Mahindra Bolero Maxitruck Plus BS III 2013 User manual

REVISION - 1
MAY - 2013
Published by - Service Engineering
Technical Hub
DIAGNOSTIC MANUAL
EMS
BOLERO MAXITRUCK PLUS
MAN - 00226
BS III & BS IV
m2DiCR

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


1
MAY 2013/Rev 1
CONTENTS
HOW TO USE THIS MANUAL 2
EMS OVERVIEW 2
WARRANTY & OTHER INFORMATION 3
RECOMMENDED TROUBLE SHOOTING PROCESS 4
INTERMITTENT PROBLEMS 4
EMS ECU CIRCUITS 5
IQA/IMA CODE PROGRAMMING 7
EMS ECU FLASHING 8
INDEX OF DTC CODES 11
DTC BASED TROUBLESHOOTING 15
SYMPTOM BASED DIAGNOSIS- WITH NO DTC CODES 242

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


2
MAY 2013/Rev 1
HOW TO USE THIS MANUAL
If the DTC code is known, then go to the Index of DTC code, and click on the group under which the
DTC appears. The codes/groups are hyperlinked to the respective trouble shooting chart/pages.
The following is the structure of the EMS Diagnostic Manual –
DTC and its description
Component location in the vehicle
Normal operation of the system
DTC detecting conditions
Probable causes
Lamp status
DTC reaction on vehicle
Healing Condition
Connector views and information
Diagnostic tree
Always use the diagnostic manual along with the vehicle’s wiring manual (MAN-00222).
EMS OVERVIEW
The EMS ECU uses the following sensors and actuators to govern all engine parameters for optimized
engine performance
Sensors/Switches
Engine Coolant Temperature Sensor
Ambient Air Pressure Sensor
Camshaft Position Sensor
Crankshaft Speed Sensor
Boost Pressure Sensor
Rail Pressure Sensor
Accelerator Pedal Module
Vehicle Speed Sensor

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


3
MAY 2013/Rev 1
Brake Switch
Clutch Sensor
Gear neutral Switch
Boost Temperature Sensor
EGR feedback sensor
Actuators
EGR Actuator
Injectors
Fuel Metering Unit
WARRANTY & OTHER INFORMATION
All failures/complaints encountered on EMS ECU and other system components should be reported
through Service Complaint Report (SCR).Replacement of any of the EMS ECU and other system
components requires approval of the TEKline. Ensure that a TAR is raised# in the TEKnet website for
approval, attaching the SCR. While raising a warranty claim, the TAR number should be quoted on the
warranty claim.
# Only a trained and certified CoTEK can raise a TAR (in TEKnet website)

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


4
MAY 2013/Rev 1
RECOMMENDED TROUBLE SHOOTINGPROCESS
INTERMITTENT PROBLEMS
Check the following for intermittent problems
 Poor mating of the connector halves/damage of connector locking
 Terminals not fully seated in the connector body
 Damage of harness and terminals
 Connector pin separation from wire
 Corrosion on pin contact points
Customer complaint Record/Understand Customer Verbatim
What happened?
When it happened?
What was the event before that?
Does it happen all the time?
Does it happen only in some condition?
Search for Published quick solution in TEK net .
Follow DTC based diagnosis
Contact TEKliner with TAR
(Technical Assistance Request)

DIAGNOSTIC MANUAL
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction,
translation, transmission, in part of or whole of the present document,are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,will amount to unauthorized use and shall be liable for penalty/
prosecution © 2013 Mahindra & Mahindra Ltd.
MAN- 00226
MAY 2013/Rev1
EMS
5

DIAGNOSTIC MANUAL
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction,
translation, transmission, in part of or whole of the present document,are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,will amount to unauthorized use and shall be liable for penalty/
prosecution © 2013 Mahindra & Mahindra Ltd.
MAN- 00226
MAY 2013/Rev1
EMS
6

