Man-00091-Bolero Pik Up - MMT CNG Bs3-Diagnotic Manual - 15.04.10

DIAGNOSTIC MANUAL (CNG BS-III)
PIK-UP CNG BS-III
MAXX MAXI TRUCK CNG BS-III
MAN-00091
RELEASED BY –
TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.
www.teknetmahindra.com Rev1 – APRIL 2010
ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP-TO-DATE AT THE TIME OF PUBLICATION. HOWEVER,
SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE. THIS MANUAL IS STRICTLY
MEANT FOR RESTRICTED INTERNAL CIRCULATION WITHIN M&M AUTHORIZED DEALER SERVICE CENTERS.
© 2010 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without
the written permission of Mahindra & Mahindra Ltd.
About the Diagnostic Manual
The diagnostic manual outlines the detailed procedures to troubleshoot complaints related to the CNG
components and Engine system fitted on Bolero Pik-up CNG – BS-III and Maxx Maxi Truck CNG BS-
III vehicles. Since the CNG components and system is sensitive and is under high pressure, only the
trained authorized persons can work on the CNG system in conjunction with M&M diagnostic tool.
The manual consists of –
 Trouble shooting and diagnosis of DTCs (Defect Trouble Codes)
 Use of Smart Tester for Diagnosis.
 Circuit diagram for complete system.
In spite of best efforts to make the manual error-free, a few errors could have inadvertently crept in. If you
identify errors, functional or typographical, please inform your TEKline or pillay.ajay@mahindra.com or
ghag.umesh@mahindra.com. Suggestions to improve the manual and make it more user-friendly are also
welcome.
© 2010 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without
the written permission of Mahindra & Mahindra Ltd.
Diagnostic Manual (CNG-BSIII) MAN-00091
BOLERO PIK-UP / MAXX MAXI TRUCK CNG - BSIII April 2010/Rev 1
CONTENTS….
 How to use this manual……………………………………….. 02
 Brief Specification of the engine…………………………….. 03
 Procedure for using Diagnostic Tool………………………. 04
 List of DTC codes………………………………………………. 12
 Conformity Check……………………………………………… 59
 Circuit Diagram…………………………………………………. 60
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra
1
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2010 Mahindra & Mahindra Ltd.
HOW TO USE THIS MANUAL

In Bolero Pik Up CNG, DTCs can be retrieved through Diagnostic Tool
After a DTC is identified, go to the DTC Index and click on the group under which the DTC appears. The
codes / groups are hyperlinked to the respective trouble shooting chart / pages.
The following is the structure of the Diagnostic Manual –
 Brief description about the sensor/actuator and its function

 Component Location with images
 Possible defect codes related to that sensor/actuator
 Normal operating conditions of the sensor/actuator
 DTC detection conditions and probable causes
 Lamp status and fault reaction
 Related circuit diagram, connectors and wiring plans
 Trouble shooting process
Always keeps the wiring manual handy while using the diagnostic manual
The Diagnostic tool has the ability to test certain actuators as well.
There are certain complaints for which no DTCs are generated.
The trouble shooting procedure for the same is covered in the Symptom based Diagnosis.
2
BRIEF SPECIFICATION OF THE ENGINE
Bore : 88.9 mm
Stroke : 101.6 mm
Power : 51.2 KW
Torque : 170 NM @1800-2200 RPM
Firing Order : 1-3-4-2
Type of ECU : ECM A53
Type of Software : A35ISO_2009.07.06.BI
3
INFORMATION ABOUT DIAGNOSTIC TOOL, CONNECTION & OPERATING PROCEDURE
Introduction of New CNG Diagnostic Tool developed to meet –
 The Diagnostic requirement for existing Bolero Pik Up / Maxi Truck Pik Up CNG BS III vehicles
The procedure for connecting this tool is as follows.
Initial Set up
 Connect Python to the vehicle (Data Link Connector) & computer
Data Link
Connector
K-Line
Connector
 Turn ignition ON
 Configure Python
Double Click on Python
Configuration Icon at Desktop
Python Connection: Auto Detect
Click to Connect to Python
4
Python Connection
Click Ok
Python Connection: Attempting to auto detect
Wait till next screen appears.
5
Python Connection: Successfully Detected
Step – 2 Click OK Step – 1 Click OK
Python Connection: Python device
Click OK
If unable to connect, check the four points stated in the message box and again click
Auto Detect, till Python is detected successfully
6
Double Click on i-SMART CNG

