BSIVDiagnostmatrix Tata

Fault Code: 1668
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid Tank Level Sensor Circuit -
Voltage below Normal or Shorted to Low Source.
Actual meaning of Fault Code: Engine Harness or DEF tank level sensor Low Signal Source wire either
open, cut or ground
Sensor & connector location in vehicle: DEF Level Sensor- 4 pole connector (Black color) with wire near
dozer pump. (refer next sheet for connector identification)
Sensors & Connectors identification and location in BSIV vehicle
Diagnostic Steps/Troubleshooting guidelines:
A) Check for any Loose connection, loose fitment of 4 pole connector of DEF level sensor or any pin of 4
pole connector bent or damaged or any wire Back-out from connector cavity/hole of DEF Level sensor.
B) Check continuity from Pin number 1 of 4 pole connector of DEF level sensor to 91 number pin of J2
connector (J2 coupler identification - refer next sheet).
1
Action Taken/to be taken:
A) Ensure connector properly tight & no pin terminal back out.

B) Engine wiring harness to be checked properly and repair in case of any abnormalities
observed.
Fault Code: 1669
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid Tank Level Sensor Circuit -
Voltage above normal or shorted to high source.
Actual meaning of Fault Code: Engine Harness or DEF tank level sensor High Signal Source wire either
open, cut or ground.
dozer pump. (Refer next sheet for connector identification).
A) Check proper fitment of 4 pole connector of DEF level Sensor near dozer pump.
B) Check proper fitment of 34 pin interface connector fitted in left side of long member near gear box
(Refer next sheet for coupler identification).
C) Check no pin/wire back out from 34 pin interface connector fitted in left side of long member near
gear box.
D) Check ECU J2 connector pin no. 91, 28 & 45 for any bent/damaged.
E) Check continuity from ECU J2 connector pin no.91 with pin no. 1 of 4 pole connector of DEF Level
Sensor.
F) Check continuity from ECU pin no. 28 with pin no.3 of 4 pole connector of DEF Level Sensor.
G) Check continuity from ECU pin no. 45 with pin 2 of 4 pole connector of DEF Level Sensor.
H) Check continuity from ECU pin no. 45 with pin 4 of 4 pole connector of DEF Level Sensor
91
72
4
50 45
2
28
28
91
28
28 4 3 2 1
28
45
50
4 3 2 1
28
45
50 4 3 2 1
28

B) Engine wiring harness to be checked properly and repair in case of any abnormalities observed.
Fault Code: 1671
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid Tank Level - Data Valid but
Below Normal Operating Range - Moderately Severe Level. - AUS32 Tank Level Too Low.
Actual meaning of Fault Code: No Electrical fault in system, loose connection or DEF level is too low in
DEF Tank.
dozer pump. (Refer next sheet for connector identification).
A) Check proper fitment of 4 pole connector of DEF level Sensor near dozer pump.
B) Check pins of DEF sensor of 4 pole connector.
C) Check continuity from ECU pin no.91 with pin no. 1 of 4 pole connector of DEF Level Sensor.
D) Check ECU pin no. 91 for any bent/damaged
E) Check ECM calibration
91
28
91
28
A) Open and refit the DEF tank level & temperature sensor connector, ensure connector tight
properly.
B) If still FC is active then calibrate the ECM
Fault Code: 1673
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid Tank Level - Data Valid but
Below Normal Operating Range - Most Severe Level. - AUS32 Tank Level Too Low
Actual meaning of Fault Code: No Electrical fault in system, DEF tank is empty. DEF tank sensor not
read the DEF level in Tank.
A) DEF tank is empty.
B) DEF tank sensor not read the DEF level in tank due to low DEF level.
A) Fill DEF tank fully.
B) Open and refit properly the DEF tank level & temperature sensor connector.
C) If still FC is active then calibrate the ECM