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


7
MAY 2013/Rev 1
IQA/IMA CODE PROGRAMMING
An ECU controlled engine needs precise metering of fuel. Due to manufacturing tolerances, each injector
deviates slightly from its idealized behavior. Thus, each injector has a correction factor, which is
engraved on top of it, in the form of a 7-character alphanumeric code , out of which the last character
"W" is a dummy value. This is known as an IQA code/IMA code. For optimal performance of the engine,
the ECU needs to know the IQA code/IMA code of each injector. This information is programmed into
the ECU when the vehicle is manufactured. However, if you need to replace an injector(s), then the IQA
code/IMA code for that new injector has to be updated in the ECU. The cylinder number starts from the
right side of the vehicle.
As a first step, you need to select the cylinder number of the injector being replaced. After the cylinder
number is selected by clicking on the check-button next to the number, the IQA code/IMA code should
be entered in the box provided.
Click the button to the right of the text box. If the Injector code is valid and accepted by the ECU, a
message is displayed, indicating that the operation is performed successfully.
A message “Invalid IQA code” will be displayed , if an incorrect IQA/IMA code is keyed in. IQA codes are
case sensitive.
Programming IQA codes is an extremely important activity. In order to ensure that the correct code has
been entered and that it has been entered in the correct cylinder, SMART tester allows you to verify the
codes that you have entered.
Select an injector, and click the button below the ”Verify” line in figure. The IQA codes present in the ECU
will be read back and displayed in the text box before this button. It is recommended that you carry out
the verification activity whenever you change an IQA code.
Please ensure to program IQA/IMA codes when you replace an Injector, ECU or Engine.
The following are the fonts of the alphanumeric characters of the IQA/IMA code, as etched on the
injectors.
Caution
Even though on the injector, 7 character alphanumeric code is engraved , while writing the IQA
code only the first 6 digits need to be entered

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


8
MAY 2013/Rev 1
EMS ECU FLASHING
The EMS ECU required to be flashed in the following conditions
BLANK ECU
Procure blank EMS ECU from spare part dept.
Check for the correct/latest part no in parts catalogue/Technical Service Bulletins.
Flash the EMS ECU dataset with a latest dataset as per TSB or at the advice of TEKline.
NOTES -
1. Flash the EMS ECU with the correct/latest dataset. The matrix of the vehicles and the related
latest dataset will be released through TSB - if in doubt ask the TEKline.
2. Wrong dataset flashing may result in vehicle not starting and can lead to ECU failure.
Software
Version ECU Type Dataset ID Type Model
EDC17C55 1037535124 Factory/
Refalshing
Bolero Maxitruck Plus
BS3 Variant
EDC17C55 1037535125 Factory/
Refalshing
Bolero Maxitruck Plus
BS4 Variant
3. Ensure that the there is no communication breakdown once the flashing begins. Check Python
connections are secure.
4. Ensure that the SMART tester has -
Enough battery reserve/Connected to AC power
Screen saver/Battery saver mode turned off
5. Ensure that
Ignition is ON
Battery terminals connected securely.
Battery earth connection is good.

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


9
MAY 2013/Rev 1
6 . Never touch the ECU pins by hand/finger
FLASHING PROCEDURE
Connect using the “Python 1BConfig0404"
Click the “EDC17 C55 field flashing tool V3.0” icon present on the desktop
The following window appears
Click on Manual Link for the Options to Open.
Enter the Following Details:
Model Name (As per VIN Plate, Not Mandatory)
VIN Number:
Engine Number: (Not Mandatory)
IQA Codes for all 4 Injectors.
Select the Corresponding Dataset Using the Browse Link as Provided.

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


10
MAY 2013/Rev 1
Select the Hex File from the link up box as shown in the Picture above
Link = C:\Program Files\EDC17C55ECUFlashTool\HEXFILE
Click on Flash for the EMS ECU Flashing Process to Begin.
Once Flashing is Complete Turn OFF ignition for 60 Secs and then Turn in ON.

