING ERROR ..................................................305

10.81 P171A — CLUTCH 90% SWITCH PLAUSIBLE ERROR(SHORT TO

10.82 P2269 — WATER PRESENCE IN FUEL ERROR ........................................................341

10.86 P126A — WATER IN FUEL LAMP OVER TEMPERATURE ERROR

10.87 P126A — WATER IN FUEL LAMP OVER TEMPERATURE ERROR (PIKUP

10.90 P126C — WATER IN FUEL LAMP SHORT TO GROUND ERROR (PIKUP)..............375

10.92 P1631 — ECU MONITORING: START OF INJECTION PLAUSIBILITY

10.93 P1632 — ECU MONITORING: ZFC NON PLAUSIBILITY ERROR ............................383

10.98 P170D — STARTER RELAY SHORT CIRCUIT TO BATTERY ERROR ....................392

10.101 P1AEC — START/STOP LAMP OVER TEMPERATURE ERROR .............................400

10.103 P1AEA — START STOP LAMP SHORT TO GROUND ERROR ................................405

10.104 P1656 — SVS NO LOAD ERROR (PIKUP)..................................................................409

10.105 P1656 — SVS NO LOAD ERROR (PIKUP EXTRA LONG) .........................................414

10.106 P1657 — SVS OVER TEMPERATURE ERROR (PIKUP) ...........................................418

10.108 P1655 — SVS SHORT CIRCUIT TO BATTERY ERROR (PIKUP) ..............................427

10.112 P160A — COOLANT TEMPERATURE OUTPUT NO LOAD (PIKUP) ........................441

10.113 P160A — COOLANT TEMPERATURE OUTPUT NO LOAD (PIKUP EXTRA

10.114 P160B — COOLANT TEMPERATURE OUTPUT EXCESS TEMP(PIKUP) ...............451

10.115 P160B — COOLANT TEMPERATURE OUTPUT EXCESS TEMP (PIKUP EXTRA

10.116 P1608 — COOLANT TEMPERATURE OUTPUT SHORT CIRCUIT TO BATTERY

10.117 P1608 — COOLANT TEMPERATURE OUTPUT SHORT CIRCUIT TO BATTERY

10.118 P1609 — COOLANT TEMPERATURE OUTPUT SHORT CIRCUIT TO GROUND

10.119 P1609 — COOLANT TEMPERATURE OUTPUT SHORT CIRCUIT TO GROUND

10.120 P1641 — SOFTWARE RESET ERROR .......................................................................475

10.121 P1707 — T50 SIGNAL ERROR ....................................................................................476

10.125 P007D — SRC FOR INTERCOOLER DOWNSTREAM TEMPERATURE SENSOR

10.126 P007C — SRC FOR INTERCOOLER DOWNSTREAM TEMPERATURE SENSOR

10.127 P1900 — ECU MONITORING: ADC NTP ERROR ......................................................493

10.128 P1628 — ECU MONITORING: SHUT OFF PATH UNDER VOLTAGE

10.129 P060D — CONTINUOS TORQUE MONITORING .......................................................496