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MAN-00105
RELEASED BY -
All information contained in this manual is most up-to-date at the time of publication.
However, specifications and procedures are subject to change without notice. This manual is
strictly meant for restricted circulation.
© 2010 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in
part, without the written permission of Mahindra & Mahindra Ltd.
About the Diagnostic Manual
The diagnostic manual outlines the detailed procedures to troubleshoot complaints related to the
CRDe components in THAR CRDe BS-IV vehicle. Since the CRDe components and system is
sensitive and requires certain level of understanding for troubleshooting; only a trained authorized
persons can work on the CRDe system in conjunction with M&M diagnostic tool.
In spite of best efforts to make the manual error-free, a few errors could have inadvertently crept in. If you
identify errors, functional or typographical, please inform your TEKline, pillay.ajay@mahindra.com or
jose.davis@mahindra.com. Suggestions to improve the manual and make it more user-friendly are also
welcome.
© 2010 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in
part, without the written permission of Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 1
Thar CRDe December 2010/Rev 1
Contents
How to use this manual
Overview of the in-vehicle communication network
Actuator Tests
Wiring Diagram
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 2
Thar CRDe December 2010/Rev 1
Always use the diagnostic manual along with the vehicle’s wiring manual (MAN-00106).
There are certain complaints for which no DTC codes are generated. The trouble shooting
procedure for the same is covered in the Symptom based Diagnosis.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 3
Thar CRDe December 2010/Rev 1
Diagnostic Engine
Connector (EMS ECU)
(DLC)
K - Line
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 4
Thar CRDe December 2010/Rev 1
Replacement of the EMS ECU requires approval of the TEKline. Ensure that a TAR
is raised# in the TEKnet website for approval, attaching the CrFR/SCR. While
raising a warranty claim, the TAR no should be quoted on the warranty claim.
# Only a trained and certified CoTEK can raise a TAR (in TEKnet website)
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 5
Thar CRDe December 2010/Rev 1
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.
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.
The following are the fonts of the alphanumeric characters of the IQA/IMA code, as
etched on the injectors.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 6
Thar CRDe December 2010/Rev 1
BLANK ECU
1. Procure blank EMS ECU from spare part dept.
2. Flash the EMS ECU dataset with a latest dataset as per TSB or at the
advice of TEKline.
1. Flash the EMS ECU with the correct/latest dataset. The matrix of the
vehicles and the related latest dataset will be released through TSB - if in
doubt ask the TEKline.
2. Wrong dataset flashing may result in vehicle not starting and can lead to
ECU failure.
Software
ECU Type Dataset ID Model
Version
Will be released through TSB THAR CRDe
Notes –
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 7
Thar CRDe December 2010/Rev 1
RE-PROGRAMMING PROCEDURE
• Connect using the “Python1BConfig0404”.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 8
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 9
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 10
Thar CRDe December 2010/Rev 1
Accelerator Pedal
P-1221 signal not plausible with
brake
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 11
Thar CRDe December 2010/Rev 1
Offset between
Error path of
P-1340 camshaft and 55
offset
crankshaft
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 12
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Minimum Temperature
P-2558
not reached within time
limit.
CTS absolute &
77
dynamic test
Minimum temperature
P-1126 or temperature raise no
reached within time limit
Voltage above upper
P-0108
Atm pressure limit
79
sensor Voltage below lower
P-0107
limit
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 13
Thar CRDe December 2010/Rev 1
Coolant P-1609
Short circuit to ground
temperature 88
output P-160A No load
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 14
Thar CRDe December 2010/Rev 1
Chip-specific errors:
P-1211
CY33X is unlocked /
CY33X init error
Chip-specific
P-1212
errors:CY33X is in Test
mode
Chip-specific errors:
P-1213 CY33X SPI
communication error
/checksum/read back
ECU 91
Chip-specific errors -
P-1214
>CY33X internal parity
error
Chip-specific errors -
P-1215
>CY33X internal
program flow error
Chip-specific errors -
P-1216
>CY33X check of inv.
