You are on page 1of 155

Sl.

No P codes Description Reactions


1 P0401 EGR valve position No Reaction only
P1205 (MS code) governor deviation MIL ON
max / EGR valve (Malfunction
jammed at closed Indicator Lamp)
position

2 P0402 EGR valve position No Reaction only


P1206 (MS code) governor deviation MIL ON
min / EGR valve
jammed at open
position
3 P2142 EGR valve Short No Reaction only
circuit to battery at MIL ON
Out1 / out2

4 P2141 EGR valve Short No Reaction only


circuit to ground at MIL ON
Out1 / out2
5 P0487 EGR Valve Open No Reaction only
load error MIL ON

6 P0405 EGR Valve position MIL ON & 40%


sensor signal Torque Limitaion
voltage below after 50 hours
lower limit
7 P0406 EGR Valve position MIL ON & 40%
sensor signal Torque Limitaion
voltage above after 50 hours
upper limit
Possible causes Check Points
1. The positive limit for the 1. Check the deviation between set
EGR deviation (EGR Desired and actual EGR valve in diagnostic
-EGR actual) of +15% has toolwhich would be more than the
been exceeded threshold
2. EGR valve sticky & EGR 2. Check for any physical monement
valve stuck blockage & Ensure the proper
electrical to EGR valve.
3. i) Using omitec diagnostic scan
tool goto actuators test via Ashok
diagnostics--->Diesel--->Engine--->
Autodetect--->Actuators test.
ii) Select EGR actuator from the list.
iii) Increase the setting in ignition
key ON condition
iv) EGR valve spring should
compress and expand as per setting.

1. The positive limit for the 1. Check the deviation between set
EGR deviation of -15% has and actual EGR valve in diagnostic
been exceeded toolwhich would be more than the
2. EGR valve sticky & EGR threshold
valve stuck 2. Check for any physical monement
blockage & Ensure the proper
electrical to EGR valve.
3. i) Using omitec diagnostic scan
tool goto actuators test via Ashok
diagnostics--->Diesel--->Engine--->
Autodetect--->Actuators test.
ii) Select EGR actuator from the list.
iii) Increase the setting in ignition
key ON condition
iv) EGR valve spring should
compress and expand as per setting.
1. Short circuit of actuator 1. Check the continuity between pin
lines with battery. no A19 on ECU connector / pin no
2. H Driver stage check – for 52 on interconnector and K01
short circuit to battery /K03/K05/K88.
supply (internal ECU) (or)
Check the continuity between A20 /
pin no 53 on interconnector and
K01 /K03/K05/K88

Thereshould not be any continuity


in both the cases

2. Check with another H bridge ECU

3. Check the continuity between pin


no 1 & 5 on EGR connector/ pin no
A19 & A20 on ECU connector
Thereshould not be any continuity
in both the cases

1. Short circuit of actuator 1. Check the continuity between pin


lines with ground no A19 on ECU connector / pin no
2. H Driver stage check – for 52 on interconnector and K02
short circuit to ground /K04/K06.
(internal ECU) (or)
Check the continuity between A20 /
pin no 53 on interconnector and
K02 /K04/K06

Thereshould not be any continuity


in both the cases

2. Check with another H bridge ECU


Loose connection / poor Visual Inspection
contact between sensor
socket & connector.

Improper locking of the


connector over the sensor
socket

Terminal backout

No electrical continuity 1. Check continuity between pin no


between ECU to sensor 1 on the sensor connector and pin
connector. no A19on the ECU connector / pin
no 52 on the interconnector

2. Check continuity between pin no


5 on the sensor connector and pin
no A20 on the ECU connector / pin
no 53 on the interconnector

There should be continuity in both


the case.

Signal line short to ground 1. Check thecontinuity between pin


no 4 on the sensor connector / pin
no A12 on the ECU connector/ pin
no 54 on the interconnector

2. Check thecontinuity between pin


no 2 on the sensor connector / pin
no A40on the ECU connector/ pin
no 55 on the interconnector

Thershould not be any continuity in


both the case.
Sensor defective 1. Check Wiring Harness continuity
& short Circuit
2. Remove sensor end connector
3. Check for the sensor error in
Tester
If Error is registered, then connect
the sensor end connector and erase
the error code
4. Check the Sensor signal voltage
thru tester (Live data-Parameter 3)
The voltage spec should be 0.6V to
0.8V when engine idling condition

ECU defective No check points

Loose connection / poor Visual Inspection


contact between sensor
socket & connector.

Improper locking of the


connector over the sensor
socket
Terminal backout
No electrical continuity 1. Check continuity between pin no
between ECU to sensor 4 on the sensor connector and pin
connector. no A40 on the ECU connector / pin
no 55 on the interconnector
2. Check continuity between pin no
2 on the sensor connector and pin
no A12 on the ECU connector / pin
no 54 on the interconnector

3. Check continuity between pin no


6 on the sensor connector and pin
no A22 on the ECU connector / pin
no 56 on the interconnector
There should be continuity in any
of the case.

Signal line short to supply Check thecontinuity between


(5Volts) 1. pin no 2 & 6 on the sensor
connector
2. pin no A12 & A22 on the ECU
connector
3. pin no 54 & 56 on the
interconnector

Thershould not be any continuity in


any of the case.

Signal line short to battery Check the voltage between


(greater than 5 Volts) 1. pin no 2 & 4 on the sensor
connector
2. pin no A12 & A40 on the ECU
connector
3. pin no 54 & 55 on the
interconnector

Ther should not be more than 5V in


any of the case.
Sensor defective 1. Check Wiring Harness continuity
& short Circuit
2. Remove sensor end connector
3. Check for the sensor error in
Tester
If Error is registered, then connect
the sensor end connector and erase
the error code
4. Check the Sensor signal voltage
thru tester (Live data-Parameter 3)
The voltage spec should be 0.6V to
0.8V when engine idling condition

ECU defective No check points


Further Actions
1. Clean the EGR valve for
accumulation of dust/ soot
2.Replace or rectify the wiring
harness if any problem in WH.
3. If still problem persists, change
the EGR Valve

1. Clean the EGR valve for


accumulation of dust/ soot
2.Replace or rectify the wiring
harness if any problem in WH.
3. If still problem persists, change
the EGR Valve
1. Rectify / Replace WH
2. If problem still persists replace
EGR Valve/ECU.

1. Rectify / Replace WH
2. If problem still persists replace
EGR Valve/ECU.
Ensure proper locking of the
connector and sensor socket

Rectify / Replace WH

Rectify / Replace WH
Replace EGR with cooler - If the
voltage out of specified limit

If all the above check points are


ok Replace ECU / Faulty ECU to
be sent for investigated

Ensure proper locking of the


connector and sensor socket
Rectify / replace Wiring Harness
Replace EGR with cooler - If the
voltage out of specified limit

If all the above check points are


ok Replace ECU / Faulty ECU to
be sent for investigated
H6 -Series Engines Diagnostic System Management for ED
Sl.No P codes Blink Codes Fault Check Name

DFC_EpmCrSErrSig
1 P0336 51

DFC_EpmCrSNoSig

[This error can be erased only


P0337
2 51 after ignition OFF wait for
P0336(OBD) 30sec and ignition ON- Crank
the engine and ensure the error
is not reappearing]

DFC_EpmCaSI1ErrSig

[This error can be erased only


P0341
3 52 after ignition OFF wait for
P0344(OBD) 30sec and ignition ON- Crank
DFC_EpmCaSI1ErrSig
[This error can be erased only
P0341
3 52 after ignition OFF wait for
P0344(OBD) 30sec and ignition ON- Crank
the engine and ensure the error
is not reappearing]

DFC_EpmCaSI1NoSig

[This error can be erased only


P0342
4 52 after ignition OFF wait for
P340(OBD) 30sec and ignition ON- Crank
the engine and ensure the error
is not reappearing]

DFC_EpmCaSI1OfsErr

[This error can be erased only


5 P0016 53 after ignition OFF wait for
30sec and ignition ON- Crank
the engine and ensure the error
is not reappearing]

6 P0183 23 DFC_FuelTSRCMax

7 P0182 23 DFC_FuelTSRCMin

8 P2229 62 DFC_EnvPSRCMax

9 P2228 62 DFC_EnvPSRCMin
10 P0238 61 DFC_PIntkVUsSRCMax

11 P0237 61 DFC_PIntkVUsSRCMin

12 P0236 61 DFC_PIntkVUsPlsHi
13 P0235 61 DFC_PIntkVUsPlsLo

14 P0193 23 DFC_RailPSRCMax

15 P0192 23 DFC_RailPSRCMin
P1104 (Ms
16 code) 31 DFC_RailMeUn0
P0087 (OBD)

P1109 (Ms
17 33 DFC_RailMeUn10
code)

P1106 (Ms
18 code) 35 DFC_RailMeUn2
P0088(OBD)

P1108 (Ms
19 code) 37 DFC_RailMeUn4
P0088(OBD)
P1125 (Ms
20 code) 36 DFC_RailMeUn3
P0112(OBD)

P1117 (Ms
21 code) 34 DFC_RailMeUn8
P0089(OBD)

P1123 (Ms
22 code) 38 DFC_RailMeUn42
P0088(OBD)
P0113
23 44 DFC_TCACDsSRCMax
P0098(OBD)

P0112
24 44 DFC_TCACDsSRCMin
P0097(OBD)

25 P0118 41 DFC_CEngDsTSRCMax
P0117
26 41 DFC_CEngDsTSRCMin

P1700 (MS
27 82 DFC_OilPSwmpPhysRngHi
code)

28 P0524 82 DFC_OilPSwmpPhysRngLo

29 P0522 82 DFC_OilPSwmpSRCMin

30 P0523 82 DFC_OilPSwmpSRCMax
30 P0523 82 DFC_OilPSwmpSRCMax

31 P0298 41 DFC_OilTNplHigh

P0198
32 45 DFC_OilTSRCMax
P0019(OBD)

P0197
33 45 DFC_OilTSRCMin
P0019(OBD)

P0090
34 21 DFC_MeUnOL
P0251(OBD)

P1119 (Ms
35 code) 21 DFC_MeUnShCirHSBatt
P0254(OBD)
P1120 (Ms
36 code) 21 DFC_MeUnShCirHSGnd
P0253(OBD)

37 P0201 22

38 P0202 22

39 P0203 22
39 P0203 22

40 P0204 22

41 P0205 22
42 P0206 22

43 P0262 22

44 P0265 22

45 P0268 22

46 P0271 22
47 P0274 22

48 P0277 22

49 P0261 22

50 P0264 22

51 P0267 22

52 P0270 22

53 P0273 22

54 P0276 22

55 P2148 22
55 P2148 22

56 P2151 22

57 P0219 55 DFC_EngPrtOvrSpd
P0123 (Ms
58 11 DFC_SRCHighAPP1
code)

P0122 (Ms
59 11 DFC_SRCLowAPP1
code)
P0223 (Ms
60 code)
11 DFC_SRCHighAPP2

61

P0222 (Ms
62 11 DFC_SRCLowAPP2
code)
P2135 (Ms
63 11 DFC_SyncAPP
code)

64 P0297 16 DFC_VehVMax

65 P0501 16 DFC_VehVPlaus

66 P0563 72 DFC_BattUSRCMax

67 P0562 72 DFC_BattUSRCMin

68 P0704 15 DFC_ClthNpl

69 P0504 14 DFC_BrkNpl
P1639 (MS
70 46 DFC_TECUSRCMax
code)

P1640 (MS
71 46 DFC_TECUSRCMin
code)

P1503 (MS
72 84 DFC_SVSOL
code)

P1504 (MS
73 84 DFC_SVSOvrTemp
code)

P1505 (MS
74 84 DFC_SVSSCB
code)

P1506 (MS
75 84 DFC_SVSSCG
code)

P1608 (MS
76 code) 22 DFC_IVDiaChp_0
P062B(OBD)

P1338 (Ms
77 27 DFC_InjCrvInjLimChrgBal
code)
P1339 (Ms
78 27 DFC_InjCrvInjLimQntBal
code)
P1340 (Ms
79 27 DFC_InjCrvInjLimSys
code)
P1115 (Ms
80 27 DFC_InjCrvNumInjRtmLim
code)
P2290 (Ms
81 23 DFC_InjVlvPresMin
code)

P1630 (Ms
82 54 DFC_Cy146SpiCom1
code)

P1631 (Ms
83 54 DFC_Cy320SpiCom
code)

P1629 (Ms
84 55 DFC_EEPEraseErr
code)

P1601 (Ms
85 55 DFC_EEPRdErr
code)
P1602 (Ms
86 55 DFC_EEPWrErr
code)

P1636 (Ms
87 55 DFC_SWReset_0
code)

P1637 (Ms
88 55 DFC_SWReset_1
code)

P1638 (Ms
89 55 DFC_SWReset_2
code)

P1632 (Ms
90 54 DFC_OCWDACom
code)

P1633 (Ms
91 59 DFC_OCWDALowVltg
code)

P1634 (Ms
92 58 DFC_OCWDAOvrVltg
code)

P1635 (Ms
93 54 DFC_OCWDAReasUnkwn
code)

P1800 (Ms
94 code) 76 DFC_SSpMon1
P0641(OBD)

P1801 (Ms
95 code) 77 DFC_SSpMon2
P0651(OBD)

P1802 (Ms
96 code) 78 DFC_SSpMon3
P0697(OBD)
P1A00 (Ms
97 73 DFC_ARlySCB_0
code)

P1A01 (Ms
98 73 DFC_ARlySCB_1
code)

P1A02 (Ms
99 code) 73 DFC_ARlySCG_0
P02670(OBD)

P1A03 (Ms
100 73 DFC_ARlySCG_1
code)(OBD)

P1126 (Ms
101 39 DFC_RailMeUn7
code)
P1100 (Ms
102 25 DFC_PRVOpn
code)

P1111 (Ms
103 25 DFC_PRVtiOpnMax
code)
P1110 (Ms
104 25 DFC_PRVctOpnMax
code)

P1113 (Ms
105 25 DFC_PRVFrOpnPresInc
code)

P1101 (Ms
106 25 DFC_PRVFrOpnPresShck
code)

P1118 (Ms
107 0 DFC_RailPGradMon
code)

108 P1127 25 DFC_RailPRV4

P1521 (Ms DFC_FlFWLvlSRCMax


109 87
code) DFC_FlWLvlSensDefSig
P1522 (Ms
110 87 DFC_FlFWLvlSRCMin
code)

P1523 (Ms
111 87 DFC_FlSys_WtDet
code)
P1103 (Ms
112 code) 21 DFC_MeUnOT
P0252(OBD)