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


11
MAY 2013/Rev 1
INDEX OF DTC's
GROUP DTC DESCRIPTION PAGE
NO
COOLANT
TEMPERATURE
SENSOR
P1128
COOLANT TEMPERATURE SENSOR ABSOLUTE TEST
NON PLAUSIBLE ERROR 15
P1126
COOLANT TEMPERATURE SENSOR DYNAMIC TEST
NON PLAUSIBLE ERROR 15
P0118
SIGNAL RANGE CHECK FOR COOLANT TEMPERATURE
SENSOR ABOVE MAXIMUM LIMIT 17
P0117
SIGNAL RANGE CHECK FOR COOLANT TEMPERATURE
SENSOR BELOW MINIMUM LIMIT 21
ECU EEPROM
MONITORING
P062F ECU EEPROM ERROR 25
P162F ECU EEPROM ERROR 27
P1630 ECU EEPROM ERROR 29
P062B
ECU MONITORING ERROR FOR INJECTOR CUT OFF
DEMAND 31
EGR
P0403 EGR VALVE OPEN LOAD ERROR 33
P1403 EGR VALVE OVER TEMPERATURE ERROR. 36
P0406 EGR VALVE SHORT TO BATTERY ERROR 38
P0405 EGR VALVE SHORT TO GROUND ERROR. 41
ENVIRONMENTAL
PRESSURE SENSOR
P2228
SIGNAL RANGE CHECK FOR ENVIRONMENTAL
PRESSURE SENSOR BELOW MINIMUM LIMIT. 44
P2229
SIGNAL RANGE CHECK FOR ENVIRONMENTAL
PRESSURE SENSOR ABOVE MAXIMUM LIMIT. 46
CAM PHASE SENSOR P0340 CAMSHAFT SENSOR NO SIGNAL ERROR 48
P0341 CAMSHAFT SENSOR SIGNAL ERROR 52
P1341 CAMSHAFT SENSOR SIGNAL OFFSET ERROR. 55
CRANKSHAFT
SENSOR
P0336 CRANKSHAFT SENSOR SIGNAL ERROR. 57
P0335 CRANKSHAFT SENSOR NO SIGNAL ERROR. 61
FUEL TEMPERATURE
SENSOR P0183
SIGNAL RANGE CHECK FOR FUEL TEMPERATURE
SENSOR ABOVE MAXIMUM LIMIT. 65
P0182
SIGNAL RANGE CHECK FOR FUEL TEMPERATURE
SENSOR BELOW MINIMUM LIMIT 69
IQA CODE
MONITORING
P268C
CYLINDER 1 INJECTOR ADJUSTMENT CODE
INCORRECT ERROR. 73
P268E
CYLINDER 2 INJECTOR ADJUSTMENT CODE
INCORRECT ERROR. 75
P268F
CYLINDER 3 INJECTOR ADJUSTMENT CODE
INCORRECT ERROR. 77
P268D
CYLINDER 4 INJECTOR ADJUSTMENT CODE
INCORRECT ERROR. 79
INJECTORS
P0201 CYLINDER 1 INJECTOR OPEN LOAD ERROR 81
P0203 CYLINDER 2 INJECTOR OPEN LOAD ERROR 84
P0204 CYLINDER 3 INJECTOR OPEN LOAD ERROR 87
P0202 CYLINDER 4 INJECTOR OPEN LOAD ERROR 90
P0261 CYLINDER 1 INJECTOR SHORT CIRCUIT ERROR 93
P0267 CYLINDER 2 INJECTOR SHORT CIRCUIT ERROR 96
P0270 CYLINDER 3 INJECTOR SHORT CIRCUIT ERROR 99
P0264 CYLINDER 4 INJECTOR SHORT CIRCUIT ERROR 102

