Vous êtes sur la page 1sur 41

Mahindra DI 3200 BS III

Diagnostic Manual

For Internal Circular Onlyy
BOOST PRESSURE SIGNAL FAULT:- 1

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0237 Manifold Pressure sensor fault - Low input. Boost pressure falls below the calibrated min threshold.
P0238 Manifold Pressure sensor fault - High input. Boost pressure exceeds the calibrated max threshold.
P1235 A-D Convertor Fault / Vext fault Analogue to Digital convertor fault.
P1236 Manifold pressure Sensor- Gradient fault. Boost pressure variation exceeds the max boost pressure
Gradient value.

S No ENVIRONMENT UNITS
1 P_L_COOLANT_TEMPERATURE deg C
2 IN_ATMOSPHERIC_PRESSURE bar
3 IN_BOOST_PRESSURE bar
4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_INLET_AIR_TEMPERATURE deg C
6 T_D_INDICATED_TORQUE Nm
7 IN_BATTERY_VOLTAGE Volt
8 ICV_VEHICLE_SPEED km/hr

RECOVERY MODE
1 Turns Check engine Lamp ON
2 Torque reduction
3 SPC disable

TO CHECK TO RECTIFY
1.Boost Sensor connection 1.Remove and connect again.
2.Electrical wiring. 2.Terminal backout, wire open circuit & short circuit.
3.ECU connection. 3.Connect properly.
4.Boost sensor malfunctioning . 4.Change sensor.
5. In case of P1235 check for Vext fault 5. Follow the fault tree of P0652, P0653 & P1651

ECU CONNECTIONS
BOOST PRESSURE CALIBRATION FAULT:- 2

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


Manifold Pressure sensor fault - Drift at key on -
P1237 Low Raw boost pressure falls below the calibrated min value
Manifold Pressure sensor fault - Drift at key on -
P1238 High Raw boost pressure exceeds the calibrated max value

S No ENVIRONMENT UNITS
1 P_L_COOLANT_TEMPERATURE deg C
2 IN_ATMOSPHERIC_PRESSURE bar
3 IN_BOOST_PRESSURE bar
4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_INLET_AIR_TEMPERATURE deg C
6 T_D_INDICATED_TORQUE Nm
7 IN_BATTERY_VOLTAGE Volt
8 ICV_VEHICLE_SPEED km/hr

RECOVERY MODE
1 None

TO CHECK TO RECTIFY
1.Boost Sensor connection 1.Remove and connect again
2.Electrical wiring 2.Terminal backout, wire open circuit & short circuit
3.ECU connection 3.Connect properly
4.Boost sensor malfunctioning 4.Change sensor

ECU CONNECTIONS
BOOST PRESSURE PLAUSIBILITY FAULT:- 3 3

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0236 Manifold Pressure sensor fault - plausibility Calculated Boost pressure is not in the expected range.

S No ENVIRONMENT UNITS
1 P_L_COOLANT_TEMPERATURE deg C
2 IN_ATMOSPHERIC_PRESSURE bar
3 IN_BOOST_PRESSURE bar
4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_INLET_AIR_TEMPERATURE deg C
6 T_D_INDICATED_TORQUE Nm
7 IN_BATTERY_VOLTAGE Volt
8 ICV_VEHICLE_SPEED km/hr

RECOVERY MODE
1 None

TO CHECK TO RECTIFY

ECU CONNECTIONS
COOLANT TEMPERATURE SIGNAL FAULTS:- 44

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


Coolant Temp. sensor electrical fault - short to low
P0117 Coolant temp. falls below the calibrated min value.
Coolant Temp. sensor electrical fault - short to high Coolant temp. exceeds the calibrated max value.
P0118
P1115 A-D Convertor Fault. Analogue to Digital convertor fault.
Coolant temp. Exceeds the max coolant temp.Gradient
P0119 Coolant Temp. Sensor -Gradient Fault. value.

S No ENVIRONMENT UNITS
1 IN_INLET_AIR_TEMPERATURE deg C
2 IN_FUEL_TEMPERATURE deg C
3 IN_BATTERY_VOLTAGE Volt
SMC_STOPPED,SMC_CRANKING,
4 SMC_ENGINE_STATE SMC_RUNNING,SMC_STALLING.
5 P_L_COOLANT_TEMPERATURE deg C
6 IN_ENGINE_CYCLE_SPEED rpm
7 ICV_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Turns Check engine lamp ON

TO CHECK TO RECTIFY
1.Coolant sensor connection 1.Remove and connect again
2.Electrical wiring 2.Terminal backout, wire open circuit & short circuit
3.ECU connection 3.Connect properly
4.Coolant Sensor malfunctioning 4.Change sensor

ECU CONNECTIONS
COOLANT TEMPERATURE SIGNAL FAULT:- 55

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0115 Coolant temperature signal-Generic. General Fault- occurs when a coolant sensor fault occurs.