Icon at Desktop
Main Screen
Default Screen
1 2 3 4
6
5
1 Connect Button
2 Disconnect Button
3 Exit Button
4 Demo Button
5 Selection Box
6 Data Window
7 Logging Window
7
DTC SCREEN
Clear Fault Codes from ECM memory & will again read the fault codes present in the ECM
1. Click to
read/clear fault
codes
2. Click to read
fault codes
Click to enable selection box &

switch to other screens
8
CLEAR DTC SCREEN

Clear Fault Codes from ECM memory & will again read the fault codes present in the ECM
1. Click to read/clear
fault codes
2. Click to view clear

fault codes window
3. Click to clear fault Click to enable selection box &

codes from memory switch to other screens
9
LIVE DATA SCREEN

Read Live parameters from the ECM
1. Click + to read live
data
2. Click to view live

data window
Click to enable selection

box & switch to other
screens
10
READ ECM ID SCREEN

Read ECM ID from the ECM.
Write new VIN no. in the ECM
Click to read ECM

identification 1. Enter new VIN No. to
change the VIN no in the ECM
Data Read From ECM
Click to enable selection box &

switch to other screens
11
LIST OF DTC CODES
SR.
P-CODE DESCRIPTION PAGE NO
NO.
1 P0107 MAP SENSOR LOW INPUT 14
2 P0108 MAP SENSOR HIGH INPUT 14
3 P0112 IAT SENSOR LOW INPUT 17
4 P0113 IAT SENSOR HIGH INPUT 17
5 P0117 ECT SENSOR LOW 21
6 P0118 ECT SENSOR HIGH 21
7 P0131 O2 BANK 1 SENSOR 1 LOW INPUT 24
8 P0132 O2 BANK 1 SENSOR 1 HIGH INPUT 24
9 P0134 O2 BANK 1 SENSOR 1 NO ACTIVITY 24
10 P0172 SYSTEM TOO RICH BANK 1 30
11 P0217 ENGINE OVERHEATING 31
12 P0219 ENNGINE OVERSPEED CONDITIION 32
13 P0562 SYSTEM VOLTAGE LOW 33
14 P0563 SYSTEM VOLTAGE HIGH 34
15 P0605 ROM/FLASH MEMORY ERROR 35
16 P0606 ECM INTERNAL FAULT 36
17 P0650 MALFUNCTION INDICATOR LAMP CONTROL CIRCUIT 37
18 P2300 INGNITION COIL 1 LOW CURRENT 39
19 P2301 INGNITION COIL 1 HIGH CURRENT 40
20 P2302 IGNITION COIL 1 SECONDARY FAULT (OPEN) 41
12
SR.
P-CODE DESCRIPTION PAGE NO
NO.
30 P1230 PRIMARY FUEL SHUTOFF SOLENOID FAULT 52
31 P1337 ENGINE POSITION SYNC FAULT 55
32 P1624 ECM CALIBRATION NOT INITIALISED 57
33 P1625 ECM CALIBRATION NOT AUTHORISED 58
13
MANIFOLD ABSOLUTE PRESSURE SENSOR P0107

P0108
Description: Engine air flow is estimated based on the pressure in the
intake manifold. If the sensor become disconnected or failed in a short
to ground condition, this fault will set. The engine may stall before the
DTC sets.
The Engine stopped low MAP DTC may set if the engine speed signal is
interrupted while the engine is still running.
MIL STATUS: ON
MAP Sensor
DTC CODES
DTC DIAGNOSTIC ITEM
P0107 MAP Sensor Low Input
P0108 MAP Sensor High Input
DTC DETECTION CONDITION PROBABLE CAUSE
Engine running test Check the electrical connection to the MAP

sensor
No sensor power supply fault recorded
Check the signal circuit for short – to– ground
MAP Signal level below 0.05 V – DTC P0107
will appear
MAP Signal level above 4.9 V – DTC P0108 will
appear
Engine speed below 6000 RPM Or throttle
position greater that 10%
Condition Exist for 1 Seconds
Engine stopped Test
MAP Sensor reading below 70 kPa

No engine speed signal
No sensor power supply fault recorded
Condition exist for 1 sec
Reaction On vehicle
Stumbling or poor driving characteristics.
14
LAYOUT/POSITION CONNECTOR P0107

P0108
MAP Sensor Location MAP Sensor Connector
MANIFOLD ABSOLUTE PRESSURE SENSOR RELATED PINS AT ECU 52 POLE CONNECTOR
15
TROUBLE SHOOTING P0107

P0108
Check for sensor power supply DTC’s, if present troubleshoot those DTC’s first
Check for 5 V power at the MAP sensor, if not present check wiring
Check sensor ground at the MAP sensor. If no continuity, repair wiring
Connect 5 V sensor power to MAP sensor input, View MAP sensor reading & verify that value is high
(Above 70kPa) Or that the MAP sensor voltage reads 5 V, If not check the sensor wiring
Check MAP sensor output, If NO output replace MAP Sensor.
Check resistance of sensor. Verify that it is within specifications.
CIRCUIT DIAGRAM FOR MANIFOLD ABSOLUTE PRESSURE SENSOR
Check for earthing