YSEL during ON failed
Chip-specific errors -
P-1217 >CY33X ON timeout for
at least 1 cylinder
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 15
Thar CRDe December 2010/Rev 1
(Hardware) CJ940
upper limit: internal
supply voltage upper
P-1631
Power Stage limit
Voltage (Hardware) 94
Monitoring
CJ940 lower limit:
P-1632 internal supply voltage
lower limit
Voltage above upper
P-1644 limit
Sensor Supply
95
Monitoring 1 Voltage below lower
P-1645 limit
Voltage above upper
P-1646 limit
Sensor Supply
97
Monitoring 2 Voltage below lower
P-1647 limit
Short Circuit to Battery
P-1654
Short Circuit to Battery
P-1655
System Lamp 100
No Load
P-1656
Excess Temperature
P-1657
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 16
Thar CRDe December 2010/Rev 1
P-1651
Short Circuit to Battery
MIL Lamp 103
P-1652 No Load
Exceeding of the
P-0503
maximum vehicle
speed
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 17
Thar CRDe December 2010/Rev 1
Coolant Overheat
ACT # 2 114
Lamp
Actuator Test
ACT # 3 Air Conditioning 115
Boost Pressure
ACT # 5 117
Actuator (BPA)
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 18
Thar CRDe December 2010/Rev 1
P-0123
Accelerator Pedal Module 1 P-0122
P-1120
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 19
Thar CRDe December 2010/Rev 1
P-0123
P-0122
Accelerator Pedal Module 1
P-1120
Description:
The Accelerator pedal module (APM) mounts in place of accelerator pedal and is
connected to the ECU by wires. The APM sensor is a variable resistor
(potentiometer) whose resistance changes according to the pedal position. ECU
applies a reference voltage to the APM sensor and then measures the voltage that
is present on the APM sensor signal circuit. The ECU uses the APM sensor signal
for further calculation of fuelling & other engine operational parameters.
Proper Performance
Sensor output voltage has continued to between 0 to
5V, varying accelerator pedal position.
Malfunction; out-of-range
• With the changing Accelerator pedal position,
the sensor output voltage has continued to be
5V or 0V.
Reaction:
• The engine speed not varying with changing
accelerator pedal position. (Constant 1200 rpm)
• The system lamp is continuously on.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 20
Thar CRDe December 2010/Rev 1
P-0123
P-0122
P-1120
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 21
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P-0123
Test Procedure APP1 – P-0122
P-1120
1. Connect the ‘Smart Tester’ to diagnostic connector.
2. Turn Ignition Switch ON.
3. Verify either P0123 or P122 or P1120 are present.
Yes No
Turn Ignition OFF
Measure the continuity between terminal Measure the continuity between
K09 in ECU and Terminal 4 of connector K45 & 2 ( Voltage)
K30 and 3 ( ground)
Continuity is OK. (resistance below 1 Ω) Repair the damaged line/
connection
Clear code
Verify that the complaint has been
eliminated.
Yes No
Yes No
Check the APP 1 resistance in both the
state 0% & 100%
Yes No
Clear the code. Replace the Accelerator pedal
Module
Verify that the complaint has been eliminated.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 22
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P-0223
Accelerator Pedal (APP2) P-0222
P-1220
Description: P-1221
The Accelerator pedal module (APM) mounts in place of accelerator pedal and is
connected to the ECU by wires. The APM sensor is a variable resistor
(potentiometer) whose resistance changes according to the pedal position. ECU
applies a reference voltage to the APM sensor and then measures the voltage that
is present on the APM sensor signal circuit. The ECU uses the APM sensor signal
for further calculation of fuelling & other engine operational parameters.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 23
Thar CRDe December 2010/Rev 1
P-0223
P-0222
P-1220
P-1221
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 24
Thar CRDe December 2010/Rev 1
P-0223
P-0222
Test Procedure APP2 – P-1220
P-1221
1. Connect the ‘Smart Tester’ to diagnostic connector.
2. Turn Ignition Switch ON.
3. Verify that either P0223/P0222/P1220 / or P1221 is present.
Yes No
Turn Ignition OFF
Measure the continuity between terminal Measure the continuity between
K31 in ECU and Terminal 6 of connector. K46 & 1 ( Voltage)
K08 and 5 ( ground)
Continuity is OK? (resistance below 1 Ω) Repair the damaged line/
connection.
Clear code
Verify that the complaint has been
eliminated.
Yes No
Reconnect. Before reconnection check Repair the damaged line/
that the pins are not bent or oxidation has connection.
not taken place.
Clear the codes. Clear code.
Does the problem persist? Verify that the complaint has been
eliminated.
Yes No
Check the APP 2 resistance in both the
state 0% & 100%
Is it within the specifications
Yes No
Replace the Accelerator pedal
Module
Clear code.