S No ENVIRONMENT UNITS
1 IN_INLET_AIR_TEMPERATURE deg C
2 IN_FUEL_TEMPERATURE deg C
3 IN_BATTERY_VOLTAGE Volt
SMC_STOPPED,SMC_CRANKING,
4 SMC_ENGINE_STATE SMC_RUNNING,SMC_STALLING.
5 P_L_COOLANT_TEMPERATURE deg C
6 IN_ENGINE_CYCLE_SPEED rpm
7 ICV_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Disables RVD on all injectors

TO CHECK TO RECTIFY
1.Coolant sensor connection 1.Remove and connect again
2.Electrical wiring 2.Terminal backout, wire open circuit & short circuit
3.ECU connection 3.Connect properly
4.Coolant Sensor malfunctioning 4.Change sensor

ECU CONNECTIONS
RAIL PRESSURE SIGNAL FAULT:- 6 6

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0192 Rail Pressure Sensor fault - signal low. Rail Pressure falls below the calibrated min value.
P0193 Rail Pressure Sensor fault - signal high. Rail Pressure exceeds the calibrated max value.
P1190 A-D Convertor Fault. Analogue to Digital Convertor fault.
P0194 Rail Pressure Sensor fault - signal drop Rail Pressure sensor - pressure drop.

S No ENVIRONMENT UNITS
1 IN_RAIL_PRESSURE_FEEDBACK bar
2 IN_FUEL_TEMPERATURE deg C
3 IN_BATTERY_VOLTAGE Volt
4 P_L_VEXT1_RAW Volt
5 P_L_COOLANT_TEMPERATURE deg C
6 IN_ENGINE_CYCLE_SPEED rpm
7 ICV_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Turns Check Engine Lamp(CEL) ON.
2 Engine stops after delay
3 Disable pilot and post injections
4 Disables RVD
5 Disable cylinder balancing
6 Torque reduction
7 Disables SPC

TO CHECK TO RECTIFY
1.Rail Sensor connection 1.Remove and connect again
2.ECU connection 2.Connect properly
3.Electrical wiring 3.Terminal backout, wire open circuit & short circuit
4.Wiring connector breakage 4.Change connector
5.Rail Pressure Sensor malfunctioing 5.Change Rail + Sensor

ECU CONNECTIONS
RAIL PRESSURE CALIBRATION FAULT:- 7 7

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


Rail Pressure Sensor fault (out of range at key on)
P1191 - MED test (drift) Rail pressure signal-sensor drift.

Rail Pressure Sensor fault (out of range at key on) Rail pressure signal falls below the calibrated min value
P1192 - signal low (Ignition ON)

Rail Pressure Sensor fault (out of range at key on) Rail pressure signal exceeds the calibrated min value
P1193 - signal high (Ignition ON)

S No ENVIRONMENT UNITS
1 IN_RAIL_PRESSURE_FEEDBACK bar
2 IN_FUEL_TEMPERATURE deg C
3 IN_BATTERY_VOLTAGE Volt
4 P_L_VEXT1_RAW Volt
5 P_L_COOLANT_TEMPERATURE deg C
6 IN_ENGINE_CYCLE_SPEED rpm
7 ICV_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Disable pilot and post injections
2 Disables RVD
3 Disable cylinder balancing
4 Disables SPC

TO CHECK TO RECTIFY
1.Rail Sensor connection 1.Remove and connect again
2.ECU connection 2.Connect properly
3.Electrical wiring 3.Terminal backout, wire open circuit & short circuit
4.Wiring connector breakage 4.Change connector
5.Rail Pressure Sensor malfunctioing 5.Change Rail + Sensor

ECU CONNECTIONS
RAIL PRESSURE ERROR 88

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0087 Rail Pressure Build Error Rail pressure does not build within the speculated time.

S No ENVIRONMENT UNITS
1 IN_RAIL_PRESSURE_FEEDBACK bar
2 IN_FUEL_TEMPERATURE deg C
3 IN_BATTERY_VOLTAGE Volt
4 RPC_IM_CRT_DMND Ma
5 P_L_COOLANT_TEMPERATURE deg C
6 IN_ENGINE_CYCLE_SPEED rpm
7 ICV_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Disables RVD
2 Disables Cylinder Balancing

TO CHECK TO RECTIFY
1. IMV fault present 1.Refer fault tree P 0251, 0253 & 0255.
2. HP sensor fault present 2.Refer fault tree P 0192, 0193, 0194 & 1190.
3. LP Circuit Problem 3. Low pressure checks:
A. Fuel level in diesel tank (check physically) A. Fill if it is empty
B. Air in the circuit B. Remove air entrapment(Do not loosen HP pipes)
C. Filter connection and LP fuel lines C. Connect properly.
D. Strainer in Fuel tank D. Strainer checks:
i. Remove & replace strainer if choked, Tighten strainer &
banjo joint properly
ii. Change if found defective
iii. Connect properly
4. HP Circuit Problem 4. Perform High Pressure Diagonistics

ECU CONNECTIONS
RAIL PRESSURE CHECK:- 9 9

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


Rail pressure exceeds the Calibrated pressure limit in absence
P0088 Rail pressure error - Over pressure of fault in pressure measurement.

