Xuv 500 PDF

EMS DIAGNOSTIC MANUAL
MAN-00152
RELEASED BY –
TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.
www.teknetmahindra.com Rev1 – OCTOBER 2011
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.
© 2011 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 MAN-00152
EMS OCT 2011/Rev 1
CONTENTS
HOW TO USE THIS MANUAL 2
OVER VIEW OF THE VEHICLE COMMUNICATION NETWORK 3
EMS OVERVIEW 4
WARRANTY & OTHER INFORMATION 5
RECOMMENDED TROUBLE SHOOTING PROCESS 6
EMS ECU PIN DETAILS 7
EMS ECU CAN SIGNALS 10
IQA/IMA CODE PROGRAMMING 11
EMS ECU FLASHING 12
INDEX OF DTC CODES 20
EMS WIRING DIAGRAM 24
DTC BASED TROUBLESHOOTING 26
SYMPTOM BASED DIAGNOSIS- WITH NO DTC CODES 325
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
1
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
EMS OCT 2011/Rev 1
HOW TO USE THIS MANUAL
If the DTC code is known, then go to the Index of DTC code, 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 EMS Diagnostic Manual –
 DTC and its description

 Component location in the vehicle
 Normal operation of the system
 DTC detecting conditions
 Probable causes
 Lamp status
 DTC reaction on vehicle
 Healing Condition
 Connector layout
 Circuit Schematic
 Connector views and information
 Diagnostic tree
Always use the diagnostic manual along with the vehicle’s wiring manual (MAN-00149).
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EMS OCT 2011/Rev 1
OVER VIEW OF THE VEHICLE COMMUNICATION NETWORK
3
EMS OCT 2011/Rev 1
EMS OVERVIEW
The EMS ECU uses the following sensors and actuators to govern all engine parameters for optimized
engine performance
Sensors/Switches
Hot Film Air Mass Flow Sensor
Engine Coolant Temperature Sensor
Ambient Air Pressure Sensor
Camshaft Position Sensor
Crankshaft Speed Sensor
Fuel Temperature Sensor
Gear Neutral Sensor
Boost Pressure Sensor
Rail Pressure Sensor
Accelerator Pedal Module
Tipple Pressure Switch
Vehicle Speed Sensor
Brake Switch
Clutch Sensor
Oil Pressure Switch
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EMS OCT 2011/Rev 1
Actuators
EGR Actuator
Fan Control
Injectors
Fuel Metering Unit
Turbo charger actuator
Glow Plugs
A/C Compressor
Boost Pressure Actuator
WARRANTY & OTHER INFORMATION
All failures/complaints encountered on 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)
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EMS OCT 2011/Rev 1
RECOMMENDED TROUBLE SHOOTINGPROCESS
Customer complaint Record/Understand Customer Verbatim
 What happened?
 When it happened?
 What was the event before that?
 Does it happen all the time?
 Does it happen only in some condition?
Search for Published quick solution in TEKnet.
Follow DTC based diagnosis
Contact TEKliner with TAR
(Technical Assistance Request)
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EMS OCT 2011/Rev 1
EMS ECU PIN DETAILS
ECU
Connector
Pin no Function Connected To Pin no
1 GROUND GROUND G3
2 GROUND GROUND G3
3 POWER HIGH SIDE INJECTOR 1 - INJECTOR 4 1
4 POWER MAIN RELAY 87
6 POWER MAIN RELAY 87
6 POWER HIGH SIDE INJECTOR 3 - INJECTOR 2 1
7 POWER LOW SIDE INJECTOR 4 2
10 POWER CLUTCH SENSOR 4
11 GROUND COOLANT TEMPERATURE SENSOR 2
12 SIGNAL FUEL TEMPERATURE SENSOR 1
18 POWER ACCELERATOR PEDAL(APP1) 2
19 OIL PRESSURE SWITCH OIL PRESSURE SWITCH 1
20 SIGNAL-HIGH/LOW TRIPPLE PRESSURE SWITCH 2
22 SIGNAL VEHICLE SPEED SENSOR 3
23 85% SIGNAL CLUTCH SENSOR 1
23 POWER GEAR NEUTRAL SENSOR 1
24 REDUNDANT SIGNAL BRAKE SWITCH 4
25 SIGNAL-MIDDLE TRIPPLE PRESSURE SWITCH 3
30 SHIELD CRANK SHAFT SPEED SENSOR 3
31 SIGNAL(AIR MASS) HOT FILM AIR MASS SENSOR 5
32 POWER RAIL PRESSURE SENSOR 3
33 SIGNAL COOLANT TEMPERATURE SENSOR 1
34 GROUND FUEL TEMPERATURE SENSOR 2
35 POWER BOOST PRESSURE SENSOR 3
40 POWER ACCELERATOR PEDAL(APP2) 1
41 15% SIGNAL CLUTCH SENSOR 2
41 SIGNAL GEAR NEUTRAL SENSOR 2
43 SIGNAL REVERSE SWITCH 2
44 GROUND CAM SHAFT POSITION SENSOR 1
45 POWER CAM SHAFT POSITION SENSOR 3
46 SIGNAL CAM SHAFT POSITION SENSOR 2
49 SIGNAL EXHAUST GAS RECIRCULATION ACTUATOR 2
50 SIGNAL MAIN RELAY 86
52 SIGNAL (+) CRANK SHAFT SPEED SENSOR 1
53 GROUND HOT FILM AIR MASS SENSOR 1
54 SIGNAL RAIL PRESSURE SENSOR 2
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EMS OCT 2011/Rev 1
ECU
Connector
Pin no Function Connected To Pin no
55 GROUND VEHICLE SPEED SENSOR 2
56 SIGNAL-P BOOST PRESSURE SENSOR 4
59 SIGNAL CLOCK SPRING 4
60 SIGNAL ACCELERATOR PEDAL (APP2) 6
61 SIGNAL ACCELERATOR PEDAL(APP1) 4
65 CAN LOW DLC CONNECTOR 14
66 CAN HIGH DLC CONNECTOR 6
68 SIGNAL COOLING FAN HIGH RELAY 86
71 POWER IGNITION SWITCH IG1
72 SIGNAL COOLING FAN LOW RELAY 86
74 SIGNAL (-) CRANK SHAFT SPEED SENSOR 2
SIGNAL REF
75 (TEMPERATURE) HOT FILM AIR MASS SENSOR 2
76 GROUND RAIL PRESSURE SENSOR 1
SIGNAL
77 (TEMPERATURE) HOT FILM AIR MASS SENSOR 4
78 GROUND BOOST PRESSURE SENSOR 1
80 MAIN SIGNAL BRAKE SWITCH 2
81 GROUND CLOCK SPRING 3
82 GROUND ACCELERATOR PEDAL(APP2) 5
83 GROUND ACCELERATOR PEDAL(APP1) 3
87 SIGNAL-T BOOST PRESSURE SENSOR 2
89 SIGNAL FUEL METERING UNIT 2
91 SIGNAL A/C CLUTCH RELAY 86
92 SIGNAL BOOST PROCEDURE ACTUATOR 2
93 SIGNAL GLOW PLUG RELAY 86
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EMS OCT 2011/Rev 1
ABBREVIATIONS
EMS Engine Management System

ABS Antilock Braking System
ESP Electronic Stability Program
MBFM Mahindra Body Function Module
IC Instrument Cluster
SRS Supplementary Restraint System
IS Infotainment System
SAS Steering Angle Sensor
HVAC Heating Ventilation and Air Conditioning
SC Sensor Cluster
RPAS Reverse Park Assist System
ITM Interactive Torque Management
ECU Electronic Control Unit
EHCU Electronic Hydraulic Control Unit
R Receiver
T Transmitter
HDC Hill Descent Control
HHC Hill Hold Control
WSS Wheel Speed Sensor
EBD Electronic Brake Distribution
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EMS OCT 2011/Rev 1
EMS ECU CAN SIGNALS
Signals Transmitted by EMS ECU

Sl
no Signal Name Reciever
1 Accelerator pedal position ESP,ITM,MBFM,IC,IS
2 Engine speed ESP,ITM,MBFM,IC,IS
3 Status of cruise control regulation ESP
4 Cruise On/Off status IC,ESP
5 Current gear ESP, MBFM,IC,IS,RPAS,SRS,ITM
6 Glow plug on/off control IC
7 Engine Oil Pressure IC,IS
8 Engine Coolant Temperature IC,HVAC
9 Vehicle Speed MBFM,IC,IS,RPAS,HVAC
10 Odometer Distance IC
11 Engine Torque ESC,ITM, MBFM
12 Clutch Status ESC,ITM, MBFM
13 ESS Start Request MBFM
14 ESS status Indication IC
15 System check lamp Indication IC
16 MIL Indication IC
17 VIN data All ECU's
18 Cruise Set Speed ESP
19 Brake Pedal Status ESP, MBFM
Signals Received by EMS ECU

Sl no Signal Name Transmitter
1 Torque Reduction Request _ESP ESP
2 Torque Increment Request ESP
3 Cruise Shut Off ESP
4 A/C Compressor ON Request HVAC
5 Water in Fuel Status IC
6 Torque Reduction Request_ITM ITM
7 Door Status MBFM
8 ESS Switch Status MBFM
9 Crash Status SRS
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EMS OCT 2011/Rev 1
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
IQA/IMA CODE PROGRAMMING
An ECU controlled engine needs precise metering of fuel. Due to manufacturing tolerances, each
injector deviates slightly from its idealized behavior. Thus, each injector has a correction factor,
which is engraved on top of it, in the form of a 8-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 right side of the vehicle.
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.
Caution
Even though on the injector, 8 character alphanumeric code is engraved , while writing
the IQA code only the first 7 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.
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EMS OCT 2011/Rev 1
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.
EMS ECU FLASHING
The EMS ECU required to be flashed in the following conditions
BLANK ECU
1. Procure blank EMS ECU from spare part dept.
1805AAA01571N ECU WITHOUT ETK EDC17C55*
* Check for the correct/latest part no in parts catalogue/Technical Service Bulletins.
2. Flash the EMS ECU dataset with a latest dataset as per TSB or at the advice of TEKline.
Notes -
1. Flash the EMS ECU with the correct/latest dataset. The matrix of the vehicles and the related latest
dataset will be released through TSB - if in doubt ask the TEKline.
2. Wrong dataset flashing may result in vehicle not starting and can lead to ECU failure.
Software
ECU Type Dataset ID Type Model
Version
Factory/
V44 EDC17C55 1037519721 XUV500
Reflashing
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EMS OCT 2011/Rev 1
3. Ensure that the there is no communication breakdown once the flashing begins. Check Python
connections are secure.
4. Ensure that the SMART tester has -
 Enough battery reserve/Connected to AC power