Verify that the complaint has been eliminated.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 25
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P-0340
Camshaft Speed Sensor P-0341
Description
The Hall effect camshaft position sensor senses the Top dead center (TDC) point
of the # 1 cylinder in the compression stroke. Which allows the ECU to determine
when to start the injection.
The 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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 26
Thar CRDe December 2010/Rev 1
Normal Operation
• When the engine is running, the Camshaft • Open or shorted
Position sensor outputs a pulse signal. camshaft position
• The ECU checks whether the pulse signal is sensor circuit,
input. loose or wrong
connection.
Malfunction • Camshaft
• Normal signal pattern has not been input for Position sensor
cylinder identification from the camshaft malfunction.
position sensor signal for 4 sec. (Engine
should be cranked to check this error).
Reaction
• Engine will not start
• System lamp will be continuously on.
P-0340
P-0341
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 27
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 28
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P-0340
P-0341
Yes No
Yes No
Yes No
Check for physical damage to pins or Repair the connection.
oxidation.
Also check if the connectors are moving Clear the error codes & verify.
backwards when inserted.
Is it OK?
Yes No
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 29
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 30
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P-0335
Crankshaft Sensor P-0336
Description - In order that the ECU can control the engine at all the position of
the crankshaft must be known so that the cylinder in compression and the
timing of the next fuel injection can be calculated. The CKP is an inductive
pulse generator, which scans protrusions on the flywheel. Two teeth are
missing, and this gap is situated at 90° before TDC.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 31
Thar CRDe December 2010/Rev 1
P-0335
P-0336
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 32
Thar CRDe December 2010/Rev 1
P-0335
Test Procedure ISS P-0336
1. Connect the ‘Smart Tester’ to diagnostic connector.
2. Turn Ignition Switch ON.
3. Verify that either P0335 or P0336 are present. Please verify while cranking
the engine.
Yes No
Yes No
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 33
Thar CRDe December 2010/Rev 1
P-0103
P-0102
Air Flow
Description –
Mass air flow rate is measured by detection of heat transfer from a hot film probe
because the change of the mass air flow rate causes change in the amount of heat
being transferred from the hot film probe surface to the air flow. The airflow sensor
generates a pulse so it repeatedly opens and closes between the 5V voltage
supplied from the engine control module. This results in the change of the
temperature of the hot film probe and in the change of resistance.
DTC Diagnostic item
P-0103 Voltage above upper Limit
P-0102 Voltage below lower Limit
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 34
Thar CRDe December 2010/Rev 1
Bat+ 12V
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 35
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 36
Thar CRDe December 2010/Rev 1
Yes No
Check the output voltage ( with engine Check fuses
running)
Signal voltage within the range Check continuity between the A29 &
4 ( voltage)
Yes No
Switch off the Ignition
Check the connectors if the pins are bent Check the continuity between the
or having oxidation. A42 & 5 ( Signal)
Clear codes & verify if the codes are Rectify
eliminated.
Clear codes and verify that the HFM
signal ratio is within limit.
No
Check the resistance of the HFM sensor ( between 5 & 3) it should be between
5.119 to 5.892 KOhms
If not OK. Replace the HFM sensor.
Clear codes & verify that the error has been removed.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 37
Thar CRDe December 2010/Rev 1
P-0113
P-0112
Air Temperature
Air Temperature
DTC Diagnostic item
P-0113 Voltage above upper limit.
P-0112 Voltage below lower limit.
Description: The function acquires the raw voltage of the induction air
temperature. The raw value is linearised and monitored for compliance with the
signal range.
The sensor is mounted in HFM.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 38
Thar CRDe December 2010/Rev 1
P-0113
P-0112
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 39
Thar CRDe December 2010/Rev 1
Yes No
Check fuses
Check continuity between the A29 & 4
( voltage)
Check continuity between A44 & 3
( Ground)
Repair the open wire.
Clear codes and verify that error has
been eliminated.
Yes No
Yes No
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 40
Thar CRDe December 2010/Rev 1
P-0193
Rail Pressure Sensor P-0192
Malfunction
• Rail pressure output voltage is below
Reaction
• When ignition is ON system lamp is glowing.
Engine is not starting & error is set in ECU
Error memory.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 41
Thar CRDe December 2010/Rev 1
P-0193
P-0192
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 42
Thar CRDe December 2010/Rev 1
Yes No
Yes No
Yes No
Change the engine speed and check the Rail pressure sensor has failed.
corresponding increase in RPS value.