S No ENVIRONMENT UNITS
1 IN_RAIL_PRESSURE_FEEDBACK bar
2 IN_FUEL_TEMPERATURE deg C
3 IN_BATTERY_VOLTAGE Volt
4 RPC_IM_CRT_DMND Ma
5 P_L_COOLANT_TEMPERATURE deg C
6 IN_ENGINE_CYCLE_SPEED rpm
7 ICV_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Engine stop

TO CHECK TO RECTIFY
1.IMV fault present 1.Refer fault tree P 0251, 0253 & 0255.
2.HP sensor fault present 2.Refer fault tree P 0192, 0193, 0194 & 1190.
3.Injector back leak Hose. 3. Check back leak pipe:
A. Remove and connect it again.
B .Replace the Back leak hose.
4.Injector block / HP Circuit problem 4.Perform High Pressure Diagonistics

ECU CONNECTIONS
RAIL PRESSURE CHECK:- 10 10

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


Rail pressure control error (pressure error too high) -
P1253 Negative Rail pressure control error (pressure error too high) - Negative
Rail pressure control error (pressure error too high) -
P1254 Positive Rail pressure control error (pressure error too high) - Positive
Rail pressure control error (IMV current trim drift) Rail pressure control error (IMV current trim drift) - Low
P1256 - Low fuel low fault fuel low fault
Rail pressure control error (IMV current trim drift) Rail pressure control error (IMV current trim drift) - Low
P1257 - Low fuel high fault fuel high fault

Rail pressure control error (IMV current trim drift) Rail pressure control error (IMV current trim drift) - High
P1258 - High fuel low fault fuel low fault
Rail pressure control error (IMV current trim drift) - Rail pressure control error (IMV current trim drift) - High
P1259 High fuel high fault fuel high fault

S No ENVIRONMENT UNITS
1 IN_RAIL_PRESSURE_FEEDBACK bar
2 IN_FUEL_TEMPERATURE deg C
3 IN_BATTERY_VOLTAGE Volt
4 RPC_IM_CRT_DMND Volt
5 P_L_COOLANT_TEMPERATURE deg C
6 IN_ENGINE_CYCLE_SPEED rpm
7 ICV_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Disables cylinder balancing
2 Torque reduction

TO CHECK TO RECTIFY
1. IMV fault present 1.Refer fault tree P 0251, 0253 & 0255.
2. HP sensor fault present 2.Refer fault tree P 0192, 0193, 0194 & 1190.
3. LP Circuit Problem 3. Low pressure checks:
A. Fuel level in diesel tank (check physically) A. Fill if it is empty
B. Air in the circuit B. Remove air entrapment(Do not loosen HP pipes)
C. Filter connection and LP fuel lines C. Connect properly.
D. Strainer in Fuel tank D. Strainer checks:
i. Remove & replace strainer if choked, Tighten strainer &
banjo joint properly
ii. Change if found defective
iii. Connect properly
4.Injector back leak Hose. 4. Check back leak pipe:
A. Remove and connect it again.
B .Replace the Back leak hose.
5.Injector block / HP Circuit problem 5.Perform High Pressure Diagonistics

ECU CONNECTIONS
ECU - SUPPLY RELAY STRUCK 11 11

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

If the power supply to ECU is continued although the time get


P0685 ECU Relay Struck Time elapsed, as specified in SMC_RELAY_STUCK_TIME_APV.

S No ENVIRONMENT UNITS
SMC_STOPPED,SMC_CRANKING,
1 SMC-ENGINE_STATE SMC_RUNNING,SMC_STALLING.
2 IN_BATTERY_VOLTAGE Volt
3 IN_IGNITION_SWITCH OFF,ON
4 P_L_COOLANT_TEMPERATURE deg C
5 IN_ENGINE_CYCLE_SPEED rpm
6 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 None

TO CHECK TO RECTIFY
1.Relay connection 1.Remove and connect again
2.ECU connection 2.Connect properly
3.Electrical wiring 3.Terminal backout, wire open circuit & short circuit
4.Relay functioning 4. Replace relay

ECU CONNECTIONS
ECU - RELAY OPEN 12 12

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P1685 ECU -Relay Stuck open. Supply Relay Open Circuit-unexpected.

S No ENVIRONMENT UNITS
SMC_STOPPED,SMC_CRANKING,
1 SMC-ENGINE_STATE SMC_RUNNING,SMC_STALLING.
2 IN_BATTERY_VOLTAGE Volt
3 IN_IGNITION_SWITCH OFF,ON
4 P_L_COOLANT_TEMPERATURE deg C
5 IN_ENGINE_CYCLE_SPEED rpm
6 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
None

TO CHECK TO RECTIFY
1.Relay connection 1.Remove and connect again
2.ECU connection 2.Connect properly
3.Electrical wiring 3.Terminal backout, wire open circuit & short circuit
4.Relay functioning 4. Replace relay

ECU CONNECTIONS
INJECTOR COMBUSTION - TOO LOW 1313

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0263 Cylinder 1- Combustion Imbalance Combustion Imbalance in cyl 1
P0272 Cylinder 2- Combustion Imbalance Combustion Imbalance in cyl 2
P0266 Cylinder 3- Combustion Imbalance Combustion Imbalance in cyl 3
P0269 Cylinder 4- Combustion Imbalance Combustion Imbalance in cyl 4

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE Volt
2 P_L_COOLANT_TEMPERATURE deg C
3 IN_ENGINE_CYCLE_SPEED rpm
4 IN_FUEL_TEMPERATURE deg C
5 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Disables SPC

TO CHECK TO RECTIFY
1. Check if any fault codes related to Injector electrical faults 1. Refer fault tree of Injector electrical fault
2. Combustion leakage 2. Take necessary action
3. Inlet manifold for clogging 3. Clean inlet ducts
4. Injector HP diagnostics 4. Replace injector if found faulty
5. ECU 5. Replace ECU

ECU CONNECTIONS
INJECTOR-OPEN CIRCUIT 14 14

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0201 Open circuit fault - Injector Cyl 1 Injector Cyl 1 Open Circuit.
P0203 Open circuit fault - Injector Cyl 3 Injector Cyl 3 Open Circuit.
P0204 Open circuit fault - Injector Cyl 4 Injector Cyl 4 Open Circuit.
P0202 Open circuit fault - Injector Cyl 2 Injector Cyl 2 Open Circuit.