LW- GROUND
24 1
BR- SIGNAL
38 2
RW- 5 V
25 3
Check for 5V
G -SIGNAL
37 4
16
INTAKE AIR TEMPERATURE SENSOR P0112

P0113
Description: Engine air flow estimation & ignition timing
required measurement of the temperature of the
incoming air. A short to ground on this sensor will
generate this fault.
MIL STATUS: ON
MAP Sensor
DTC CODES
DTC DIAGNOSTIC ITEM
P0112 IAT Sensor Low Input
P0113 IAT Sensor High Input
If Intake Air Temperature sensor (IATS) Signal Check the electrical connection to the IAT
below 0.1V & this condition exists for 1 Sec – sensor
DTC P0112 will appear Check the signal circuit for short – to– ground
If Intake Air Temperature sensor (IATS) Signal
above 4.85V & this condition exists for 1 Sec –
DTC P0113 will appear
Reaction on vehicle
Difficulty in starting in the case of extreme

actual ambient temperatures.
Cooling fan stays on.
17
LAYOUT/POSITION CONNECTOR P0112

P0113
MAP Sensor Location MAP Sensor Connector
INTAKE AIR TEMPERATURE SENSOR RELATED PINS AT ECU 52 POLE CONNECTOR
TROUBLE SHOOTING
Connect the Diagnostic Tester

Turn ignition Key ON, Keep the engine stopped
The vehicle should stabilize at ambient temperature
Disconnect sensor. Verify temperature sensor voltage reads 5 V. If not, check wiring for short circuit to
ground or adjacent terminals.
Jumper across IATS harness sensor (sensor ground to IATS). Verify temperature sensor voltage reads 0 V.
If not, check harness for continuity.
18
CIRCUIT DIAGRAM FOR INTAKE AIR TEMPERATURE SENSOR P0112

P0113
Check for earthing LW- GROUND

24 1
BR- SIGNAL
38 2
RW- 5 V
25 3
Check for 5V
G -SIGNAL
37 4
19
For DTC P0112 - IAT Sensor Low Input P0112

P0113
IATS Voltage reads below 0.1 V
Yes No
Disconnect the IATS Connector Fault is intermittent, Observe if it

continue replace the sensor
If IATS read more than 4.85 V
Yes No
Fault at Sensor or connection at sensor Fault is sensor signal wire shorted to

ground or sensor ground
Replace or repair & confirm the operation
For DTC P0113 - IAT Sensor High Input Check for short & repair as required
IATS Voltage reads above 4.85 V
Yes No
Disconnect the IATS Connector Fault is intermittent, Observe if it

continue replace the sensor
If IATS read less than 0.1 V
Yes No
Fault at Sensor or connection at sensor Fault is sensor signal wire shorted to

ground or sensor ground
O2 SENSOR
Replace or repair & confirm the operation
Check for short & repair as required
20
COOLANT TEMP SENSOR P0118

P0117
Description: The water temp sensor is located in coolant passage of the cylinder head.
The CTC sensor is a variable resistor, whose resistance is changes as the temperature of
engine coolant flowing pass the sensor. When the coolant temp is low the sensor
resistance is high and when the coolant temp is high the sensor resistance is low. The
ECM checks the voltage and uses the information to stabilize the engine performance
MIL STATUS: ON
CTS DTC CODES
DTC DIAGNOSTIC ITEM
P0118 ECT Sensor High
P0117 ECT Sensor Low
Background
Open or shorted Engine Coolant Temperature
The engine coolant temperature sensor
Sensor Circuit Or Loose or wrong connection
converts the engine coolant temperature to a
Engine Coolant Temperature sensor failed
voltage and outputs it.
The ECU checks whether the voltage is within
specified limit, in addition it checks that the
engine coolant temperature does not drop
while engine is warming up.
Malfunction; Out Of Range
Sensor output voltage has continued to be 5 V

or Higher, for 5 Sec – P0118 DTC will appear
Sensor output voltage has continued to 0.1 V
or Higher for, 4 Sec– P0117 DTC will appear
Other effect:
Engine will Continue to run with Water

Temperature of 120°C
21
LAYOUT / POSITION CONNECTOR P0118

P0117
Sensor Location Connector
COOLANT TEMP SENSOR RELATED PINS AT ECU 52 POLE CONNECTOR
TROUBLE SHOOTING
Ignition “ON”, Disconnect the sensor, Verify temperature voltage 5V, If not check wiring for short circuit
to ground or adjacent terminal
If Wiring Short is short repair/replace accordingly, And if voltage is not as specified then replace sensor
Check for voltage
Y- SIGNAL
12 1
LW- GROUND
24 2
Check for proper earthing
22
TEST PROCEDURE COOLANT TEMPERATURE SENSOR P0118

P0117
Codes – P0117 & P0118
Connect the Diagnostic Tester

Turn ignition Key ON
Verify DTC P0117 Or P0118 are present

Turn the ignition OFF
Disconnect the DTC Connector
Turn the ignition ON & check the voltage between CTS Signal Terminal 1 & Ground
It should be 5 V when ignition ON
Is It
Yes No
Turn the ignition OFF Open or Short between CTS Signal
Measure continuity between ECM & Repair as necessary

Connector Terminal
Measure Continuity between ECM &

Connector Terminal
Is it OK?
Yes No
Connect CTS connector Open or Short between CTS Signal

terminal & ECM
Turn Ignition ON
Repair as necessary
Check the Voltage of CTS
Is it as per specification (5 V)
Yes No
Return the vehicle to original condition, Replace ECT Sensor

Clear all DTC
23
OXYGEN SENSOR (LAMBDA SENSOR) P0131

P0132
Description: The ECM utilizes lambda sensor voltage to determine the air P0134
fuel ratio of the engine. For lowest emission the goal is for the air fuel ratio
to oscillate around lambda of approx. 0.995. If the oxygen sensor is unable to
read the DTC code P0131, P0132 & P0134 will appear.
MIL STATUS: ON
O2 Sensor DTC CODES
DTC DIAGNOSTIC ITEM
P0131 O2 Bank 1 Sensor 1 Low Input
P0132 O2 Bank 1 Sensor 1 High Input
P0134 O2 Bank 1 Sensor 1 No Activity
For DTC P0131 –
At least 600 Sec since the engine was stopped Disconnect the sensor
Oxygen sensor voltage below 0.05 V Check the wiring circuit for short – to– ground
Coolant temperature below 45°C
This condition exists for 1 Sec
For DTC P0132 –
Oxygen sensor voltage above 0.88V Disconnect the sensor
At least 600 Sec since the engine was stopped Check the wiring circuit for short – to– ground
Coolant temperature below 45°C
For DTC P0134 –
Oxygen sensor voltage between 0.4 to 0.55 V Verify connection of Oxygen Sensor & Heater
24
Engine speed above 500 RPM between ECM & Sensor Connector
Engine Load above 10% Check for other oxygen sensor faults (Including
heater faults). Troubleshoot these first
Condition exists for 60 Sec, If the ECT is below 55°C
Condition exists for 150 Sec, If the ECT is Above Verify heater power is available at sensor
55°
If sensor does not generate the signal after
sufficient warm up time replace sensor.
P0131
P0134
O2 Sensor Location O2 Sensor Connector
OXYGEN SENSOR (LAMBDA SENSOR) RELATED PINS AT ECU 52 POLE CONNECTOR
25
For DTC P0131 – O2 Bank 1 Sensor 1 Low Input P0131

P0132
P0134
STEP ACTION VALUE YES NO
1 Turn ignition key OFF Less Go to step 2 Fault is

Connect to Diagnostic Tool than intermittent
Start the Engine 0.05 V observe otherwise
Run the engine until it reaches to replace the Sensor
proper operating temperature
Check O2 Sensor voltage
2 Disconnect the O2 Sensor electrical Less Go to step 2 Go to step 3

connector than
Check O2 Sensor Voltage 0.05 V
3 Check the O2 Sensor signal wire for a -- Repair & ECM is damaged.
short to ground or sensor ground in the confirm the Replace & confirm
harness operation the operation
Is there a short?
4 Using a multimeter, check the following Less Sensor is Exhaust leak before
pin out on the O2 Sensor connector than Shorted. the Oxygen sensor.
(Sensor Side) 100Ω Replace & Repair & confirm
Resistance between terminal 1 & 3 confirm the operation
Resistance between terminal 2 & 3 operation
26
For DTC P0132 – O2 Bank 1 Sensor 1 High Input P0131

P0132
P0134
STEP ACTION VALUE YES NO
1 Turn ignition key OFF More Go to Fault is intermittent

Connect to Diagnostic Tool than step 2 observe otherwise replace
Start the Engine 0.88 V the Sensor
Run the engine until it reaches to
proper operating temperature
Check O2 Sensor voltage
2 Disconnect the O2 Sensor electrical More Go to Sensor Or connection at

connector than step 2 sensor end is at fault.
Check O2 Sensor Voltage 0.88 V Replace or repair as
necessary & confirm
Operation
3 Check the O2 Sensor signal wire for a -- Repair & ECM is damaged. Replace
short to ground or sensor ground in Confirm & confirm the operation
the harness Operation
Is there a short?
27
For DTC P0134 – O2 Bank 1 Sensor 1 No Activity P0131

P0132
P0134
Step Action Value Yes No
1 Turn ignition key OFF -- There is an Go to step 2

Connect to Diagnostic Tool exhaust leak
Turn ignition key to the “ON” present, Locate &
Position but do not start repair the leak
Oxygen sensor should slowly then confirm
warn to the touch (It takes proper oxygen
about 10 Min to warm) sensor operation
Does it?
2 Inspect sensor & wiring -- Repair wiring as Oxygen sensor has been
harness open circuits necessary contaminated, Replace &
Have you found anything? check the engine condition
for burning oil or foreign
contaminates in the intake
air or exhaust system.
28
P0131
P0132
P0134
V- SIGNAL
48 4
BRW- SIGNAL
36 3
Check for earthing