( This can be done using the live data in Change the Rail assembly ( RPS is
the ‘Smart Tester’) not recommended to service
separately)
Is there a change in the RPS. Clear codes & verify
Yes No
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 43
Thar CRDe December 2010/Rev 1
The ECU compares the rail pressure monitored • Defective fuel tank
through the RPS against the expected pressure cap ( improper
generated due to HPP ( Based on MPROP position breathing)
and the engine RPM and other parameters) • Fuel filter
• Filter assembly
Malfunction; out-of-range • Tank strainer choked.
• If the deviation is more then error is • Injector stuck in open
generated. condition
• M-Prop valve stuck
Reaction
• Engine will be switched OFF
• Engine can not be started
• System Check lamp is ON
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 44
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 45
Thar CRDe December 2010/Rev 1
Yes No
Change Filter No
Not
assembly along OK
with copper
washer Clean tank strainer
& fuel line
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 46
Thar CRDe December 2010/Rev 1
P- 1194
Rail Pressure Deviation
The negative pressure deviation is within the limit Metering unit is stuck in
open position,
Malfunction; out-of-range Metering unit without
The error is reported if the negative rail pressure power due to electrical
deviation is more then the specified in the map error.
and at the same time the flow rate is also less
Reaction
• The fuelling is controlled
• System Check lamp is ON
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 47
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 48
Thar CRDe December 2010/Rev 1
Reaction
• The engine is switched off.
• System Check lamp is ON
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 49
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 50
Thar CRDe December 2010/Rev 1
No Yes
No Yes
Check connectivity between K25 and Check the voltage between the
diagnostic connector pin no 7. connector pins16 & pin 4/5. It should
show 12 V continuously.
If is not OK, then repair. If it is not showing, repair the
connection.
Check the voltage. Otherwise, it indicates
less/poor/intermittent contact.
Is it OK. Repair
Yes No
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 51
Thar CRDe December 2010/Rev 1
P-0406
P-0405
EGR power stage P-0403
Description P-0404
A pulse-width-modulated signal is the output for the Exhaust Gas Recirculation
actuator control. Converting the air control output into duty cycle carries this out.
The possible defects are short circuit to battery, ground & no load.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 52
Thar CRDe December 2010/Rev 1
P-0406
P-0405
P-0403
P-0404
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 53
Thar CRDe December 2010/Rev 1
P-0406
P-0405
P-0403
P-0404
Yes No
Yes No
Yes No
Replace EGR solenoid with known good Rectify the wiring harness.
components.
Clear codes & verify EGR solenoid is within limits.
If problem persist, replace EGR.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 54
Thar CRDe December 2010/Rev 1
P-1340
Reaction
• Engine is not being cranked.
• System lamp will continuously ON.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 55
Thar CRDe December 2010/Rev 1
P-1340
Cam Phase Sensor
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 56
Thar CRDe December 2010/Rev 1
P-1340
Yes No
Yes No
Open the timing cover and check the Correct the mounting.
chain, the adjusters and the plastic
guides
Clear codes & verify that the signal is Clear codes & verify that the signal
within limit. is within limit.
If it is not in limit, change the
corresponding sensor.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 57
Thar CRDe December 2010/Rev 1
P-0182
P-0183
Fuel Temperature Sensor
Description –
Fuel temperature sensor acquires the raw value of the fuel temperature. The raw
value is linearised and monitored for compliance with the signal range. The sensor
is a NTC type
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 58
Thar CRDe December 2010/Rev 1
P-0182
P-0183
• Is it?
Yes No
Yes No
Yes No
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 60
Thar CRDe December 2010/Rev 1
P-1252
P-1253
P-1250
Metering unit pump -Power stage P-1251
Malfunction
• When ignition is ON pump is not getting PWM
signal from ECU.
Reaction
• Engine is not starting & error is recorded in ECU
error memory.
• Fuel output is not available from pump.
• System lamp will remain ON.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 61
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 62
Thar CRDe December 2010/Rev 1
Yes No
No Yes
No
The Error Code P 1251 can also be generated if there is leakage in the HPP
adaptor.