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE Volt
2 P_L_COOLANT_TEMPERATURE deg C
3 IN_ENGINE_CYCLE_SPEED rpm
4 IN_FUEL_TEMPERATURE deg C
5 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Turns Check Engine Lamp(CEL) ON.
2 Disable pulse width correction
3 Disables RVD
4 Disable SPC strategy
5 Torque reduction

TO CHECK TO RECTIFY
1. Key off & check injector connection 1.Remove and connect again
2. ECU connection 2.Connect properly

ECU CONNECTIONS
INJECTOR-SHORT CIRCUIT 15 15

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0261 Short circuit HSD to LSD (Injector Cyl 1) Short circuit HSD to LSD (Injector Cyl 1)
P0267 Short circuit HSD to LSD (Injector Cyl 3) Short circuit HSD to LSD (Injector Cyl 3)
P0270 Short circuit HSD to LSD (Injector Cyl 4) Short circuit HSD to LSD (Injector Cyl 4)
P0264 Short circuit HSD to LSD (Injector Cyl 2) Short circuit HSD to LSD (Injector Cyl 2)

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE Volt
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_FUEL_TEMPERATURE deg C
SMC_STOPPED,SMC_CRANKING,
6 SMC_ENGINE_STATE SMC_RUNNING,SMC_STALLING.
7 IN_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Turns Check Engine Lamp(CEL) ON.
2 Disable pulse width correction
3 Disable SPC strategy
4 Deactivates ISO test for injector
5 Disables cylinder balancing
6 Activates reduced torque mode

TO CHECK TO RECTIFY
1.Electrical wiring 1.Terminal backout, wire short circuit
2. Defective injector 2.Change corr. Injector and update I2C

ECU CONNECTIONS
IMV-INLET METERING VALVE 16 16

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0001 IMV drive fault (electrical)-short circuit IMV drive Fault-Short Circuit to Positive.
P0004 IMV drive fault (electrical)-short to GND IMV drive Fault-Short Circuit to Ground.
P0003 IMV drive fault (electrical)-open circiut IMV Drive Fault- Open circuit.

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE Volt
2 IN_RAIL_PRESSURE_FEEDBACK bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_FUEL_TEMPERATURE deg C
6 RPC_IM_CRT_DMND %
7 ICV_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Turns Check Engine Lamp(CEL) ON.
2 Engine stops after delay
3 Disable pilot and post injections
4 Disables cylinder balancing
5 Disables SPC strategy
6 Torque reduction

TO CHECK TO RECTIFY
1. IMV connection 1.Remove and connect again
2. Electrical wiring 2.Terminal backout, wire open circuit & short circuit
3. ECU connection 3.Connect properly
4. IMV electrical resistance on HP pump (5.3 max) 4.Change IMV

ECU CONNECTIONS
CAM SIGNAL FAULT 17 17

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0340 CAM signal fault - missing event Cam wheel has Stalled (or)Cam Signal Lost.
Cam Signal has been detected but not Synchronized
P0341 CAM signal fault - not synchronised with crank with Crank.

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE Volt
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_FUEL_TEMPERATURE deg C
SMC_STOPPED,SMC_CRANKING,
6 SMC_ENGINE_STATE SMC_RUNNING,SMC_STALLING.
7 IN_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Turns Check Engine Lamp(CEL) ON.

TO CHECK TO RECTIFY
1.CAM sensor connection 1.Remove and connect again
2. Electrical wiring 2.Terminal backout, wire open circuit & short circuit
3. ECU connection 3.Connect properly
4. Cam Target wheel position with TDC 4.Take necessary action
5. Crank missing teeth position w.r.t TDC 5.Take necessary action

ECU CONNECTIONS
CRANKSHAFT SIGNAL FAULT 18 18

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0335 Crank signal Lost Crank Wheel has stalled (Or) Crank Signal is lost.
P0336 Crank signal fault - loss of gap Crank Signal fault- No gap detected.
P0371 Crank signal fault - edges too close Crank Shaft event is too close to the previous one.
P0372 Crank signal fault - missing tooth Shifted/Missing cam edge

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE Volt
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
SMC_STOPPED,SMC_CRANKING,
5 SMC_ENGINE_STATE SMC_RUNNING,SMC_STALLING.
6 ICV_VEHICLE_SPEED Km/hr
7 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Turns Check Engine Lamp(CEL) ON.