P1116 (Ms
113 21 DFC_MeUnIntCtct
code)

P1121 (Ms
114 code) 21 DFC_MeUnShCirLSBatt
P0254(OBD)
P1122 (Ms
115 code) 21 DFC_MeUnShCirLSGnd
P0253(OBD)

116 P0659 72 DFC_DevLibBattUHi

117 P0658 72 DFC_DevLibBattULo

P1405 (Ms
120 71 DFC_MoCADCNTP
code)
P1406 (Ms
121 71 DFC_MoCADCTst
code)
P1407 (Ms
122 71 DFC_MoCADCVltgRatio
code)
P1408 (Ms
123 71 DFC_MoCComErrCnt
code)
P1409 (Ms
124 71 DFC_MoCComSPI
code)
P1410 (Ms
125 71 DFC_MoCROMErrXPg
code)

P1411 (Ms
126 71 DFC_MoCSOPErrMMRespByte
code)

P1431 (Ms
127 71 DFC_MoCSOPErrNoChk
code)

P1412 (Ms
128 71 DFC_MoCSOPErrRespTime
code)

P1413 (Ms
129 71 DFC_MoCSOPErrSPI
code)

P1415 (Ms
130 71 DFC_MoCSOPLoLi
code)
P1416 (Ms
131 71 DFC_MoCSOPMM
code)

P1417 (Ms
132 71 DFC_MoCSOPOSTimeOut
code)

P1432 (Ms
133 71 DFC_MoCSOPPsvTstErr
code)

P1419 (Ms
134 71 DFC_MoCSOPTimeOut
code)

P1420 (Ms
135 71 DFC_MoCSOPUpLi
code)

P1427 (Ms
136 71 DFC_MoFOvR
code)

137 P0215 71 DFC_EngICO

138 P1641 55 DFC_StopCntTmr

139 P1533 88 DFC_StopLmpOL

140 P1534 88 DFC_StopLmpOvrTemp

141 P1535 88 DFC_StopLmpSCB

142 P1536 88 DFC_StopLmpSCG

P1136
143 P0113 25 DFC_PRVRPOutOfRng
(OBD)

144 P1435 DFC_MoFOvRHtPrt

P0401
145 93 DFC_EGRVlvGovDvtMax

P0402
146 93 DFC_EGRVlvGovDvtMin
147 P0490 91 DFC_EGRVlvHbrgSCB

148 P0489 91 DFC_EGRVlvHbrgSCG

149 P0487 91 DFC_EGRVlvHbrgOL

150 P0405 92 DFC_EGRVlvSRCMin

151 P0406 92 DFC_EGRVlvSRCMax


151 P0406 92 DFC_EGRVlvSRCMax

P0191(OBD)
152 P25E6 0 DFC_RailPOfsTstMin

P0191(OBD)
153 P25E5 0 DFC_RailPOfsTstMax

P0116(OBD)
154 P251D (MS 0 DFC_CEngDsTAbsTst
Code)
P0116(OBD)
155 P251E(MS 0 DFC_CEngDsTDynTst
Code)

156 P1526 86 DFC_EngSpdSCG

164 P1527 0 DFC_EngSpdOL

204 P0217 41 CEngDsTPhysRngHi

205 P0127 44 TCACDsPhysRngHi

P0650 (MS
206 0 DFC_MILOL
code)

P0651 (MS
207 0 DFC_MILOvrTemp
code)

P0652 (MS
208 0 DFC_MILSCB
code)

P0653 (MS
209 0 DFC_MILSCG
code)

210 P2535 0 DFC_T50Err


211 P0615 0 DFC_StrtOL_C

212 P0618 0 DFC_StrtSCB_C


P1019(MS
213 Code) 0 DFC_ComTSC1VETO
P0113(OBD)

214 P1205 93 DFC_EGRVlvJamVlvclsd

215 P1206 93 DFC_EGRVlvJamVlvOpn


ostic System Management for EDC17CV54 - CB18 & CB28 - BS4
Description Reactions H6 Reactions H4

Engine rpm limitation Engine rpm limitation


Crank shaft sensor signal Error - disturbed signal at 1750. at 1570

Engine rpm limitation Engine rpm limitation


Crank shaft sensor signal Error - no signal at 1750. at 1570

Engine rpm limitation Engine rpm limitation


Cam shaft sensor signal Error - disturbed signal at 1750. at 1570
Engine rpm limitation Engine rpm limitation
Cam shaft sensor signal Error - disturbed signal at 1750. at 1570

Engine rpm limitation Engine rpm limitation


Cam shaft sensor signal Error - no signal at 1750. at 1570

Engine rpm limitation Engine rpm limitation


at 1750. at 1570.
Camshaft to Crankshaft offset angle exceeded 40 % Torque 40 % Torque
Limitation Limitation

SRC High for Fuel temperature sensor

Fuel temp sensor open circuit or short to No Reactions No Reactions


batery

SRC Low for Fuel temperature sensor


No Reactions No Reactions
Fuel temp sensor short to ground

Environment pressure sensor signal voltage below No Reactions No Reactions


lower limit.

Environment pressure sensor signal voltage below No Reactions No Reactions


lower limit
Boost pressure sensor signal voltage above upper Vehicle Pickup loss Vehicle Pickup loss
limit

Boost pressure sensor signal voltage below lower Vehicle Pickup loss Vehicle Pickup loss
limit

Boost Pressure sensor High plausibility error Vehicle Pickup loss Vehicle Pickup loss
Boost Pressure sensor low plausibility error Vehicle Pickup loss Vehicle Pickup loss

Rail Pressure Sensor signal voltage above upper


limit

40% Torque 40% Torque


limitation / PRV open limitation / PRV open

Rail Pressure Sensor signal voltage below lower


limit

40% Torque 40% Torque


limitation / PRV open limitation / PRV open
maximum positive deviation of rail pressure 40% Torque
exceeded (Actual Rail pressure below the set point) 40% Torque limitation limitation

Leakage is detected based on fuel quantity balance


(Leakage is detected based on Metering unit flow No Reactions No Reactions
volume exceeded the set point)

maximum negative rail pressure deviation with


metering unit on lower limit is exceeded (Actual 40% Torque Limitaion 40% Torque Limitaion
Rail pressure exceeded the set point)

maximum rail pressure exceeded 40% Torque Limitaion 40% Torque Limitaion
minimum rail pressure exceeded No Reactions No Reactions

setpoint of metering unit in idle mode not plausible 40% Torque Limitaion 40% Torque Limitaion

maximum rail pressure exceeded (second stage) Engine Shut Off Engine Shut Off
Boost temperature sensor signal voltage above No Reactions No Reactions
upper limit

Boost temperature sensor signal voltage below No Reactions No Reactions


lower limit

Coolant temperature sensor signal voltage above 40% Torque


40% Torque Limitation
upper limit Limitation
Coolant temperature sensor signal voltage below 40% Torque
40% Torque Limitation
lower limit Limitation

Maximum oil pressure error in plausibility check No Reactions No Reactions

Minimum oil pressure error in plausibility check 80% Torque Limitaion NA

Engine rpm limitation


at 1750.
Oil pressure sensor signal voltage below lower limit NA

40% Torque limitation

Engine rpm limitation


at 1750.
Oil pressure sensor signal voltage above upper limit NA
40% Torque limitation
Engine rpm limitation
at 1750.
Oil pressure sensor signal voltage above upper limit NA
40% Torque limitation

Oil temperature too high plausibility error No Reactions No Reactions

Oil Temperature sensor signal voltage above upper No Reactions No Reactions


limit

Oil Temperature sensor signal voltage below lower No Reactions No Reactions


limit

40% Torque 40% Torque Limitaion


Metering unit output open load error Limitaion / PRV Open / PRV Open

Metering unit high side short circuit to battery 40% Torque 40% Torque Limitaion
error Limitaion / PRV Open / PRV Open
Metering unit high side short circuit to ground 40% Torque 40% Torque Limitaion
error Limitaion / PRV Open / PRV Open

Engine rpm limitation Engine rpm limitation


Open load Injector1 at 1750. at 1570.

Engine rpm limitation Engine rpm limitation


Open load Injector2 at 1750. at 1570.

Engine rpm limitation Engine rpm limitation


Open load Injector3 at 1750. at 1570.
Engine rpm limitation Engine rpm limitation
Open load Injector3 at 1750. at 1570.

Engine rpm limitation Engine rpm limitation


Open load Injector4 at 1750. at 1570.

Engine rpm limitation


Open load Injector5 NA
at 1750.

Engine rpm limitation


Engine rpm limitation
Open load Injector6 NA
at 1750.

Engine rpm limitation Engine rpm limitation


Injector 1 general short circuit at 1750. at 1570.

Engine rpm limitation Engine rpm limitation


Injector 2 general short circuit at 1750. at 1570.

Engine rpm limitation Engine rpm limitation


Injector 3 general short circuit at 1750. at 1570.

Engine rpm limitation Engine rpm limitation


Injector 4 general short circuit at 1750. at 1570.
NA

Engine rpm limitation


Injector 5 general short circuit at 1750.

NA

Engine rpm limitation


Injector 6 general short circuit at 1750.

Injector 1 short circuit Low Side to High Side Engine rpm limitation Engine rpm limitation
at 1750. at 1570.

Injector 2 short circuit Low Side to High Side Engine rpm limitation Engine rpm limitation
at 1750. at 1570.

Injector 3 short circuit Low Side to High Engine rpm limitation Engine rpm limitation
at 1750. at 1570.

Injector 4 short circuit Low Side to High Side Engine rpm limitation Engine rpm limitation
at 1750. at 1570.

Injector 5 short circuit Low Side to High Side Engine rpm limitation NA
at 1750.

Injector 6 short circuit Low Side to High Side Engine rpm limitation NA
at 1750.

Engine rpm limitation Engine rpm limitation


Injector Bank 1 short circuit at 1750. at 1570.
Engine rpm limitation Engine rpm limitation
Injector Bank 1 short circuit at 1750. at 1570.

Engine rpm limitation Engine rpm limitation


Injector Bank 2 short circuit at 1750. at 1570.

Engine Overspeed detected No Reactions No Reactions


Accelerator pedal sensor 1 signal voltage above AccPed loss of AccPed loss of
upper limit response till repress response till repress

Accelerator pedal sensor 1 signal voltage below AccPed loss of AccPed loss of
lower limit response till repress response till repress
AccPed loss of AccPed loss of
Accelerator pedal sensor 2 signal voltage above response till repress response till repress
upper limit

Accelerator pedal sensor 2 signal voltage below AccPed loss of AccPed loss of
lower limit response till repress response till repress
Limp home function Limp home function
Non-plausibility error between APP1 & APP2 (1350rpm) (1350rpm)

Maximum threshold error for Vehicle speed sensor No Reactions No Reactions

Vehicle Speed Vehicle Speed


limitation/Engine limitation/Engine
Plausibility defect for vehicle speed Speed limitation w.r.to Speed limitation w.r.to
drive line drive line
configuration configuration

SRC high for battery voltage sensor No Reactions No Reactions

SRC low for battery voltage sensor No Reactions No Reactions

Clutch not plausible No Reactions No Reactions

Plausibility check for Brake No Reactions No Reactions


ECU temperature sensor signal voltage above upper
limit No Reactions No Reactions

ECU temperature sensor signal voltage below lower No Reactions No Reactions


limit

Diagnostic lamp Open load error No Reactions No Reactions

ECU Defective - Diagnostic lamp over temperature No Reactions No Reactions


error

Diagnostic lamp Short circuit to battery error No Reactions No Reactions

Short circuit to ground error No Reactions No Reactions

ECU Defective - CY33X is defect Injector bank / Engine Injector bank / Engine
(injector chip error) shutt off shutt off

Number of injections is limited by charge balance of No Reactions No Reactions


booster capacity
Number of injections is limited by charge balance of No Reactions No Reactions
booster capacity

Number of injections is limited by system No Reactions No Reactions

Number of injections is limited by runtime No Reactions No Reactions

check of minimum rail pressure No Reactions No Reactions

Reported SPI and COM-Errors of a Cy146 No Reactions No Reactions

SPI/COM-Errors of the Cy320


No Reactions No Reactions
Not clear - Need more clarity

EEP Read Error based on the error for more blocks No Reactions No Reactions

EEP Read Error based on the error for more blocks No Reactions No Reactions
EEP Write Error based on the error for one block No Reactions No Reactions

Visibility of SoftwareResets 0 in DSM No Reactions No Reactions

Visibility of SoftwareResets 1 in DSM No Reactions No Reactions

Visibility of SoftwareResets 2 in DSM No Reactions No Reactions

ECU Defective - Diagnostic fault check to report


WDA active due to errors in query-/response No Reactions No Reactions
communication

Diagnostic fault check to report "ABE active" due to No Reactions No Reactions


under voltage detection

Diagnostic fault check to report "ABE active" due to No Reactions No Reactions


overvoltage detection

Diagnostic fault check to report "WDA/ABE active" No Reactions No Reactions


due to unknown reason

Engine rpm limitation Engine rpm limitation


at 1350 rpm at 1350 rpm

Error Sensor power supply 1

Engine rpm limitation Engine rpm limitation


at 1350 rpm at 1350 rpm

Error Sensor power supply 2

Error Sensor power supply 3 PRV Open PRV Open


Acuator relay Short circuit to battery error No Reactions No Reactions

Acuator relay Short circuit to battery error No Reactions No Reactions

Acuator relay Short circuit to ground error No Reactions No Reactions

Acuator relay Short circuit to ground error No Reactions No Reactions

setpoint of metering unit in overrun mode not 40% Torque Limitaion 40% Torque Limitaion
plausible
PRV open 40% Torque Limitaion 40% Torque Limitaion

PRV reached maximun allowed open time 40% Torque Limitaion 40% Torque Limitaion

PRV reached maximun allowed opening count 40% Torque Limitaion 40% Torque Limitaion

PRV is forced to open; perform pressure increase No Reactions No Reactions

PRV forced open (pressure shock) No Reactions No Reactions

Rail pressure raw value is intermittent No Reactions No Reactions

Maximum rail pressure in limp home mode with No Reactions No Reactions


PRV

Water-in-Fuel Sensor signal voltage above upper No Reactions No Reactions


limit
Water-in-Fuel Sensor signal voltage below lower No Reactions No Reactions
limit

water in Fuel Detection 40% Torque Limitaion 40% Torque Limitaion

Metering unit (ECU) Over temperature error 40% Torque Limitaion 40% Torque Limitaion

Intermittent contact between ECU and Metering No Reactions No Reactions


Unit

Metering unit output short circuit to battery error 40% Torque Limitaion 40% Torque Limitaion

Metering unit output short circuit to ground error 40% Torque Limitaion 40% Torque Limitaion

Powerstage diagnosis could be disabled due to high No Reactions No Reactions


Battery voltage
Powerstage diagnosis could be disabled due to low No Reactions No Reactions
Battery voltage
ECU Defective - Diagnostic fault check to report the No Reactions No Reactions
NTP error in ADC monitoring
ECU Defective - Diagnostic fault check to report the No Reactions No Reactions
ADC test error
ECU Defecive - Diagnostic fault check to report the No Reactions No Reactions
error in Voltage ratio in ADC monitoring
ECU Defective - Diagnostic fault check to report No Reactions No Reactions
errors in query-/response- communication
ECU Defective - Diagnostic fault check to report No Reactions No Reactions
errors in SPI-communication
Diagnostic fault check to report multiple error No Reactions No Reactions
while checking the complete ROM-memory

Loss of synchronization sending bytes to the MM No Reactions No Reactions


from CPU.

DFC to set a torque limitation once an error is No Reactions No Reactions


detected before MoCSOP’s error reaction is set

Wrong set response time No Reactions No Reactions

Too many SPI errors during MoCSOP execution. No Reactions No Reactions

Diagnostic fault check to report the error in under No Reactions No Reactions


voltage monitoring
Diagnostic fault check to report that WDA is not No Reactions No Reactions
working correct

OS timeout in the shut off path test. Failure setting No Reactions No Reactions
the alarm task period.

Diagnostic fault check to report that the positive No Reactions No Reactions


test failed

Diagnostic fault check to report the timeout in the No Reactions No Reactions


shut off path test

Diagnostic fault check to report the error in No Reactions No Reactions


overvoltage monitoring

Diagnostic fault check to report the error due to


Over No Reactions No Reactions
Run
Injection cut off demand (ICO) for shut off Engine shutt off Engine shutt off
coordinator
No Reactions No Reactions

No Load Error No Reactions No Reactions

Over temperature error in ECU power stage No Reactions No Reactions

No Reactions No Reactions

No Reactions No Reactions

Averaged rail pressure is outside the expected 40% Torque Limitaion 40% Torque Limitaion
tolerance range

No Reactions No Reactions

No reaction. Error No reaction. Error


EGR valve position governor deviation max / EGR Cannot be erased till Cannot be erased till
valve jammed at closed position 9600hrs 9600hrs

No reaction. Error No reaction. Error


EGR valve position governor deviation min / EGR
valve jammed at open position Cannot be erased till Cannot be erased till
9600hrs 9600hrs
No reaction. Error No reaction. Error
EGR valve Short circuit to battery at Out1 / out2 Cannot be erased till Cannot be erased till
9600hrs 9600hrs

No reaction. Error No reaction. Error


EGR valve Short circuit to ground at Out1 / out2 Cannot be erased till Cannot be erased till
9600hrs 9600hrs

No reaction. Error No reaction. Error


EGR Valve Open load error Cannot be erased till Cannot be erased till
9600hrs 9600hrs

40% Torque Limitaion 40% Torque Limitaion


EGR Valve position sensor signal voltage below after 50 hours. after 50 hours.
lower limit Errors cannot be Errors cannot be
erased till 9600hrs. erased till 9600hrs.

40% Torque Limitaion 40% Torque Limitaion


EGR Valve position sensor signal voltage above after 50 hours. after 50 hours.
upper limit Errors cannot be Errors cannot be
erased till 9600hrs. erased till 9600hrs.
40% Torque Limitaion 40% Torque Limitaion
EGR Valve position sensor signal voltage above after 50 hours. after 50 hours.
upper limit Errors cannot be Errors cannot be
erased till 9600hrs. erased till 9600hrs.

Rail pressure raw value is below minimum Engine speed Engine speed
offset limitation at 1750rpm limitation at 1570rpm

Rail pressure raw value is below Maximum Engine speed Engine speed
offset limitation at 1750rpm limitation at 1570rpm

defect fault check for Absolute plausibility test 40% Torque Limitation 40% Torque
Limitation
defect fault check for dynamic plausibility test 40% Torque Limitation 40% Torque
Limitation

Short circuit to ground error on the engine speed No reactions No reactions


output

Engine speed Open load No reactions NA

Engine Coolant Over Temperature Condition No Reactions No Reactions

Intake Air Temperature Too High No Reactions No Reactions

Malfunction indication lamp Open load error No Reactions No Reactions

Malfunction Indication lamp over temperature No Reactions No Reactions


error

Malfuntion Indication lamp Short circuit to ground No Reactions No Reactions


error

Malfunction Indication lamp Short circuit to ground No Reactions No Reactions


error

Defective T50 switch No Reactions No Reactions


Starter relay No load error No Reactions No Reactions

Starter relay short circuit to battery error No Reactions No Reactions


Timeout Error of CAN-Receive-Frame TSC1VE(SCR) No reactions No reactions

1. The positive limit for the EGR deviation of +10%


has been exceeded longer than the applicated value No reactions No reactions
of 10 sec.

1. The Negative limit for the EGR deviation of -10%


has been exceeded longer than the applicated value No reactions No reactions
of 10 sec.
28 - BS4
Possible causes
Loose connection / poor contact of socket.
(between sensor & connector)

Improper locking of the connector over the sensor socket

Connection swapped in the circuit

Short circuit b/w positive & negative of crank sensor circuit.

Crank shaft sensor failure

Incorrect air gap between tooth & sensor (spec 0.3mm - 1.8mm).

No of holes on flywheel not as per spec (58holes equally and two missing holes)

Electrical Noise in crank sensor signal due to Shielding is not available for crank
signal line.
ECU defective

Loose connection / poor contact of socket.


(between sensor & connector)

Improper locking of the connector over the sensor socket

No electrical continuity between ECU to crank sensor connector.

Crank shaft sensor failure


Sensor mounting bolt loosen.

Air gap between tooth & sensor above spec (spec 0.3mm - 1.8mm).

ECU defective

Loose connection / poor contact of socket.


(between sensor & connector)
Connection swapped in the circuit

Short circuit b/w positive & negative of cam sensor circuit.

Electrical Noise in crank sensor signal due to Shielding is not available for cam signal
line.

Cam shaft sensor failure


Sensor loosen.
Cam shaft tone wheel wobbling

ECU defective

Loose connection / poor contact of socket.


(between sensor & connector)

No electrical continuity between ECU to cam sensor connector.

Cam shaft sensor failure


Sensor loosen.
ECU defective

Deviation between cam and crank sensors signals exceeds +/- 10deg Crank during
plausibility check.

Defective trigger wheel / tone wheel

FIP timing

1. Sensor not connected


2. Short circuit to battery
3. Wiring harness problem
4. Wrong sensor fitted

1. Short circuit to ground


2. Wiring harness problem
3. Wrong sensor fitted

Sensor failure at ECU.

Sensor failure at ECU.


Loose connection / poor contact of socket.

No electrical continuity between ECU to Boost pressure sensor connector

Signal line short to supply (5Volts)

Signal line short to battery (greater than 5 Volts)

Sensor defective

ECU defective

Signal line short to ground

Sensor defective

ECU defective

1. Mal function of Boost or environmental pressure sensor / actual engine boost


pressure is not changing with respect to engine speed.
1. Mal function of Boost or environmental pressure sensor / actual engine boost
pressure is not changing with respect to engine speed.

1. Loose connection.

2. No electrical continuity between ECU to sensor connector.

Signal line short to supply (5Volts)

Signal line short to battery (greater than 5 Volts)

Sensor defective

ECU defective

Signal line short to ground

Sensor defective

ECU defective

Rail pressure deviation exceed the spec below the set point.
Set value of metering unit delivery exceeds the defined upper limit w.r.t to
engine speed (Rail_dvolMeUnCtlUpLim_CUR)
Chocked fuel return lines,zero delivery throttle clogged up.
Leaking in PRV

Leakage in the high pressure line


Leakage in the Low pressure line
Worn high pressure pump
Gear pump input pressure too low
Gear pump outlet pressure too low
Worn injector

Injector nozzle stuck in the open position


Filter clogged

incorrect/small/sharp bend in diameter fuel return lines.


Chocked fuel return lines,zero delivery throttle clogged up.
Leaking in PRV

Leakage in the high pressure line


Leakage in the Low pressure line
Worn high pressure pump
Possible error in low pressure stage Metering unit reflux too low
Possible error in low pressure system Zero delivery is not present for metering unit
leakage in metering unit is more
Worn injector
Injector nozzle stuck in the open position

Injector nozzle stuck in the open position


Filter/ fuel tank strainer clogged

Incorrect/small/sharp bend in diameter fuel return lines.

Chocked fuel return lines,zero delivery throttle clogged up.


Pump metering unit is stuck in open position

Injector struck in closed possition


Pump metering unit wiring ahrness issues

Rail pressure sensor wiring harness issues


Incorrect/small/sharp bend in diameter fuel return lines.

Chocked fuel return lines,zero delivery throttle clogged up.


Pump metering unit is stuck in open position

Injector struck in closed possition

Rail pressure sensor wiring harness issues


Pump metering unit wiring ahrness issues

Rail pressure below the min value w.r.t engine speed

Chocked fuel return lines,zero delivery throttle clogged up.


Leaking in PRV

Leakage in the high pressure line


Leakage in the Low pressure line
Worn high pressure pump
Gear pump input pressure too low
Gear pump outlet pressure too low
Worn injector

Injector nozzle stuck in the open position


Filter clogged

incorrect/small/sharp bend in diameter fuel return lines.

Chocked fuel return lines,zero delivery throttle clogged up.


Leaking in PRV

Leakage in the high pressure line


Leakage in the Low pressure line
Worn high pressure pump
Possible error in low pressure stage Metering unit reflux too low
Possible error in low pressure system Zero delivery is not present for metering unit
leakage in metering unit is more
Worn injector
Injector nozzle stuck in the open position

Injector nozzle stuck in the open position


Filter clogged

Rail pressure exceed the max value of 1890bar

Incorrect/small/sharp bend in diameter fuel return lines.

Chocked fuel return lines,zero delivery throttle clogged up.


Pump metering unit is stuck in open position

Injector struck in closed possition


Pump metering unit wiring ahrness issues

Rail pressure sensor wiring harness issues


Loose connection / poor contact of socket.
No electrical continuity between ECU to Boost temperature sensor connector

Signal line short to supply (5Volts)

Signal line short to battery (greater than 5 Volts)

Sensor defective

ECU defective

Signal line short to ground

Sensor defective

ECU defective

Loose connection / poor contact of socket.

No electrical continuity between ECU to Coolant temperature sensor connector

Signal line short to battery (greater than 5 Volts)


Sensor defective

ECU defective

Signal line short to ground

Sensor defective

ECU defective

Engine oil pressure exceeds 7 bar (absolute).

Engine oil pressure relief valve failure at oil module.


Sensor faulty

1. Engine minimum oil pressure 1.5 bar at idling.

Minimum Oil level in engine


Oil filter clogged.

Signal line short to ground

Sensor defective

ECU defective

Loose connection / poor contact between sensor socket & connector.

Improper locking of the connector over the sensor socket


No electrical continuity between ECU to sensor connector.
Signal line short to supply (5Volts)
Signal line short to battery (greater than 5 Volts)
Sensor defective
ECU defective

Oil temperature exceeds 115degC.


Oil temperature sensor drift.
Cooling system failure.

Loose connection / poor contact of socket.


No electrical continuity between ECU to Oil temperature sensor connector
Signal line short to supply (5Volts)
Signal line short to battery (greater than 5 Volts)
Sensor defective
ECU defective
Signal line short to ground
Sensor defective

ECU defective
Loose connection.
No electrical continuity between ECU to sensor connector.

Actuator defective (Fuel metering unit failure)

ECU defective

Short circuit with battery supply.


1. Short circuit with gnd.

No electrical continuity between ECU to injector connector.

Injector terminals(nut) loosen.

Injector(Actuator) defective

ECU defective

No electrical continuity between ECU to injector connector.

Injector terminals loosen.

Actuator defective

ECU defective

No electrical continuity between ECU to injector connector.

Injector terminals loosen.


Actuator defective

ECU defective

No electrical continuity between ECU to injector connector.

Injector terminals loosen.

Actuator defective

ECU defective

No electrical continuity between ECU to injector connector.

Injector terminals loosen.

Actuator defective

ECU defective

No electrical continuity between ECU to injector connector.

Injector terminals loosen.


Actuator defective

ECU defective

Injector low side line short with High side

Injector low side line short with supply

Injector electrical connection short with injector body

1. Injector high side line short with gnd.

1. Injector low side line short with supply.

Injector electrical connection short with injector body

1. Injector high side line short with gnd.

1. Injector low side line short with supply.

Injector electrical connection short with injector body

1. Injector high side line short with gnd.

1. Injector low side line short with supply.

Injector electrical connection short with injector body


1. Injector high side line short with gnd.

1. Injector low side line short with supply.

Injector electrical connection short with injector body

1. Injector high side line short with gnd.

1. Injector low side line short with supply.

Injector electrical connection short with injector body

Injector wires short circuit.

Injector terminals loosen & short circuit.

Injector wires short circuit.

Injector terminals loosen & short circuit.

Injector wires short circuit.

Injector terminals loosen & short circuit.

Injector wires short circuit.

Injector terminals loosen & short circuit.

Injector wires short circuit.

Injector terminals loosen & short circuit.

Injector wires short circuit.

Injector terminals loosen & short circuit.

Any One cyl in Bank 1 (Cyl 1,2,3)


High side short to gnd
Any One cyl in Bank 1 (Cyl 1,2,3)
High side short to battery

Any One cyl in Bank 1 (Cyl 1,2,3)


low side short to gnd

Any One cyl in Bank 1 (Cyl 4,5,6)


High side short to gnd

Any One cyl in Bank 1 (Cyl 4,5,6)


High side short to battery

Any One cyl in Bank 1 (Cyl 4,5,6)


low side short to gnd

Engine speed exceeds 3000 rpm.


Down hill drive.
Improper downshifting of gears during downhill drive

Loose connection / poor contact between sensor socket & connector.

Improper locking of the connector over the sensor socket

Open circuit of ground


Signal line short to supply (5Volts)

Signal line short to battery (greater than 5 Volts)

Sensor defective

ECU defective

Loose connection / poor contact between sensor socket & connector.

Improper locking of the connector over the sensor socket

No electrical continuity between ECU to sensor connector.

Signal line short to gnd

Sensor defective

ECU defective
Loose connection / poor contact between sensor socket & connector.