Caution: Till date all the cases investigated have been due to external power supply given
directly to Metering unit resulting in ECU track failure. Please check for external tampering
or unauthorized work done.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 63
Thar CRDe December 2010/Rev 1
P121A
Main relay P121B
Engine not cranking – ‘Smart Tester’ is not responding. The check lamp as well as
the overheat lamp will not glow
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 64
Thar CRDe December 2010/Rev 1
Yes No
Yes No
Measure the voltage at ECU terminal Check that the terminal K 28 of ECU
K05/K01/K3. Or at terminal 87 of the is showing 12 Volts. If not repair the
relay. connection.
It should show 12 Volts.
Yes No
Clear codes and verify that the main relay Replace the relay with a known
is working properly. good component.
Clear codes and verify that the main
relay is working properly.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 65
Thar CRDe December 2010/Rev 1
Battery P-0563
P-0562
Description:
The system voltage has to guarantee to perform diagnosis functions. The
Electronic Control Unit (ECU) monitors battery voltage. If this code is set, the
System Lamp is off.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 66
Thar CRDe December 2010/Rev 1
P-0563
P-0562
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 67
Thar CRDe December 2010/Rev 1
Malfunction
• The sensor output voltage has continued to
be 0V in spite of brake pedal being
pressed/not pressed
• The sensor output voltage has continued to
12V in spite of brake pedal being pressed/not
pressed
• Main or redundant switch is not working.
Reaction
• System lamp will be off
• Cruise control will be deactivated.
• Engine start stop system will be deactivated
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 68
Thar CRDe December 2010/Rev 1
P-1792
P-1791
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 69
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P-1792
Test Procedure Brake switch -- P-1791
Yes No
Turn the Ignition OFF. Check the 15 Amp fuse after the
main relay.
Connect the brake switch connector. Check the supply to K01 & K05.
(Fuses of K01 & K05)
Check the voltage at K80 of ECU input pin Repair connections as necessary.
when the brake is in released position.
Yes No
No Yes
Repair the connection as necessary. Replace the brake switch with
known good component
Clear the error and verify.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 70
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Description
The clutch signal is acquired as a hardware signal. The signal is checked for
plausibility using gear information. Error is detected, if there is a valid gear change
without the clutch being pressed during the time that elapsed since the last gear
change.
Malfunction
• The sensor output voltage has continued to
be 0V in spite of clutch pedal being
pressed/not pressed.
• The sensor output voltage has continued to
12V in spite of clutch pedal being pressed/not
pressed.
Reaction:
• System lamp will be off.
• Cruise control is deactivated.
• Low idle governing will be influenced.
• Engine Start stop system is deactivated.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 71
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P-0704
Verify that no error related to vehicle speed (vehicle speed sensor related) is
present. If present, first attend to those complaints then verify if the error P 0704 is
present and then proceed.
Disconnect clutch switch connector.
Turn the ignition ON.
Check supply voltage to clutch switch on connector.
It should be 12 V, when Ignition is ON. Is it?
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 72
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Yes No
Yes No
If the problem persists, replace with a Remove clutch switch connection &
known good clutch switch. check continuity between terminal
K58 with clutch switch connector.
Clear the codes & verify. Is it OK?
No Yes
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 73
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P-0118
P-0117
Description: The Coolant temperature sensor (CTS) is located in the coolant pipe
of the cylinder head. 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 Diagnostic item
P-0118 Voltage above upper limit
P-0117 Voltage below lower limit
Reaction:
• System lamp will be on.
Engine will continue to run with water
temperature of 120 deg C..
• Power will be reduced
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 74
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P-0118
P-0117
P-0118
P-0117
Yes No
Yes No
Yes No
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 76
Thar CRDe December 2010/Rev 1
It also compares the rate of rise with a defined rate • Thermostat stuck in
of rise open condition
• Thermostat removed.
Malfunction; out-of-range
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.
Reaction
System check lamp : OFF
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 77
Thar CRDe December 2010/Rev 1
Not Ok
Replace the
temperature sensor
Present
Check if thermostat
opening is OK
Not Ok Replace OK
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 78
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P-0108
Atmospheric pressure sensor P-0107
Normal Operation
• Ignition switch: ON
• Malfunction lamp: OFF after 2 Sec
• Battery voltage is 8V to 12V.
• No error reported in error memory.
Malfunction
• The sensor output voltage has continued to be
5V or higher.
• The sensor output voltage has continued to be
0V or lower.
Reaction
• System lamp will blink.
• Engine will run with default atmospheric
Pressure of sea level.
Yes No
Repeat the clear error, for 3 times.