TO CHECK TO RECTIFY
1. Crank Sensor connection 1.Remove and connect again
2. Electrical wiring 2.Terminal backout, wire open circuit & short circuit
3. Sensor malfunctioning 3.Clean / Change sensor
4. Air Gap 4.Put Copper washer
5. Engine Cam shaft / Crank Shaft timing 5.Check timing and rectify
6. Flywheel Teeth Dimension / Flywheel reference 6.Clean / Change wheel. Check flywheel reference

ECU CONNECTIONS
INJECTOR-HARNESS RESISTANCE FAULT 19
19

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


Measured resistance value equal to or less than the calibrated
P1286 Wiring Harness resistance too Low - (Injector Cyl 1).threshold Value - INJECTOR Cyl 1
Measured resistance value equal to or greater than the
P1287 Wiring Harness resistance too high - (Injector Cyl 1).calibrated threshold value - INJECTOR Cyl 1
Measured resistance value equal to or less than the calibrated
P1290 Wiring Harness resistance too Low - (Injector Cyl 3).threshold Value - INJECTOR Cyl 3
Measured resistance value equal to or greater than the
P1291 Wiring Harness resistance too high - (Injector Cyl 3).calibrated threshold value - INJECTOR Cyl 3
Measured resistance value equal to or less than the calibrated
P1292 Wiring Harness resistance too Low - (Injector Cyl 4).threshold Value - INJECTOR Cyl 4
Measured resistance value equal to or greater than the
P1293 Wiring Harness resistance too high - (Injector Cyl 4).calibrated threshold value - INJECTOR Cyl 4
Measured resistance value equal to or less than the calibrated
P1288 Wiring Harness resistance too Low - (Injector Cyl 2).threshold Value - INJECTOR Cyl 2
Measured resistance value equal to or greater than the
P1289 Wiring Harness resistance too high - (Injector Cyl 2).calibrated threshold value - INJECTOR Cyl 2

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE Volt
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
SMC_STOPPED,SMC_CRANKING,
5 SMC_ENGINE_STATE SMC_RUNNING,SMC_STALLING.
6 ICV_VEHICLE_SPEED Km/hr
7 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Disables injector pulse width correction

TO CHECK TO RECTIFY
1. Disconnect Injector and check connector 1. Rectify terminal back out/ Replace connector
2. Continuity between two injector terminals 2. Replace injector if open circuit
3. ECU connection 3. Remove and refit connector.
4. Electrical continuity in wiring harness 4. Perform necessary repair
5. If problem persists 5. Replace injector
6. ECU 6. Replace ECU

ECU CONNECTIONS
ECU MEMORY INTEGRITY FAULT 2020

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P1603 ECU memory integrity fault-Code integrity Memory failure - in the coding region of the ECU.
P1604 ECU memory integrity fault-Calibration integrity Memory failure - in the calibration region of the ECU.
P1605 ECU memory integrity fault-RAM integrity Memory failure - in the RAM region of the ECU.

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE volt
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_IGNITION_SWITCH OFF,ON
SMC_STOPPED,SMC_CRANKING,
6 SMC_ENGINE_STATE SMC_RUNNING,SMC_STALLING.
7 ICV_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Engine Stops
TO CHECK TO RECTIFY

1. Correct Electrical Problem


Conformity of ground connection
2. Replace ECU
SENSOR 5 V SUPPLY FAULT(Vext 1) 2124

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0642 5 volt Sensor Supply - Low.(Vext 1) Sensor Supply voltage falls below the calibrated value.
P0643 5 volt Sensor Supply - High.(Vext 1) Sensor Supply voltage exceeds the calibrated value.
P1641 A-D Convertor fault. Analogue to Digital Convertor Fault.

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE Volt
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 ICV_VEHICLE_SPEED Km/hr
6 P_L_VEXT1_RAW Volt
7 P_L_VEXT2_RAW Volt
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Disables Pilot and Post injection
2 Engine stop after delay
3 Disables RVD
4 Disables cylinder balancing
5 Torque reduction

TO CHECK TO RECTIFY
1.Sensor connection supplied by ECU (TMap, RP, Pedal track1,
1.Check individual corretion and connect
MAF)
2.Apply Diagonastic charts of respective sensors 2.Remove and connect again.
3.Terminal backout, wire short circuit.
4.Connect properly.
5.Change sensor.

SENSOR 5 V SUPPLY FAULT(Vext 2) 22

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0652 5 volt Sensor Supply - Low.(Vext 2) Sensor Supply voltage falls below the calibrated value.
P0653 5 volt Sensor Supply - High.(Vext 2) Sensor Supply voltage exceeds the calibrated value.
P1651 A-D Convertor fault. Analogue to Digital Convertor Fault.

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE Volt
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 ICV_VEHICLE_SPEED Km/hr
6 P_L_VEXT1_RAW Volt
7 P_L_VEXT2_RAW Volt
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Torque reduction

TO CHECK TO RECTIFY

1.Sensor connection supplied by ECU (Cam & Pedal track2) 1.Check individual corretion and connect

2.Apply Diagonastic charts of respective sensors 2.Remove and connect again.


3.Terminal backout, wire open circuit & short circuit.
4.Connect properly.
5.Change sensor.
BATTERY VOLTAGE SIGNAL FAULT 23 26

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0562 Battery voltage signal – low (short circuit) Battery Voltage falls below 6 volts.
P0563 Battery voltage signal – high (open circuit) Battery Voltage falls below 18 volts.
P1560 Battery voltage monitoring signal fault A-D Convertor Fault.