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


12
MAY 2013/Rev 1
P2146 SHORT CIRCUIT IN BANK 0 105
METERING UNIT
P0001 METERING UNIT OPEN LOAD ERROR 110
P0004
METERING UNIT OUTPUT SHORT CIRCUIT TO BATTERY
ERROR 113
P0003
METERING UNIT OUTPUT SHORT CIRCUIT TO GROUND
ERROR 116
BOOST PRESSURE
SENSOR P0238
SRC HIGH FOR CHARGED AIR COOLER PRESSURE
(DOWN STREAM) 119
P0237
SRC LOW FOR CHARGED AIR COOLER PRESSURE
(DOWN STREAM) 123
RAIL PRESSURE
SENSOR
P0193
SIGNAL RANGE CHECK FOR RAIL PRESSURE SENSOR
ABOVE MAXIMUM LIMIT 127
P0192
SIGNAL RANGE CHECK FOR RAIL PRESSURE SENSOR
BELOW MINIMUM LIMIT 131
P0191
RAIL PRESSURE OFFSET VALUE ABOVE MAXIMUM
LIMIT 134
P1191
RAIL PRESSURE OFFSET VALUE ABOVE MINIMUM
LIMIT 136
ACCELERATOR
PEDAL MODULE
P2123
SIGNAL RANGE CHECK FOR APP PEDAL SENSOR 1
ABOVE MAXIMUM LIMIT 138
P2128
SIGNAL RANGE CHECK FOR APP PEDAL SENSOR 2
ABOVE MAXIMUM LIMIT 142
P2138
PLAUSIBILITY ERROR BETWEEN APP SIGNAL1 AND
SIGNAL2 146
P1138 ACC PEDAL PLAUSIBLE CHECK WITH THE BRAKE 152
VEHICLE SPEED
SENSOR
P0501 VEHICLE SPEED SENSOR PLAUSIBILITY ERROR 153
SENSOR SUPPLY
MONITORING
P0641 SENSOR SUPPLY VOLTAGE1 MONITORING ERROR 157
P0651 SENSOR SUPPLY VOLTAGE 2 MONITORING ERROR 159
P0697 SENSOR SUPPLY VOLTAGE 3 MONITORING ERROR 161
RAIL PRESSURE
GOVERNOR
P1B87
RAIL PRESSURE POSITIVE GOVERNOR DEVIATION
ERROR IN METERING UNIT MODE 163
P1C87
POSITIVE GOVERNOR DEVIATION AND SET POINT
VALUE OF THE FUEL VOLUME FLOW THROUGH THE
METERING UNIT 166
P1B88
RAIL PRESSURE NEGATIVE GOVERNOR DEVIATION
ERROR IN METERING UNIT MODE 169
P1D87
RAIL PRESSURE BELOW MINIMUM LIMIT ERROR IN
METERING UNIT MODE 171
P1C88
RAIL PRESSURE ABOVE MAXIMUM LIMIT ERROR IN
METERING UNIT MODE 174
MAIN RELAY P068A MAIN RELAY EARLY OPENING ERROR
176
P068B MAIN RELAY STRUCK ERROR 176
BOOST PRESSURE
GOVERNOR
P0069 PLAUSIBILITY DEFECT BETWEEN CACDSP AND ENVP 180
BRAKE SWITCH
P0504 BRAKE SIGNAL PLAUSIBILITY ERROR. 181
CLUTCH SENSOR P0704 CLUTCH NON PLAUSIBLE ERROR 185
P172A CLUTCH 90% SWITCH PLAUSIBLE ERROR 189
P171A CLUTCH 90% SWITCH PLAUSIBLE ERROR 192