 Screen saver/Battery saver mode turned off
 Vehicle’s ignition is ON
 Battery terminals connected securely.
 Battery earth connection is good.
5. Never touch the ECU pins by hand/finger
FLASHING PROCEDURE
1. Connect using the "Python 1BConfig0404"
2. Click the “XUV500 field flashing tool” icon present on the desktop
The following window appears
3. Click on "Connect" . The following window appears
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EMS OCT 2011/Rev 1
4 . Click on " READ VIN NUMBER " . The following window appears
5. Manually enter the VIN NUMBER in the box as shown and the following window appears
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EMS OCT 2011/Rev 1
6. Click on " READ MODEL NUMBER " . The following window appears
7. Manually enter the MODEL NUMBER in the box as shown and the following window appears
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EMS OCT 2011/Rev 1
8. Select "EMS " from the drop down list. The following window appears
9. The current data set is selected by default in the browse tab .Click " START FLASHING " to start flashing
. The following window appears after the flashing is successful.
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EMS OCT 2011/Rev 1
10. Once the EMS ECU is flashed successfully , follow the below sequence to write VIN NUMBER ,
MODEL NUMBER , VARIANT CODING.
For writing the VIN click on "WRITE VIN NUMBER". The following window appears
11. For writing MODEL NUMBER click "WRITE MODEL NUMBER ". The following window
appears
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EMS OCT 2011/Rev 1
12. For writing VARIANT CODING click "WRITE VARIANT CODING ". The following window
appears
Confirm VIN NUMBER , MODEL NUMBER and VARIANT CODING are successfully written in the
task bar
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EMS OCT 2011/Rev 1
13. Click on "CONFIG" . The following window appears
14. Enter carefully the 7 digit "IQA code" against each cylinder as shown.
Click on "WRITE IQA Values" to write the IQA values
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EMS OCT 2011/Rev 1
INDEX OF DTC's
PAGE
GROUP DTC DESCRIPTION NO
Signal range check for HFM7 sensor signal above
P0103 maximum limit 26
Signal range check for HFM7 sensor signal below
P0102 minimum limit 30
HFM SENSOR- AIR P1100 Signal Error for HFM7 sensor 35
FLOW
P0100 Battery voltage error of HFM6 sensor 39
HFM7 sensor drift Compensation beyond the limit at Low
P0101 Idle. 41
HFM7 sensor drift Compensation beyond the limit at
P1101 loaded condition. 41
P0563 Battery voltage high error 43
BATTERY P0562 Battery voltage low error 45
Coolant Temperature Sensor Absolute Test non plausible
P1128 error
50
Coolant Temperature Sensor Dynamic Test non plausible
COOLANT
P1126 error
TEMPERATURE
SENSOR Signal Range Check for coolant temperature sensor
P0118 above maximum limit 52
Signal Range Check for coolant temperature sensor
P0117 below minimum limit 57
P062F ECU EEPROM error 62
EEPROM P162F ECU EEPROM error 64
MONITORING P1630 ECU EEPROM error 66
P062B ECU monitoring error for Injector cut off demand 68
P0403 EGR Valve open load error 70
P1403 EGR Valve over temperature error 74
EGR
P0406 EGR Valve short to battery error 76
P0405 EGR Valve short to ground error 80
Signal Range Check for Environmental pressure sensor
ENVIRONMENT Signal Range Check for Environmental pressure
PRESSURE SENSOR P2228 sensor below minimum limit 86
P0340 Camshaft sensor no signal error 88
CAM PHASE
P0341 Camshaft sensor signal error 93
SENSOR
P1341 Camshaft sensor signal offset error 97
CRANKSHAFT P0336 Crankshaft sensor signal error 99
SPEED SENSOR P0335 Crankshaft sensor no signal error 104
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EMS OCT 2011/Rev 1
PAGE
P0480 Low speed fan open load 109
P0481 High speed fan open load 112
P0692 Low speed fan short to battery 115
COOLING FAN RELAY
P0694 High speed fan short to battery 119
P0691 Low speed fan short to ground 123
P0693 High speed fan short to ground 126
Signal range check for fuel temperature sensor above
FUEL TEMPERATURE Signal range check for fuel temperature sensor below
SENSOR P0182 minimum limit 133
P268C Cylinder1 injector adjustment code incorrect error 138
IQA CODE P268D Cylinder2injector adjustment code incorrect error 140
MONITORING P268E Cylinder 3 injector adjustment code incorrect error 142
P268F Cylinder4 injector adjustment code incorrect error 144
P0201 Cylinder1 injector open load error 146
INJECTORS P0261 High side - Low side short circuit for cylinder1 injector 162
P0264 High side - Low side short circuit for cylinder2 injector 166
P2146 Short circuit in bank 0 178
P0001 Metering unit open load error 181
METERING UNIT P0004 Metering unit output short circuit to battery error 185
P0003 Metering unit output short circuit to ground error 189
Signal range check for manifold absolute pressure sensor
BOOST PRESSURE Signal range check for intake manifold absolute pressure
SENSOR P0237 sensor below minimum limit 198
Signal range check for intercooler downstream
P007D temperature sensor above maximum limit 203
BOOST TEMPERATURE Signal range check for intercooler downstream
SENSOR P007C temperature sensor below minimum limit 208
Signal range check for rail pressure sensor above
Signal range check for rail pressure sensor below
RAIL PRESSURE
P0192 minimum limit 217
SENSOR
P0191 Rail pressure offset value above maximum limit 222
P1191 Rail pressure offset value above minimum limit 225
P169F Rail pressure raw value is intermittent 228
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EMS OCT 2011/Rev 1
PAGE
Signal range check for APP sensor1 above maximum
P2123 limit 231
ACCELERATOR PEDAL
Signal range check for APP sensor2 above maximum
MODULE
P2128 limit 236
P2138 Plausibility error between APP signal1 and signal2 241
Signal range check for HFM 7 temperature sensor
HFM SENSOR- P0113 above maximum limit 248
TEMPERATURE Signal range check for HFM 7temperature sensor
P0112 below minimum limit 253
P0045 Boost pressure modulator open load error 257
BOOST PRESSURE P0048 Boost pressure modulator short circuit to battery 261
MODULATOR P0047 Boost pressure modulator short circuit to ground 265
P1645 Boost pressure modulator over temperature error 269
VEHICLE SPEED
SENSOR P0501 Vehicle speed sensor plausibility error 273
P0641 Sensor supply voltage1 monitoring error 278
SENSOR SUPPLY
P0651 Sensor supply voltage2 monitoring error 282
MONITORING
P0697 Error Sensor supplies 3 284
Rail pressure positive governor deviation error in
P1B87 Metering Unit mode 286
Positive governor deviation and setpoint value of the
P1C87 fuel volume flow through the metering unit. 289
RAIL PRESSURE Rail pressure negative governor deviation error in
GOVERNOR P1B88 Metering Unit mode 292
Rail pressure below minimum limit error in Metering
P1D87 Unit mode 294
Rail pressure above maximum limit error in Metering
P1C88 Unit mode 295
P068A Main relay early opening error 297
MAIN RELAY
P068B Main relay struck error 297
BRAKE SWITCH P0504 Brake Signal plausibility error. 303
CLUTCH SENSOR P0704 Clutch non plausible error 308
GEAR NEUTRAL
SENSOR P1704 Gear Neutral Signal is not plausible 313
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EMS OCT 2011/Rev 1
PAGE
P1900 ECU Monitoring: ADC NTP error
P163B ECU Monitoring: ADC test error
P163C ECU Monitoring: Voltage ratio error in ADC
P1621 ECU Monitoring: Query response communication error
318
P1622 ECU Monitoring: SPI communication error
P0605 ECU Monitoring: ROM memory error
P1623 ECU Monitoring: CPU error
P1625 ECU Monitoring: Response time error in ECU
ECU Monitoring: Shut off path test SPI communication
P1626 error
P1628 ECU Monitoring: Shut off path under voltage error
P1629 ECU Monitoring: WDA not working
P162A ECU Monitoring: Time out error 319
P162C ECU Monitoring: Positive test failure error
CONTINUOUS P162D ECU Monitoring: Time out error for shut off path test
TORQUE P060D ECU Monitoring: Accelerator position error
MONITORING P061C ECU Monitoring: Engine speed error
ECU Monitoring: Rail pressure monitoring plausibility 320
P1638 error
P060A ECU Monitoring: Energising time plausibility error
P1631 ECU Monitoring: Start of Injection plausibility error 321
P1632 ECU Monitoring: ZFC non plausibility error 322
P1633 ECU Monitoring: PoI2 qty error
P1634 ECU Monitoring:PoI2 shut off error
P1635 ECU Monitoring:PoI3 efficiency factor error
P1636 ECU Monitoring: Overrun monitoring error 323
P1637 ECU Monitoring: Injection quantity correction error
P061B ECU Monitoring: Torque comparison error
P163E ECU Monitoring: Torque monitoring level2 error
P1639 ECU Monitoring: Lead torque monitoring level2 error
P163D ECU Monitoring: Set torque monitoring level2 error
P1832 Immobiliser authentication error
IMMOBILISER
P183F Immobiliser not present in vehicle 324
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EMS OCT 2011/Rev 1
EMS ECU WIRING DIAGRAM
24
EMS OCT 2011/Rev 1
25
EMS OCT 2011/Rev 1
P0103 - Signal range check for HFM7 sensor signal above maximum limit
HOT FILM AIR MASS SENSOR (HFM)
Mass air flow rate is measured by detection of heat transfer from a hot film probe because the change of
the mass air flow rate causes change in the amount of heat being transferred from the hot film probe
surface to the air flow. The airflow sensor generates a pulse so it repeatedly opens and closes between
the 5V voltage supplied from the engine control module. This results in the change of the temperature of
the hot film probe and in the change of resistance.
COMPONENT LOCATION
NORMAL  During ignition ON , HFM sensor outputs a voltage with respect to the intake
OPERATION
air flow to EMS ECU and is within the range
DTC DETECTING
 The measured output voltage of the sensor is more than 5.25 V for 0.5 Second
CONDITION
PROBABLE  HFM (air mass) signal wire short to battery

CAUSES
 HFM sensor internal failure
LAMP STATUS  OBD lamp ON
DTC REACTION
 EGR switches OFF
HEALING  Ignition Off/On
CONDITION
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EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
27
EMS OCT 2011/Rev 1
CONNECTOR VIEWS AND INFORMATION
CONNECTOR
NOMENCLATURE PIN NO FUNCTION
E1 5 SIGNAL(AIR MASS)
28
EMS OCT 2011/Rev 1
STEP 1
Connect the smart tester
Turn the ignition ON
Initialise the diagnostic tool
Record the DTC and clear
Turn ignition OFF
Turn ignition ON
Verify if P0103 is present?
YES Is P0103 present? NO
STEP 2
Intermittent problem exists
Ignition OFF Refer the intermittent problem
HFM sensor wiring harness inspection procedure
connector DISCONNECTED
Ignition ON
Check the voltage between pin
5 of the HFM sensor wiring
harness connector and battery
ground
YES Is the value >5.25 V? NO
Examine the short circuit of

Suspect internal failure of HFM HFM sensor air mass signal wire
sensor to battery
Replace the HFM sensor with a Repair/replace the wiring
new one harness
Clear the DTC and verify Clear the DTC and verify
29
EMS OCT 2011/Rev 1
P0102- Signal range check for HFM7 sensor signal below minimum limit
HOT FIL AIR MASS SENSOR
COMPONENT LOCATION
NORMAL
OPERATION  During ignition ON , HFM sensor outputs a voltage with respect to the intake
air flow to EMS ECU and is within the range
DTC DETECTING
CONDITION  The measured output voltage of the sensor is less than 0.5 V for 0.5 Second
 HFM power supply wire short to ground/open

PROBABLE  HFM (air mass) signal wire short to ground/open
CAUSES  HFM ground wire open
LAMP STATUS  OBD lamp ON
DTC REACTION
CONDITION
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EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
31
EMS OCT 2011/Rev 1
CONNECTOR

53 HFM GROUND
5 SIGNAL(AIR MASS)
E1 1 HFM GROUND
3 POWER SUPPLY
32
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
STEP 2
Ignition ON
ground
YES Is the value = Vbat? NO
Examine the short to ground /

STEP 3 open circuit of HFM sensor
Ignition OFF power supply wire
HFM sensor wiring harness Repair/replace the wiring
connector DISCONNECTED harness
Check the resistance between Clear the DTC and verify
pin 5 of the HFM sensor wiring
ground
YES Is the value =∞Ω? NO
STEP 4 Examine the short to ground of

Ignition OFF HFM sensor air mass signal wire
HFM sensor wiring harness Repair/replace the wiring
EMS ECU wiring harness Clear the DTC and verify
Check the resistance between
harness connector and pin 31 of
the EMS ECU wiring harness
connector
NO Is the value < 1Ω? NO
Examine the open circuit of of

Go to STEP 5 HFM sensor air mass signal wire
Repair/replace the wiring
harness
Clear the DTC and verify
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EMS OCT 2011/Rev 1
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EMS OCT 2011/Rev 1
P1100 - Signal Error for HFM7 sensor
COMPONENT LOCATION
NORMAL
OPERATION  During ignition ON , EMS ECU continuously monitors the HFM DTC's and no
prolonged existence of HFM related DTC's noticed
DTC DETECTING
CONDITION
 Prolonged existence of HFM related DTC's
PROBABLE
CAUSES  HFM (air mass) signal wire short to ground/open
 HFM ground wire open
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
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EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
36
EMS OCT 2011/Rev 1
CONNECTOR

53 HFM GROUND
1 HFM GROUND
37
EMS OCT 2011/Rev 1
38
EMS OCT 2011/Rev 1
P0100 - Battery voltage error of HFM7 sensor
COMPONENT LOCATION
NORMAL
OPERATION
 HFM sensor receives 9 to 16.8 Volt supply when the ignition is ON
DTC DETECTING
CONDITION
 The battery supply voltage to HFM sensor is more than 16.8 V for 100 ms.
PROBABLE
CAUSES  Faulty Battery
 Faulty Charging System
 Malfunctioning EMS ECU
LAMP STATUS
 System Check Lamp Blinks
DTC REACTION
 Reference signal monitoring is not available
CONDITION
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EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
STEP 2
Ignition ON
Refer the intermittent problem
Engine running at high idle
inspection procedure
Check the voltage between
battery positive and battery
negative terminals
YES Is the value >16.8V? NO
Suspect the charging circuit

Check and confirm the proper Clear the DTC and verify
functioning of charging circuit
40
EMS OCT 2011/Rev 1
P0101 - HFM7 sensor drift Compensation beyond the limit at Low Idle.
P1101 - HFM7 sensor drift Compensation beyond the limit at loaded condition.
COMPONENT LOCATION
NORMAL
OPERATION  During ignition ON , HFM sensor outputs a voltage with respect to the intake
air flow to EMS ECU and is within the range and compensates the drift in the
value
DTC DETECTING
CONDITION
 The drift in the value goes beyond the value it can be compensated
PROBABLE
CAUSES  Contaminated HFM sensor
 Faulty HFM sensor
LAMP STATUS
 System Check Lamp Blinks
DTC REACTION
 Engine will continue to run in default air flow
CONDITION
41
EMS OCT 2011/Rev 1
42
EMS OCT 2011/Rev 1
P0563 - Battery voltage high error
BATTERY
The system voltage has to guarantee to perform diagnosis functions. The Electronic Control Unit (ECU)
monitors battery voltage
COMPONENT LOCATION
NORMAL
OPERATION
 EMS ECU receives 8 to 16.8 Volt supply when the ignition is ON
DTC DETECTING
CONDITION  The supply voltage to EHCU is more than 16.8 V for 100 ms.
PROBABLE  Faulty Battery

CAUSES  Faulty Charging System
LAMP STATUS  System Check Lamp ON
DTC REACTION
 EMS ECU switches off
CONDITION
43
EMS OCT 2011/Rev 1
44
EMS OCT 2011/Rev 1
P0562 - Battery voltage low error
BATTERY
The system voltage has to guarantee to perform diagnosis functions. The Electronic Control Unit (ECU)
monitors battery voltage
COMPONENT LOCATION
NORMAL
OPERATION
 EMS ECU receives 8 to 16.8 Volt supply when the ignition is ON
DTC DETECTING
CONDITION  The supply voltage to EMS ECU is less than 8 V for 100 ms.
 Open/Short Wiring Harness

PROBABLE  Faulty Battery
CAUSES  Faulty Charging System
LAMP STATUS
 System Check Lamp ON
DTC REACTION
CONDITION
45
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
46
EMS OCT 2011/Rev 1
CONNECTOR
71 IGNITION POWER
E18 1 GROUND
2 GROUND
47
EMS OCT 2011/Rev 1
48
EMS OCT 2011/Rev 1
49
EMS OCT 2011/Rev 1
P1128 - Coolant Temperature Sensor Absolute Test non plausible error
P1126 - Coolant Temperature Sensor Dynamic Test non plausible error
ABSOLUTE / DYNAMIC PLAUSIBILTY
When the engine is switched ON then the ECU detects the temperature. After that when the engine runs
then the temperature output on a time frame is detected and compared against predetermined slope.
COMPONENT LOCATION
Thermostat
NORMAL  The coolant temperature rises to a specified temperature within a specific time
OPERATION period - absolute test
 It also compares the rate of rise with a predefined rate of rise defined during
calibration- dynamic test
DTC DETECTING  The coolant temperature do not rise enough within a specific time period,
CONDITION  The coolant temperature does not reach a warmed-up fuel control
temperature within a specific time.
PROBABLE
CAUSES  Thermostat removed
 Thermostat malfunctioning
LAMP STATUS
 No lamp indication
DTC REACTION
 No reaction
HEALING  Self healing
CONDITION
50
EMS OCT 2011/Rev 1
51
EMS OCT 2011/Rev 1
P0118 - Signal Range Check for coolant temperature sensor above maximum limit
COOLANT TEMPERATURE SENSOR
The CTS sensor is a variable resistor whose resistance changes as the temperature of the engine coolant
flowing past the sensor changes.(NTC resistor) When the coolant temperature is low, the sensor
resistance is high; when the coolant temperature is high, the sensor resistance is low. The ECU checks CTS
voltage and uses the information to help smoothen the engine operation.
COMPONENT LOCATION
NORMAL  During ignition ON , the measured output voltage value of the coolant
OPERATION
temperature sensor is between 0.1 to 3.3 V
DTC DETECTING
CONDITION  The measured output voltage of the coolant temperature sensor is more than
3.3 V for 4 seconds
PROBABLE  Open coolant temperature sensor wiring harness

CAUSES  Short to battery of coolant temperature wiring harness
 Faulty coolant temperature sensor
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
 Coolant temperature value is set as 110 °C

DTC REACTION
 Fan high speed continuously ON
 Glow plug OFF
HEALING  Ignition OFF/ON

CONDITION
52
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
53
EMS OCT 2011/Rev 1
CONNECTOR
E18 33 SIGNAL
11 GROUND
E10 1 SIGNAL
2 GROUND
54
EMS OCT 2011/Rev 1
55
EMS OCT 2011/Rev 1
STEP 4
Ignition OFF
Coolant temperature sensor
wiring harness connector
DISCONNECTED
EMS ECU wiring harness
pin 11 EMS ECU wiring harness
connector and pin 2 of the of
the coolant temperature sensor
YES Is the value < 1Ω? NO
STEP 5 Examine the open circuit of

coolant temperature sensor
Ignition OFF
ground wire
harness
DISCONNECTED
pin 1 and pin 2 of the coolant
temperature sensor
Is the value >2.2

YES NO
<2.7 KΩ at 20°C?
Suspect EMS ECU malfunction

Replace EMS ECU with a new Suspect open circuit in coolant
one. temperature sensor
Check and verify for any new Replace the sensor with a new
DTC’s one
56
EMS OCT 2011/Rev 1
P0117-Signal Range Check for coolant temperature sensor below minimum limit
COOLANT TEMPERATURE SENSOR

The CTS sensor is a variable resistor whose resistance changes as the temperature of the engine coolant
flowing past the sensor changes.(NTC resistor) When the coolant temperature is low, the sensor
resistance is high; when the coolant temperature is high, the sensor resistance is low. The ECU checks CTS
voltage and uses the information to help smoothen the engine operation.
COMPONENT LOCATION
NORMAL  During ignition ON , the measured output voltage value of the coolant
OPERATION
temperature sensor is between 0.1 to 3.3 V
DTC DETECTING
CONDITION  The measured output voltage of the coolant temperature sensor is less than
0.1 V for 4 seconds
PROBABLE
CAUSES  Short coolant temperature sensor wiring harness
 Faulty coolant temperature sensor
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
 Coolant temperature value is set as 110 °C

DTC REACTION
 Fan high speed continuously ON
 Glow plug OFF

CONDITION
57
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
58
EMS OCT 2011/Rev 1
CONNECTOR
E18 33 SIGNAL
11 GROUND
E10 1 SIGNAL
2 GROUND
59
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
STEP 2
Coolant temperature sensor inspection procedure
DISCONNECTED
Ignition ON
1 of the coolant temperature
sensor wiring harness
connector and battery ground
NO Is the value =5 ± 0.25 YES

V?
STEP 3
Go to STEP 4
Ignition OFF
DISCONNECTED
pin 1 of the coolant
temperature sensor wiring
STEP 4 and battery
harness connector
ground
Suspect EMS ECU malfunction Examine the short circuit of

Replace EMS ECU with a new coolant temperature sensor
one. signal wire to ground
Check and verify for any new Repair/replace the wiring
DTC’s harness
60
EMS OCT 2011/Rev 1
61
EMS OCT 2011/Rev 1
P062F - ECU EEPROM error
EEPROM
EEPROM (Electrically Erasable Programmable Read Only Memory) is a storage device inside the EMS ECU
COMPONENT LOCATION
NORMAL
OPERATION  During ignition ON , the EEPROM can be flashed, read & written- this happens
during the overrun period.
DTC DETECTING
CONDITION
 During flashing the sector erase cannot be performed
PROBABLE
CAUSES
 Faulty EMS ECU
LAMP STATUS
 System Check lamp ON
DTC REACTION

CONDITION
62
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Wait for 2 minutes
Turn ignition ON
Verify if P062F is present?
YES Is P062F present? NO
Suspect EMS ECU EEPROM Intermittent problem exists

failure Refer the intermittent problem
Replace EMS ECU with a new inspection procedure
one.
Check and verify for any new
DTC’s
63
EMS OCT 2011/Rev 1
P162F - ECU EEPROM error
EEPROM
COMPONENT LOCATION
NORMAL
DTC DETECTING
CONDITION
 The block cannot be read more than 3 times from the EEPROM
PROBABLE
CAUSES
 Faulty EMS ECU
LAMP STATUS
DTC REACTION

CONDITION
64
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Wait for 2 minutes
Turn ignition ON
Suspect EMS ECU EEPROM Intermittent problem exists

failure Refer the intermittent problem
Replace EMS ECU with a new inspection procedure
one.
DTC’s
65
EMS OCT 2011/Rev 1
P1630 - ECU EEPROM error
EEPROM
COMPONENT LOCATION
NORMAL
DTC DETECTING
CONDITION
 The block cannot be written more than 3 times
PROBABLE
CAUSES
 Faulty EMS ECU
LAMP STATUS
DTC REACTION

CONDITION
66
EMS OCT 2011/Rev 1
67
EMS OCT 2011/Rev 1
P062B - ECU monitoring error for Injector cut off demand
ICO MONITORING
Injection cut off monitoring is used to limit the engine speed to a controllable engine speed band
COMPONENT LOCATION
NORMAL
OPERATION  The engine speed is less than or equal to the maximum engine speed for
injections in injection cut off
DTC DETECTING
CONDITION
 The engine speed exceeds the threshold speed in Injection cut off monitoring
PROBABLE
CAUSES  Faulty EMS ECU
LAMP STATUS
DTC REACTION

CONDITION
68
EMS OCT 2011/Rev 1
69
EMS OCT 2011/Rev 1
P0403 - EGR Valve open load error
EGR
A pulse-width-modulated signal is output for the Exhaust Gas Recirculation actuator control. Converting
the air control output into duty cycle carries this out
COMPONENT LOCATION
NORMAL  Engine runs as per the EGR mapping and no errors detected during self check
OPERATION
on Ignition ON
DTC DETECTING
CONDITION  Open load is detected by the EMS ECU
PROBABLE
CAUSES  EGR actuator control wire open
 Faulty EGR actuator
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
70
DIAGNOST
TIC MANUA
AL MAN-00152
EMS OCT 2011/Rev 1
CONNECTTOR LAYOUT
CIRCUIT SCHEMATIC
The repair methods give en by the manufacturer in this document are based on the technical spe ecifications, current at th
he time of release. The methods
m may be modifieed as a result of change es introduced by the
manufacturer in the prod duction of the various co
omponent units and acce essories from which the vehicles
v are manufacture ed. The reproduction, traanslation, transmission, in part of or whole of the
e present document,
are prohibited without the prior written consent off Mahindra & Mahindra Ltd.
L The use of this docu
ument by any person othe er than the trained perso
onnel, at the Authorized S
Service Centre of Mahind dra & Mahindra Ltd.,
71
will amount to unauthorizzed use and shall be liab
ble for penalty/prosecution© 2011 Mahindra & Ma ahindra Ltd.
EMS OCT 2011/Rev 1
CONNECTOR
E18 49 CONTROL SIGNAL
E20 01 POSITIVE
02 CONTROL SIGNAL
72
EMS OCT 2011/Rev 1
73
EMS OCT 2011/Rev 1
P1403 - EGR Valve over temperature error
EGR
COMPONENT LOCATION
OPERATION
on Ignition ON
DTC DETECTING
CONDITION
 Power stage overheating is detected by the EMS ECU
PROBABLE
CAUSES  EGR actuator control wire open
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
74
EMS OCT 2011/Rev 1
75
EMS OCT 2011/Rev 1
P0406 - EGR Valve short to battery error
EGR
COMPONENT LOCATION
OPERATION
on Ignition ON
DTC DETECTING
CONDITION
 Short to battery in detected by the EMS ECU
PROBABLE
CAUSES  Short to battery in EGR circuit
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
76
DIAGNOST
TIC MANUA
AL MAN-00152
EMS OCT 2011/Rev 1
CONNECTO
OR LAYOUT
CIRCUIT SCHEMATIC
e present document,
77
EMS OCT 2011/Rev 1
CONNECTOR
E20 01 POSITIVE
02 CONTROL SIGNAL
78
EMS OCT 2011/Rev 1
79
EMS OCT 2011/Rev 1
P0405 - EGR Valve short to ground error
EGR
COMPONENT LOCATION
OPERATION
on Ignition ON
DTC DETECTING
CONDITION
 Short to ground in detected by the EMS ECU
PROBABLE
CAUSES  Short to ground in EGR circuit
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
80
DIAGNOST
TIC MANUA
AL MAN-00152
EMS OCT 2011/Rev 1
R LAYOUT
CONNECTOR
CIRCUIT SCHEMATIC
e present document,
81
EMS OCT 2011/Rev 1
CONNECTOR
E20 01 POSITIVE
02 CONTROL SIGNAL
82
EMS OCT 2011/Rev 1
83
EMS OCT 2011/Rev 1
P2229 - Signal Range Check for Environmental pressure sensor above maximum limit
ENVIRONMENT PRESSURE SENSOR
The atmospheric pressure sensor is located on the EMS ECU. The sensor gives the atmospheric pressure
value . The ECU checks the sensor signal for the range. If it is outside the range then an error is registered
COMPONENT LOCATION
NORMAL  During Ignition ON, EMS ECU receives an output voltage signal from
OPERATION
environment pressure sensor and is within the range
DTC DETECTING
CONDITION  The output voltage signal received from the environment pressure sensor is
out of range
PROBABLE
CAUSES  Faulty Environment Pressure sensor
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
84
EMS OCT 2011/Rev 1
85
EMS OCT 2011/Rev 1
P2228 - Signal Range Check for Environmental pressure sensor below minimum limit
ENVIRONMENT PRESSURE SENSOR
The atmospheric pressure sensor is located on the EMS ECU. The sensor gives the atmospheric pressure
value . The ECU checks the sensor signal for the range. If it is outside the range then an error is registered
COMPONENT LOCATION
NORMAL  During Ignition ON, EMS ECU receives an output voltage signal from
OPERATION
environment pressure sensor and is within the range
DTC DETECTING
CONDITION  The output voltage signal received from the environment pressure sensor is
out of range
PROBABLE
CAUSES  Faulty Environment Pressure sensor
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
86
EMS OCT 2011/Rev 1
87
EMS OCT 2011/Rev 1
P0340 - Camshaft sensor no signal error
CAM SHAFT POSITION SENSOR
The Hall Effect camshaft position sensor senses the Top dead center (TDC) point of the # 1 cylinder in the
compression stroke ,which allows the ECU to determine when to start the injection. The trigger is
mounted in the exhaust camshaft
COMPONENT LOCATION
NORMAL  During engine running, the EMS ECU receives the output signal from cam shaft
OPERATION
position sensor and is within the range
DTC DETECTING  Normal signal pattern has not been input for cylinder identification from the
CONDITION camshaft position sensor signal for 4 sec. (Engine should be cranked to check
this error).
PROBABLE
CAUSES  Open/short cam shaft position sensor circuit
 Faulty cam shaft position sensor
LAMP STATUS
DTC REACTION  Engine will not start.