Improper locking of the connector over the sensor socket

Open circuit of ground

Signal line short to supply (5Volts)

Signal line short to battery (greater than 5 Volts)

Sensor defective

ECU defective

Loose connection / poor contact between sensor socket & connector.

Improper locking of the connector over the sensor socket

No electrical continuity between ECU to sensor connector.

Signal line short to gnd

Sensor defective
ECU defective

1. Sensor defective.
2. WH problem

1. Vehicle speed exceeds the maximum setpoint speed


2. Faulty sensor.

1. Vehicle speed sensor loose connection.


2. Sensor not connected
3. Mounting loose
4. Wiring harness problem

1. Battery raw signal exceeds 3832mv at ECU

1. Battery raw signal below 1040mv at ECU


1. Clutch switch connector not connected
2. Loose connection of clutch connector

Wiring harnes faulty


3. Clutch switch failure

If the main brake contact Brk_stMn and the redundant brake contact Brk_stRed are
not in the same state.
Sensor failure at ECU.

Sensor failure at ECU.

1. Lamp not connected


2. Wiring harness problem
3. Lamp is damaged
4. Lamp failure

ECU defective

1.Wiring harness problem


2.Short circuit to Battery

1.Wiring harness problem


2.Short circuit to Ground

ECU defective

Low battery voltage (lower than 8.7V)

Low battery voltage (lower than 8.7V)

Low battery voltage (lower than 8.7V)

Number of injections requested is more than allowed injections for current battery
volatage and engine speed
Not enough rail pressure in the system

Hardware failure inside the ECU

1. Communication errors in Cy320 chip


2.damaged cy320 chip.

1. ECU internal error - EEPROM erase not possible


2.damaged EEPROM

1. ECU internal error - EEPROM read not possible


2.damaged EEPROM
1. ECU internal error - EEPROM write not possible
2.damaged EEPROM

Not Applicable

Not Applicable

1. If injection happens during overrun condition (e.g. downhill drive)


2. Low Battery voltage (<5V)
3.Memory monitoring (MOC) related errors
Note: For all MOC related errors, SWReset is hard -coded

Hardware failure inside the ECU

Hardware failure inside the ECU

Hardware failure inside the ECU

Hardware failure inside the ECU

SSPMon1 Supply line(incl of Sensor, W.H, ECU) short with Battery/Ground

SSPMon2 Supply line(incl of Sensor, W.H, ECU) short with Battery/Ground

SSPMon3 Supply line(incl of Sensor, W.H, ECU) short with Battery/Ground


UB2 lines [K68, K41, K14, K18, K37, K32, K15, K38, K22, K66, K71, K48, K40, K29,
K72, K27, K47, K70, K65, A35, A45] inlcusive of component, W.H & ECU shorted with
Battery

(this error reports only during afterrun)

UB3 lines [K51, K26, K25, K89, K92, K93, K94, K50, K90, K28] inlcusive of
component, W.H & ECU shorted with Battery

(this error reports only during afterrun)

UB2 lines [K68, K41, K14, K18, K37, K32, K15, K38, K22, K66, K71, K48, K40, K29,
K72, K27, K47, K70, K65, A35, A45] inlcusive of component, W.H & ECU shorted with
Ground

UB3 lines [K51, K26, K25, K89, K92, K93, K94, K50, K90, K28] inlcusive of
component, W.H & ECU shorted with Ground

1. Leakage in the high pressure section


2. worn high pressure pump/defective high pressure
3. injection nozzle stuck in open position
4. worn injector
5. leaking pressure limiting valve
6. Possible error in low pressure system Zero delivery is not present for metering
unit (leakage in metering unit is more)/Possible error in low pressure system
metering unit faulty
1. Pump metering unit connector loose/not connected
2. Pump metering unit failure
3. Rail pressure sensor connector loose/not connected
4. Rail pressure sensor failure.
5. overrun monitoring error

Total time for PLV open condition exceeded the limit

Total counter for PLV open condition exceeded the limit

1. Pump metering unit connector loose/not connected


2. Pump metering unit failure
3. Rail pressure sensor connector loose/not connected
4. Rail pressure sensor failure

1. Pump metering unit connector loose/not connected


2. Pump metering unit failure
3. Rail pressure sensor connector loose/not connected
4. Rail pressure sensor failure

Loose connection / poor contact of socket.

No electrical continuity / shortcircuit between ECU to waterlevel sensor.

Sensor defective

fuse blown
Signal line short to ground

Sensor defective

1. Excess water accumulated in the water separator

Intermettent Loose connection of MeUn (A04/05)

1. Pump metering unit short circuit to battery


2. Wiring harness loose connection on -ve

Short circuit with Ground

Batery voltage is high (32V)

Batery voltage is low (9V)

1. Error detectetd in the plausibility check of the ADC by no load test pulse test. The
ECU has an internal error.( ADC error)
1.Error detected in the plausibility check of the ADC by voltage test signal. The ECU
has an internal error. ( ADC error)
1. Error detected in the plausibility check of the ADC in the voltage ratio. The ECU has
an internal error. (ADC error)
1. Error in the plausbility of FC and MM communication. The ECU has an internal
error.
error in SPI-communication

1. Injector error
2. The ECU has an internal error.
1. Injector error
2. The ECU has an internal error.

1. Injector error
2. The ECU has an internal error.

1. Injector error
2. The ECU has an internal error.

1. Injector error
2. The ECU has an internal error.

1. Injector error
2. The ECU has an internal error.
1. Injector error
2. The ECU has an internal error.

1. Injector error
2. The ECU has an internal error.

1. Injector error
2. The ECU has an internal error.

1. Injector error
2. The ECU has an internal error.

1. Injector error
2. The ECU has an internal error.

1. Error in the plausibility of current energising time with maximum permitted


energising time during overrun. The ECU has an internal error.
2. Violation of Overrun condition
Overrun monitoring fault (DFC_MoFOvR) will trigger this error

1. Connector open or loose connection.


2. No electrical continuity between ECU & stop lamp

Permanent Short Circuit to Battery

1.Wiring harness problem


2.Short circuit to Battery
1.Wiring harness problem
2.Short circuit to Ground
1. Pump metering unit connector loose/not connected
2. Pump metering unit failure
3. Rail pressure sensor connector loose/not connected
4. Rail pressure sensor failure

1. Error in the plausibility of current energising time with maximum permitted


energising time during overrun when cooling injections are active. The ECU has an
internal error.
2. Violation of Overheat protection

1. The positive limit for the EGR deviation (EGR Desired -EGR actual) of +15% has
been exceeded
2. EGR valve sticky & EGR valve stuck

1. The positive limit for the EGR deviation of -15% has been exceeded
2. EGR valve sticky & EGR valve stuck
1. Short circuit of actuator lines with battery.
2. H Driver stage check – for short circuit to battery supply (internal ECU)

1. Short circuit of actuator lines with ground


2. H Driver stage check – for short circuit to ground (internal ECU)
Loose connection / poor contact between sensor socket & connector.

Improper locking of the connector over the sensor socket

No electrical continuity between ECU to sensor connector.


Signal line short to ground

Sensor defective

ECU defective

Loose connection / poor contact between sensor socket & connector.

Improper locking of the connector over the sensor socket

No electrical continuity between ECU to sensor connector.


Signal line short to supply (5Volts)

Signal line short to battery (greater than 5 Volts)

Sensor defective

ECU defective

1. Rail pressure sensor malfunction/ drif

1. Rail pressure sensor malfunction/ drif

1.1.Thermostat is always open


2. Coolant temperature sensor not connected
properly to Engine block.
3. Coolant temperature signal wire shorted to battery/Gnd wire
4.Wrong specification sensor / faulty sensor
.1.Thermostat is always open
2. Coolant temperature sensor not connected
properly to Engine block.
3. Coolant temperature signal wire shorted to battery/Gnd wire
4.Wrong specification sensor / faulty sensor

Engine Over heating

Engine Over heating

1. Lamp not connected


2. Wiring harness problem
3. Lamp is damaged
4. Lamp failure

ECU defective

1.Wiring harness problem


2.Short circuit to Battery

1.Wiring harness problem


2.Short circuit to Ground

Wiring harness problem


Wiring harness problem

1. Wiring harness problem


2. Short circuit to Battery
EGR valve is stuck in closed position

EGR valve is stuck in open position


Check Points
Visual Inspection -

1.Check continuity between pin no 2 on the sensor and A39 on the ECU connector.
(interconnector pin 24)
2. Check continuity between pin no 1 on the sensor and A54 on the ECU connector.
(interconnector 25)

There should be continuity in both the case

Check thecontinuity between A39 & A54/ at sensor end 1 & 2/ 25 & 24 at Interconnector
[Thershould not be any continuity]
Measure resistance across the terminals it should be 774ohm to 946 ohm
Visual inspection

Check air gap and check for foreign particle deposited on sensor

Visual inspection

Visual inspection
Check the continuity between shield at sensor end to A38.
No check points

Visual Inspection

Check continuity b/w end of sensor connector pin no 1 to A54 (interconnector pin 25) & check
continuity end of sensor connector pin no 2 to A39 (inter connector pin 24)

Measure resistance across the terminals it should be 774ohm to 946 ohm


Visual inspection

Check air gap.

No check points

Visual Inspection
1. Check continuity between pin no 1 on the sensor connector and pin no A52 on the ECU
connector / pin no 34 on the interconnector.

2.Check continuity between pin no 2 on the sensor connector and pin no A37 on the ECU
connector / pin no 35 on the interconnector.

There should be continuity in both the case.

1.Check continuity between pin no 2 on the sensor connector and pin no A37 on the ECU
connector / pin no 35 on the interconnector

There should be continuity in both the case.

1. Visual inspection of condition of shield


2. Check the continuity between shield at sensor end to A53. [Thershould be Continuity]

Measure resistance across the terminals it should be 774ohm to 946 ohm


Visual inspection
Visual inspection

No check points

Visual Inspection

Check continuity between check continuity b/w end of sensor connector pin no 1 to A52 (inter
connector pin 34) & check continuity end of sensor connector pin no 2 to A37 (inter connector
pin 35)
Measure resistance across the terminals it should be 774ohm to 946 ohm
Visual inspection
No check points

1. Ensure the both crank and cam sensor proper installation (without any loose connection).

check proper angle between tone & trigger wheel mounting slot to sync tooth and missing
tooth respectively as per the spec.
Check and align FIP timing.

1.Check for proper connection in the connector


2. Check wiring harness for short circuit/continuity (sensor connector pins 1,2 and ECU pins
A11, A29 respectively).
3. Change the sensor if the problem persists

1.Check for proper connection in the connector


2. Check wiring harness for short circuit/continuity (sensor connector pins 1,2 and ECU pins
A11, A29 respectively).
3. Change the sensor if the problem persists

No check points

No check points
Visual Inspection

1. Check continuity between pin no 4 on the sensor connector and pin no A43 on the ECU
connector / pin no 32 on the interconnector

2. Check continuity between pin no 3 on the sensor connector and pin no A09 on the ECU
connector / pin no 31 on the interconnector

3. Check continuity between pin no 1 on the sensor connector and pin no A42 on the ECU
connector / pin no 29 on the interconnector

There should be continuity in any of the case.

Check the continuity between


1. pin no 3 & 4 on the sensor connector
2. pin no A09 & A43 on the ECU connector
3. pin no 31 & 32 on the interconnector

Thershould not be any continuity in any of the case.

Check the voltage between


1. pin no 4 & 1 on the sensor connector
2. pin no A43 & A42 on the ECU connector
3. pin no 32 & 29 on the interconnector

Ther should not be more than 5V in any of the case.

1. Check Wiring Harness continuity & short Circuit


2. Remove sensor end connector
3. Check for the sensor error in Tester
If Error is registered, then connect the sensor end connector and erase the error code
4. Check the Sensor signal voltage thru tester (Parameter 3)
5. Voltage should be 1.18V at standard atmoshpheric pressure (pamb=101kPa)

No check points

Check thecontinuity between


1. pin no1 & 4 on the sensor connector
2. pin no A42 & A43 on the ECU connector
3. pin no 29 & 32 on the interconnector

Thershould not be any continuity in any of the case.


1. Check Wiring Harness continuity & short Circuit
2. Remove sensor end connector
3. Check for the sensor error in Tester
If Error is registered, then connect the sensor end connector and erase the error code
4. Check the Sensor signal voltage thru tester (Parameter 3)
5. Voltage should be 1.18V at standard atmoshpheric pressure (pamb=101kPa)

No check points

Check the atmospheric & boost value through tester and ensure both the pressure values are
same at ignition on condition(ie atmosheric prresure reading only)
Check the atmospheric & boost value through tester and ensure both the pressure values are
same at ignition on condition(ie atmosheric prresure reading only)

Visual Inspection

1. Check continuity between pin no 1 on the sensor connector and pin no A25 on the ECU
connector / pin no 36 on the interconnector

2. Check continuity between pin no 2 on the sensor connector and pin no A26 on the ECU
connector / pin no 37on the interconnector

3. Check continuity between pin no 3 on the sensor connector and pin no A07 on the ECU
connector / pin no 38 on the interconnector

There should be continuity in any of the case.

Check thecontinuity between


1. pin no 2 & 3 on the sensor connector
2. pin no A26 & A07 on the ECU connector
3. pin no 37 & 38 on the interconnector

Thershould not be any continuity in any of the case.

Check the voltage between


1. pin no 2 & 1 on the sensor connector
2. pin no A26 & A25 on the ECU connector
3. pin no 37 & 36 on the interconnector

Ther should not be more than 5V in any of the case.

1. Check Wiring Harness continuity & short Circuit


2. Remove sensor end connector
3. Check for the sensor error in Tester
If Error is registered, then connect the sensor end connector and erase the error code
4. Check the Sensor signal voltage thru tester (Parameter 3)
5. Voltage should be 500±48mV.

No check points

Check thecontinuity between pin no


1. 2 & 1 on the sensor connector
2. pin no A26 & A25 on the ECU connector
3. pin no 37 & 36 on the interconnector

Thershould not be any continuity in any of the case.


1. Check Wiring Harness continuity & short Circuit
2. Remove sensor end connector
3. Check for the sensor error in Tester
If Error is registered, then connect the sensor end connector and erase the error code
4. Check the Sensor signal voltage thru tester (Parameter 3)
5. Voltage should be 500±48mV.

No check points

1. Check for the bends/crimps in the fuel suction line.


2. Check the fuel level in fuel tank
Remove the return line and check for blockage
Check the common rail return line pipe outer surface tem (If temp observed very high, might be
problem with PRV opening- Leakage in PLV return).
Check the leakage in the high pressure pipes line.
Check for leakage in low pressure cicuit
No check points
No check points
No check points
No check points
No check points

Fuel filter functionality check.

Visual inspection-Check for the bends/crimps in the fuel return line.


Remove the return line and check for blockage
Check the common rail return line pipe outer surface tem (If temp observed very high, might be
problem with PRV opening- Leakage in PLV return).
Check the leakage in the high pressure pipes line.
Check for leakage in low pressure cicuit
No check points
No check points
No check points

No check points
No check points
No check points

Check fuel filter/strainer

Visual inspection-Check for the bends/crimps in the fuel return line.

Remove the return line and check for blockage


i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel---
>Engine---> Autodetect--->Actuators test.
ii) Select metering unit from the list.
iii) Increase the duty cycle to 40% in engine idling condition.
iv) Engine should shut off

engine vibration check, MORSE test for Injector through tester .


Ensure the metering unit wiring harness check. (Refer check point --- P0193 & P0192 (Sl no16
& 17 )
Ensure Rail pressure wiring harness check. (Refer check point of p code ---P0090, P1119 &
P1120 (Sl no32, 33 & 34 )
Visual inspection-Check for the bends/crimps in the fuel return line.

Remove the return line and check for blockage


i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel---
>Engine---> Autodetect--->Actuators test.
ii) Select metering unit from the list.
iii) Increase the duty cycle to 40% in engine idling condition.
iv) Engine should shut off

engine vibration check, MORSE test for Injector through tester .


Ensure the rail pressure wiring harness check. (Refer check point --- P0193 & P0192 (Sl no16
& 17 ) -
Ensure pump metering unit wiring harness check. (Refer check point of p code ---P0090, P1119
& P1120 (Sl no32, 33 & 34
1. Check for the bends/crimps in the fuel suction line.
2. Check the fuel level in fuel tank
Remove the return line and check for blockage
Check the common rail return line pipe outer surface tem (If temp observed very high, might be
problem with PRV opening- Leakage in PLV return).
Check the leakage in the high pressure pipes line.
Check for leakage in low pressure cicuit
No check points
No check points
No check points
No check points
No check points

Check fuel filter/strainer

Visual inspection-Check for the bends/crimps in the fuel return line.

Remove the return line and check for blockage


Check the common rail return line pipe outer surface tem (If temp observed very high, might be
problem with PRV opening- Leakage in PLV return).
Check the leakage in the high pressure pipes line.
Check for leakage in low pressure cicuit
No check points
No check points
No check points

No check points
No check points
No check points

Fuel filter functionality check.

Visual inspection-Check for the bends/crimps in the fuel return line.

i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel---
>Engine---> Autodetect--->Actuators test.
ii) Select metering unit from the list.
iii) Increase the duty cycle to 40% in engine idling condition.
iv) Engine should shut off

engine vibration check, MORSE test for Injector through tester .


Ensure the metering unit wiring harness check. (Refer check point --- P0193 & P0192 (Sl no16
& 17 )
Ensure Rail pressure wiring harness check. (Refer check point of p code ---P0090, P1119 &
P1120 (Sl no32, 33 & 34 )

Visual Inspection
1. Check continuity between pin no 1 on the sensor connector and pin no A42 on the ECU
connector / pin no 29 on the interconnector

2. Check continuity between pin no 2 on the sensor connector and pin no A27 on the ECU
connector / pin no 30 on the interconnector

There should be continuity in both the case.

Check thecontinuity between


1. pin no 3 & 2 on the sensor connector
2. pin no A09 & A27 on the ECU connector
3. pin no 31 & 30 on the interconnector

Thershould not be any continuity in any of the case.

Check the voltage between


1. pin no 1 & 2 on the sensor connector
2. pin no A42 & A27 on the ECU connector
3. pin no 29, 30 on the interconnector

Ther should not be more than 5V in any of the case.

Check the resistance value b/w pin no 2 & 1 of boost pressure sensor - It should be in between
1) 1990 Ohms to 2123 kOhms (25°C)
2) 1139 ohms to 1209(40°C)
3) 579.7 ohms to 611 ohms(60°C)
4. 315 ohms to 330 ohms(80°C)

No check points

Check thecontinuity between


1. pin no 2 & 1 on the sensor connector
2. pin no A27 & A42 on the ECU connector
3. pin no 30 & 29 on the interconnector

Thershould not be any continuity in any of the case.


Check the resistance value b/w pin no 2 & 1 of boost pressure sensor - It should be in between
1) 1990 Ohms to 2123 kOhms (25°C)
2) 1139 ohms to 1209(40°C)
3) 579.7 ohms to 611 ohms(60°C)
4. 315 ohms to 330 ohms(80°C)

No check points

Visual Inspection

1. Check continuity between pin no 1 on the sensor connector and pin no A28 on the ECU
connector / pin no 27 on the interconnector

2. Check continuity between pin no 2 on the sensor connector and pin no A29 on the ECU
connector / pin no 28 on the interconnector

There should be continuity in any of the case.

Check the voltage between


1. pin no 1 & 2 on the sensor connector
2. pin no A28 & A29 on the ECU connector
3. pin no 27, 28 on the interconnector

Ther should not be more than 5V in any of the case.


Check the resistance value b/w pin no 2 & 1 of coolant pressure sensor - It should be in
between
1) 1940 Ohms to 2173 kOhms (25°C)
2) 1118 ohms to 1231(40°C)
3) 573 ohms to 618 ohms(60°C)
4. 313 ohms to 332 ohms(80°C)

No check points

Check the continuity between


1. pin no 1 & 2 on the sensor connector
2. pin no A28 & A29 on the ECU connector
3. pin no 27 & 28 on the interconnector

Thershould not be any continuity in any of the case.


Check the resistance value b/w pin no 2 & 1 of coolant pressure sensor - It should be in
between
1) 1940 Ohms to 2173 kOhms (25°C)
2) 1118 ohms to 1231(40°C)
3) 573 ohms to 618 ohms(60°C)
4. 313 ohms to 332 ohms(80°C)

No check points

1. Check any blockage in oil flow path.


2. Ensure oil grade spec against the specified

Ensure engine pressure relief valve functionality.


Check the voltage of the sensor signal with respect to ground (Spec 0.87V) (Check the value
with tester)
Check any oil leakgae in the engine.

Check oil level


Check whether the oil filter is clogged.

Check the continuity between


1. pin no1 & 4 on the sensor connector
2. pin no A57 & A44 on the ECU connector
3. pin no 43 & 46 on the interconnector

Thershould not be any continuity in any of the case.

1. Check Wiring Harness continuity & short Circuit


2. Remove sensor end connector
3. Check for the sensor error in Tester
If Error is registered, then connect the sensor end connector and erase the error code
4. Check the Sensor signal voltage thru tester (Parameter 3)
5. Voltage should be 0.87V at standard atmoshpheric pressure (pamb=101kPa)

No check points

Visual Inspection
1. Check continuity between pin no 4 on the sensor connector and pin no A44 on the ECU
connector / pin no 46between
Check thecontinuity on the interconnector
1. pin no
Check 3voltage
& 4 on the
thecontinuity sensor connector
between
2.
2. Check
pin no A24 & A44 between
on the ECU pinconnector
no 3 on the sensor connector and pin no A24 on the ECU
1.
1. pin no
Check
connector 4 &
Wiring 1
/ pin on the
Harness
noon sensor
45the connector
continuity
on interconnector.& short Circuit
the interconnector
3.
2. pin
pin no
no 45
A44 &&46A57 on the ECU connector
2.
No Remove
check sensor end connector
points
3.
3. pin no for
Check 46 & 43sensor
the
continuity onbetween
the interconnector
error in Tester
pin no
Thershould not be any continuity in1any
on of the sensor
the case. connector and pin no A57 on the ECU
If Error
connector
1. Ensureis registered,
/ pin
the oil no 43 then
on connect
the the sensor
interconnector end connector and erase the error code
There
4. should
Check the notlevel.
Sensor besignal
more than 5V thru
voltage in any of the
tester case.
(Parameter 3)
2.
5. Check
Check the
the correct
wiring oil grade.
harness connection of the Oil temperature
5. Voltage
There
3. should
Check should
for oilbe be 0.87V
continuity
Leakage at
.P0197instandard
any of theatmoshpheric
case. pressuresensor as mentioned for Refer
(pamb=101kPa)
check
1.Checkpoint ---
the coolantP0198 &
temperature (Sl no26 & 27 )
4. Any blockage in the oil circuit. through tester.
2. Check the coolant leakage.
3. Check the wiring harness connection of the coolant temp sensor Refer check point --- P0118
Visual
& P0117Inspection
(Sl no30 & 31)
1. Check continuity between pin no 1 on the sensor connector and pin no A57 on the ECU
connector / pin no 43between
Check the continuity on the interconnector
1. pin no
Check 3voltage
& 2 on the
thecontinuity sensor connector
between
2.
2. Check
pin between pinconnector
no 2 on the sensor connector and pin no A59 on the ECU
1. pin no
Check no
the
connector
A24
/ 1&on
2resistance
&pin A59
no the
44
onsensor
the ECU
value
on b/w
the connector
pin no 2 & 1 of oil pressure sensor - It should be in between
interconnector
3.
2. pin
pin no 45
A59&&44
noOhms A57ononthetheinterconnector
ECU(25°C)
connector
1)
No 1990
check points to 2123 kOhms
3.
2) pin no
1139
There 44,
ohms
should 43be
toon the interconnector
1209(40°C)
continuity in both
Thershould
Check not be any continuity inthe
anycase.
of the case.
3) 579.7 ohms to 611between
thecontinuity ohms(60°C)
1.
4. pin
Ther
Check no
the
ohms2resistance
315should &not1 on
to bethe
330 sensor
more
value than
ohms(80°C) b/wconnector
5V
pininno
any2 of
& 1the
of case.
oil pressure sensor - It should be in between
2. pin no A59 & A57 on the
1) 1990 Ohms to 2123 kOhms (25°C) ECU connector
3.
2) pin noohms
1139 44 & 43 on the interconnector
to 1209(40°C)
3) 579.7 ohms to 611 ohms(60°C)
Thershould
4. 315 ohmsnot be any
to 330 continuity in any of the case.
ohms(80°C)

No check points
Visual Inspection
1. Check continuity between pin no 1 on the sensor connector and pin no A04 on the ECU
connector / pin no 20 on the interconnector

2. Check continuity between pin no 2 on the sensor connector and pin no A05 on the ECU
connector / pin no 21 on the interconnector

There should be continuity in both the case.

i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel---
>Engine---> Autodetect--->Actuators test.
ii) Select metering unit from the list.
iii) Increase the duty cycle to 40% in engine idling condition.
iv) Engine should shut off

No check points

Check continuity between A04 on the ECU connector / pin 20 on Interconnector and supply
pins (K01/K03/K05/K88) on the ECU connector.

There should be continuity in any of the case.

Check continuity between


1. pin no A04 & A05 on the ECU connector
2. pin no 20 & 21 on Interconnector
3. pin no 1 &2 on metering unit connector

There should be continuity in any of the case.


Check continuity between A04 on the ECU connector / pin 20 on Interconnector and supply
pins (K02/K04/K06) on the ECU connector.

There should be continuity in any of the case

Check the continuity between pin no A33 & A16 with (Interconnector 3 & 4 ) injector
connector 1 & 2

Visual inspection

Check the resistance value b/w terminal of injector- It should be in between 218mohm to
241mohm.

Check the injector1 functionality thru tester.


i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel--->
Engine--->Autodetect--->Actuators test.
ii) Select Cylinders shutoff from the list.
iii) Select 4 or 6 Cylinders menu.
iv) Turn OFF individual cylinders and observe the engine vibrations on number of injectors
turned off.

No check points

Check the continuity between pin no A47 & A17 with (Interconnector 5 & 6 ) injector
connector 1 & 2.

Visual inspection

Check the resistance value b/w terminal of injector- It should be in between 218mohm to
241mohm.

Check the injector2 functionality thru tester.


i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel--->
Engine--->Autodetect--->Actuators test.
ii) Select Cylinders shutoff from the list.
iii) Select 4 or 6 Cylinders menu.
iv) Turn OFF individual cylinders and observe the engine vibrations on number of injectors
turned off.

No check points

Check the continuity between pin no A48 & A18 with (Interconnector 7 & 8 ) injector
connector 1 & 2.
Visual inspection
Check the resistance value b/w terminal of injector- It should be in between 218mohm to
241mohm.

Check the injector3 functionality thru tester.


i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel--->
Engine--->Autodetect--->Actuators test.
ii) Select Cylinders shutoff from the list.
iii) Select 4 or 6 Cylinders menu.
iv) Turn OFF individual cylinders and observe the engine vibrations on number of injectors
turned off.

No check points

Check the continuity between pin no A31 & A01 with (Interconnector 9 & 10 ) injector
connector 13 & 14

Visual inspection

Check the resistance value b/w terminal of injector- It should be in between 218mohm to
241mohm.

Check the injector4 functionality thru tester.


i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel--->
Engine--->Autodetect--->Actuators test.
ii) Select Cylinders shutoff from the list.
iii) Select 4 or 6 Cylinders menu.
iv) Turn OFF individual cylinders and observe the engine vibrations on number of injectors
turned off.

No check points

Check the continuity between pin no A46 & A03 with (Interconnector 13 & 14 ) injector
connector 1 & 2.
Visual inspection

Check the resistance value b/w terminal of injector- It should be in between 218mohm to
241mohm.

Check the injector5 functionality thru tester.


i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel--->
Engine--->Autodetect--->Actuators test.
ii) Select Cylinders shutoff from the list.
iii) Select 4 or 6 Cylinders menu.
iv) Turn OFF individual cylinders and observe the engine vibrations on number of injectors
turned off.

No check points

Check the continuity between pin no A32 & A02 with (Interconnector 11 & 12 ) injector
connector 1 & 2
Visual inspection
Check the resistance value b/w terminal of injector- It should be in between 218mohm to
241mohm.

Check the injector6 functionality thru tester.


i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel--->
Engine--->Autodetect--->Actuators test.
ii) Select Cylinders shutoff from the list.
iii) Select 4 or 6 Cylinders menu.
iv) Turn OFF individual cylinders and observe the engine vibrations on number of injectors
turned off.

No check points

Check continuity between A33 (Interconnector pin 3) to ECU K02/04/06 or K01/03/05/88


(there should not be any continuity)

Check continuity between A16 (Interconnector pin 4) to ECU K01/03/05/88 or K02/04/06


(there should not be any continuity)

Remove injector from clyinder head, check continuity between injector terminal to injector
body. There should not be any body short

Check continuity between A47 (Interconnector pin 5) to ECU K02/04/06 or K01/03/05/88


(there should not be any continuity)

Check continuity between A17 (Interconnector pin 6) to ECU K01/03/05/88 or K02/04/06


(there should not be any continuity)

Remove injector from clyinder head, check continuity between injector terminal to injector
body. There should not be any body short

Check continuity between A48 (Interconnector pin 7) to ECU K02/04/06 or K01/03/05/88


(there should not be any continuity)

Check continuity between A18 (Interconnector pin 8) to ECU K01/03/05/88 or K02/04/06


(there should not be any continuity)

Remove injector from clyinder head, check continuity between injector terminal to injector
body. There should not be any body short

Check continuity between A31 (Interconnector pin 09) to ECU K02/04/06 or K01/03/05/88
(there should not be any continuity)

Check continuity between A01 (Interconnector pin 10) to ECU K01/03/05/88 or K02/04/06
(there should not be any continuity)
Remove injector from clyinder head, check continuity between injector terminal to injector
body. There should not be any body short
Check continuity between A46 (Interconnector pin 13) to ECU K02/04/06 or K01/03/05/88
(there should not be any continuity)
Check continuity between A03(Interconnector pin 14) to ECU K01/03/05/88 or K02/04/06
(there should not be any continuity)
Remove injector from clyinder head, check continuity between injector terminal to injector
body. There should not be any body short
Check continuity between A32 (Interconnector pin 11) to ECU K02/04/06 or K01/03/05/88
(there should not be any continuity)
Check continuity between A02 (Interconnector pin 12) to ECU K01/03/05/88 or K02/04/06
(there should not be any continuity)
Remove injector from clyinder head, check continuity between injector terminal to injector
body. There should not be any body short
Check the continuity between A33 & A16 / 1 & 2 of injector connector of internal wiring
harness / 3 & 4 of Interconnector.(there should not be any continuity)
Visual inspection.

Check the continuity between A47 & A17 / 1 & 2 injector connector of internal wiring
harness / 5 & 6 of Interconnector.(there should not be any continuity)
Visual inspection.

Check the continuity between A48 & A18 / 3 & 4 of injector connector of internal wiring
harness / 7 & 8 of Interconnector.(there should not be any continuity)
Visual inspection.

Check the continuity between A31 & A01 / 1 & 2 of injector connector of internal wiring
harness / 9 & 10 of Interconnector.(there should not be any continuity)
Visual inspection.

Check the continuity between A46 & A03 / 1 & 2 of injector connector of internal wiring
harness / 13 & 14 of Interconnector.(there should not be any continuity)
Visual inspection.

Check the continuity between A32 & A02 / 1 & 2 of injector connector of internal wiring
harness / 11 & 12 of Interconnector.(there should not be any continuity)
Visual inspection.

Check continuity between,


1) pin no 1 on the injector connector / pin no 3 on the interconnector /pin no A33 on the ECU
connector and K02/K04/K06.
2) pin no 1 on the injector onnector / pin no 5 on the interconnector /pin no A47 on the ECU
connector and K02/K04/K06.
3) pin no 1 on the injector connector / pin no 7 on the interconnector /pin no A48 on the ECU
connector and K02/K04/K06.

There should not be continuity in any of the case.


Check continuity between,
1) pin no 1 on the injector connector / pin no 3 on the interconnector /pin no A33 on the ECU
connector and K01/K03/K05/K88.
2) pin no 1 on the injector onnector / pin no 5 on the interconnector /pin no A47 on the ECU
connector and K02/K04/K06.
3) pin no 1 on the injector connector / pin no 7 on the interconnector /pin no A48 on the ECU
connector and K01/K03/K05/K88.
There should not be continuity in any of the case.

Check continuity between,


1) pin no 2 on the injector connector / pin no 4 on the interconnector /pin no A16 on the ECU
connector and K02/K04/K06.
2) pin no 2 on the injector onnector / pin no 6 on the interconnector /pin no A17 on the ECU
connector and K02/K04/K06.
3) pin no 2 on the injector connector / pin no 8 on the interconnector /pin no A18 on the ECU
connector and K02/K04/K06.

There should not be continuity in any of the case.

Check continuity between,


1) pin no 1 on the injector connector / pin no 10 on the interconnector /pin no A01 on the ECU
connector and K02/K04/K06.
2) pin no 1 on the injector onnector / pin no 12 on the interconnector /pin no A02 on the ECU
connector and K02/K04/K06.
3) pin no 1 on the injector connector / pin no 14 on the interconnector /pin no A03 on the ECU
connector and K02/K04/K06.

There should not be continuity in any of the case.

Check continuity between,


1) pin no 1 on the injector connector / pin no 10 on the interconnector /pin no A01 on the ECU
connector and K01/K03/K05/K88.
2) pin no 1 on the injector onnector / pin no 12 on the interconnector /pin no A02 on the ECU
connector and K02/K04/K06.
3) pin no 1 on the injector connector / pin no 14 on the interconnector /pin no A03 on the ECU
connector and K01/K03/K05/K88.

There should not be continuity in any of the case.

Check continuity between,


1) pin no 2 on the injector connector / pin no 10 on the interconnector /pin no A01 on the ECU
connector and K02/K04/K06.
2) pin no 2 on the injector onnector / pin no 12 on the interconnector /pin no A02 on the ECU
connector and K02/K04/K06.
3) pin no 2 on the injector connector / pin no 14 on the interconnector /pin no A03 on the ECU
connector and K02/K04/K06.

There should not be continuity in any of the case.

Ensure engine/ exhaust brake functionality if applicable

Visual Inspection

1. Check continuity between pin no 3 (Tyco connector)/ pin no B (Metri connector) on the
sensor connector and pin no K62 on the ECU connector.

There should be continuity in both the case.


1. Check continuity b/w
1. pin no K61 & K45 on the ECU connector
2. pin no A & C (metri connector)/ pin no 1 & 2 (tyco connector)

2. Check continuity b/w


1. pin no K61 & K44 on the ECU connector
2. pin no A & D (metri connector)/ pin no 1 & 5 (tyco connector)
Thershould not be any continuity in both the case.

Check the voltage between


pin no A & B (metri connector)/ pin no 1 & 3 (tyco connector)

There should not be more than 5V in any of the case.

1. Check resistance of the Acc ped sensor(Pin no 1 &3) : 2.21 kOhms ± 0.4 kOhms in Zero
Position and 1.44 kOhms ± 0.4 kOhms in Max. Position.
2. Check accelearator pedal 1 and pedal 2 raw voltage and ensure the pedal voltage 2 is half of
pedel voltage 1
3.Enure with diagnostic tool by pressing the accped from 0 to 100% reading

No check points

Visual Inspection

1. Check continuity between pin no 1 (Tyco connector)/ pin no A (Metri connector) on the
sensor connector and pin no K61 on the ECU connector.

2. Check continuity between pin no 2 (Tyco connector)/ pin no C (Metri connector) on the
sensor connector and pin no K45 on the ECU connector.

There should be continuity in both the case.

1. Check continuity b/w


1. pin no K61 & K62 on the ECU connector
2. pin no A & B (metri connector)/ pin no 1 & 3 (tyco connector)

2. Check continuity b/w


1. pin no K61 & K84 on the ECU connector
2. pin no A & E (metri connector)/ pin no 1 & 6 (tyco connector)

There should not be continuity in both the case.

1.Check resistance of the Acc ped sensor (Pin no A & B) : 2.21 kOhms ± 0.4 kOhms in Zero
Position and 1.44 kOhms ± 0.4 kOhms in Max. Position.
2. Check accelearator pedal 1 and pedal 2 raw voltage and ensure the pedal voltage 2 is half of
pedel voltage 1
3.Enure with diagnostic tool by pressing the accped from 0 to 100% reading

No check points
Visual Inspection

1. Check continuity between pin no 6 (Tyco connector)/ pin no E (Metri connector) on the
sensor connector and pin no K84 on the ECU connector.

There should be continuity in both the case.

1. Check continuity b/w


1. pin no K83 & K44 on the ECU connector
2. pin no F & D (metri connector)/ pin no 4 & 5 (tyco connector)

2. Check continuity b/w


1. pin no K83 & K45 on the ECU connector
2. pin no F & C (metri connector)/ pin no 4 & 2 (tyco connector)

Thershould not be any continuity in both the case.

Check the voltage between


pin no F& E (metri connector)/ pin no 4 & 6 (tyco connector)

There should not be more than 5V in any of the case.

1.Check resistance of the Acc ped sensor(Pin no 1 &3) : 2.21 kOhms ± 0.4 kOhms in Zero
Position and 1.44 kOhms ± 0.4 kOhms in Max. Position.
2. Check accelearator pedal 1 and pedal 2 raw voltage and ensure the pedal voltage 2 is half of
pedel voltage 1
3.Enure with diagnostic tool by pressing the accped from 0 to 100% reading

No check points

Visual Inspection

1. Check continuity between pin no 4 (Tyco connector)/ pin no F (Metri connector) on the
sensor connector and pin no K83 on the ECU connector.

2. Check continuity between pin no 5 (Tyco connector)/ pin no D (Metri connector) on the
sensor connector and pin no K44 on the ECU connector.

There should be continuity in both the case.

1. Check continuity b/w


1. pin no K83 & K84 on the ECU connector
2. pin no F & E (metri connector)/ pin no 4 & 6 (tyco connector)

2. Check continuity b/w


1. pin no K83 & K62 on the ECU connector
2. pin no F & B (metri connector)/ pin no 4 & 3 (tyco connector)

There should not be continuity in both the case.

1.Check resistance of the Acc ped sensor(Pin no 4 &6) :


2.80 kOhms 0.4 kOhms in Zero Position and 2.26 kOhms ± 0.4 kOhms in Max. Position.
2. Check accelearator pedal 1 and pedal 2 raw voltage and ensure the pedal voltage 2 is half of
pedel voltage 1
3.Enure with diagnostic tool by pressing the accped from 0 to 100% reading
No check points

ACC pad1
Check resistance of the Acc ped sensor(Pin no 1 &3) : 2.21 kOhms ± 0.4 kOhms in Zero Position
and 1.44 kOhms ± 0.4 kOhms in Max. Position.

ACC pad2
Check resistance of the Acc ped sensor (Pin nos 4 & 6) :2.80 kOhms ± 0.4 kOhms in Zero
Position and 2.26 kOhms ± 0.4 kOhms in Max. Position.

1. Ensure vehicle speed sensor proper installation

2. Check wiring harness


1. Check continuity between pin no 1 on the sensor connector and pin no K11 on the ECU
connector

2. Check continuity between pin no 2 on the sensor connector and pin no K34 on the ECU
connector

3. Check continuity between pin no 3 on the sensor connector and pin no K68 on the ECU
connector

There should be continuity in all the case.

4. Check 5A fuse in fuse module.

1. Ensure vehicle speed sensor proper installation

2. Check wiring harness


1. Check continuity between pin no 1 on the sensor connector and pin no K11 on the ECU
connector

2. Check continuity between pin no 2 on the sensor connector and pin no K34 on the ECU
connector

3. Check continuity between pin no 3 on the sensor connector and pin no K68 on the ECU
connector

There should be continuity in all the case.

4. Check 5A fuse in fuse module.

Check the Battery Voltage (32V)

Check the Battery Voltage 9V (consider start condition)


1. Ensure the clutch switch (loose connection / stuck at one position)

2. Check wiring harness


( Check continuity/shortcircuit between K15 & K68 to clutch connector end)

3. Check for the clutch switch status through diagnostic tester

4.Ensure the IPU connection setting

1. Ensure the brake switch (loose connection / stuck at one position)


2. Check for the brake switch status through diagnostic tester
3. Check wiring harness
( Check continuity/shortcircuit between K41, K14 & K68 to brake switch connector end)
4.Ensure the IPU connection setting
1. Check for the proper connection of connector to the instrument cluter
2. Check wiring harness (K70 continuity)
3. Check for the blown fuse and replace if required
4. Check the functionlity of the lamp through tester.Procedure is mentioned below,
i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel---
>Engine---> Autodetect--->Actuators test.
ii)select Diagnostic Lamp from the list.
iii) Turn ON & OFF the lamp and verify the lamp functionality.

1. Switch ON & Off the ignition key(with complete afterrun)


2. Clear the error.
3. Try the above step once again

1. Check the functionlity of the lamp through tester.

2. Check the continuity between Pin K70 on the ECU connector and ECU supply pins
K01/K03/K05.

There should not be continuity in this case

1. Check the functionlity of the lamp through tester.

2. Check the continuity between Pin K70 on the ECU connector and ECU supply pins
K01/K03/K05.

There should not be continuity in this case

No check points

Check the battery voltage

Check the battery voltage

Check the battery voltage

Check the battery voltage

Check the fuel circuit for fuel starvation

1. Switch ON & Off the ignition key(with complete afterrun)


2. Clear the error.
3. Try the above step once again
1. Switch ON & Off the ignition key(with complete afterrun)
2. Clear the error.
3. Try the above step once again

1. Switch ON & Off the ignition key(with complete afterrun)


2. Clear the error.
3. Try the above step once again
1. Switch ON & Off the ignition key(with complete afterrun)
2. Clear the error.
3. Try the above step once again
1. Switch ON & Off the ignition key(with complete afterrun)
2. Clear the error.
3. Try the above step once again
1. Switch ON & Off the ignition key(with complete afterrun)
2. Clear the error.
3. Try the above step once again
1. Switch ON & Off the ignition key(with complete afterrun)
2. Clear the error.
3. Try the above step once again
1. Switch ON & Off the ignition key(with complete afterrun)
2. Clear the error.
3. Try the above step once again

1. Switch ON & Off the ignition key(with complete afterrun)


2. Clear the error.
3. Try the above step once again
1. Switch ON & Off the ignition key(with complete afterrun)
2. Clear the error.
3. Try the above step once again
1. Switch ON & Off the ignition key(with complete afterrun)
2. Clear the error.
3. Try the above step once again
1. Switch ON & Off the ignition key(with complete afterrun)
2. Clear the error.
3. Try the above step once again
1. Isolate the W.H and Check for SSPMon1pin[A09, A21, A24, K43, K44] (connecter end) short
circuit with Battery/ground
2. Check all the component connected to SSPMon1 is shorted with battery/ground.Components
are
1. Boost pressure sensor (A09)
2. Oil pressure and temperature sensor (A24)

1. Isolate the W.H and Check for SSPMon2pin[A08, A22, K23, K45, K46 (connecter end)
continuity with Battery/ground
- If continuity is there, replace/rectify W.H
2. Check all the component connected to SSPMon2 is shorted with battery/ground.Components
are
1. EGR valve position sensor (A22)
2. Accelarator pedal(K45)

1. Isolate the W.H and Check for SSPMon3pin[A07, K24] (connecter end) continuity with
Battery/ground
- If continuity is there, replace/rectify W.H
2. Check all the component connected to SSPMon3 is shorted with battery/ground
Components are
1.Rail pressure sensor (A07)
1. Isolate the W.H and Check for UB2(connecter end) continuity with K01/03/05
- If continuity is there, replace/rectify the W.H
2. Check any short in ECU connector side between UB2[….] and battery pin
3. Check all the component connected to UB2 is shorted with battery
UB2 connected components K68
1. Brake switch (K68, K41 & K14)
2. Cruise control (K18, K37, K32)
3. Clutch switch (K15)
4. Parking brake switch (K38)
5. AC request switch (K22)
6. Diagnostic request switch (K66)
7. OBD lamp (K71)
8. Cold start lamp (K48)
9. Engine brake switch (K40)
UB2 connected components K29
10. Grid heater relay (K72)
11. Fuel heater relay (K27)
12. Exhaust flap (K47)
13. Diagnostic lamp (K70, K65)
UB2 connected components A45
14. EGR valve (A35, A45)

1. Isolate the W.H and Check for UB3(connecter end) continuity with K01/03/05
- If continuity is there, replace/rectify the W.H
2. Check any short in ECU connector side between UB3[….] and battery pin
3. Check all the component connected to UB3 is shorted with battery
UB3 connected components K51
AC compressor relay(K26)
Fan relay(K25)
UB3 connected components K89
Water in fuel lamp(K92)
Coolant temperature warning lamp (K93)
Oil pressure warning lamp (K94)
EGR shut off valve (K50)
UB3 connected components K90
Starter relay

1. Isolate the W.H and Check for UB2(connecter end) continuity with Ground/K02/04/06
- If continuity is there, replace/rectify the W.H
2. Check any short in ECU connector side between UB2[….] and any ground pin
3. Check all the component connected to UB2 is shorted with ground

1. Isolate the W.H and Check for UB3 pins (connecter end) continuity with Ground/K02/04/06
- If continuity is there, replace/rectify the W.H
2. Check any short in ECU connector side between UB3 pins and any ground pin
3. Check all the component connected to UB3 is shorted with ground

1. Check for leakage in high pressure circuit /check tightness of hydraulic circuit.
2.PLV return line check for fuel
1. Check whether the pump metering unit connector is connected properly.
2. Check whether the rail pressure sensor connector is connected properly.
3. Check the check points of Metering unit, Rail pressure sensors & SW reset related errors
(refer 1. P0193, P0192,
2. P0090, P01119, P1120, P1121, P1122 &
3. P1636, P1637, P1638)

Check total time through tester

Check count through tester

1. Check whether the pump metering unit connector is connected properly


2. Check whether the rail pressure sensor connector is connected properly
3. Check the connectivity between metering unit connector pin and ECU connector pin
4. Check the connectivity between rail pressure sensor connector pin and ECU connector pin
5. Check the check points of Metering unit, Rail pressure sensors & SW reset related errors
(refer 1. P0193, P0192,
2. P0090, P01119, P1120, P1121, P1122 &
3. P1636, P1637, P1638)

1. Check whether the pump metering unit connector is connected properly


2. Check whether the rail pressure sensor connector is connected properly
3. Check the connectivity between metering unit connector pin and ECU connector pin
4. Check the connectivity between rail pressure sensor connector pin and ECU connector pin
5. Check the check points of Metering unit, Rail pressure sensors & SW reset related errors
(refer 1. P0193, P0192,
2. P0090, P01119, P1120, P1121, P1122 &
3. P1636, P1637, P1638)

Visusal inspection

Fleet guard
Check the wiring harenss continuity from K36 on ECU pin to 1 on the sensor pin.

Check the wiring harenss continuity from K21 on ECU pin to 2 on the sensor pin.

MHBI
Check the wiring harenss continuity from K68 on ECU pin to 1 on the sensor pin.

Check the wiring harenss continuity from K36 on ECU pin to 2 on the sensor pin.

Check the wiring harenss continuity from K21 on ECU pin to 3 on the sensor pin.

There should be continuity in both the cases.

For Fleet guard fuel filter


Measure resistance across the terminals of crank shaft sensor, it should be 2.63K ohm
ohm to 4940K ohm.

For MHBI fuel filter


No check points

Check the 5A fuse in fuse box


Fleetguard
Check the wiring harenss continuity between
1. pin no K36 & K21 on ECU
2. pin to 1 on the sensor & 2 /ECU ground pins K02/K04/K06
MHBI
Check the wiring harenss continuity between
1. pin no K36 & K21 on ECU
2. pin to 2 on the sensor & 3 /ECU ground pins K02/K04/K06
There shoul not be any continuty in any of the case

For Fleet guard fuel filter


Measure resistance across the terminals of crank shaft sensor, it should be 2.63K ohm
ohm to 4940K ohm.

For MHBI fuel filter


No check points

Visusal inspection

1. Switch ON & Off the ignition key(with complete afterrun)


2. Clear the error.
3. Try the above step once again
1. Check any loose connection for A04/A05
2. Check any signal distubace on the connector due to stress & vibration
3. check for any wire backout
Check the continuity between pin no A05 on the ECU connector and ECU supply lines
K01/03/05/K88/A04
There should not be any continuity in this case.
Check the continuity between pin no A05 on the ECU connector and ECU supply lines
K02/04/06
There should not be any continuity in this case.
Check the Battery Voltage

Check the Battery Voltage (consider start condition)

No check points

No check points

No check points

No check points

No check points

Check for injector related error in the tester, if any take corrective action (Pcodes are P0201,
P0202, P0203, P0204,P0205,P0206, P0262, P0265, P0268, P0271, P0274, P0277, P2148,
P2151)
Check for injector related error in the tester, if any take corrective action (Pcodes are P0201,
P0202, P0203, P0204,P0205,P0206, P0262, P0265, P0268, P0271, P0274, P0277, P2148,
P2151)
Check for injector related error in the tester, if any take corrective action (Pcodes are P0201,
P0202, P0203, P0204,P0205,P0206, P0262, P0265, P0268, P0271, P0274, P0277, P2148,
P2151)
Check for injector related error in the tester, if any take corrective action (Pcodes are P0201,
P0202, P0203, P0204,P0205,P0206, P0262, P0265, P0268, P0271, P0274, P0277, P2148,
P2151)
Check for injector related error in the tester, if any take corrective action (Pcodes are P0201,
P0202, P0203, P0204,P0205,P0206, P0262, P0265, P0268, P0271, P0274, P0277, P2148,
P2151)
Check for injector related error in the tester, if any take corrective action (Pcodes are P0201,
P0202, P0203, P0204,P0205,P0206, P0262, P0265, P0268, P0271, P0274, P0277, P2148,
P2151)
Check for injector related error in the tester, if any take corrective action (Pcodes are P0201,
P0202, P0203, P0204,P0205,P0206, P0262, P0265, P0268, P0271, P0274, P0277, P2148,
P2151)
Check for injector related error in the tester, if any take corrective action (Pcodes are P0201,
P0202, P0203, P0204,P0205,P0206, P0262, P0265, P0268, P0271, P0274, P0277, P2148,
P2151)
Check for injector related error in the tester, if any take corrective action (Pcodes are P0201,
P0202, P0203, P0204,P0205,P0206, P0262, P0265, P0268, P0271, P0274, P0277, P2148,
P2151)
Check for injector related error in the tester, if any take corrective action (Pcodes are P0201,
P0202, P0203, P0204,P0205,P0206, P0262, P0265, P0268, P0271, P0274, P0277, P2148,
P2151)
No check points

No check points

1. Visual inspection
2. Check the ECU connector K92 control line is not short circuited
3. Check the functionlity of the lamp through tester.Procedure is mentioned below,
i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel---
>Engine---> Autodetect--->Actuators test.
ii) select water in fuel Lamp from the list.
iii) Turn ON & OFF the lamp and verify the lamp functionality.

Check the ECU connector K92 control line is not short circuited to Battery.

Check the ECU connector K92 control line is not short circuited to Ground.

1. Check whether the pump metering unit connector is connected properly.


2. Check whether the rail pressure sensor connector is connected properly.
3. Check the check points of Metering unit, Rail pressure sensors (refer P0193, P0192, P0090,
P1119, P1120, P1121, P1122)

No check points

1. Check the deviation between set and actual EGR valve in diagnostic toolwhich would be more
than the threshold
2. Check for any physical monement blockage & Ensure the proper electrical to EGR valve.

1. Check the deviation between set and actual EGR valve in diagnostic toolwhich would be more
than the threshold
2. Check for any physical monement blockage & Ensure the proper electrical to EGR valve.
1. Check the continuity between pin no A19 on ECU connector / pin no 52 on interconnector
and K01 /K03/K05/K88.
(or)
Check the continuity between A20 / pin no 53 on interconnector and K01 /K03/K05/K88
Thereshould not be any continuity in both the cases

2. Check with another H bridge ECU

1. Check the continuity between pin no A19 on ECU connector / pin no 52 on interconnector
and K02 /K04/K06.
(or)
Check the continuity between A20 / pin no 53 on interconnector and K02 /K04/K06

Thereshould not be any continuity in both the cases

2. Check with another H bridge ECU

Visual Inspection

1. Check continuity between pin no 1 on the sensor connector and pin no A19on the ECU
connector / pin no 52 on the interconnector

2. Check continuity between pin no 5 on the sensor connector and pin no A20 on the ECU
connector / pin no 53 on the interconnector

There should be continuity in both the case.


1. Check thecontinuity between pin no 4 on the sensor connector / pin no A12 on the ECU
connector/ pin no 54 on the interconnector

2. Check thecontinuity between pin no 2 on the sensor connector / pin no A40on the ECU
connector/ pin no 55 on the interconnector

Thershould not be any continuity in both the case.

1. Check Wiring Harness continuity & short Circuit


2. Remove sensor end connector
3. Check for the sensor error in Tester
If Error is registered, then connect the sensor end connector and erase the error code
4. Check the Sensor signal voltage thru tester (Live data-Parameter 3)
The voltage spec should be 0.6V to 0.8V

No check points

Visual Inspection

1. Check continuity between pin no 4 on the sensor connector and pin no A40 on the ECU
connector / pin no 55 on the interconnector

2. Check continuity between pin no 2 on the sensor connector and pin no A12 on the ECU
connector / pin no 54 on the interconnector

3. Check continuity between pin no 6 on the sensor connector and pin no A22 on the ECU
connector / pin no 56 on the interconnector

There should be continuity in any of the case.


Check thecontinuity between
1. pin no 2 & 6 on the sensor connector
2. pin no A12 & A22 on the ECU connector
3. pin no 54 & 56 on the interconnector

Thershould not be any continuity in any of the case.

Check the voltage between


1. pin no 2 & 4 on the sensor connector
2. pin no A12 & A40 on the ECU connector
3. pin no 54 & 55 on the interconnector

Ther should not be more than 5V in any of the case.

1. Check Wiring Harness continuity & short Circuit


2. Remove sensor end connector
3. Check for the sensor error in Tester
If Error is registered, then connect the sensor end connector and erase the error code
4. Check the Sensor signal voltage thru tester (Live data-Parameter 3)
The voltage spec should be 0.6V to 0.8V when ignition ON condition

No check points
Check the Sensor signal voltage thru tester (Parameter 3) when ignition is on.
Voltage should be 500±48mV.

Check the Sensor signal voltage thru tester (Parameter 3) when ignition is on.
Voltage should be 500±48mV.

Check the Sensor signal voltage thru tester (Parameter 3) when ignition is on.
Voltage should be 500±48mV.
Check the continuity between
1. pin no 1 & 2 on the sensor connector
2. pin no A28 & A29 on the ECU connector
3. pin no 27 & 28 on the interconnector

Thershould not be any continuity in any of the case.


Check the resistance value b/w pin no 2 & 1 of coolant pressure sensor - It should be in
between
1) 1940 Ohms to 2173 kOhms (25°C)
2) 1118 ohms to 1231(40°C)
3) 573 ohms to 618 ohms(60°C)
4. 313 ohms to 332 ohms(80°C)

1. Inspect the cooling system

Inspect the air intake system

1. Check for the proper connection of connector to the instrument cluter


2. Check wiring harness
3. Check for the blown fuse and replace if required
4. Check the functionlity of the lamp through tester.Procedure is mentioned below,
i) Using omitec diagnostic scan tool goto actuators test via Ashok diagnostics--->Diesel---
>Engine---> Autodetect--->Actuators test.
ii)select MIL Lamp from the list.
iii) Turn ON & OFF the lamp and verify the lamp functionality.

1. Switch ON & Off the ignition key(with complete afterrun)


2. Clear the error.
3. Try the above step once again

1. Check the functionlity of the lamp through tester.

2. Check the continuity between Pin K71 on the ECU connector and ECU supply pins
K01/K03/K05.

There should not be continuity in this case

1. Check the functionlity of the lamp through tester.

2. Check the continuity between Pin K71 on the ECU connector and ECU supply pins
K01/K03/K05.

There should not be continuity in this case

Check continuity between K35 and T50 switch.


1. Check Starter relay
2. Check Continuity bw K28 to Starter relay (85) & K35 to Starter relay(86).
1. Check Starter relay
2. Check Continuity bw K28 to Starter relay (85) & K35 to Starter relay(86).
1. Check for any physical monement blockage

1. Check for any physical monement blockage


Further Actions
Ensure proper locking of the connector and socket

Rectify / replace Wiring Harness If continuity is missing

If the resistance is out of specified limit - Replace sensor


Ensure proper tightening.

Remove sensor & check at the sensor tip for any burr / metal chip presence. If
so, clean and refit it.
Also mention the correct thickness of sensor mounting plate for all 14" / 15" &
diaphragm clutch.

1. Ensure no of holes
2. check for hole blocking by foreign particles
Replace WH with proper WH

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Ensure proper connections

Rectify / Replace WH if there is no continuity.

If the resistance is out of specified limit - Replace sensor


Ensure proper tightening.

Remove sensor & check at the sensor tip for any burr / metal chip presence. If
so, clean and refit it.
Also mention the correct thickness of sensor mounting plate for all 14" / 15" &
diaphragm clutch.