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE Volt
2 P_L_VEXT1_RAW Volt
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 P_L_BATTERY_RAW Volt
SMC_STOPPED,SMC_CRANKING,
6 SMC_ENGINE_STATE SMC_RUNNING,SMC_STALLING.
7 ICV_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Disable injector pulse width correction
2 Disable RVD

TO CHECK TO RECTIFY
1. Battery and ECU connections Connect properly
2. Resistance between chassis & ECU ground Fix ECU & Battery ground firmly
3. Battery charge circuit (Insulation on battery
Change battery positive cable
positive cable)(Alternator circuit)
4. Battery voltage at key on (min 9 V)
(Min voltage for ECU is 6 volts - considering Change battery
2.5 Volts reduction during cranking)
WATER IN FUEL FAULT 24 27

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P2269 Water in Fuel fault. Water in fuel detected.

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE volt
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_FUEL_TEMPERATURE deg C
6 IN_RAIL_PRESSURE_FEEDBACK bar
7 ICV_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Turns WIF Lamp ON.
2 Torque reduction

TO CHECK TO RECTIFY
1. Presence of water in filter Drain and check for water in LP circuit

ECU CONNECTIONS
WATER IN FUEL SENSOR FAULT 2528

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P2266 Water in fuel feedback fault fault due to Short circuit
P2264 Water in fuel feedback fault fault due to open circuit or VBAT

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE volt
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_FUEL_TEMPERATURE deg C
6 IN_RAIL_PRESSURE_FEEDBACK bar
7 ICV_VEHICLE_SPEED Km/hr
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Turns CE Lamp ON.
2 Torque Reduction

TO CHECK TO RECTIFY
1. Sensor connection Remove and connect again
2. Electrical wiring Terminal backout, wire open circuit & short circuit
3. Sensor malfunctioning Change sensor

ECU CONNECTIONS
INJECTOR DRIVE FAULT 26 29

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P2147 Injector bank 1 fault Injector bank 1 fault - shorted to GND
P2148 Injector bank 1 fault Injector bank 1 fault - shorted to VBATT

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE Volt
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_FUEL_TEMPERATURE deg C
6 ICV_VEHICLE_SPEED Km/hr
SMC_STOPPED,SMC_CRANKING,
7 SMC_ENGINE_STATE SMC_RUNNING,SMC_STALLING.
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Turns Check Engine Lamp(CEL) ON.
2 Disables Cylinder Balancing
4 Disable IM trim calculations
5 Disable pulse width correction

TO CHECK TO RECTIFY
check continuity in wiring harness Terminal back out and continuity of wires
change wiring harness

ECU CONNECTIONS
BOOST TEMPERATURE FAULT : - 27

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0097 T2 BOOST TEMPERATURE SIGNAL - LOW Boost temperature signal falls below a calibrated value
P0098 T2 BOOST TEMPERATURE SIGNAL - HIGH Boost temperature signal falls above a calibrated value

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE V
2 IN_ATMOSPHERIC_PRESSURE bar
2 IN_ENGINE_CYCLE_SPEED rpm
3 IN_INLET_AIR_TEMPRATURE deg C
4 IN_BOOST_PRESSURE bar
5 P_L_VEXT1_RAW V
6 T_D_INDICATED_TORQUE Nm
7 P_L_COOLANT_TEMPERATURE deg C

RECOVERY MODE
1 Torque Reduction
2 Turns Check Engine Lamp(CEL) ON.
3 Disables SPC

TO CHECK TO RECTIFY

1.Boost Sensor connection 1.Remove and connect again.


2.Electrical wiring. 2.Terminal backout, wire open circuit & short circuit.
3.ECU connection. 3.Connect properly.
4.Boost sensor malfunctioning . 4.Change sensor.

ECU CONNECTIONS
ATMOSPHERIC PRESSURE FAULT 28

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P1107 ATMOSPHERIC PRESSURE FAULT Global Atmospheric pressure fault

S No ENVIRONMENT UNITS

1 IN_BATTERY_VOLTAGE V
2 IN_ENGINE_CYCLE_SPEED rpm
3 ICV_VEHICLE_SPEED km/hr
4 P_L_BATTERY_RAW V
5 P_L_COOLANT_TEMPERATURE deg C
6 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Turns Check engine Lamp ON

TO CHECK TO RECTIFY

ECU Replace ECU

ECU CONNECTIONS

INTERNAL TO ECU
ATMOSPHERIC PRESSURE SENSOR FAULT 29

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0107 ATMOSPHERIC PRESSURE SENSOR FAULT LOWAtmospheric sensor low fault
P0108 ATMOSPHERIC PRESSURE SENSOR FAULT HIGHAtmospheric sensor high fault
P1105 ATMOSPHERIC PRESSURE SENSOR FAULT EXTERNAL
Atmospheric sensor ADC fault
P0109 ATMOSPHERIC PRESSURE SENSOR FAULT GRADABILITY
Atmospheric sensor gradability fault

S No ENVIRONMENT UNITS

1 IN_BOOST_PRESSURE bar
2 IN_ATMOSPHERIC_PRESSURE bar
3 IN_ENGINE_CYCLE_SPEED rpm
4 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Torque Reduction

TO CHECK TO RECTIFY

ECU Replace ECU

ECU CONNECTIONS

INTERNAL TO ECU
PEDAL TRACK FAULT 30

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

P0122 PEDAL TRACK1 FAULT LOW Pedal sensor fault(electrical,track1)