Replace the ECU
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 79
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P-1623
Injector Energising time P-1625
P-161F
P-1621
Description: Controller not able to control power stage
Test Procedure –
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 80
Thar CRDe December 2010/Rev 1
Test Procedure:
1. Switch ON Ignition
2. Using smart tester, clear the ECU faults.
3. Switch OFF Ignition key and wait for 2 minutes.
4. Switch ON Ignition.
5. Using smart tester check whether any of the above mentioned fault is present.
6. If fault is still present, switch OFF ignition.
7. Replace the ECU with a new one and repeat steps 4 & 5.
8. If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M.
9. Note : Please send CrFr and get approval before step 8
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 81
Thar CRDe December 2010/Rev 1
Test Procedure:
1. Switch ON Ignition
2. Using smart tester, clear the ECU faults.
3. Switch OFF Ignition key and wait for 2 minutes.
4. Switch ON Ignition.
5. Using smart tester check whether any of the above mentioned fault is present.
6. If fault is still present, switch OFF ignition.
7. Replace the ECU with a new one and repeat steps 4 & 5.
8. If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M.
9. Note : Please send CrFr and get approval before step 8
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 82
Thar CRDe December 2010/Rev 1
Reaction:
Test Procedure:
1. Switch ON Ignition.
2. Using ‘Smart Tester’, clear the ECU faults.
3. Switch OFF Ignition key and wait for 2 minutes.
4. Switch ON Ignition.
5. Using smart tester check whether any of the above mentioned fault is present.
6. If fault is still present, switch OFF ignition.
7. Replace the ECU with a new one and repeat steps 4 & 5.
8. If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M.
9. Note : Please send CrFr and get approval before step 8
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 83
Thar CRDe December 2010/Rev 1
Test Procedure:
1. Switch ON Ignition.
2. Using ‘Smart Tester’, clear the ECU faults.
3. Switch OFF Ignition key and wait for 2 minutes.
4. Switch ON Ignition.
5. Using smart tester check whether any of the above mentioned fault is present.
6. If fault is still present, switch OFF ignition.
7. Replace the ECU with a new one and repeat steps 4 & 5.
8. If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M.
9. Note : Please send CrFr and get approval before step 8
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 84
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P-160C
P-160D
Error path for the Tachometer signal P-160E
Malfunction
• When engine is running it wouldn't show
corresponding engine speed on dash panel.
Reaction
• No impact on vehicle performance. Only
engine speed indication on dash panel can not
be seen.
• Cruise control will not work.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 85
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P-160C
P-160D
P-160E
7. Is it OK?
Yes No
Check if any other error is set for speed Repair the connections.
sensor and check for short circuit.
Check for short with battery or Ground Clear codes & verify that signal is as
per the limit.
Is it?
Yes No
Correct the error and check for Repair cluster connections, or they
tachometer error is not available. are not connected properly.
Clear codes & verify signal is as per the limit.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 87
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P1608
Error path of coolant temperature output P1609
P160A
Description P160B
The component driver for the coolant temperature outputs the variable as a PWM
signal to the power stage. (Output on the cluster) In normal operation, the PWM
power stage is tested for short circuit to battery, to ground, open circuit and excess
temperature.
Malfunction
• No indication of water temperature on the
instrument cluster.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 88
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 89
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P1608
Test Procedure Coolant temperature output -- P1609
P160A
1. Connect the ‘Smart Tester’ to diagnostic connector. P160B
2. Turn Ignition Switch ON.
3. Verify that the either of the error codes P1608 or P1609 or P160A or P160B is
present.
Turn the Ignition OFF.
Yes No
Yes No
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 90
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P-1210
P-1211
Injector power stage- chip specific errors P-1212
P-1213
P-1214
Description: P-1215
P-1216
Injector power stage inside ECU defective P-1217
Test Procedure –
1. Switch ON Ignition.
2. Using ‘Smart Tester’ clear the ECU faults.
3. Switch OFF Ignition key and wait for 2 minutes.
4. Switch ON Ignition.
5. Using diagnostic tester check whether any of the above mentioned fault is
present.