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


13
MAY 2013/Rev 1

WATER IN FUEL
SENSOR
P2269 WATER PRESENCE IN FUEL ERROR 195
P2265 WATER IN FUEL SENSOR FAULTY 197
CONTINIOUS
TORQUE
MONITORING
P1900 NTP error in ADC monitoring
201
P163B ECU Monitoring: ADC test error
P163C ECU Monitoring: Voltage ratio error in ADC
P1621 ECU Monitoring: Query response communication error
P1622 ECU Monitoring: SPI communication error
P0605 ECU Monitoring: ROM memory error
P1623 ECU Monitoring: CPU error
P1625 ECU Monitoring: Response time error in ECU
P1626
ECU Monitoring: Shut off path test SPI communication
error
P1628 ECU Monitoring: Shut off path under voltage error
202
P1629
ECU Monitoring: WDA not working
P162A ECU Monitoring: Time out error
P162C ECU Monitoring: Positive test failure error
P162D ECU Monitoring: Time out error for shut off path test
P060D ECU Monitoring: Accelerator position error
203
P061C
ECU Monitorin
g
: En
g
ine speed error
P1638
ECU Monitoring: Rail pressure monitoring plausibility
error
P060A
ECU Monitoring: Energising time plausibility error
CONTINUOUS
TORQUE
MONITORING
P1631 ECU Monitoring: Start of Injection plausibility error 204
P1632 ECU Monitoring: ZFC non plausibility error 205
GNS
P1704 GEAR NEUTRAL SIGNAL IS NOT PLAUSIBLE 207
GNS RELAY
P1712 GNS RELAY NO LOAD 209
P1713 GNS RELAY SHORT TO BATTERY ERROR 211
P1714 GNS RELAY SHORT TO GROUND ERROR 213
P1716 GNS RELAY PLAUSIBLE ERROR 215
STARTER RELAY P170F STARTER RELAY OPEN LOAD 217
P170D STARTER RELAY SHORT CIRCUIT TO BATTERY ERROR 219
P170E STARTER RELAY SHORT CIRCUIT TO GROUND ERROR 221
ECU
P1641 SOFTWARE RESET ERROR 223
T50
P1707 T50 signal error 224
BATTERY P0071
SIGNAL RANGE CHECK FOR BATTERY SENSOR SIGNAL
ABOVE MAXIMUM LIMIT 225
P0562
SIGNAL RANGE CHECK FOR BATTERY SENSOR SIGNAL
BELOW MINIMUM LIMIT 227

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


14
MAY 2013/Rev 1

EGR FEEDBACK
SENSOR P1406
SIGNAL RANGE CHECK FOR EGR FEEDBACK SENSOR
ABOVE MAXIMUM LIMIT 230
P1405
SIGNAL RANGE CHECK FOR EGR FEEDBACK SENSOR
ABOVE MAXIMUM LIMIT 233
BOOST
TEMPERATURE
SENSOR
P007D
SIGNAL RANGE CHECK FOR INTERCOOLER
DOWNSTREAM TEMPERATURE SENSOR ABOVE
MAXIMUM LIMIT 237
P007C
SIGNAL RANGE CHECK FOR INTERCOOLER
DOWNSTREAM TEMPERATURE SENSOR BELOW
MINIMUM LIMIT 240

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


15
MAY 2013/Rev 1
P1128
P1126
COOLANT TEMPERATURE SENSOR ABSOLUTE TEST NON PLAUSIBLE ERROR
COOLANT TEMPERATURE SENSOR DYNAMIC TEST NON PLAUSIBLE ERROR
COOLANT TEMPERATURE SENSOR: ABSOLUTE & DYNAMIC TEST
When the engine is switched ON then the ECU detects the coolant temperature. After that when the
engine runs then the temperature output on a time frame is detected and compared against
predetermined values.
DTC INFORMATION PROBABLE CAUSES OF FAILURE
NORMAL OPERATION
Engine running
The coolant temperature rises to a specified temperature
within a specific time period.
The coolant temperature rises to a specified temperature
within a specific time period - Absolute test
The coolant temperature rises to a minimum temperature
within a specific time period - Dynamic test
DTC DETECTING CONDITIONS
Engine running
EMS ECU supply voltage 8-16 V
The coolant temperature do not rise enough within a
specific time period,
The coolant temperature do not reach a warmed-up fuel
control temperature within a specific time period
DTC REACTIONS
No lamp indication
HEALING CONDITION
Ignition Off/On
Defective temperature sensor.
Thermostat stuck in open
condition
Thermostat removed.
Thermostat