 If this failure occurs when the engine is running then engine will keep on
running
CONDITION
88
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
89
EMS OCT 2011/Rev 1
CONNECTOR
45 POWER
E18 46 SIGNAL
44 GROUND
03 POWER
02 SIGNAL
E20 01 GROUND
90
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
Crank the engine
STEP 2
Camphase sensor wiring inspection procedure
harness connector
DISCONNECTED
Ignition ON
3 of the cam phase sensor
wiring harness connector and
battery ground

V?
STEP 3
Ignition OFF Go to STEP 5
Camphase sensor wiring
harness connector
DISCONNECTED
between pin 3 of the cam
phase sensor wiring harness
connector and ground
STEP 4
Ignition OFF cam phase sensor power wire
Camphase sensor wiring to ground
harness connector Repair/replace the wiring
DISCONNECTED harness
connector and pin 45 of the EMS
ECU wiring harness connector
Suspect EMS ECU malfunction Examine the open circuit of

Replace EMS ECU with a new cam phase sensor power wire
one. Repair/replace the wiring
Check and verify for any new harness
DTC’s Clear the DTC and verify
91
EMS OCT 2011/Rev 1
STEP 5
Ignition OFF
Camphase sensor wiring
harness connector
DISCONNECTED
STEP 6 Examine the short circuit of

Ignition OFF cam phase sensor signal wire
Camphase sensor wiring to ground
between pin 1of the cam phase
sensor wiring harness
Suspect cam phase sensor Examine the open circuit of

internal failure cam phase sensor ground and/
Replace cam phase sensor with or signal wire
a with a new one. Repair/replace the wiring
92
EMS OCT 2011/Rev 1
P0341 - Camshaft sensor signal error
compression stroke. Which allows the ECU to determine when to start the injection. The trigger is
COMPONENT LOCATION
NORMAL
OPERATION  During engine running, the EMS ECU receives the output signal from cam shaft
position sensor and is within the range
DTC DETECTING  Normal signal pattern has not been input for cylinder identification from the
CONDITION camshaft position sensor signal for 4 sec. (Engine should be cranked to check
this error).
PROBABLE  Increased air gap between cam shaft position sensor and the trigger wheel
CAUSES  Sensor mounting loosened
 Increased Cam shaft end play
 Faulty cam shaft position sensor
LAMP STATUS
 Engine will not start.
DTC REACTION  If this failure occurs when the engine is running then engine will keep on
running
CONDITION
93
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
94
EMS OCT 2011/Rev 1
CONNECTOR
45 POWER
E18 46 SIGNAL
44 GROUND
03 POWER
02 SIGNAL
E20 01 GROUND
95
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
Crank the engine
STEP 2
Camphase sensor wiring inspection procedure
harness connector
DISCONNECTED
Check for proper fitment of the
cam phase sensor mounting bolt
NO Is the bolt fitted YES

properly?
STEP 3
Fix the bolt properly and tighten
Ignition OFF it to the torque specified
Camphase sensor wiring Clear the DTC and verify
harness connector
DISCONNECTED
Remove the cam phase sensor
Check for any damage on the
cam phase sensor front face
Is there any
NO YES
damage?
STEP 4
Suspect for any foreign particles
presence.
Check the cam shaft end play Identify the cause and rectify
Replace the cam phase sensor
with a new one
YES Is the end paly with NO

in limits?
Suspect cam phase sensor Identify the root cause of the

internal failure cam shaft end play and rectify
Replace cam phase sensor with Clear the DTC and verify
a with a new one.
DTC’s
96
EMS OCT 2011/Rev 1
P1341 - Camshaft sensor signal offset error
compression stroke. Which allows the ECU to determine when to start the injection. The trigger is
COMPONENT LOCATION
NORMAL
OPERATION  During engine starting, the EMS ECU compares the crankshaft sensor signal
and cam shaft position sensor signal and the deviation is within the range
DTC DETECTING  The cam shaft position sensor and crankshaft speed sensor are not
CONDITION
synchronized
 Increased air gap between cam shaft position sensor and the trigger wheel
PROBABLE
CAUSES  Increased air gap between crank shaft speed sensor and the trigger wheel
 Sensor mountings loosened
 Timing disturbed
LAMP STATUS
DTC REACTION  Engine will not start.

 If this failure occurs when the engine is running then engine will keep on
running
CONDITION
97
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
Crank the engine
STEP 2
Check the flywheel mounting Refer the intermittent problem
bolts for tightness inspection procedure
Check the cam shaft/crankshaft
mounting bolts for tightness
NO Are the bolts tight? YES
STEP 3
Tighten the bolts to the torque
Check for any damage on the specified
trigger wheel teeth Clear the DTC and verify
Check for proper mounting of
trigger wheel mounting screws
Is there any
NO damage/screws YES
loosened?
STEP 4 If the screws are loosened ,

tighten to torque
Check the sprockets and chain If toner wheel damaged, replace
for any damage it with a new one
YES Is there any NO

damage ?
Check for proper functioning of Replace the chain/sprocket

hydraulic chain tensioner assembly with a new one
If not functioining properly , Clear the DTC and verify
replace with a new one
98
EMS OCT 2011/Rev 1
P0336 - Crankshaft sensor signal error
CRANKSHAFT SPEED SENSOR
The crankshaft speed sensor is an inductive type sensor. It is mounted on front LH bottom side of the
engine and measures the speed of the trigger wheel mounted on the crankshaft
COMPONENT LOCATION
NORMAL
OPERATION  During engine cranking and running, the EMS ECU receives the output signal
from crankshaft speed sensor and is within the range
DTC DETECTING  Normal signal pattern has not been input from the crankshaft speed sensor for
CONDITION 4 sec. (Engine should be cranked to check this error).
 Disturbed signal form
 Increased air gap between crankshaft speed sensor and the trigger wheel
PROBABLE
CAUSES  Trigger wheel damaged/mounting loosened
 Sensor mounting loosened
 EMI noise
 Open crankshaft speed sensor circuit
LAMP STATUS
DTC REACTION
 If this failure occurs when the engine is running then engine shuts off
CONDITION
99
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
100
EMS OCT 2011/Rev 1
CONNECTOR
52 SIGNAL (+)
E18 74 SIGNAL (-)
30 SHIELD
01 SIGNAL (+)
02 SIGNAL (-)
E15 03 SHIELD
101
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
Crank the engine
STEP 2
Crankshaft speed sensor wiring inspection procedure
harness connector
DISCONNECTED
Check the continuity between
pin 2 of the crankshaft speed
sensor wiring harness connector
and pin 74 of the EMS ECU

Ignition OFF crank shaft speed sensor signal
Check and correct if any loose wire
connections noticed in the Repair/replace the wiring
crankshaft speed sensor wiring harness
harness connector Clear the DTC and verify
crank shaft speed sensor
mounting bolt
NO Is the bolt fitted YES
properly?
STEP 4
Fix the bolt properly and tighten
Ignition OFF
it to the torque specified
Crankshaft speed sensor wiring
harness connector
DISCONNECTED
Remove the crank shaft speed
sensor
crankshaft speed sensor front
face
Is there any
NO YES
damage?
Go to STEP 5 Suspect for any foreign particles
presence.
Identify the cause and rectify
Replace the crankshaft speed
sensor with a new one
102
EMS OCT 2011/Rev 1
STEP 5
Check the crankshaft end play
YES Is the end paly with NO

in limits?
STEP 6
Identify the root cause of the
crank shaft end play and rectify
trigger wheel teeth
Check for proper mounting of
trigger wheel mounting screw
Is there any
NO damage/screws YES
loosened?
If the screws are loosened ,
STEP 7 tighten to torque
Check whether the crankshaft If toner wheel damaged, replace
speed sensor wire routing is it with a new one
closer to starter motor Clear the DTC and verify
NO Is the wire closer to YES

starter motor?
Suspect crankshaft speed Route the wires correctly

sensor internal failure (Refer wiring manual for proper
Replace crankshaft speed sensor routing)
with a with a new one. Clear the DTC and verify
DTC’s
103
EMS OCT 2011/Rev 1
P0335 - Crankshaft sensor no signal error
CRANKSHAFT SPEED SENSOR
The crankshaft speed sensor is an inductive type sensor. It is mounted on front LH bottom side of the
engine and measures the speed of the trigger wheel mounted on the crankshaft
COMPONENT LOCATION
NORMAL
OPERATION  During engine cranking and running, the EMS ECU receives the output signal
from crankshaft speed sensor and is within the range
DTC DETECTING  Normal signal pattern has not been input from the crankshaft speed sensor for
CONDITION 4 sec. (Engine should be cranked to check this error).
 Disturbed signal form
PROBABLE
CAUSES  Sensor mounting loosened
 Open/short crankshaft speed sensor circuit
 Faulty crankshaft speed sensor
LAMP STATUS
DTC REACTION
 If this failure occurs when the engine is running then engine shuts off
CONDITION
104
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
105
EMS OCT 2011/Rev 1
CONNECTOR
52 SIGNAL (+)
E18 74 SIGNAL (-)
30 SHIELD
01 SIGNAL (+)
02 SIGNAL (-)
E15 03 SHIELD
106
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
Crank the engine
YES Is P0335present? NO
STEP 2 Intermittent problem exists

Ignition OFF
Check and correct if any loose
connections noticed in the
crankshaft speed sensor wiring
harness connector
crank shaft speed sensor
mounting bolt
YES Are the bolts tight? NO
STEP 3 Fix the bolt properly and tighten

Ignition OFF it to the torque specified
Crankshaft speed sensor wiring Clear the DTC and verify
harness connector
DISCONNECTED
pin 1 and pin 2 of the
crankshaft speed sensor wiring
harness connector
Go to STEP 4 Examine the short circuit of

crankshaft speed sensor signal
wires
harness
107
EMS OCT 2011/Rev 1
108
EMS OCT 2011/Rev 1
P0480 - Low speed fan open load
LOW SPEED COOLING FAN
The cooling fan is controlled by EMS ECU . The low speed cooling fan will be ON whenever A/C is
switched ON (middle pressure switch is OFF) or coolant temperature is more than 98°C and less than
101°C
COMPONENT LOCATION
NORMAL  Depending upon the AC ON status or coolant temperature , the EMS ECU
OPERATION
controls the low speed cooling fan
DTC DETECTING  Electrical fan driver detects open load

CONDITION
PROBABLE
CAUSES  Open low speed fan control signal wire
LAMP STATUS
 No warning lamp indication
DTC REACTION
 No reaction
CONDITION
109
EMS OCT 2011/Rev 1
CONNECTOR
E18 72 LOW SPEED CONTROL SIGNAL
110
EMS OCT 2011/Rev 1
111
EMS OCT 2011/Rev 1
P0481- High speed fan open load
HIGH SPEED COOLING FAN
The cooling fan is controlled by EMS ECU . The high speed cooling fan will be ON whenever the cooling
temperature is more than 101°C or A/C middle pressure switch is On
COMPONENT LOCATION
NORMAL
OPERATION  Depending upon the coolant temperature , the EMS ECU controls thehigh
speed cooling fan
DTC DETECTING
CONDITION  Electrical fan driver detects open load
PROBABLE
CAUSES  Open high speed fan control signal wire

LAMP STATUS
DTC REACTION
 Torque limitations
CONDITION
112
EMS OCT 2011/Rev 1
CONNECTOR
E18 68 FAN HIGH SPEED CONTROL SIGNAL
113
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition OFF
Ensure the fan high speed relay
is fixed properly in the
connector of the engine
compartment fuse box
Remove the fan high speed
relay
Check the functioning of relay by
providing 12V to terminal 85
and ground to terminal 86
YES Is a clicking sound NO

heard?
STEP 3
Ignition OFF Replace the fan high speed relay
EMS ECU wiring harness with a new one
DISCONNECTED Clear the DTC and verify
relay
pin 86 of the fan high speed
relay seating and pin 68 of the
connector
Suspect EMS ECU malfunction Examine the open circuit of of

Replace EMS ECU with a new fan high speed relay control wire
one. from EMS ECU
Check and verify for any new Ensure the holding bolts of BEC
DTC’s connectors are intact
harness
114
EMS OCT 2011/Rev 1
P0692 - Low speed fan short to battery
The cooling fan is controlled by EMS ECU . The low speed cooling fan will be ON whenever A/C is
switched ON (middle pressure switch is OFF) or coolant temperature is more than 98°C and less than
101°C
COMPONENT LOCATION
NORMAL
OPERATION  Depending upon the AC ON status or coolant temperature , the EMS ECU
DTC DETECTING  Electrical fan driver detects short to battery

CONDITION
PROBABLE
CAUSES  Low speed cooling fan control signal wire short to battery
LAMP STATUS
DTC REACTION
 No reaction
CONDITION
115
EMS OCT 2011/Rev 1
CONNECTOR
E18 72 FAN LOW SPEED CONTROL SIGNAL
116
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition OFF
Ensure the fan low speed relay
Remove the fan low speed
relay

heard?
STEP 3
Ignition OFF Replace the fan low speed relay
Remove the fan low speed relay with a new one
pin 30 and pin 86 of the fan
low speed relay
Go to STEP 4 Replace the fan low speed relay

with a new one
117
EMS OCT 2011/Rev 1
118
EMS OCT 2011/Rev 1
P0694 - High speed fan short to battery
The cooling fan is controlled by EMS ECU . The high speed cooling fan will be ON whenever the cooling
temperature is more than 101°C or A/C middle pressure switch is On
COMPONENT LOCATION
NORMAL
OPERATION  Depending upon the coolant temperature , the EMS ECU controls the high
speed cooling fan
DTC DETECTING  Electrical fan driver detects short to battery

CONDITION
PROBABLE
CAUSES  High speed cooling fan control signal wire short to battery
LAMP STATUS
DTC REACTION
CONDITION
119
EMS OCT 2011/Rev 1
CONNECTOR
120
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition OFF
Ensure the fan high speed relay
relay

heard?
STEP 3
Ignition OFF Replace the fan high speed relay
Remove the fan high speed with a new one
relay Clear the DTC and verify
pin 30 and pin 86 of the fan
high speed relay
Go to STEP 4 Replace the fan high speed relay

with a new one
121
EMS OCT 2011/Rev 1
122
EMS OCT 2011/Rev 1
P0691 - Low speed fan short to ground
The cooling fan is controlled by EMS ECU. The low speed cooling fan will be ON whenever A/C is switched
ON (middle pressure switch is OFF) or coolant temperature is more than 98°C and less than 101°C
COMPONENT LOCATION
NORMAL
OPERATION  Depending upon the AC ON status or coolant temperature , the EMS ECU
DTC DETECTING  Electrical fan driver detects short to ground

CONDITION
PROBABLE
CAUSES  Low speed cooling fan control signal wire short to ground
LAMP STATUS
DTC REACTION
 No reaction
CONDITION
123
EMS OCT 2011/Rev 1
CONNECTOR
E18 72 FAN LOW SPEED CONTROL SIGNAL
124
EMS OCT 2011/Rev 1
125
EMS OCT 2011/Rev 1
P0693- High speed fan short to ground
The cooling fan is controlled by EMS ECU. The high speed cooling fan will be ON whenever the cooling
temperature is more than 101°C or A/C middle pressure switch is On.
COMPONENT LOCATION
NORMAL
OPERATION  Depending upon the coolant temperature , the EMS ECU controls the high
speed cooling fan
DTC DETECTING  Electrical fan driver detects short to ground

CONDITION
PROBABLE
CAUSES  High speed cooling fan control signal wire short to ground
LAMP STATUS
DTC REACTION
CONDITION
126
EMS OCT 2011/Rev 1
CONNECTOR
127
EMS OCT 2011/Rev 1
128
EMS OCT 2011/Rev 1
P0183 -Signal range check for fuel temperature sensor above maximum limit
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.
COMPONENT LOCATION
NORMAL  During ignition ON , the measured output voltage value of the fuel temperature
OPERATION
sensor is between 0.1 to 3.3 V
DTC DETECTING
CONDITION  The measured output voltage of the fuel temperature sensor is more than 3.3
V for 4 seconds
PROBABLE  Open fuel temperature wiring harness

CAUSES  Short to battery of fuel temperature wiring harness
 Faulty fuel temperature sensor
 Faulty EMS ECU
LAMP STATUS
DTC REACTION
 Engine will run with a default fuel temperature of 20 °C
CONDITION
129
EMS OCT 2011/Rev 1
CIRCUIT SCHEMATIC
CONNECTOR
E18 12 SIGNAL
34 GROUND
EC2 1 SIGNAL
2 GROUND
130
EMS OCT 2011/Rev 1
131
EMS OCT 2011/Rev 1
132
EMS OCT 2011/Rev 1
P0182-Signal range check for fuel temperature sensor below minimum limit
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.
COMPONENT LOCATION
NORMAL  During ignition ON , the measured output voltage value of the fuel temperature
OPERATION
sensor is between 0.1 to 3.3 V
DTC DETECTING
CONDITION  The measured output voltage of the fuel temperature sensor is less than 0.1
V for 4 seconds
PROBABLE
CAUSES  Short fuel temperature wiring harness
 Faulty fuel temperature sensor
 Faulty EMS ECU
LAMP STATUS
DTC REACTION
 Engine will run with a default fuel temperature of 20 °C
CONDITION
133
EMS OCT 2011/Rev 1
CIRCUIT SCHEMATIC
CONNECTOR
E18 12 SIGNAL
34 GROUND
EC2 1 SIGNAL
2 GROUND
134
EMS OCT 2011/Rev 1
CONNECTOR
E18 12 SIGNAL
34 GROUND
EC2 1 SIGNAL
2 GROUND
135
EMS OCT 2011/Rev 1
136
EMS OCT 2011/Rev 1
137
EMS OCT 2011/Rev 1
P268C - Cylinder 1 injector adjustment code incorrect error
IQA MONITORING
IQA monitoring monitors the missing or faulty programming of IQA values
COMPONENT LOCATION
NORMAL  During ignition ON , the ECU monitors the checksum of cylinder 1 IQA code
OPERATION
and is within the range
DTC DETECTING
CONDITION  No IQA code read by EEPROM
 The checksum of IQA code is not correct
PROBABLE
CAUSES  IQA code not written
 Faulty EMS ECU
LAMP STATUS
DTC REACTION
 Cylinder 1 injector adjustment will not happen
CONDITION
138
EMS OCT 2011/Rev 1
139
EMS OCT 2011/Rev 1
P268D - Cylinder 2 injector adjustment code incorrect error
IQA MONITORING
COMPONENT LOCATION
OPERATION
DTC DETECTING
PROBABLE
 Faulty EMS ECU
LAMP STATUS
DTC REACTION
CONDITION
140
EMS OCT 2011/Rev 1
141
EMS OCT 2011/Rev 1
P268E - Cylinder 3 injector adjustment code incorrect error
IQA MONITORING
COMPONENT LOCATION
OPERATION
DTC DETECTING
PROBABLE
 Faulty EMS ECU
LAMP STATUS
DTC REACTION
CONDITION
142
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
Verify if P268E is present?
YES Is P268E present? NO

Ignition ON
Using diagnostic tool , check
whether the 3rd cylinder 7 digit
IQA code is written properly
Is the IQA code

YES NO
written correctly?
Suspect EMS ECU malfunction Write the correct IQA code

Replace EMS ECU with a new Clear the DTC and verify
one.
DTC’s
143
EMS OCT 2011/Rev 1
P268F - Cylinder 4 injector adjustment code incorrect error
IQA MONITORING
COMPONENT LOCATION
OPERATION
DTC DETECTING
PROBABLE
 Faulty EMS ECU
LAMP STATUS
DTC REACTION
CONDITION
144
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition ON
Using diagnostic tool , check
whether the 4th cylinder 7 digit
IQA code is written properly
Is the IQA code

YES NO
written correctly?
Suspect EMS ECU malfunction Write the correct IQA code

Replace EMS ECU with a new Clear the DTC and verify
one.
DTC’s
145
EMS OCT 2011/Rev 1
P0201 - Cylinder1 injector open load error
INJECTORS
The injectors are solenoid actuated and controlled by EMS ECU. The EMS ECU measures the voltage drop
through fixed resistors and controls it.
COMPONENT LOCATION
NORMAL  The PWM control signal of the injector is monitored and is within the range
OPERATION
DTC DETECTING
CONDITION  A open load is detected in injector 1 circuit
PROBABLE
CAUSES  Open in injector 1 circuit
 Faulty Injector 1
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
 Injection in cylinder 1 will not happen
CONDITION
146
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
147
EMS OCT 2011/Rev 1
CONNECTOR
E18 3 POWER HIGH SIDE INJECTOR 1

73 POWER LOW SIDE INJECTOR 1
148
EMS OCT 2011/Rev 1
149
EMS OCT 2011/Rev 1
P0202 - Cylinder 2 injector open load error
INJECTORS
COMPONENT LOCATION
OPERATION
DTC DETECTING
PROBABLE
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
150
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
151
EMS OCT 2011/Rev 1
CONNECTOR

152
EMS OCT 2011/Rev 1
153
EMS OCT 2011/Rev 1
INJECTORS
COMPONENT LOCATION
OPERATION
DTC DETECTING
PROBABLE
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
154
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
155
EMS OCT 2011/Rev 1
CONNECTOR

156
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition OFF
Injector 3 wiring harness
pin 2 of Injector 3 wiring harness
connector and pin 29 of the
connector

Injector 3 high side and low side
Ignition OFF wires
Injector 3 wiring harness Repair/replace the wiring
pin 1 and pin 2 of the injector 2
YES Is the value =0.255 ± NO

0.040 Ω?
Suspect EMS ECU malfunction Suspect internal failure of the
Replace EMS ECU with a new Injector 3
157
EMS OCT 2011/Rev 1
INJECTORS
COMPONENT LOCATION
OPERATION
DTC DETECTING
PROBABLE
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
158
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
159
EMS OCT 2011/Rev 1
CONNECTOR

160
EMS OCT 2011/Rev 1
161
EMS OCT 2011/Rev 1
P0261 - High side - Low side short circuit for cylinder 1 injector
INJECTORS
The injectors are solenoid actuated an controlled by EMS ECU. The EMS ECU measures the voltage drop
COMPONENT LOCATION
OPERATION
DTC DETECTING
CONDITION  A short between injector 1 low side and high side detected
PROBABLE
CAUSES  Short in injector 1 circuit
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
162
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
163
EMS OCT 2011/Rev 1
CONNECTOR

164
EMS OCT 2011/Rev 1
165
EMS OCT 2011/Rev 1
INJECTORS
COMPONENT LOCATION
OPERATION
DTC DETECTING
CONDITION
 A short between injector 2 low side and high side detected
PROBABLE
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
166
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
167
EMS OCT 2011/Rev 1
CONNECTOR

168
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition OFF
pin 2 and pin 1 of Injector 2

Ignition OFF wires

0.040 Ω?
169
EMS OCT 2011/Rev 1
INJECTORS
COMPONENT LOCATION
OPERATION
DTC DETECTING
PROBABLE
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
170
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
171
EMS OCT 2011/Rev 1
CONNECTOR

172
EMS OCT 2011/Rev 1
173
EMS OCT 2011/Rev 1
INJECTORS
COMPONENT LOCATION
OPERATION
DTC DETECTING
PROBABLE
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
174
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
175
EMS OCT 2011/Rev 1
CONNECTOR

176
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition OFF
pin 2 and pin 1 of Injector 4

Ignition OFF wires

0.040 Ω?
177
EMS OCT 2011/Rev 1
P2146 - Short circuit in bank 0
INJECTORS
COMPONENT LOCATION
NORMAL
OPERATION
 The injector bank is checked while running and initialization and found normal
DTC DETECTING
CONDITION  Short in injection bank detected
PROBABLE
CAUSES  Short in injector bank
 Faulty Injectors
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
 Engine shuts off
CONDITION
178
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
STEP 2
Ignition OFF Intermittent problem exists
Injector 1,2,3 and 4 wiring Refer the intermittent problem
harness connector inspection procedure
DISCONNECTED
Ignition ON
Check the voltage between pin 2
of Injector 1 wiring harness
YES Is the value =0V? NO
STEP 3
Ignition OFF injector low side wire/s to
Injector 1,2,3 and 4 wiring battery positive

injector low side wire/s to
Go to STEP 4
ground
harness
179
EMS OCT 2011/Rev 1
180
EMS OCT 2011/Rev 1
P0001 - Metering unit open load error
METERING UNIT
The component driver for the metering unit regulates the opening and closing f the metering unit based
on the rail pressure set point and the actual value
COMPONENT LOCATION
NORMAL
OPERATION  When ignition ON , no malfunction detected by EMS ECU in the metering unit
circuit
DTC DETECTING
CONDITION  A open load is detected in metering unit circuit
PROBABLE
CAUSES  Open in metering circuit
 Faulty metering unit
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
181
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
182
EMS OCT 2011/Rev 1
CONNECTOR
E18 89 METERING UNIT GROUND(CONTROL SIGNAL)
E14 1 METERING UNIT POWER
2 METERING UNIT GROUND(CONTROL SIGNAL)
183
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition OFF
Check and confirm the proper
function of fuse EF7 in engine
Fuel metering unit wiring
harness connector
DISCONNECTED
Ignition ON
Check the voltage between
between pin 1 of fuel metering
unit wiring harness connector
and battery ground
YES Is the value =Vbat? NO
STEP 3 Examine the open/short to

ground of fuel metering unit
Ignition OFF power supply wire from main
Fuel metering unit wiring relay
harness connector Repair/Replace the wiring
EMS ECU wiring harness Check and verify for any new
connector DISCONNECTED DTC’s
pin 2 of fuel metering unit
pin 89 of the EMS ECU wiring
harness connector
Suspect fuel metering unit Examine the open circuit of fuel

internal failure metering unit control wire
Replace fuel pump with a new Repair/replace the wiring
one. harness
Check and verify for any new Clear the DTC and verify
DTC’s
184
EMS OCT 2011/Rev 1
P0004 - Metering unit output short circuit to battery error
METERING UNIT
COMPONENT LOCATION
NORMAL
circuit
DTC DETECTING
CONDITION  Short to battery is detected in metering unit circuit
PROBABLE
CAUSES  Short in metering circuit
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
185
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
186
EMS OCT 2011/Rev 1
CONNECTOR
187
EMS OCT 2011/Rev 1
188
EMS OCT 2011/Rev 1
P0003 - Metering unit output short circuit to ground error
METERING UNIT
COMPONENT LOCATION
NORMAL
circuit
DTC DETECTING
CONDITION  Short to ground is detected in metering unit circuit
PROBABLE
CAUSES  Short in metering circuit
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
189
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
190
EMS OCT 2011/Rev 1
CONNECTOR
191
EMS OCT 2011/Rev 1
192
EMS OCT 2011/Rev 1
P0238 - Signal range check for manifold absolute pressure sensor above maximum limit
BOOST PRESSURE SENSOR
The boost pressure signal is monitored. This signal is used as a feedback for the control of the VGT and
also for the EGR. The boost pressure sensor is mounted on the outlet of the intercooler
COMPONENT LOCATION
NORMAL
OPERATION  During Ignition ON, EMS ECU receives an output voltage signal from boost
pressure sensor and is within the range
DTC DETECTING
CONDITION  The output voltage signal received from the boost pressure sensor is above
the maximum limit
PROBABLE
CAUSES  Short in boost pressure sensor circuit
 Faulty boost pressure sensor
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
 Default air mass values taken
CONDITION
193
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
194
EMS OCT 2011/Rev 1
CONNECTOR
35 POWER
E18 56 SIGNAL (P)
78 G ROUND
3 POWER
4 SIGNAL (P)
E9 1 G ROUND
195
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition OFF
Boost pressure sensor wiring
harness connector
DISCONNECTED
Ignition ON
3 of boost pressure sensor
battery ground
NO Is the value > 5.25 YES

V?

Ignition OFF boost pressure sensor power
Boost pressure sensor wiring wire with battery positive
pin 3 and pin 4 of boost If the DTC still exists, replace the
pressure sensor wiring harness EMS ECU with a new one
connector Check and verify for any new
DTC’s
Go to STEP 4 Examine the short circuit of

boost pressure sensor power
and signal wires
harness
196
EMS OCT 2011/Rev 1
197
EMS OCT 2011/Rev 1
P0237 - Signal range check for intake manifold absolute pressure sensor below minimum limit
BOOST PRESSURE SENSOR
The boost pressure signal is monitored. This signal is used as a feedback for the control of the VGT and
also for the EGR. The boost pressure sensor is mounted on the outlet of the intercooler
COMPONENT LOCATION
NORMAL
DTC DETECTING
CONDITION  The output voltage signal received from the boost pressure sensor is below
the minimum limit
PROBABLE
CAUSES  Short /open in boost pressure sensor circuit
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
 Default air mass values taken
CONDITION
198
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
199
EMS OCT 2011/Rev 1
CONNECTOR
35 POWER
E18 56 SIGNAL (P)
78 GROUND
3 POWER
4 SIGNAL (P)
E9 1 GROUND
200
EMS OCT 2011/Rev 1
201
EMS OCT 2011/Rev 1
202
EMS OCT 2011/Rev 1
P007D - Signal range check for intercooler downstream temperature sensor above maximum
BOOST PRESSURE TEMPERATURE SENSOR
The boosted pressure temperature sensor is an integral part of boost pressure sensor and is used to
monitor the intercooler downstream temperature
COMPONENT LOCATION
NORMAL
temperature sensor and is within the range
DTC DETECTING
CONDITION  The output voltage signal received from the boost temperature sensor is
above the maximum limit
PROBABLE  Open boost temperature sensor circuit

CAUSES  Short to battery of boost temperature sensor circuit
 Faulty EMS ECU
LAMP STATUS
DTC REACTION
 Default boost temperature value taken for calculations
CONDITION
203
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
204
EMS OCT 2011/Rev 1
CONNECTOR
E18 87 SIGNAL (T)

78 GROUND
E9 2 SIGNAL (T)
1 GROUND
205
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
Verify if P007D is present?
YES Is P007D present? NO
STEP 2
Boost pressure sensor wiring inspection procedure
harness connector
DISCONNECTED
Ignition ON
2 of the boost pressure sensor
battery ground

V?
STEP 3
Go to STEP 4
If the Voltage is greater than
5.25V , check for short to
battery of the boost
temperature signal wire
Ignition OFF
Boost pressure sensor wiring
harness connector
DISCONNECTED
pin 87 EMS ECU wiring harness
connector and pin 2 of the of
the boost pressure sensor
Suspect EMS ECU malfunction

Replace EMS ECU with a new Examine the open circuit of
one. boost temperature signal wire
DTC’s harness
206
EMS OCT 2011/Rev 1
207
EMS OCT 2011/Rev 1
P007C - Signal range check for intercooler downstream temperature sensor below minimum limit
BOOST PRESSURE TEMPERATURE SENSOR
The boosted pressure temperature sensor is an integral part of boost pressure sensor and is used to
monitor the intercooler downstream temperature
COMPONENT LOCATION
NORMAL
temperature sensor and is within the range
DTC DETECTING
CONDITION  The output voltage signal received from the boost temperature sensor is
below the minimum limit
PROBABLE
CAUSES  Short in boost temperature sensor circuit
 Faulty boost temperature sensor
 Faulty EMS ECU
LAMP STATUS
DTC REACTION
 Default boost temperature value taken for calculations
CONDITION
208
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
209
EMS OCT 2011/Rev 1
CONNECTOR
E18 87 SIGNAL (T)

78 GROUND
E9 2 SIGNAL (T)
1 GROUND
210
EMS OCT 2011/Rev 1
211
EMS OCT 2011/Rev 1
P0193 - Signal range check for rail pressure sensor below maximum limit
RAIL PRESSURE SENSOR
The rail pressure sensor is mounted on the common rail and is used to measure the rail pressure. The
EMs ECU determines the optimum fuel injection quantity at specific engine condition based on rail
pressure sensor
COMPONENT LOCATION
NORMAL
 During Ignition ON, EMS ECU receives an output voltage signal from rail
OPERATION
DTC DETECTING
CONDITION  The output voltage signal received from the rail pressure sensor is above the
maximum limit
PROBABLE
CAUSES  Short in rail pressure sensor circuit
 Faulty rail pressure sensor
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
212
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
213
EMS OCT 2011/Rev 1
CONNECTOR
32 POWER
E18 54 SIGNAL
76 GROUND
3 POWER
2 SIGNAL
E7 1 GROUND
214
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition OFF
Rail pressure sensor wiring
harness connector
DISCONNECTED
Ignition ON
3 of rail pressure sensor wiring
ground

V?
STEP 3 Examine the short circuit of rail

Ignition OFF pressure sensor power wire
Rail pressure sensor wiring with battery positive
pin 3 and pin 2 of rail pressure If the DTC still exists, replace the
sensor wiring harness connector EMS ECU with a new one
DTC’s
Go to STEP 4 Examine the short circuit of rail

pressure sensor power and
signal wires
harness
215
EMS OCT 2011/Rev 1
216
EMS OCT 2011/Rev 1
P0192 - Signal range check for rail pressure sensor below minimum limit
pressure sensor
COMPONENT LOCATION
NORMAL
OPERATION  During Ignition ON, EMS ECU receives an output voltage signal from rail
DTC DETECTING
CONDITION  The output voltage signal received from the rail pressure sensor is below the
minimum limit
PROBABLE
CAUSES  Short /open in rail pressure sensor circuit
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
217
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
218
EMS OCT 2011/Rev 1
CONNECTOR
32 POWER
E18 54 SIGNAL
76 GROUND
3 POWER
2 SIGNAL
E7 1 GROUND
219
EMS OCT 2011/Rev 1
220
EMS OCT 2011/Rev 1
221
EMS OCT 2011/Rev 1
P0191 - Rail pressure offset value above maximum limit
pressure sensor
COMPONENT LOCATION
NORMAL
OPERATION  During after run the EMS ECU monitors the raw value of the rail pressure and is
within the limits
DTC DETECTING
CONDITION  The raw value of the rail pressure sensor is above the maximum set point
during after run
PROBABLE
CAUSES  Kinked /Blocked return line
LAMP STATUS
DTC REACTION
 Torque limitations in next ignition cycle
CONDITION
222
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
223
EMS OCT 2011/Rev 1
224
EMS OCT 2011/Rev 1
P1191 - Rail pressure offset value above minimum limit
pressure sensor
COMPONENT LOCATION
NORMAL
OPERATION  During after run the EMS ECU monitors the raw value of the rail pressure and is
within the limits
DTC DETECTING
CONDITION  The raw value of the rail pressure sensor is below the minimum set point
during after run
PROBABLE
CAUSES  Faulty rail pressure sensor
LAMP STATUS
DTC REACTION
 Torque limitations in next ignition cycle
CONDITION
225
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
226
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
Suspect Rail pressure sensor Intermittent problem exists

Replace the rail pressure sensor Refer the intermittent problem
with a new one. inspection procedure
227
EMS OCT 2011/Rev 1
P169F - Rail pressure raw value is intermittent
A loose contact in the rail pressure sensor wiring can lead to incorrect measuring of the rail pressure. If
this does occur, it is typical for the measure pressure to increase considerably for a brief time (jumps in
the magnitude of greater than 100 bar in a 10 ms time). This kind of extreme pressure increases does not
occur in the system when the rail pressure sensor is functioning properly. To determine a malfunction
based on this appearance, gradient monitoring of the rail pressure is performed Rail pressure gradient
monitoring. This is set if the rail pressure gradient pressure fluctuations exceed a certain level
COMPONENT LOCATION
NORMAL
OPERATION  EMS ECU monitors the rail pressure for sudden increase over a small time and
is within the range
DTC DETECTING
CONDITION  Extreme pressure increase noticed and fluctuation exceed a certain level
PROBABLE
CAUSES
 Loose connections in rail pressure circuit
LAMP STATUS
DTC REACTION
 Nil
CONDITION
228
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
229
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
Check and correct if any loose Intermittent problem exists

connections in rail pressure Refer the intermittent problem
circuit inspection procedure
Check and correct if any pin
bent/back out or oxidation
If the DTC still exists replace
the rail pressure sensor with a
new one
230
EMS OCT 2011/Rev 1
P2123-Signal range check for APP sensor 1 above maximum limit
ACCELERATOR PEDAL
The Accelerator pedal module (APM) is mounted in place of accelerator pedal and is connected to the ECU
by wires. The APM is a potentiometer whose output voltage changes according to the pedal position. ECU
applies a reference voltage to the APM sensor and then measures the voltage that is present on the APM
sensor signal circuit. The ECU uses the APM sensor signal for further calculation of fuelling & other engine
operational parameters.
COMPONENT LOCATION
NORMAL
OPERATION  During Ignition ON, EMS ECU receives an output voltage signal from the
accelerator pedal module and is within the specified range
DTC DETECTING
CONDITION  The output voltage signal received from the accelerator pedal module is
PROBABLE
CAUSES  Short /open in accelerator pedal module sensor circuit
 Faulty accelerator pedal module
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
231
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
232
EMS OCT 2011/Rev 1
CONNECTOR
18 APP 1 POWER
E18 61 APP 1 SIGNAL
83 APP 1 GROUND
2 APP 1 POWER
4 APP 1 SIGNAL
EC5 3 APP 1 GROUND
233
EMS OCT 2011/Rev 1
234
EMS OCT 2011/Rev 1
235
EMS OCT 2011/Rev 1
P2128 - Signal range check for APP sensor 2 above maximum limit
ACCELERATOR PEDAL
The Accelerator pedal module (APM) is mounted in place of accelerator pedal and is connected to the ECU
by wires. The APM is a potentiometer whose output voltage changes according to the pedal position. ECU
applies a reference voltage to the APM sensor and then measures the voltage that is present on the APM
sensor signal circuit. The ECU uses the APM sensor signal for further calculation of fuelling & other engine
operational parameters.
COMPONENT LOCATION
NORMAL
OPERATION  During Ignition ON, EMS ECU receives an output voltage signal from the
accelerator pedal module and is within the specified range
DTC DETECTING
CONDITION  The output voltage signal received from the accelerator pedal module is
PROBABLE
CAUSES  Short /open in accelerator pedal module sensor circuit
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
236
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
237
EMS OCT 2011/Rev 1
CONNECTOR
40 APP 2 POWER
E18 60 APP 2 SIGNAL
82 APP 2 GROUND
1 APP 2 POWER
6 APP 2 SIGNAL
EC5 5 APP 2 GROUND
238
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition OFF
Accelerator pedal wiring
harness connector
DISCONNECTED
Ignition ON
1 of accelerator pedal wiring
ground

V?

Ignition OFF accelerator pedal sensor 2
Accelerator pedal wiring power wire with battery
harness connector positive
DISCONNECTED Repair/replace the wiring
Check the resistance between harness
pin 1 and pin 6 of accelerator Clear the DTC and verify
pedal wiring harness connector If the DTC still exists, replace the
EMS ECU with a new one
DTC’s
Go to STEP 4
accelerator pedal sensor 2
power and signal wires
harness
239
EMS OCT 2011/Rev 1
240
EMS OCT 2011/Rev 1
P2138 - Plausibility error between APP signal 1 and signal 2
ACCELERATOR PEDAL PLAUSIBILITY
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
COMPONENT LOCATION
NORMAL
OPERATION  During Ignition ON, EMS ECU compares both APP1 and APP2 signals and the
difference is within the maximum range
DTC DETECTING
CONDITION  The difference between APP1 and APP2 signals is more than the maximum
range
PROBABLE
CAUSES  Short /open in accelerator pedal module sensors circuit
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
 Engine rpm limited to 1200 .Vehicle in limp home mode
CONDITION
241
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
242
EMS OCT 2011/Rev 1
CONNECTOR
40 APP 2 POWER
60 APP 2 SIGNAL
E18 82 APP 2 GROUND
18 APP 1 POWER
61 APP 1 SIGNAL
83 APP 1 GROUND
1 APP 2 POWER
6 APP 2 SIGNAL
EC5 5 APP 2 GROUND
2 APP 1 POWER
4 APP 1 SIGNAL
3 APP 1 GROUND
243
EMS OCT 2011/Rev 1
244
EMS OCT 2011/Rev 1
STEP 5
Ignition OFF
harness connector
DISCONNECTED
pin 4 of accelerator pedal
harness connector
YES Is the value < 1Ω? YES

signal wire
Ignition ON
1 of accelerator pedal wiring
ground
YES Is the value = 5±0.25 YES

V?
STEP 7 Go to STEP 9
Ignition OFF
harness connector
DISCONNECTED
battery ground

Go to STEP 8 accelerator pedal sensor 2
power wire with battery ground
harness
245
EMS OCT 2011/Rev 1
STEP 8
Ignition OFF
harness connector
DISCONNECTED
harness connector
Suspect EMS ECU malfunction Examine the open circuit of

Replace EMS ECU with a new accelerator pedal sensor 2
one. power wire
DTC’s harness
STEP 9
Ignition OFF
harness connector
DISCONNECTED
harness connector
Examine the open circuit of

Go to STEP 10 accelerator pedal sensor 1
signal wire
harness
246
EMS OCT 2011/Rev 1
STEP 10
Ignition OFF
harness connector
DISCONNECTED
pin 4 and pin 3 of accelerator
pedal wiring harness connector

Accelerator pedal wiring signal wire with battery ground
pin 6 and pin 5 of accelerator
pedal wiring harness connector

Suspect accelerator pedal accelerator pedal sensor 2
sensor internal failure signal wire with battery ground
Replace accelerator pedal with Repair/replace the wiring
a new one. harness
Check and verify for any new Clear the DTC and verify
DTC’s
247
EMS OCT 2011/Rev 1
P0113 - Signal range check for HFM temperature sensor above maximum limit
HFM TEMPERATURE SENSOR
The HFM temperature sensor is a variable resistor whose resistance changes as the temperature of the air
flowing past the sensor changes.(NTC resistor) When the intake air temperature is low, the sensor
resistance is high; when the intake air temperature is high, the sensor resistance is low.
COMPONENT LOCATION
NORMAL  During ignition ON , the measured output voltage value of the intake air
OPERATION
temperature sensor is within the specified range
DTC DETECTING
CONDITION  The measured output voltage of the intake air temperature sensor is more
than the specified range
PROBABLE  Open HFM temperature sensor wiring harness

CAUSES  Short to battery of HFM temperature sensor wiring harness
 Faulty HFM temperature sensor
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
 Engine will run with default air temperature as 20°C
CONDITION
248
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
249
EMS OCT 2011/Rev 1
CONNECTOR
E18 77 SIGNAL
53 GROUND
E1 4 SIGNAL
1 GROUND
250
EMS OCT 2011/Rev 1
251
EMS OCT 2011/Rev 1
252
EMS OCT 2011/Rev 1
P0112 - Signal range check for HFM temperature sensor below minimum limit
HFM TEMPERATURE SENSOR
The HFM temperature sensor is a variable resistor whose resistance changes as the temperature of the air
flowing past the sensor changes(NTC resistor) .When the intake air temperature is low, the sensor
resistance is high; when the intake air temperature is high, the sensor resistance is low.
COMPONENT LOCATION
NORMAL  During ignition ON , the measured output voltage value of the intake air
OPERATION
temperature sensor is within the specified range
DTC DETECTING
CONDITION  The measured output voltage of the intake air temperature sensor is less than
the specified range
PROBABLE
CAUSES  Short HFM temperature sensor wiring harness
 Faulty HFM temperature sensor
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
 Engine will run with default air temperature as 20°C
CONDITION
253
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
254
EMS OCT 2011/Rev 1
CONNECTOR
E18 77 SIGNAL
53 GROUND
E1 4 SIGNAL
1 GROUND
255
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition ON
ground

V?
STEP 3
Suspect internal short in HFM
Ignition OFF sensor
HFM sensor wiring harness Replace the sensor with a new
connector DISCONNECTED one
ground
Suspect EMS ECU malfunction Examine the short circuit of

Replace EMS ECU with a new HFM sensor air intake
one. temperature sensor signal wire
Check and verify for any new to ground
DTC’s Repair/replace the wiring
harness
256
EMS OCT 2011/Rev 1
P0045 - Boost pressure modulator open load error
BOOST PRESSURE MODULATOR
The boost pressure modulator controls the variable vanes of the VGT to attain the desired boost pressure
thru controlling the vacuum to boost pressure actuator .In normal operation and during an actuator test,
the PWM power stage of ECU is tested for short circuit to battery voltage, short circuit to ground, open
circuit and excess temperature. Once the errors are confirmed, the power stage is switched off.
COMPONENT LOCATION
ORMAL
OPERATION  When ignition ON , no malfunction detected by EMS ECU in the boost
pressure modulator circuit
DTC DETECTING
CONDITION  A open load is detected in boost pressure modulator circuit
PROBABLE
CAUSES  Open in boost pressure modulator circuit
 Faulty boost pressure modulator
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
 Boost pressure actuator will not work
CONDITION
257
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
258
EMS OCT 2011/Rev 1
CONNECTOR
E18 92 GROUND(CONTROL SIGNAL)
E21 1 POWER
2 GROUND(CONTROL SIGNAL)
259
EMS OCT 2011/Rev 1
260
EMS OCT 2011/Rev 1
P0048 - Boost pressure modulator short circuit to battery
COMPONENT LOCATION
NORMAL
DTC DETECTING
CONDITION  Short to battery is detected in boost pressure modulator circuit
PROBABLE
CAUSES  Short in boost pressure modulator circuit
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
261
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
262
EMS OCT 2011/Rev 1
CONNECTOR
E21 1 POWER
263
EMS OCT 2011/Rev 1
264
EMS OCT 2011/Rev 1
P0047 - Boost pressure modulator short circuit to ground
COMPONENT LOCATION
NORMAL
DTC DETECTING
CONDITION  Short to ground is detected in boost pressure modulator circuit
PROBABLE
CAUSES  Short in boost pressure modulator circuit
 Faulty EMS ECU
LAMP STATUS
 OBD lamp ON
DTC REACTION
CONDITION
265
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
266
EMS OCT 2011/Rev 1
CONNECTOR
E21 1 POWER
267
EMS OCT 2011/Rev 1
268
EMS OCT 2011/Rev 1
P1645 - Boost pressure modulator over temperature error
COMPONENT LOCATION
NORMAL
pressure modulator circuit and no surge voltage detected
DTC DETECTING
CONDITION  Overheating in power stage
PROBABLE
CAUSES
 Loosen boost pressure modulator wiring harness connectors
 Faulty EMS ECU
LAMP STATUS
 System Check Lamp ON
DTC REACTION
CONDITION
CONNECTOR LAYOUT
269
EMS OCT 2011/Rev 1
CIRCUIT SCHEMATIC
270
EMS OCT 2011/Rev 1
CONNECTOR
E21 1 POWER
271
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
Check and correct if there is

any wiring harness connector Intermittent problem exists
loose connections Refer the intermittent problem
Check and correct for any pin inspection procedure
back out or oxidation
If the DTC still exists, replace the
EMS ECU with a new one
Check for any new DTC’s
272
EMS OCT 2011/Rev 1
P0501 - Vehicle speed sensor plausibility error
VEHICLE SPEED SENSOR
Vehicle Speed Sensor(VSS) is hall sensor type and senses the rotating speed of differential gear mounted
on transaxle. Comparing engine speed with vehicle speed calculated based on vehicle speed sensor signal,
ECU recognizes engaged gear. And based on the information about engaged gear, ECU performs optimum
fuel injection quantity correction
COMPONENT LOCATION
NORMAL
OPERATION  When the vehicle is driven , VSS outputs a pulse signal to the EMS ECU and is
within the range
DTC DETECTING
CONDITION  Clutch is engaged and gear not in neutral but the VSS sensor output remains
same for more than 4 sec
PROBABLE
CAUSES  Short /open in VSS circuit
 Faulty VSS
LAMP STATUS
DTC REACTION  All the load dependent function e.g. FBC, ZFC are switched off.
 Vehicle may feel jerky while driving.

CONDITION
273
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
274
EMS OCT 2011/Rev 1
CONNECTOR
50 POWER
E18 22 SIGNAL
55 GROUND
E19 3 SIGNAL
2 GROUND
275
EMS OCT 2011/Rev 1
276
EMS OCT 2011/Rev 1
STEP 4
Ignition OFF
VSS wiring harness connector
DISCONNECTED
the VSS wiring harness
connector
the VSS wiring harness
connector
Suspect faulty VSS Examine the open circuit of the

Replace VSS with anew one VSS signal wire and ground wire
Clear the DTC and verify to EMS ECU
harness
277
EMS OCT 2011/Rev 1
P0641 - Sensor supply voltage1 monitoring error
SENSOR SUPPLY VOLTAGE MONITORING
EMS ECU monitors the reference voltage of the critical sensors and registers a DTC if the voltage is not
within the range
NORMAL  EMS ECU monitors the reference supply voltage to coolant temperature sensor,
OPERATION
fuel temperature sensor and rail pressure sensor and are within the range
DTC DETECTING
CONDITION  The sensor supply voltage to the fuel temperature sensor, rail pressure sensor
and coolant temperature sensor are out of the range
PROBABLE
CAUSES  Short in sensor supply wire
 Faulty sensor
LAMP STATUS
 System check lamp ON
DTC REACTION
 Default values taken for the sensor signal/s
 Torque limitation
CONDITION
278
EMS OCT 2011/Rev 1
CIRCUIT SCHEMATIC
279
EMS OCT 2011/Rev 1
280
EMS OCT 2011/Rev 1
281
EMS OCT 2011/Rev 1
P0651 - Sensor supply voltage 2 monitoring error
within the range
NORMAL
OPERATION  EMS ECU monitors the reference supply voltage to APP2 and are within the
range
DTC DETECTING
CONDITION  The sensor supply voltage to the APP2 is out of the range
PROBABLE
 Faulty APP2 sensor
LAMP STATUS
DTC REACTION
CONDITION
CIRCUIT SCHEMATIC
282
EMS OCT 2011/Rev 1
283
EMS OCT 2011/Rev 1
P0697 - Error Sensor supplies 3
within the range
NORMAL
OPERATION  EMS ECU monitors the reference supply voltage to APP1 and are within the
range
DTC DETECTING
CONDITION  The sensor supply voltage to the APP1 is out of the range
PROBABLE
 Faulty APP1 sensor
LAMP STATUS
DTC REACTION
CONDITION
CIRCUIT SCHEMATIC
284
EMS OCT 2011/Rev 1
285
EMS OCT 2011/Rev 1
P1B87 - Maximum positive Rail pressure deviation exceeded
NORMAL  The ECU compares the rail pressure monitored through the rail pressure sensor
OPERATION against the expected pressure generated due to HPP ( Based on MPROP
position and the engine RPM and coolant temperature )
DTC DETECTING
CONDITION  The positive governor deviation is more than the range
 Leak on fuel lines

PROBABLE  Defective fuel tank cap
CAUSES  Defective fuel filter
 Fuel tank strainer choked
 Injector struck in open condition
 M prop valve struck
LAMP STATUS
DTC REACTION
CONDITION
286
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
Verify if P1B87 is present?
YES Is P1B87 present? NO

Check and verify the last fuel Refer the intermittent problem
filter change kilometers inspection procedure
Is the DTC registered in

YES < 2000 kms after fuel
NO
filter change?
STEP 3 Replace the fuel filter with anew

Carry out the fuel system one
bleeding at the injector nuts Clear the DTC and verify
Check and verify for the DTC
Is the DTC still

YES NO
present?
STEP 4
Replace the fuel filter with a Diagnosis completed
new one
Is the DTC still

YES NO
present?
STEP 5
Diagnosis completed
Clean the fuel strainer and fuel
lines
Is the DTC still

YES NO
present?
Go to STEP 6
Diagnosis completed
287
EMS OCT 2011/Rev 1
288
EMS OCT 2011/Rev 1
P1C87- Positive governor deviation and set point value of the fuel volume flow through the
metering unit.
NORMAL
OPERATION  The ECU compares the rail pressure monitored through the rail pressure sensor
against the expected pressure generated due to HPP
DTC DETECTING
CONDITION  The positive governor deviation is more than the range and the high pressure
pump delivery is more than the limit
 Leak on fuel lines

PROBABLE  Defective fuel tank cap
CAUSES  Defective fuel filter
 Fuel tank strainer choked
 Injector struck in open condition
 M prop valve struck
LAMP STATUS
DTC REACTION
CONDITION
289
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON
Verify if P1C87 is present?
YES Is P1C87 present? NO

Check and verify the last fuel Refer the intermittent problem
filter change kilometers inspection procedure
Is the DTC registered in

YES < 2000 kms after fuel
NO
filter change?
STEP 3 Replace the fuel filter with anew

Carry out the fuel system one
bleeding at the injector nuts Clear the DTC and verify
Is the DTC still

YES NO
present?
STEP 4
Replace the fuel filter with a Diagnosis completed
new one
Is the DTC still

YES NO
present?
STEP 5
Diagnosis completed
Clean the fuel strainer and fuel
lines
Is the DTC still

YES NO
present?
Go to STEP 6
Diagnosis completed
290
EMS OCT 2011/Rev 1
291
EMS OCT 2011/Rev 1
P1B88 - Rail pressure negative governor deviation error in Metering Unit mode
DTC DETECTING
CONDITION  The negative governor deviation is less than the range and the set point for
fuel flow thru metering unit is lesser than the limit
PROBABLE
CAUSES  M prop valve struck
 Zero delivery throttle clogged
 Metering unit without power due to electrical error
LAMP STATUS
DTC REACTION
CONDITION
292
EMS OCT 2011/Rev 1
293
EMS OCT 2011/Rev 1
P1D87 - Rail pressure below minimum limit error in Metering Unit mode
DTC DETECTING
CONDITION  Rail pressure falls below the limiting value
PROBABLE  Clogged Fuel filter, leakage in fuel lines

CAUSES  Leakage in high pressure pipes, injector stuck in open position, worn HPP,
worn injectors
LAMP STATUS
DTC REACTION

CONDITION
294
EMS OCT 2011/Rev 1
P1C88 - Rail pressure above maximum limit error in Metering Unit mode
DTC DETECTING
CONDITION  Rail pressure exceeds above the limiting value
PROBABLE  M prop valve struck

CAUSES  Zero delivery throttle clogged
 Metering unit without power due to electrical error
LAMP STATUS
DTC REACTION  Engine shuts off
 Ignition OFF/ON
HEALING
CONDITION
295
EMS OCT 2011/Rev 1
296
EMS OCT 2011/Rev 1
P068A - Main relay early opening error

P068B - Main relay struck error
COMPONENT LOCATION
 EMS ECU checks the main relay actuation time during initialization and is within
NORMAL
OPERATION the range
 ECU checks the main relay during operation and no sticky operation noticed
DTC DETECTING
CONDITION  The main relay is not operating in the set time
PROBABLE  Open /short wiring harness

CAUSES  Loosen wiring harness connectors
 Sticky relay
 Faulty BEC
LAMP STATUS
DTC REACTION
 Engine will not start
 No communication from EMS
CONDITION
Note- This DTC's will be viewed in the diagnostic tool in healed condition only
297
EMS OCT 2011/Rev 1
CIRCUIT SCHEMATIC
Note -
The EMS main relay will reset 15 seconds after ignition OFF
298
EMS OCT 2011/Rev 1
CONNECTOR
4 MAIN RELAY OUTPUT TO EMS
E18 6 MAIN RELAY OUTPUT TO EMS
50 MAIN RELAY CONTROL SIGNAL
71 EMS ECU IGNITION SUPPLY
2 MAIN RELAY OUTPUT TO EMS
BC4 3 MAIN RELAY OUTPUT TO EMS
30 MAIN RELAY CONTROL SIGNAL
299
EMS OCT 2011/Rev 1
STEP 1
Is EMS ECU
NO communicates with YES
the tool?

Ignition OFF
Ensure the main relay is fixed
properly in the connector of the
engine compartment fuse box
Remove the main relay

heard?
STEP 3
Ignition OFF Replace the main relay with a
Remove the main relay new one
Check the voltage between pin Clear the DTC and verify
85 of the main relay seating on
BEC and battery ground
pin 30 of the main relay seating
on BEC and battery ground
YES Is the value =Vbat? NO
Go to STEP 4 Ensure the 150 A main fuse

(MF2) is functioning properly
Ensure the battery to BEC
connections are intact
Replace the BEC with a new one
300
EMS OCT 2011/Rev 1
301
EMS OCT 2011/Rev 1
302
EMS OCT 2011/Rev 1
P0504 - Brake Signal plausibility error.
BRAKE SIGNAL
The main and redundant brake signals are received from the brake switch to EMS ECU . They are
mutually and individually checked for plausibility.
COMPONENT LOCATION
NORMAL  During ignition ON, the brake switch outputs a voltage which corresponds to
OPERATION the brake position and is within the range.
 Main brake signal is ON and redundant signal is OFF and vice versa
DTC DETECTING
CONDITION  The brake switch output remains same in spite of brake pressed or not pressed
 The main and redundant switch status remains same
PROBABLE
CAUSES  Open /short wiring harness
 Improper brake switch adjustment
 Faulty brake switch
LAMP STATUS
 Accelerator plausibility error detection stopped.

DTC REACTION
 Under braking condition detection stopped
 ABS/ESP malfunctioning
CONDITION
303
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
304
EMS OCT 2011/Rev 1
CONNECTOR
E18 24 REDUNDANT SIGNAL

80 MAIN SIGNAL
1 POWER SUPPLY
EC17 2 MAIN SIGNAL
3 POWER SUPPLY
4 REDUNDANT SIGNAL
305
EMS OCT 2011/Rev 1
306
EMS OCT 2011/Rev 1
307
EMS OCT 2011/Rev 1
P0704 - Clutch non plausible error
CLUTCH SIGNAL
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
COMPONENT LOCATION
NORMAL  During ignition ON, the clutch pedal sensor outputs a signal which corresponds
OPERATION to the clutch pedal position and is within the range.
 The clutch signals are received every time a gear change is detected
DTC DETECTING
CONDITION  Gear change detected without clutch signal
PROBABLE
CAUSES  Open /short wiring harness
 Improper clutch pedal sensor adjustment
 Faulty clutch sensor
LAMP STATUS
DTC REACTION  Under braking condition detection stopped

 ZFC shuts off
CONDITION
308
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
309
EMS OCT 2011/Rev 1
CONNECTOR
23 85% SIGNAL
E18 41 15% SIGNAL
10 POWER SUPPLY
1 85% SIGNAL
EC16 2 15% SIGNAL
3 GROUND
4 POWER SUPPLY
Note- Ensure the clutch pedal sensor is properly adjusted (refer repair manual) before proceeding
diagnosis as below
310
EMS OCT 2011/Rev 1
STEP 1
Turn ignition OFF
Turn ignition ON

Ignition OFF
Clutch sensor wiring harness
Ignition ON
4 of the clutch sensor wiring
ground
YES Is the value =5 ±0.25 NO

V?
STEP 3 Examine the open /short circuit
in clutch sensor power supply
Ignition OFF wire
EMS ECU wiring harness Repair/replace the wiring
Clutch sensor wiring harness Clear the DTC and verify
connector DISCONNECTED If the DTC still exists suspect
Check the resistance between EMS ECU.
pin 1 of the clutch sensor wiring Replace the EMS ECU with a
harness connector and pin 23 of new one
connector
pin 2 of the clutch sensor wiring
connector
Examine the open circuit in

Go to STEP 4
clutch sensor signal wires to
EMS ECU
harness
311
EMS OCT 2011/Rev 1
STEP 4
Ignition OFF
Clutch sensor wiring harness
ground
ground
STEP 5
Examine the short circuit in
Ignition OFF clutch sensor signal wires to
EMS ECU wiring harness ground
connector DISCONNECTED Repair/replace the wiring
Clutch sensor wiring harness harness
connector DISCONNECTED Clear the DTC and verify
harness connector and ground
Suspect faulty clutch sensor Examine the open circuit in

Replace the sensor with a new clutch signal ground wire
one Repair/replace the wiring
Clear the DTC and verify harness
312
EMS OCT 2011/Rev 1
P1704 - Gear Neutral Signal is not plausible
GEAR NEUTRAL SENSOR

The gear neutral sensor is a inductive based sensor. It is mounted on the transaxle and detects the
movement of the of the shift sleeve through which it provides gear neutral position information
COMPONENT LOCATION
NORMAL  During ignition ON, on every gear change the gear lever passes through the
OPERATION neutral position and a level transition in gear neutral signal .
 The clutch signals are received every time a gear change is detected
DTC DETECTING
CONDITION
 Gear change detected without transition in gear neutral sensor signal
PROBABLE
CAUSES  Loosened gear neutral sensor
 Open /short wiring harness
 Faulty gear neutral sensor
LAMP STATUS
DTC REACTION  Stop start system will not work

 No updation of neutral position in instrument cluster
CONDITION
313
EMS OCT 2011/Rev 1
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
314
EMS OCT 2011/Rev 1
CONNECTOR
E18 13 POWER SUPPLY

47 SIGNAL
1 POWER SUPPLY
EC16 2 SIGNAL
3 GROUND
315
EMS OCT 2011/Rev 1
316
EMS OCT 2011/Rev 1
STEP 4
Ignition OFF
Gear neutral sensor wiring
harness connector
DISCONNECTED
pin 2 of the gear neutral sensor
battery ground
STEP 5
Examine the short circuit in
Ignition OFF gear neutral sensor signal wire
EMS ECU wiring harness to ground
connector DISCONNECTED Repair/replace the wiring
Gear neutral sensor wiring harness
harness connector Clear the DTC and verify
DISCONNECTED
pin 3 of the gear neutral sensor
ground
Suspect faulty gear neutral Examine the open circuit in

sensor gear neutral sensor ground wire
Replace the sensor with a new Repair/replace the wiring
one harness
Clear the DTC and verify Clear the DTC and verify
317
EMS OCT 2011/Rev 1
CONTINOUS TORQUE MONITORING
DTC Description Monitored Component Malfunction
NTP error in ADC The ADC ( Analog to Digital

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

P163B
test error monitoring test voltage
ECU Monitoring: Ratiometry correction Error in plausibility of

P163C Voltage ratio error in ratiometry correction
ADC monitored
ECU Monitoring: Function controller Error in plausibility of

P1621 Query response monitored function controller and
communication error monitoring module
ECU Monitoring: SPI SPI communication Interrupted SPI

P1622
communication error monitored communication
ECU Monitoring: ROM ROM memory monitored Multiple error in complete

P0605
memory error ROM test during post drive
ECU Monitoring: CPU MM response to CPU is Too less bytes received by

P1623
error monitored MM from CPU as response
ECU Monitoring: MM response time is Error in MM response time

P1625 Response time error in monitored
ECU
ECU Monitoring: Shut SPI communication Error detected in SPI

P1626 off path test SPI monitored communication
communication error
Lamp Status - No lamp indication
DTC reaction - Engine will not start
Corrective Action -
1. Using diagnostic tester clear the DTC.
2. Turn ignition OFF/ON
3. Check for the DTC . If the DTC still exists , repeat the steps 1 and 2 for 3 times
4. If DTC still exists replace the EMS ECU with a new one
318
EMS OCT 2011/Rev 1
ECU Monitoring: Shut Shut off path test Error in shut off path test of
off path under voltage monitored for under the under voltage detection
P1628 error voltage
ECU Monitoring: WDA Shut off path check Error in shut off path check
P1629 not working monitored monitoring
ECU Monitoring: Time Time out in calling Error in calling operative

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

P162D out error for shut off shut off path test shut off path test
path test
Corrective Action -
319
EMS OCT 2011/Rev 1
P060D ECU Monitoring: Two voltage values of Implausible accelerator

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

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

Energising time quantities monitored the programmed energizing
plausibility error time and the measured
energizing time exceeds a
limit then this error will be
registered
Corrective Action -
320
EMS OCT 2011/Rev 1
P1631 - ECU Monitoring: Start of Injection plausibility error
NORMAL
OPERATION
 The start of the energizing time is monitored
DTC DETECTING
CONDITION  If the start of the energizing time is outside the plausible valid range then this
error is registered
PROBABLE
CAUSES  EMI interference in the signal from the Engine speed sensor ( look at the starter
motor cable & starter motor condition.)
 Faulty EMS ECU
LAMP STATUS
DTC REACTION  Engine shuts off

CONDITION
Corrective Action -
1. Check and rectify if any EMI interference in signal from the Engine sensor ( possible cause can be
starter motor cable or starter motor taking extra load )
321
EMS OCT 2011/Rev 1
P1632 - ECU Monitoring: ZFC non plausibility error
NORMAL  The maximum plausible energising time of the ZFC results, depending on the
OPERATION rail pressure of level is compared with a curve, while the minimum energizing
time is also compared with a curve
DTC DETECTING
CONDITION  If the actual value is beyond the curves then this error is set
PROBABLE
CAUSES  Injector worn/ stuck
 Faulty EMS ECU
LAMP STATUS

CONDITION
Corrective Action -
1. Check for injector stuck or worn ( thru fuel leak off test)
322
EMS OCT 2011/Rev 1
DTC Description
P1633 ECU Monitoring: PoI2 qty error
P1634 ECU Monitoring:PoI2 shut off error
P1635 ECU Monitoring:PoI3 efficiency factor error
P1637 ECU Monitoring: Injection quantity correction error
P061B ECU Monitoring: Torque comparison error
P163E ECU Monitoring: Torque monitoring level2 error
P1639 ECU Monitoring: Lead torque monitoring level2 error
P163D ECU Monitoring: Set torque monitoring level2 error
NORMAL
OPERATION  The voltage monitoring of the injector energizing time is found OK
DTC DETECTING  If the difference between the programmed energizing time and the measured
CONDITION energizing time exceeds a limit then this error will be registered
PROBABLE
CAUSES  Faulty EMS ECU
LAMP STATUS

CONDITION
Corrective Action -
323
EMS OCT 2011/Rev 1
P1832 - Immobilizer authentication error
P183F- Immobilizer not present in vehicle
Refer Immobilser diagnostic manual for diagnosing the above mentioned DTC's
324
EMS OCT 2011/Rev 1
SYMPTOM BASED DIAGNOSTICS- 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 then 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 :
Thru diagnostic tester Open the "LIVE DATA" in EMS ECU .
Check the "Info for trouble in engine starting"
325
EMS OCT 2011/Rev 1
Note the value.
Convert it into binary.
See the bit position of first occurrence of "1" from right and look against the bit position in the table
below
Bit
Position Conditions to be met Implication Action to be taken
The engine speed is Check the fuel level in fuel tank
above the minimum Check for any restriction in fuel
No pressure built
threshold , but the filter
0 up in the fuel
pressure built up in Check injector back leaks.
circuit
the rail is not If all of the above is OK, replace
sufficient the HPP
Check for battery for less

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

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

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

When there is a start
Starter
attempt a check is Check for any immobiliser
5 engagement
made whether the related errors
status
starter has been
released or not
326
EMS OCT 2011/Rev 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

0
in the event of a system error
Limiting torque for differential

1
protection
Limiting torque for engine mechanics
2
protection
3 Limiting torque for smoke limitation
Limiting torque due to quantity

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

5
overheating
Limiting torque for the propulsion in the
6
event 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
9
pump unit
Limiting torque due to inner engine
13
torque
14 Limiting torque for engine protection
327
EMS OCT 2011/Rev 1
Synchronization state
Code Description
0 INIT: Basic initialization of state machine
1 RECOVER: Resetting the counters
2 TIMEOUT: Engine stops or error case in which all engine speed sensors of system are defective
3 INTERIMS: Additional asynchronous interrupts which is generated when engine position is detected
based on the time condition of system.
4 WAIT_INC: Plausibility test is done on the events of the redundant sensor system w/o the mail
sensor system delivering events. Interrupts are generated with min. system freq.
5 PHASE_FREQ_CHK: Plausibility test is done on the events of the redundant sensor system w/o the
mail sensor system delivering events. Interrupts are generated with max. system freq.
8 PHASE_PLAUS_CHK: Plausibility test is done on the events of the redundant sensor system w/o the
main system delivering events.
16 POLLING: The overall system behaves frq. Synchronous & waits for further events to determine the
phases.
32 WAIT_PHASE: Waits for the unique positioning by the phase system.
33 VERIFY A unique positioning of the system has occurred. A plausibility test is run on all sensor
systems wrt each other in their status & angle info.
34 RESYNC_OVERFLOW: No unique position was found
35 RESYNC_OFFSET
48
64 POST: The system wait until there is a complete engine stop.
128 VERIFY_BACKUP
129 BACK UP
130 START_BACKUP
131 WAIT_BACKUP: Engine has decelerated. Metering unit no longer be activated.
328
EMS OCT 2011/Rev 1
CONFORMITY CHECK
Resistance Values
Coolant temperature Sensor/ Fuel Temperature sensor
Temperature °C Resistance Min kΏ Resistance Max kΏ
10 8.244 10.661
20 2.262 2.76
80 0.304 0.342
100 0.178 0.196
Accelerator pedal
Accelerator pedal position APP1 APP2
Accelerator pedal:- 0% 2.160 KΏ 2.672 KΏ
Accelerator pedal :-100% 1.321 KΏ 2.112 KΏ
329

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EMS DIAGNOSTIC MANUAL

TECHNICAL PUBLICATION CELL

www.teknetmahindra.com Rev1 – OCTOBER 2011

OVER VIEW OF THE VEHICLE COMMUNICATION NETWORK 3

WARRANTY & OTHER INFORMATION 5

RECOMMENDED TROUBLE SHOOTING PROCESS 6

EMS ECU PIN DETAILS 7

EMS ECU CAN SIGNALS 10

IQA/IMA CODE PROGRAMMING 11

EMS ECU FLASHING 12

INDEX OF DTC CODES 20

EMS WIRING DIAGRAM 24

DTC BASED TROUBLESHOOTING 26

SYMPTOM BASED DIAGNOSIS- WITH NO DTC CODES 325

HOW TO USE THIS MANUAL

The following is the structure of the EMS Diagnostic Manual –

 DTC and its description

OVER VIEW OF THE VEHICLE COMMUNICATION NETWORK

Hot Film Air Mass Flow Sensor

Engine Coolant Temperature Sensor

Ambient Air Pressure Sensor

Camshaft Position Sensor

Crankshaft Speed Sensor

Fuel Temperature Sensor

Gear Neutral Sensor

Boost Pressure Sensor

Rail Pressure Sensor

Accelerator Pedal Module

Tipple Pressure Switch

Vehicle Speed Sensor

Oil Pressure Switch

Fuel Metering Unit

Turbo charger actuator

Boost Pressure Actuator

WARRANTY & OTHER INFORMATION

RECOMMENDED TROUBLE SHOOTINGPROCESS

Customer complaint Record/Understand Customer Verbatim

Search for Published quick solution in TEKnet.

Follow DTC based diagnosis

Contact TEKliner with TAR

(Technical Assistance Request)

EMS ECU PIN DETAILS

EMS Engine Management System

EMS ECU CAN SIGNALS

Signals Transmitted by EMS ECU

Signals Received by EMS ECU

Check the following for intermittent problems

 Poor mating of the connector halves/damage of connector locking

IQA/IMA CODE PROGRAMMING

EMS ECU FLASHING

The EMS ECU required to be flashed in the following conditions

1. Procure blank EMS ECU from spare part dept.

1805AAA01571N ECU WITHOUT ETK EDC17C55*

* Check for the correct/latest part no in parts catalogue/Technical Service Bulletins.

4. Ensure that the SMART tester has -

 Enough battery reserve/Connected to AC power

5. Never touch the ECU pins by hand/finger

1. Connect using the "Python 1BConfig0404"

The following window appears

3. Click on "Connect" . The following window appears

MODEL NUMBER , VARIANT CODING.

13. Click on "CONFIG" . The following window appears

Click on "WRITE IQA Values" to write the IQA values