P0123 PEDAL TRACK1 FAULT HIGH Pedal sensor fault(electrical,track1)
P0222 PEDAL TRACK2 FAULT LOW Pedal sensor fault(electrical,track2)
P0223 PEDAL TRACK2 FAULT HIGH Pedal sensor fault(electrical,track2)
P1120 PEDAL TRACK1 EXTERNAL FAULT Pedal sensor fault(electrical,track1)
P1220 PEDAL TRACK2 EXTERNAL FAULT Pedal sensor fault(electrical,track2)

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE V
2 IN_VEHICLE_SPEED Kmph
2 IN_ENGINE_CYCLE_SPEED rpm
3 P_L_VEXT2_RAW V
4 IN_BOOST_PRESSURE bar
5 P_L_VEXT1_RAW V
6 T_D_INDICATED_TORQUE Nm
7 P_L_COOLANT_TEMPERATURE deg C

RECOVERY MODE
1 Turns Check Engine Lamp ON
2 Turns Limph Home Mode ON (No Pedal Response, Raised Idle Speed)

TO CHECK TO RECTIFY

1 Pedal sensor connection 1.Remove and connect again


2 Electrical wiring 2.Terminal backout, wire open circuit & short circuit
3 ECU connection 3.Connect properly
4 Pedal Sensor malfunctioning 4.Change sensor

ECU CONNECTIONS
PEDAL CORRELATION FAULT 31

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P2135 PEDAL CORRELATION FAULT Pedal sensor fault (correlation between tracks 1 and 2)

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE V
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 ICV_VEHICLE_SPEED km/hr
6 P_L_VEXT1_RAW V
7 T_D_INDICATED TORQUE Nm

RECOVERY MODE
1 Turns Check Engine Lamp ON
2 Turns Limph Home Mode ON (No Pedal Response, Raised Idle Speed)

TO CHECK TO RECTIFY

1 Pedal sensor connection 1.Remove and connect again


2 Electrical wiring 2.Terminal backout, wire open circuit & short circuit
3 ECU connection 3.Connect properly
4 Pedal Sensor malfunctioning 4.Change sensor

ECU CONNECTIONS
VEHICLE SPEED CONSISTENCY FAULT 32

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0501 VEHICLE SPEED CONSISTENCY FAULT Vehicle speed sensor output not consistant (erratic)

S No ENVIRONMENT UNITS

1 IN_BATTERY_VOLTAGE V
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_GEAR_RATIO
6 ICV_VEHICLE_SPEED km/hr
7 T_D_INDICATED _TORQUE Nm

RECOVERY MODE
none

TO CHECK TO RECTIFY
1 vehicle speed is displayed on dashboard and check replace vehicle speed sensor
continuity from sensor to dashboard and if
continuity is ok
2 if problem persists replace cluster
3 vehicle speed is displayed on dashboard and check remove intermediate connector,check pin connection,oxidation or
continuity from dashboard and ecu rust
4 if problem persists replace ecu

ECU CONNECTIONS
VEHICLE SPEED OVERRUN FAULT 33

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0503 VEHICLE SPEED OVERRUN FAULT Vehicle speed sensor fault (speed too high)

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE V
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C

4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_GEAR_RATIO
6 ICV_VEHICLE_SPEED km/hr
7 T_D_INDICATED _TORQUE Nm

RECOVERY MODE
none

TO CHECK TO RECTIFY
1 vehicle speed is displayed on dashboard and check replace vehicle speed sensor
continuity from sensor to dashboard and if
continuity is ok
2 if problem persists replace cluster
3 vehicle speed is displayed on dashboard and check remove intermediate connector,check pin connection,oxidation or
continuity from dashboard and ecu rust
4 if problem persists replace ecu

ECU CONNECTIONS
VEHICLE SPEED SIGNAL LOSS FAULT 34

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0502 VEHICLE SPEED SIGNAL LOSS FAULT Vehicle speed sensor fault (signal lost)

S No ENVIRONMENT UNITS

1 IN_BATTERY_VOLTAGE V
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 IN_GEAR_RATIO
6 ICV_VEHICLE_SPEED km/hr
7 T_D_INDICATED _TORQUE Nm

RECOVERY MODE
none

TO CHECK TO RECTIFY
1 vehicle speed is displayed on dashboard and check replace vehicle speed sensor
continuity from sensor to dashboard and if
continuity is ok
2 if problem persists replace cluster
3 vehicle speed is displayed on dashboard and check remove intermediate connector,check pin connection,oxidation or
continuity from dashboard and ecu rust
4 if problem persists replace ecu

ECU CONNECTIONS
VEHICLE SPEED FAULT 35

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0500 VEHICLE SPEED FAULT Vehicle speed fault(global)

S No ENVIRONMENT UNITS

1 IN_BATTERY_VOLTAGE V
2 IN_ENGINE_CYCLE_SPEED rpm
3 IN_INLET_AIR_TEMPERATURE deg C
4 IN_GEAR_RATIO
5 P_L_COOLANT_TEMPERATURE V
6 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Disables SPC
2 Torque reduction

TO CHECK TO RECTIFY
1 vehicle speed is displayed on dashboard and check replace vehicle speed sensor
continuity from sensor to dashboard and if
continuity is ok
2 if problem persists replace cluster
3 vehicle speed is displayed on dashboard and check remove intermediate connector,check pin connection,oxidation
continuity from dashboard and ecu or rust
4 if problem persists replace ECU