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Ensure proper connections
Rectify / replace Wiring Harness If continuity is there

Replace WH with proper WH

If the resistance is out of specified limit - Replace sensor


Ensure proper tightening
Ensure proper tightening .
Replace the trigger wheel if wobbling after proper tightening
If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Ensure proper connections

Rectify / Replace WH

If the resistance is out of specified limit - Replace sensor


Ensure proper tightening
If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
1. Ensure proper sensor installation and connection.

Replace the defective tone & trigger wheel.

Remove & refit FIP with correct timing procedure

Replace wiring harness or sensor based on requirement

Replace wiring harness or sensor based on requirement

Ensure the atnmospheric preaaure reading is same to boost pressure in


ignition on condition ie current atmospheric pressure at the location.(for
chennai1000mbar)
Replace ECU
Faulty ECU to be sent for investigation

Ensure the atnmospheric preaaure reading is same to boost pressure in


ignition on condition ie current atmospheric pressure at the location.(for
chennai1000mbar)
Replace ECU
Faulty ECU to be sent for investigation
Ensure proper connections

Rectify / Replace WH if there is no continuity.

Rectify / Replace WH if there is a continuity.

Rectify / replace Wiring Harness If the measured voltage is above 5 V.

If the voltage spec is not matching replace the sensor

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Rectify / Replace WH if there is a continuity.

If the voltage spec is not matching replace the sensor

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated

1. Change boost pressure sensor.


2.Change ECU if problem persists
1. Change boost pressure sensor.
2.Change ECU if problem persists

Ensure proper connections

Rectify / Replace WH if there is no continuity.

Rectify / Replace WH if there is a continuity.

Rectify / replace Wiring Harness If the measured voltage is above 5 V.

If the voltage is out of specified limit - Replace sensor

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Rectify / Replace WH if there is a continuity.

If the voltage is out of specified limit - Replace sensor

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Change the fuel return lines
Fill fuel in sufficient level
Change the fuel return lines
Change the rail if the PRV open count & time is elapsed

Rectify the leakage


Rectify the leakage
Remove the pump and get it checked from the authorised dealer

Remove the injector and get it checked from the authorised dealer

1. Change the fuel filter


2. Clean the strainer
Change the fuel return lines
Change the fuel return lines
Change the rail if the PRV open count & time is elapsed

Rectify the leakage


Rectify the leakage
Remove the pump and get it checked from the authorised dealer

Remove the injector and get it checked from the authorised dealer

1. Change the fuel filter


2. Clean the fuel tank strainer
Change the fuel return lines

Replace the metering unit.

Repalce the injector .


Remove the pump and get it checked from the authorised dealer

Replace / Rectify the wiring harnness

Change the fuel return lines

Replace the metering unit.

Replace the injector .


Replace / Rectify the wiring harnness
Remove the pump and get it checked from the authorised dealer

Change the fuel return lines


Fill fuel in sufficient level
Change the fuel return lines
Change the rail if the PRV open count & time is elapsed

Rectify the leakage


Rectify the leakage
Remove the pump and get it checked from the authorised dealer

Remove the injector and get it checked from the authorised dealer

1. Change the fuel filter


2. Clean the fuel tank strainer
Change the fuel return lines

Change the fuel return lines


Change the rail if the PRV open count & time is elapsed

Rectify the leakage


Rectify the leakage
Remove the pump and get it checked from the authorised dealer

Remove the injector and get it checked from the authorised dealer

1. Change the fuel filter


2. Clean the strainer
Change the fuel return lines

Replace the metering unit.

Repalce the injector .


Remove the pump and get it checked from the authorised dealer

Replace / Rectify the wiring harnness

Ensure proper connections


Rectify / Replace WH if there is no continuity.

Rectify / Replace WH if there is a continuity.

Rectify / replace Wiring Harness If the measured voltage is above 5 V.

If the resistance is out of specified limit - Replace sensor

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Rectify / Replace WH if there is a continuity.

If the resistance is out of specified limit - Replace sensor

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Ensure proper connections

Rectify / Replace WH

Rectify / replace Wiring Harness If the measured voltage is above 5 V.


If the resistance is out of specified limit - Replace sensor

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Rectify / Replace WH if there is a continuity.

If the resistance is out of specified limit - Replace sensor

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
1. Engine relief valve functionality to be ensured.
2. Use correct oil spec.

Rectify /Change the Engine oil cooler module

Arrest oil leakage.

Fill sufficient oil level.


Replace oil filter

Rectify / replace Wiring Harness

Replace sensor - If the voltage out of specified limit

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Ensure proper locking of the connector and sensor socket
Rectify / replace Wiring Harness If continuity is there.

Replace sensor - If the voltage out of specified limit


If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
1. Fill suficient oil level
2.
1. Use correct
Replace oil grade.
/ Rectify wiring harness
3.
2. Rectify
Replace the oil
sensor leakage
if faulty
1.
4. Rectify
Clean thecoolant leakage.
oil circuit pipes
2.
5. Replace
Replace // Rectify
Rectify wiring
wiring harness
harness
3.
6. Replace
Replace sensor
sensor if faulty
if faulty
Ensure proper locking of the connector and sensor socket
Rectify / replace Wiring Harness

Replace sensor - If the resistance is out of specified limit.


If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Rectify / Replace WH
If the resistance is out of specified limit - Replace sensor

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Ensure proper connections
Rectify / Replace WH if there is no continuity.

Replace Metering unit if the resistance value is not as per spec.

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
1. Rectify / Replace wire harness if ther is a continuity & do one afterrun check
the error
3. If error still there, change ECU and do one afterrun.
1. Rectify / Replace wire harness if ther is a continuity.clear the error and heck
for error.
2. Change the metering unit(pump) if error present & check for error.
3. If error still there, change ECU
4. After changing the ECU, clear the error anc check, if error still present,
check with the different Metering unit(pump)

Rectify / Replace wire harness if ther is a continuity

Ensure proper tightening

If the resistance is out of specified limit - Replace injector

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Rectify / Replace wire harness if ther is a continuity

Ensure proper tightening

If the resistance is out of specified limit - Replace injector

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Rectify / Replace wire harness if ther is a continuity

Ensure proper tightening (Tightening torque - 1.5 ±0.25Nm)


If the resistance is out of specified limit - Replace injector

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Rectify / Replace wire harness if ther is a continuity

Ensure proper tightening

If the resistance is out of specified limit - Replace injector

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Rectify / Replace wire harness if ther is a continuity

Ensure proper tightening

If the resistance is out of specified limit - Replace injector

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Rectify / Replace wire harness if ther is a continuity

Ensure proper tightening


If the resistance is out of specified limit - Replace injector

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Rectify / Replace wire harness if ther is a continuity

replace the injector

Rectify / Replace wire harness if ther is a continuity

replace the injector

Rectify / Replace wire harness if ther is a continuity

replace the injector

Rectify / Replace wire harness if ther is a continuity

replace the injector


Rectify / Replace wire harness if ther is a continuity

replace the injector

Rectify / Replace wire harness if ther is a continuity

replace the injector

Rectify / Replace wire harness if there is a continuity

Ensure proper fitment

Rectify / Replace wire harness if ther is a continuity

Ensure proper fitment

Rectify / Replace wire harness if ther is a continuity

Ensure proper fitment

Rectify / Replace wire harness if ther is a continuity

Ensure proper fitment

Rectify / Replace wire harness if ther is a continuity

Ensure proper fitment

Rectify / Replace wire harness if ther is a continuity

Ensure proper fitment

Rectify / Replace wire harness if ther is a continuity


Rectify / Replace wire harness if ther is a continuity

Rectify / Replace wire harness if ther is a continuity

Rectify / Replace wire harness if ther is a continuity

Rectify / Replace wire harness if ther is a continuity

Rectify / Replace wire harness if ther is a continuity

1. Advise Proper driving


Do not downshift the gear by higher shifts (eg.from 5th gear to 2nd gear)
2. Use exhaust brake when descending from hills

Ensure proper locking of the connector and sensor socket

Rectify / replace Wiring Harness


If resistance is not as per spec replace sensor

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Ensure proper connections

Rectify / Replace WH if there is no continuity.

If resistance is not as per spec replace sensor

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Ensure proper locking of the connector and sensor socket

Rectify / replace Wiring Harness

If resistance is not as per spec replace sensor

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Ensure proper connections

Rectify / Replace WH if there is no continuity.

If resistance is not as per spec replace sensor


If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
1.Replace the accelarator pedal.
2. Rectify/Replace the WH.

1. Change the vehicle speed sensor


2. Rectify/Replace the WH.

1. Change the vehicle speed sensor


2. Rectify/Replace the WH.
3. Replace fuse.

Replace Battery
Change ECU if problem perstists
Replace Battery
Change ECU if problem perstists
1 Adjust the clutch sw if required

2. Rectify/Replace the WH.

3. Replace Clutch switch

4.Reset the IPU connection

Replace Brake switch

Reset the IPU connection


Replace ECU & faulty ECU to be sent for investigation

Replace ECU & faulty ECU to be sent for investigation

Change the lamp

Still error is present, check with a diff ECU

If problem still persists, replace SVS lamp

If problem still persists, replace SVS lamp

1. Switch ON & Off the ignition key(with complete afterrun)


2. Clear the error.
3. Try the above step once again
4. Still error is present, check with a diff ECU

Change the battery

Change the battery

Change the battery

Change the battery

Still error is present, check with a diff ECU

Still error is present, check with a diff ECU

Still error is present, check with a diff ECU

Still error is present, check with a diff ECU


Still error is present, check with a diff ECU

Still error is present, check with a diff ECU

Still error is present, check with a diff ECU

Still error is present, check with a diff ECU

Still error is present, check with a diff ECU

Still error is present, check with a diff ECU

Still error is present, check with a diff ECU

Still error is present, check with a diff ECU

1. replace/rectify W.H.
2. replace ECU.
3. replace Booat pressure and Oil pressure sensor

1. replace/rectify W.H.
2. replace ECU.
3. replace EGRVlv position sensor and Accelerator pedal

1. replace/rectify W.H.
2. replace ECU.
3. replace Rail pressure sensor
replace WH/Components connected

replace WH/Components connected

If error still persists, replace the ECU

If error still persists, replace the ECU

1. Replace the High pressure lines with leakage


3. Change the rail
4. Remove the pump and get it checked from the authorised dealer
5. Remove the injector and get it checked from the authorised dealer
1. Change the rail
2. Change the metering unit.

Change the rail

Change the rail

1. Change the pump


2. Change the rail

1. Change the pump


2. Change the rail

Rectify/Replace the WH

Change the sensor

Replace the fuse.


Rectify/Replace the WH

Change sensor with filter

1. Drain the accumulated water in the fuel filter through the drain cock

Still error is present, check with a diff ECU

1. Replace/Rectify the W.H

1. Replace/Rectify the W.H


2. If still error persists, change the Metering Unit(Pump)

1. Replace/Rectify the W.H


2. If still error persists, change the Metering Unit(Pump)

Replace Battery
Change ECU if problem perstists
Replace Battery
Change ECU if problem perstists
1. Clear the error through the diagnostic tester.
2. If the problem persists, replace the ECU
1. Clear the error through the diagnostic tester.
2. If the problem persists, replace the ECU
1. Clear the error through the diagnostic tester.
2. If the problem persists, replace the ECU
1. Clear the error through the diagnostic tester.
2. If the problem persists, replace the ECU
1. Clear the error through the diagnostic tester.
2. If the problem persists, replace the ECU
1. Clear the error through the diagnostic tester.
2. If the problem persists, replace the ECU
1. Clear the error through the diagnostic tester.
2. If the problem persists, replace the ECU

1. Clear the error through the diagnostic tester.


2. If the problem persists, replace the ECU

1. Clear the error through the diagnostic tester.


2. If the problem persists, replace the ECU

1. Clear the error through the diagnostic tester.


2. If the problem persists, replace the ECU

1. Clear the error through the diagnostic tester.


2. If the problem persists, replace the ECU
1. Clear the error through the diagnostic tester.
2. If the problem persists, replace the ECU

1. Clear the error through the diagnostic tester.


2. If the problem persists, replace the ECU

1. Clear the error through the diagnostic tester.


2. If the problem persists, replace the ECU

1. Clear the error through the diagnostic tester.


2. If the problem persists, replace the ECU

1. Clear the error through the diagnostic tester.


2. If the problem persists, replace the ECU

1. Clear the error through the diagnostic tester.


2. If the problem persists, replace the ECU

1. Clear the error through the diagnostic tester.


2. If the problem persists, replace the ECU

1. Ensure proper connections.


2.. Rectify/ Replace wiring harness

1. Switch ON & Off the ignition key(with complete afterrun)


2. Clear the error.
3. Try the above step once again
4. Still error is present, check with a diff ECU

If problem still persists, replace stop lamp

If problem still persists, replace stop lamp

1. Change the rail


2. Change the metering unit.

1. Clear the error through the diagnostic tester.


2. If the problem persists, replace the ECU

1. Clean the EGR valve for accumulation of dust/ soot


2.Replace or rectify the wiring harness if any problem in WH.
3. If still problem persists, change the EGR Valve

1. Clean the EGR valve for accumulation of dust/ soot


2.Replace or rectify the wiring harness if any problem in WH.
3. If still problem persists, change the EGR Valve
1. Rectify / Replace WH
2. If problem still persists replace EGR Valve/ECU.

1. Rectify / Replace WH
2. If problem still persists replace EGR Valve/ECU.

Ensure proper locking of the connector and sensor socket

Rectify / Replace WH
Rectify / Replace WH

Replace EGR with cooler - If the voltage out of specified limit

If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated

Ensure proper locking of the connector and sensor socket


Rectify / replace Wiring Harness

Replace EGR with cooler - If the voltage out of specified limit


If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Replace sensor if the voltage is not with in specification.

Replace sensor if the voltage is not with in specification.

Rectify / Replace WH
Rectify / replace Wiring Harness If the measured voltage is above 5 V
If the resistance is out of specified limit - Replace sensor
Rectify / Replace WH
Rectify / replace Wiring Harness If the measured voltage is above 5 V
If the resistance is out of specified limit - Replace sensor

Change the lamp

Still error is present, check with a diff ECU

If problem still persists, replace MIL lamp

If problem still persists, replace MIL lamp

If problem still persists, Change starter relay

If problem still persists, Change starter relay


If the still persist Change the EGR Valve

If the still persist Change the EGR Valve


P Blink Fault Check Name
Sl.No codes Description Reactions H6
Codes
Engine Coolant Over
1 P0217 41 CEngDsTPhysRngHi Temperature No Reactions
Condition
Possible
Reactions H4 Check Points Further Actions
causes
Engine Over 1. Inspect the
No Reactions heating cooling system

You might also like