6. If fault is still present, switch OFF ignition.
7. Replace the ECU with a new one and repeat steps 4 & 5.
8. If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M.
9. Before doing that please send a CrFr and get the approval from the
Tekliner/Tekhub.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 91
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P-1664
Monitoring module communication Monitoring
Test Procedure –
1. Switch ON Ignition.
2. Using ‘Smart Tester’, clear the ECU faults.
3. Switch OFF Ignition key and wait for 2 minutes.
4. Switch ON Ignition.
5. Using smart tester check whether any of the above mentioned fault is present.
6. If fault is still present, switch OFF ignition.
7. Replace the ECU with a new one and repeat steps 4 & 5.
8. If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M.
9. Before doing that please send a CrFr and get the approval from the
Tekliner/Tekhub.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 92
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P-1641
Power Stage Monitoring P-1642
P-1643
Description: Controller not able to control power stage
Test Procedure –
1. Switch ON Ignition.
2. Using ‘Smart Tester’, clear the ECU faults.
3. Switch OFF Ignition key and wait for 2 minutes.
4. Switch ON Ignition.
5. Using smart tester check whether any of the above mentioned fault is present.
6. If fault is still present, switch OFF ignition.
7. Replace the ECU with a new one and repeat steps 4 & 5.
8. If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M.
9. Before doing that please send a CrFr and get the approval from the
Tekliner/Tekhub.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 93
Thar CRDe December 2010/Rev 1
Test Procedure –
1. Switch ON Ignition.
2. Using ‘Smart Tester’, clear the ECU faults.
3. Switch OFF Ignition key and wait for 2 minutes.
4. Switch ON Ignition.
5. Using smart tester check whether any of the above mentioned fault is present.
6. If fault is still present, switch OFF ignition.
7. Replace the ECU with a new one and repeat steps 4 & 5.
8. If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M.
9. Before doing that please send a CrFr and get the approval from the
Tekliner/Tekhub.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 94
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P-1644
Sensor supply monitoring 1 P-1645
Malfunction
The voltages are beyond the range.
Reactions
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 95
Thar CRDe December 2010/Rev 1
P-1644
P-1645
• This is related to the cam shaft sensor supply & also APP1 supply voltage.
• Check the connection of the cam shaft sensor supply & accelerator pedal
connector.
• Is it OK?
Yes No
Remove the sensor connections of the Repair the connection.
camshaft sensor & the Accelerator pedal.
Clear the error. Clear codes and verify.
If the error heals then the problem may be
due to poor connection.
Does it heal?
No Yes
Clear the codes & verify. Check the continuity between the
ECU connector A11 and the
camshaft terminal 3.&Between ECU
connector K 45 and Accelerator
pedal Terminal 2.
Repair the connection.
If the error is still present, then the ECU is Reconnect everything.
suspect.
Replace ECU with a known good one. Clear codes and check cam phase
Clear codes & verify. sensor and Accelerator pedal are
working properly.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 96
Thar CRDe December 2010/Rev 1
P-1646
Sensor supply monitoring 2 P-1647
Malfunction
The voltages are beyond the range.
Reactions
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 97
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P-1646
P-1647
Yes No
No Yes
Clear the codes & verify. Check the continuity between the
ECU connector A 29 and the HFM
terminal 4.
Check the continuity between the
Rail pressure connector terminal 3
and terminal A14 of the ECU
Check the continuity of between
terminal 1 of the Accelerator pedal
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 98
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 99
Thar CRDe December 2010/Rev 1
P-1654
P-1655
P-1656
P-1657
System lamp -Power Stage fault status
Malfunction
• When ignition is switched ON the system lamp
does not glow ON.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 100
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 101
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Go to the Actuator Test # ACT 2. If the system check lamp works with the
actuator test then the system check lamp, wiring & ECU are OK.
Yes No
Yes No
Lamp failure Repair the connection.
Replace Instrument cluster. Clear codes and verify that the
system lamp is working properly.
Clear codes and verify that the system
lamp is working properly.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 102
Thar CRDe December 2010/Rev 1
P-1650
P-1651
P-1652
P-1653
MIL lamp -Power Stage fault status
Malfunction
• When ignition is switched ON the system lamp
does not glow ON.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 103
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 104
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Yes No
Yes No
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 105
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Yes No
Turn the Ignition OFF. Follow the Main relay fault finding
procedure.
Measure the continuity of the wire Clear the error codes & verify.
between the K28 terminal of the ECU and
the Ignition switch (Terminal 15).
Is it OK?
Yes No
Check for loose or intermittent Repair the connection.
connection.
Repair the connection Clear the codes and verify that the
vehicle is working perfectly.