BL - GROUND
33 2
R +VE
18 1
Check for 5 V
29
DTC CODES P0172
DTC DIAGNOSTIC ITEM
P0172 System too Rich Bank 1
Description: This DTC Code will appear when problem with fuel delivery or Fuel feedback control.
MIL STATUS: OFF
DTC Code : P0172

Check for misfire or other DTC code first and
This DTC code will mainly occur when there is rectify them and confirm that this DTC code
problem with fuel delivery or problem with Fuel reappear.
feedback system i.e. Problem with O2 Sensor. Check for any gas leakage or listen for gas leakage.
Check for Exhaust restrictions.
Reaction on Vehicle Confirm pressure regulator out let pressure and
confirm proper functioning of pressure regulator.
Exhaust smell or poor driving in some cases
TROUBLE SHOOTING
If problem remain open even after rectifying/attending above problems – Replace O2 Sensor
30
DTC CODES P0217
DTC DIAGNOSTIC ITEM
P0217 Engine Over Heating
Description: Operating the engine with excessive coolant temperature may result in engine damage.
This DTC code is set when engine is operated at an excessive coolant temp. i.e. More than 105 °C and
minimum run time is 30 Sec.
MIL STATUS: OFF. It will be shown by Dash board Indicator.
DTC Code : P0217

Check the Coolant Level
This DTC code will mainly occur when Engine is Check for Thermostat operation
operating with High Coolant temperature. Check for Thermostat temperature rating is
correct
More than 105 °C Check for water pump functioning
Check for blockages in radiator or hoses
Engine Run Time: 30 Sec.
Check for correct cooling fan operation.
Reaction on Vehicle
Potential engine damage.
TROUBLE SHOOTING
Repair Or Replace above mentioned non functioning parts.
31
DTC CODES P0219
DTC DIAGNOSTIC ITEM
P0219 Engine Over speeding
Description: In order to prevent engine damage, fuelling is disabled above programmed engine speed. If
the engine is operated at a very high speed, engine damage may occur. This may include either
catastrophic engine failure (Valve/piston contact, tossed connecting rods) to engine life reduction.
This DTC code will appear when engine is continuously running above 4500 RPM for more than 2.5 Sec.
MIL STATUS: OFF
DTC Code : P0219

Incorrect Transmission operation.
This DTC code will mainly occur when Engine Stuck open throttle.
speed Exceeds the safe limits of operation.
More than 4500 RPM
Engine Run Time: More than 2.5 Sec.
Reaction on Vehicle
Customer may not notice any issue until hardware

damage occurs. Potential damage to valve train.
TROUBLE SHOOTING
32
DTC CODES P0562
DTC DIAGNOSTIC ITEM
P0562 System voltage low
Description: The system voltage has to guarantee to perform diagnosis functions. The Electronic control
unit (ECM) monitors the battery voltage. And its function is dependent on stable system voltage. This
DTC code indicates that the charging system or battery is unable to maintain a nominal system voltage.
MIL STATUS: OFF
DTC Code : P0562

Check Battery and Alternator for proper
This DTC code will mainly occur when system operation.
voltage is below specified system voltage. Check fluid level of battery
Check for scaling at battery terminal
Less than : 9V Check all ground – Harness, Engine & vehicle.
Reaction on Vehicle
ECM or other electrical equipment may be

damage.
TROUBLE SHOOTING
33
DTC CODES P0563
DTC DIAGNOSTIC ITEM
P0563 System voltage High
Description: The system voltage has to guarantee to perform diagnosis functions. The Electronic control
unit (ECM) monitors the battery voltage. And its function is dependent on stable system voltage. This
DTC code indicates that the charging system or battery is unable to maintain a nominal system voltage.
High voltage may damage or reduce the life of ECM and peripheral components. This DTC code must be
rectified immediately
MIL STATUS: OFF.
DTC Code : P0563

Check Battery and Alternator for proper
This DTC code will mainly occur when system operation.
voltage is below specified system voltage. Check fluid level of battery
Check for scaling at battery terminal
More than : 16V Check all ground – Harness, Engine & vehicle.
Reaction on Vehicle
ECM or other electrical equipment may be

damage.
TROUBLE SHOOTING
34
DTC CODES P0605
DTC DIAGNOSTIC ITEM
P0605 ROM/Flash memory error.
Description: The ECM firmware is stored in flash memory. This DTC code related to Internal Control
Module Read Only Memory (ROM) Error. If the checksum is incorrect, the ECM will not run and this DTC
code will be reported. In addition if the firmware file is corrupt or inoperative, after several attempts to
restart the ECM will enter a firmware update mode and this code will appear.
MIL STATUS: ON.
DTC Code : P0605 Problem with ECM memory.

This DTC code will mainly occur when Internal Replace ECM
control module Read only memory (ROM) error
occur. Or blank or corrupted operating program.
This is related to ECM memory error.
Reaction on Vehicle
Engine will not start.
TROUBLE SHOOTING
35
DTC CODES P0606
DTC DIAGNOSTIC ITEM
P0606 ECM Internal fault.
Description: The This DTC code will appear if it is not passed the functional check during malfunctioning
or if the ROM (Read only memory) corrupted.
MIL STATUS: ON
DTC Code : P0606 Problem with ECM memory.

This DTC code will mainly occur when Internal Replace ECM
control module Read only memory (ROM) error
occur or corrupted. Or blank or corrupted
operating program. This is related to ECM internal
fault.
Reaction on Vehicle
TROUBLE SHOOTING
36
DTC CODES P0650
DTC DIAGNOSTIC ITEM
P0650 Malfunction Indicator Lamp Control Circuit
Description: The Electronic Control Module (ECM) uses the MIL lamp to call attention to Emission or
Drivability related faults. This DTC code will appear if the MIL has a circuit fault.
MIL STATUS: OFF
DTC Code : P0650 Verify the MIL indicator lamp is not burnt out
This DTC code will mainly related to MIL circuit Check if the rest of the instrument cluster is
fault. operational.
Reaction on Vehicle Check wiring connection to lamp.
MIL Lamp will not glow even if the Check for continuity between ECM and lamp
emissions/Drivability related faults are appearing. connection.
Customer will not know even if these faults are Check for signal wire short to ground.
reported on vehicles as the MIL will not glow.
This may affect the performance of vehicle.
TROUBLE SHOOTING
Replace MIL In case of burnt
Replace or Repair wiring in case of short.
37
P0650
MIL CIRCUIT DIAGRAM
38
DTC CODES P2300
DTC DIAGNOSTIC ITEM
P2300 Ignition coil 1 Low current
Description: This diagnostic trouble code indicates that a wiring problem exists between the ECM and
the Ignition coil, or that the Ignition coil is faulty.
MIL STATUS: ON
DTC Code : P2300

Check the electrical connection to the ignition coil.
This DTC code will mainly related problem in
And Ensure Ignition power is available at coils.
wiring between ECM or Ignition coil or Ignition coil
itself is faulty. Check the wiring between the ECM and the
ignition coil.
This code will appear if
Check the Ignition coil primary resistance to
The primary current is less than 2 AMP During ensure that Ignition coil is not damaged.
Dwell - on time
Reaction on Vehicle
Misfiring/rough running engine, possibly exhaust

smell.
Potential catalyst damage may occur.
TROUBLE SHOOTING
Check for wiring between ECM & Ignition Coil & replace Ignition coil if it is required
39
DTC CODES P2301
DTC DIAGNOSTIC ITEM
P2301 Ignition coil 1 High current
the Ignition coil, or that the Ignition coil is faulty. This code will appear if the Ignition current exceeded
9.5 amps during dwell-on time. Or that the Ignition power voltage is considerably lower in voltage than
the power at the Ignition coil.
MIL STATUS: ON
DTC Code : P2301

Check if the Ignition coil is connected
This DTC code will mainly related problem in backwards(+ve and –ve leads swapped)
itself is faulty. Check the electrical connection to the ignition coil.
This code will appear if Check the wiring between the ECM and the
ignition coil.
The primary current is More than 9 AMP
Reaction on Vehicle

smell.
TROUBLE SHOOTING
40
DTC CODES P2302
DTC DIAGNOSTIC ITEM
P2302 Ignition coil 1 Secondary Fault (Open)
Description: This diagnostic trouble code indicates that a wiring problem exists between the Ignition coil
and spark plug. Only an open circuit can be diagnosed. A short circuit, cracked spark plug, degraded wire
insulation cannot be diagnosed via this DTC code. A misfire fault without a corresponding ignition
system fault is an indication of this type of problem. This is diagnosed by detecting the ignition energy
not being delivered to the spark plug but rather being sent back to the ECM at the end of the dwell time.
MIL STATUS: ON
DTC Code : P2302

Check for disconnected sparkplug wire at the
This DTC code will mainly occur when no power to
sparkplug.
actuator.
Check sparkplug wire for continuity.
No spark detected by ECM
Replace spark plug if it faulty
Reaction on Vehicle
Replace Ignition coil if it is faulty.
smell.
TROUBLE SHOOTING
Check for disconnection at spark plug wire & replace spark plug if it is required
Check for disconnection of spark plug wire at coil & replace Ignition coil if it is required
41
DTC CODES 8 P2303
DTC DIAGNOSTIC ITEM
the Ignition coil or that the Ignition coil faulty,
MIL STATUS: ON
DTC Code : P2303

ignition coil.
The primary current is less than 1 AMP ensure that Ignition coil is not damaged.
Reaction on Vehicle

smell.
TROUBLE SHOOTING
42
DTC CODES P2304
DTC DIAGNOSTIC ITEM
the Ignition coil, or that the Ignition coil is faulty. This code will appear if the Ignition current
exceeded 9 AMPs during dwell-on time. Or that the Ignition power voltage is considerably lower
in voltage than the power at the Ignition coil.
MIL STATUS: ON
DTC Code : P2304

backwards(+ve and –ve leads swapped)
ignition coil.
Reaction on Vehicle

smell.
TROUBLE SHOOTING
43
DTC CODES P2305
DTC DIAGNOSTIC ITEM
MIL STATUS: ON
DTC Code : P2305 Check for disconnected sparkplug wire at the

sparkplug.
actuator. Check spark plug wire for continuity.
No spark detected by ECM Replace spark plug if it faulty
Reaction on Vehicle Replace Ignition coil if it is faulty.

smell.
TROUBLE SHOOTING
44
DTC CODES P2306
DTC DIAGNOSTIC ITEM
MIL STATUS: ON
DTC Code : P2306

ignition coil.
Reaction on Vehicle

smell.
TROUBLE SHOOTING
45
DTC CODES P2307
DTC DIAGNOSTIC ITEM
MIL STATUS: ON
DTC Code : P2307

ignition coil.
Reaction on Vehicle

smell.
TROUBLE SHOOTING
46
DTC CODES P2308
DTC DIAGNOSTIC ITEM
MIL STATUS: ON
DTC Code : P2308

Check for disconnected sparkplug wire at the
sparkplug.
actuator.
Check spark plug wire for continuity.
No spark detected by ECM
Replace spark plug if it faulty
Reaction on Vehicle
Replace Ignition coil if it is faulty.
smell.
TROUBLE SHOOTING
47
DTC CODES P2309
DTC DIAGNOSTIC ITEM
MIL STATUS: ON
DTC Code : P2309

ignition coil.
Reaction on Vehicle

smell.
TROUBLE SHOOTING
48
DTC CODES P2310
DTC DIAGNOSTIC ITEM
MIL STATUS: ON
DTC Code : P2310 Check if the Ignition coil is connected

wiring between ECM or Ignition coil or Ignition coil Check the electrical connection to the ignition coil.
itself is faulty.
Check the wiring between the ECM and the
This code will appear if ignition coil.
Reaction on Vehicle

smell.
TROUBLE SHOOTING
49
DTC CODES P2311
DTC DIAGNOSTIC ITEM
MIL STATUS: ON
DTC Code : P2311 Check for disconnected sparkplug wire at the

sparkplug.
actuator. Check spark plug wire for continuity.
No spark detected by ECM Replace spark plug if it faulty
Reaction on Vehicle Replace Ignition coil if it is faulty.

smell.
TROUBLE SHOOTING
50
P2311
IGNITION COIL CIRCUIT DIAGRAM
51
FUEL SOLENOID VALVE P1230
Description: The control circuit to the fuel shut off solenoid is

tested for continuity. A faulty solenoid or wiring problems will
typically causes this DTC codes.
SOLENOID VALVE
DTC CODES
DTC DIAGNOSTIC ITEM
P1230 Primary Fuel Shut Off Solenoid Fault
MIL STATUS: ON
DTC Code : P1230

Verify continuity and resistance of the solenoid
coil.
actuator.
Verify wiring between solenoid and ECM
Actuator power control relay commanded on.
Verify actuator power (Controlled by main
Output driver IC records high voltage fault. (Short actuator power control relay) is available at the
to power)
fuel shut off control solenoid.
Reaction on Vehicle
No fuel supply to engine.
Engine will crank, Vehicle will not start.
52
Solenoid Location Solenoid Connector
FUEL SOLENOID VALVE RELATED PINS AT ECU 52 POLE CONNECTOR
TROUBLE SHOOTING
Verify wiring between solenoid and ECM. If wiring is short replace or repair & if required replace
solenoid
53
P1230
FUEL SOLENOID CIRCUIT
54
ENGINE POSITION SENSOR P1337
Description: The crack shaft sensor is used to synchronize the ignition

and injection to the engine position. If any problem occur in this circuit
the engine will not start as engine will not able to locate its TDC position
and because of that injection will not take place.
Engine Position Sensor

DTC CODES
DTC DIAGNOSTIC ITEM
P1337 Engine Position sync Fault
MIL STATUS: ON
DTC Code : P1337 Check the wiring of this signal for open or short
circuits
This DTC code will mainly occur if when
This is hall effect sensor and it is require power.
No power to crack shaft sensor. Ensure power is present for this type of sensor.
No signal is received while running of crack shaft Check the sensor for any mechanical damage
Reaction on Vehicle
Engine will crank, Vehicle will not start.
LAYOUT/ POSITION CONNECTOR
Engine Position Sensor Location Engine Position Sensor