ECU CONNECTIONS
INJECTOR CORRECTION 36

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P268C C2I data fault Incorrect or No I2C / I3C written on 1st Cylinder
P268E C2I data fault Incorrect or No I2C / I3C written on 3rd Cylinder
P268F C2I data fault Incorrect or No I2C / I3C written on 4th Cylinder
P268D C2I data fault Incorrect or No I2C / I3C written on 2nd Cylinder

S No ENVIRONMENT UNITS
None

RECOVERY MODE
None

TO CHECK TO RECTIFY
1 Read I2C / I3C from ECU Enter correct I2C / I3C values

CHECK ENGINE LAMP FAULT 37

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P1656 CHECK ENGINE LAMP FAULT Electrical fault on CE lamp (Open Circuit)
P1655 CHECK ENGINE LAMP FAULT Electrical fault on CE lamp (Short Circuit to Ground)

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE V
2 IN_ENGINE_CYCLE_SPEED rpm
3 ICV_VEHICLE_SPEED km/hr
4 IN_BOOST_PRESSURE bar
SMC_STOPPED,SMC_CRANKING,
5 SMC_ENGINE_STATE SMC_RUNNING,SMC_STALLING.
6 T_D_INDICATED_TORQUE Nm
7 P_L_COOLANT_TEMPERATURE deg C
8 IN_GEAR_RATIO

RECOVERY MODE
1 None

TO CHECK TO RECTIFY
1 Check continuity Fix Harness
2 If problem persists Replace CE lamp

ECU CONNECTIONS
FUEL PUMP FAULT 38

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION


P0627 Feed pump relay fault Feed pump relay - Open circuit
P0629 Feed pump relay fault Feed pump relay - Short circuit to Vbat
P0628 Feed pump relay fault Feed pump relay - Short circuit to Ground

S No ENVIRONMENT UNITS
1 IN_BATTERY_VOLTAGE Volt
2 IN_BOOST_PRESSURE bar
3 P_L_COOLANT_TEMPERATURE deg C
4 IN_ENGINE_CYCLE_SPEED rpm
5 P_L_VEXT1_RAW Volt
6 P_L_BATTERY_RAW Volt
7 IN_FUEL_TEMPERATURE deg C
8 T_D_INDICATED_TORQUE Nm

RECOVERY MODE
1 Check engine lamp illuminates.

TO CHECK TO RECTIFY

ECU CONNECTIONS
HIGH PRESSURE DIAGNOSTICS

OBJECTIVE
- To analyse the hydraulic system status of common rail fie components
- To understand and differentiate the problem associated with pressure production, regulation and consumption

TESTS

1. INJECTOR
a. Static Leak test - Vehicle not starting or difficult to start condition
b. Dynamic Leak test - Vehicle in starting condition but lack of power and stalls while running

2. UPCR PUMP
a. Closed Rail Test - Vehicle not starting condition

PROCEDURE
STATIC BACK
LEAK TEST

Disconnect IMV connector from UPCR


pump and electrical connections from
Injectors

Connect Dummy IMV in Wiring harness

Connect clear plastic tubes (supplied


with kit) to injector backleak

Close venturi connection pipe with plug


to avoid air entry in low pressure
circuit

Crank for 5 seconds only


(Cranking more than 5 seconds is
dangerous)

Measure length of fuel collected in cm


for all injectors after cranking

Replace injector whose value is more


than specified limit (Ref Table)

Repeat test if individual injectors are


replaced and confirm values within
specification before starting vehicle
DYNAMIC BACK
LEAK TEST

Start & Warm up engine > 65 deg C


coolant temp

Stop engine

Connect all containers to injector back


leak connectors

Close venturi connection pipe with plug


to avoid air entry in low pressure
circuit

Start the engine & Set diagnostic tool


(laptop/desktop) for the HP leak
detection test.

Run the engine at idle for “X” seconds


and launch “Y” consecutive leak
detection cycles (see reference table
for X and Y values).

Once leak detection cycle is over, stop


the engine

Measure the volume of fuel collected in


bottle, for all injectors and replace the
injector whose value is more than
specified limit (Ref Table).

Repeat test if individual injectors are


replaced and confirm values within
specification before starting vehicle
CLOSED RAIL TEST

Disconnect IMV connector from UPCR


pump and electrical connections from
Injectors

Open the HP pipe conenction at Rail


Inlet. Close the rail inlet with dust cap

Connect the HP pipe open end to


closed rail

Connect the Rail pressure display unit


to rail pressure sensor on closed rail

Crank for 5 seconds only


(Cranking more than 5 seconds is
dangerous)

If pressure read on rail pressure


display unit is less than 1050 bar
replace the HP pump (Confirm NO
external fuel leaks)
INJECTOR DIAGNOSTICS - BACKLEAK VALUES IN STATIC AND DYNAMIC CONDITION

STATIC TEST DYNAMIC TEST


Back Leak in
APPLICATION
Back Leak in Cranking Container (in Number of Leak
Pipe (in cm) Time ml) Idle Time Detection Cycles
MAHINDRA 1 Cycle (consisting
MDITC LCCR of 4 ramps up
BS3/BS4 / LCV BS3 10 cm 5s 36 ml 5s routines)