Clear the codes and verify that the
vehicle is working perfectly.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 106
Thar CRDe December 2010/Rev 1
P-0503
P-0500
Vehicle speed sensing P-0501
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 107
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P-0503
1. Connect the ‘Smart Tester’ to diagnostic connector P-0500
2. Turn Ignition Switch ON P-0501
3. Verify that either P0503 or P0500 or P0501 is present.
Yes No
Turn the Ignition OFF. Repair the cable K 75 to pin no 19
in the instrument cluster.
Inspect the interface between the VSS Clear the error codes & verify.
and the speedometer gear in the
Gearbox.
Is it OK?
Yes No
Disconnect VSS Repair the interface between he
speedometer & the VSS
Disconnect ECU connector Clear codes & verify that VSS signal
is within limit.
Measure the continuity between the ECU
terminal K75 and sensor terminal 3
Is it OK?
Yes No
Check the open circuit between the Repair the wire between VSS
sensor Ground & positive supply connector & ECU terminal
Is it OK Clear codes & verify that VSS signal
is within limit.
Yes No
Verify that the ECU connections are OK Repair short circuit to Ground or
another circuit in wire between VSS
harness connector
If OK replace VSS with a known good Clear codes and verify that the VSS
VSS signal is within range.
Clear codes and verify that the VSS
signal is within range.
If problem persist- replace ECU
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 108
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EEPROM ERROR
Probable Cause:
Corrective Action:
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 109
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P- 0201
P-1201
Fault path bank1-specific errors -> stop engine P-1203
P-1204
Reaction
• The Engine is switched off.
• System check lamp is ON
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 110
Thar CRDe December 2010/Rev 1
P- 1205
Fault path bank1-specific warning -> stop engine P-1206
P-1207
P-1208
DTC Diagnostic item
P-1205 Injector bank 1specific warning : depending on application
P-1206 Injector bank 1specific warning : depending on application
P-1207 Injector bank 1specific warning open load
P-1208 Injector bank 1specific warning depending on application
Malfunction; out-of-range
If rail pressure exceeds the limits specified in the
map then the error is generated
Reaction
• The Engine is switched off.
• System check lamp is ON
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 111
Thar CRDe December 2010/Rev 1
Actuator Tests
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 112
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ACT # 1
ACT # 1 - System Lamp
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 113
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ACT # 2
ACT # 2– Coolant Overheat Lamp Test
Expected Result: The coolant overheat lamp at the end of the temperature scale
will light up.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 114
Thar CRDe December 2010/Rev 1
ACT # 3
ACT # 3– Air Conditioning Actuator
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 115
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Test condition:
Action: Put EGR quantity >80%. In the Enter duty cycle. Actuate
The air mass quantity and the injection quantity should change. The value are very
small Air mass by around 4 and fuel quantity change of around 0.47.
Note: If not released manually, the system will automatically release the entered
duty cycle after 30 seconds
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 116
Thar CRDe December 2010/Rev 1
ACT # 5
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 117
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 118
Thar CRDe December 2010/Rev 1
SBD #1
Synchronization state
Code Description
2 TIMEOUT: Engine stops or error case in which all engine speed sensors of
system are defective
16 POLLING: The overall system behaves frq. Synchronous & waits for further
events to determine the phases.
128 VERIFY_BACKUP
129 BACK UP
130 START_BACKUP
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 119
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Applicable to
2.49 CRDe
DTC code
• None
( Will happen when injectors stuck close)
• P1193/P1192
( Will happen when injectors are stuck open)
Engine Status
• Can not be started
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 120
Thar CRDe December 2010/Rev 1
SBD #2
Caution - The ID of the tube is important; hence please use this part number.
Over flow
pipe
inserted in
the
injector.
Start Engine.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 121
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Insert the pipes open end in to the test tubes as shown in photograph).
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 122
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SBD #2
The root cause for the injectors stuck open or close is the presence of water in the
fuel or poor fuel quality.
In case of water – please advise the customer how to drain water when the
indicator comes ON.
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 123
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Conformity Check
Resistance Values
Accelerator pedal
Poti 1 Poti 2
Accelerator pedal:- 0% 2.160KOhm, 2.672KOhm
Accelerator pedal :-100% 1.321KOhm 2.112KOhm
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 124
Thar CRDe December 2010/Rev 1
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© 2010 Mahindra & Mahindra Ltd.
Diagnostic Manual (EMS) MAN-00105- 125
Thar CRDe December 2010/Rev 1
All copyrights reserved. 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 whole of the present document, are prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd