Professional Documents
Culture Documents
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
Terminal backout
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
DFC_EpmCrSErrSig
1 P0336 51
DFC_EpmCrSNoSig
DFC_EpmCaSI1ErrSig
DFC_EpmCaSI1NoSig
DFC_EpmCaSI1OfsErr
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)
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)
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)
P1136
143 P0113 25 DFC_PRVRPOutOfRng
(OBD)
P0401
145 93 DFC_EGRVlvGovDvtMax
P0402
146 93 DFC_EGRVlvGovDvtMin
147 P0490 91 DFC_EGRVlvHbrgSCB
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)
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)
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
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
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
NA
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.
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)
ECU Defective - CY33X is defect Injector bank / Engine Injector bank / Engine
(injector chip error) shutt off shutt off
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
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
Metering unit (ECU) Over temperature error 40% Torque Limitaion 40% Torque Limitaion
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
OS timeout in the shut off path test. Failure setting No Reactions No Reactions
the alarm task period.
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
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
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
Air gap between tooth & sensor above spec (spec 0.3mm - 1.8mm).
ECU defective
Electrical Noise in crank sensor signal due to Shielding is not available for cam signal
line.
ECU defective
Deviation between cam and crank sensors signals exceeds +/- 10deg Crank during
plausibility check.
FIP timing
Sensor defective
ECU defective
Sensor defective
ECU defective
1. Loose connection.
Sensor defective
ECU defective
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
Sensor defective
ECU defective
Sensor defective
ECU defective
ECU defective
Sensor defective
ECU defective
Sensor defective
ECU defective
ECU defective
Loose connection.
No electrical continuity between ECU to sensor connector.
ECU defective
Injector(Actuator) defective
ECU defective
Actuator defective
ECU defective
ECU defective
Actuator defective
ECU defective
Actuator defective
ECU defective
ECU defective
Sensor defective
ECU defective
Sensor defective
ECU defective
Loose connection / poor contact between sensor socket & connector.
Sensor defective
ECU defective
Sensor defective
ECU defective
1. Sensor defective.
2. WH problem
If the main brake contact Brk_stMn and the redundant brake contact Brk_stRed are
not in the same state.
Sensor failure at ECU.
ECU defective
ECU defective
Number of injections requested is more than allowed injections for current battery
volatage and engine speed
Not enough rail pressure in the system
Not Applicable
Not Applicable
UB3 lines [K51, K26, K25, K89, K92, K93, K94, K50, K90, K28] inlcusive of
component, W.H & ECU shorted with Battery
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
Sensor defective
fuse blown
Signal line short to ground
Sensor defective
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. 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)
Sensor defective
ECU defective
Sensor defective
ECU defective
ECU defective
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)
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)
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.
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
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.
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
No check points
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
No check points
No check points
No check points
No check points
No check points
No check points
No check points
No check points
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
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
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
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
No check points
No check points
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 ¬1 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
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.
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.
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.
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.
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.
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.
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.
No check points
Remove injector from clyinder head, check continuity between injector terminal to injector
body. There should not be any body short
Remove injector from clyinder head, check continuity between injector terminal to injector
body. There should not be any body short
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.
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.
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.
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.
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.
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.
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
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
2. Check the continuity between Pin K70 on the ECU connector and ECU supply pins
K01/K03/K05.
2. Check the continuity between Pin K70 on the ECU connector and ECU supply pins
K01/K03/K05.
No check points
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)
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.
Visusal inspection
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.
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
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
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
2. Check thecontinuity between pin no 2 on the sensor connector / pin no A40on the ECU
connector/ pin no 55 on the interconnector
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
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
2. Check the continuity between Pin K71 on the ECU connector and ECU supply pins
K01/K03/K05.
2. Check the continuity between Pin K71 on the ECU connector and ECU supply pins
K01/K03/K05.
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
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
Rectify / Replace WH
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 all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
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 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
Remove the injector and get it checked from the authorised dealer
Remove the injector and get it checked from the authorised dealer
Remove the injector and get it checked from the authorised dealer
Remove the injector and get it checked from the authorised dealer
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 all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Ensure proper connections
Rectify / Replace WH
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 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.
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.
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 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)
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
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
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
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
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
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
If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Ensure proper connections
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
If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
Ensure proper connections
Replace Battery
Change ECU if problem perstists
Replace Battery
Change ECU if problem perstists
1 Adjust the clutch sw if required
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
Rectify/Replace the WH
1. Drain the accumulated water in the fuel filter through the drain cock
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. Rectify / Replace WH
2. If problem still persists replace EGR Valve/ECU.
Rectify / Replace WH
Rectify / Replace WH
If all the above check points are ok Replace ECU / Faulty ECU to be sent for
investigated
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