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


16
MAY 2013/Rev 1
STEP1
Connect the smart tester
Turn the ignition ON
Initialise the diagnostic tool
Record the DTC and clear
Turn ignition OFF
Turn ignition ON
Verify if P1128/P1126 is
present?
IsP1128/P1126
present?
Intermittent problem exists
Refer the intermittent problem
inspection procedure
STEP2
Is the thermostat
properly fitted ?
Check and ensure the coolant
temperature sensor is
functioning properly
Check for proper fittment of
thermostat in thermostat
housing
Fix the thermostat in its correct
positon
Clear the DTC and verify
Remove the thermostat and
check whether thermostat is
strucked in open position.
Replace the thermostat with a
new one
Clear the DTC and verify
NOYES
NOYES
P1128
P1126

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


1
7
MAY 2013/Rev 1
P0118 SIGNAL RANGE CHECK FOR COOLANT TEMPERATURE SENSOR ABOVE
MAXIMUM LIMIT
COOLANT TEMPERATURE SENSOR
The CTS sensor is a variable resistor whose resistance changes as the temperature of the engine
coolant flowing past the sensor changes.(NTC resistor) When the coolant temperature is low, the
sensor resistance is high; when the coolant temperature is high, the sensor resistance is low. The ECU
checks CTS voltage and uses the information to help smoothen the engine operation.
DTC INFORMATION PROBABLE CAUSES OF FAILURE
NORMAL OPERATION
Ignition ON
The measured output voltage value of the coolant
temperature sensor is within the range
DTC DETECTING CONDITIONS
Ignition ON
EMS ECU supply voltage 8-16V
The measured output voltage of the coolant temperature
sensor is higher than the maximum range.
DTC REACTIONS
OBD lamp continuously ON.
Coolant temperature value set as 110 °C
HEALING CONDITION
Ignition Off/On
Open coolant
temperature sensor
wires
Short to battery of
coolant temperature
wires
Faulty coolant
temperature sensor
Malfunctioning EMS ECU

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


18
MAY 2013/Rev 1
CONNECTOR VIEWS AND INFORMATION
CONNECTOR DESCRIPTION PIN NO FUNCTION
EMS ECU
33 SIGNAL
11 GROUND
COOLANT TEMPERATURE
SENSOR
1SIGNAL
2GROUND
P 0118

DIAGNOSTIC MANUAL MAN-00226
EMS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2013 Mahindra & Mahindra Ltd.


19
MAY 2013/Rev 1
STEP1
Connect the smart tester
Turn the ignition ON
Initialise the diagnostic tool
Record the DTC and clear
Turn ignition OFF
Turn ignition ON
Verify if P0118 is present?
Is P0118 present?
Intermittent problem exists
Refer the intermittent problem
inspection procedure
STEP2
Is the value =5 ±
0.25 V?
Check the voltage between pin
1 of the coolant temperature
sensor wiring harness
connector and battery ground
STEP3Go to STEP 4
If the Voltage is greater than
5.25V , check for short to
battery of the coolant
temperature signal wire
Check the continuity between
pin 33 of EMS ECU wiring
harness connector and pin 1 of
the of the coolant temperature
sensor wiring harness
connector
Is the continuity
exists?
Examine the open circuit of
coolant temperature sensor
signal wire
Replace the wiring harness
Clear the DTC and verify
Suspect EMS ECU malfunction
Replace EMS ECU with a new
one.
Check and verify for any new
DTC’s
NO
NO
NOYES
YES
YES
P
0118