Connector
55
ENGINE POSITION SENSOR RELATED PINS AT ECU 52 POLE CONNECTOR P1337
TROUBLE SHOOTING
If NO power at sensor end & replace sensor or repair wiring as required
If sensor is damage replace the sensor
LW- GROUND
24 2
G- SIGNAL
5 1
56
DTC CODES P1624
DTC DIAGNOSTIC ITEM
P1624 ECM Calibration not initialized
Description: The ECM firmware and calibration are stored in flash memory. They can updated
separately. If the firmware file is updated but if it is not compatible with the calibration file stored in
flash memory, in that case this DTC code will appear
MIL STATUS: ON
DTC Code : P1624

Error occurred during calibration of file.
This DTC code will mainly relate to mismatch of
firmware and calibration file. ECM to be updated with new firmware if not
possible replace with new flashed ECM.
Reaction on Vehicle
TROUBLE SHOOTING
If errors occur during calibration of file replace the ECM
57
DTC CODES P1625
DTC DIAGNOSTIC ITEM
P1625 ECM calibration not authorized
Description: The ECM firmware and calibration are stored in flash memory. They can update separately.
In some cases calibration is not authorized if we try to try to do unauthorized operation this code will
appear
MIL STATUS: ON
DTC Code : P1625

Error occurred during calibration of file.
This DTC code will mainly relate unauthorized
calibration of ECM. Replace with new flashed ECM.
Reaction on Vehicle
TROUBLE SHOOTING
If errors occur during calibration of file replace the ECM
58
CONFORMITY CHECK
RESISTANCE VALUES
MANIFOLD ABSOLUTE PRESSURE SENSOR
Air Pressure - 70 kPa
COOLANT TEMPERATURE SENSOR
Temperature °C Resistance Min KΩ Resistance Max KΩ
20 2.351 2.649
40 1.118 1.231
80 0.313 0.332
59
CIRCUIT DIAGRAM
60

Man-00091-Bolero Pik Up - MMT CNG Bs3-Diagnotic Manual - 15.04.10

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Man-00091-Bolero Pik Up - MMT CNG Bs3-Diagnotic Manual - 15.04.10

Uploaded by

Copyright:

Available Formats

DIAGNOSTIC MANUAL (CNG BS-III)

PIK-UP CNG BS-III

MAXX MAXI TRUCK CNG BS-III

TECHNICAL PUBLICATION CELL

The manual consists of –

 Trouble shooting and diagnosis of DTCs (Defect Trouble Codes)

 Use of Smart Tester for Diagnosis.

 Circuit diagram for complete system.

 How to use this manual……………………………………….. 02

 Brief Specification of the engine…………………………….. 03

 Procedure for using Diagnostic Tool………………………. 04

 List of DTC codes………………………………………………. 12

HOW TO USE THIS MANUAL

The following is the structure of the Diagnostic Manual –

 Brief description about the sensor/actuator and its function

There are certain complaints for which no DTCs are generated.

BRIEF SPECIFICATION OF THE ENGINE

Torque : 170 NM @1800-2200 RPM

Firing Order : 1-3-4-2

Type of ECU : ECM A53

Type of Software : A35ISO_2009.07.06.BI

INFORMATION ABOUT DIAGNOSTIC TOOL, CONNECTION & OPERATING PROCEDURE

Introduction of New CNG Diagnostic Tool developed to meet –

The procedure for connecting this tool is as follows.

Python Connection: Auto Detect

Click to Connect to Python

Wait till next screen appears.

Python Connection: Successfully Detected

Step – 2 Click OK Step – 1 Click OK

Python Connection: Python device

Auto Detect, till Python is detected successfully

Double Click on i-SMART CNG

Click to enable selection box &

CLEAR DTC SCREEN

2. Click to view clear

3. Click to clear fault Click to enable selection box &

LIVE DATA SCREEN

2. Click to view live

Click to enable selection

READ ECM ID SCREEN

Write new VIN no. in the ECM

Click to read ECM

Data Read From ECM

Click to enable selection box &

LIST OF DTC CODES

1 P0107 MAP SENSOR LOW INPUT 14

2 P0108 MAP SENSOR HIGH INPUT 14

3 P0112 IAT SENSOR LOW INPUT 17

4 P0113 IAT SENSOR HIGH INPUT 17

5 P0117 ECT SENSOR LOW 21

6 P0118 ECT SENSOR HIGH 21

7 P0131 O2 BANK 1 SENSOR 1 LOW INPUT 24

8 P0132 O2 BANK 1 SENSOR 1 HIGH INPUT 24

9 P0134 O2 BANK 1 SENSOR 1 NO ACTIVITY 24

10 P0172 SYSTEM TOO RICH BANK 1 30

11 P0217 ENGINE OVERHEATING 31

12 P0219 ENNGINE OVERSPEED CONDITIION 32

13 P0562 SYSTEM VOLTAGE LOW 33

14 P0563 SYSTEM VOLTAGE HIGH 34

15 P0605 ROM/FLASH MEMORY ERROR 35

16 P0606 ECM INTERNAL FAULT 36

17 P0650 MALFUNCTION INDICATOR LAMP CONTROL CIRCUIT 37

18 P2300 INGNITION COIL 1 LOW CURRENT 39