Fault Code: 1677
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid Tank Temperature Sensor -
Actual meaning of Fault Code: DEF tank temperature sensor low Signal Source wire either open, cut or
1
ground.
Sensor & connector location in vehicle: DEF tank temperature Sensor- 4 pole connector (Black color)
with wire near dozer pump. (Refer next sheet for connector identification).
A) Check proper fitment of 4 pole connector of DEF level & temperature sensor near dozer pump.
B) Check proper fitment of 34 pin interface connector fitted in left side of long member near gear box
(Refer next sheet for coupler identification).
C) Check no pin back out from 34 pin interface connector fitted in left side of long member near gear
box and DEF tank level & temperature sensor connector.
D) Check continuity from ECU pin no.91 with pin no. 1 of 4 pole connector of DEF Level Sensor.
E) Check continuity from ECU pin no. 28 with pin no.3 of 4 pole connector of DEF Level Sensor.
F) Check continuity from ECU pin no. 45 with pin 2 of 4 pole connector of DEF Level Sensor.
G) Check continuity from ECU pin no. 45 with pin 4 of 4 pole connector of DEF Level Sensor.
91
28
28 4 3 2 1
28
45
4 3 2 1
28
45
4 3 2 1
28
B) Engine wiring harness to be checked properly and repair in case of any abnormalities observed.
Fault Code: 1678
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid Tank Temperature Sensor -
Actual meaning of Fault Code: DEF tank temperature sensor high Signal Source wire either open, cut or
ground.
Sensor & connector location in vehicle: DEF tank temperature Sensor- 4 pole connector (Black color)
with wire near dozer pump. (Refer next sheet for connector identification).
A) Check continuity from ECU pin no.91 with pin no. 1 of 4 pole connector of DEF Level Sensor.
B) Check continuity from ECU pin no. 28 with pin no.3 of 4 pole connector of DEF Level Sensor.
C) Check continuity from ECU pin no. 45 with pin 2 of 4 pole connector of DEF Level Sensor.
D) Check continuity from ECU pin no. 45 with pin 4 of 4 pole connector of DEF Level Sensor.
91
28
28 4 3 2 1
28
45
4 3 2 1
28
45
4 3 2 1
28
A) Engine wiring harness to be checked properly and repair in case of any abnormalities observed.
Fault Code: 1682
Fault Description (As per INSITE): After treatment 1 Diesel Exhaust Fluid Dosing Unit Input Lines -
Condition Exists
Actual meaning of Fault Code: Problem in DEF input and supply line, either electrical or mechanical.
Sensor & connector location in vehicle:
1. Dozer return valve -14 pin round connector fitted back side of dozer unit.
2. ASOV 2 pin connector fitted back side of dozer unit
DEF Return valve -14 pin round

connector
ASOV 2 pole connector
A) Low DEF level in the DEF tank.
B) DEF supply to Dozer nozzle line blocked/ restricted.
C) DEF supply lines/transfer pipe either blocked, restricted, kinked, broken, disconnected or frozen.
D) DEF tank filter chocked/ restricted or plugged.
E) Dozing unit filter chocked/ restricted or plugged.
F) Check battery connection (ensure series connection).
G) Check 2 pole ASOV connector of dozer unit for any damage/loose fitment/open circuit.
H) Checked Supply voltage on ASOV (2 pin connector) on both wire and it must be 24 and 12V.
I) Checked supply voltage on Pin number-E (24 Volt) of Dozer return valve 14 pin round connector.
J) Remove J2 connector and check pin number 30 and 13 for terminal back-out or pin damage.
K) Check Continuity from pin no. 1 of ASOV (2 pin connector-refer next sheet for connector
identification) to J 2 connector pin no.13
.
12V 24V
24V
30
13
28
1 2
1
3
28
A) Check the after treatment DEF dosing unit.

B) Check the after treatment DEF dosing unit and circuit.
C) Check the after treatment DEF tank filter.
D) Perform the Diesel Exhaust Fluid Doser Pump Override Test.
Fault Code: 1694
Fault Description (As per INSITE): After treatment Outlet NOx Sensor - Data Erratic, Intermittent, or
Incorrect.
Actual meaning of Fault Code: ECM has detected higher or lower range value of Nox reading as
defined in ECU, No electrical fault in system
Sensor & connector location in vehicle: Nox ECU fitted on chassis frame or 2nd/3rd cross member
Nox sensor connector

A) Check Exhaust pipe physically for any leakage or damage.
B) Check Nox sensor and its coupler physically for any damages.
C) Heavy carbon deposition on the tip of the sensor.
D) Check fuel Quality (No adulteration).
E) Nox sensor position and height also need to check.
F) Nox sensor loose fitment or an incorrectly installed in Exhaust system.
A) Check Exhaust system and Nox sensor position properly in EGP.

B) Change Nox sensor in case of any external damages.
C) ECM calibration
Fault Code: 1887
Fault Description (As per INSITE): After treatment Outlet NOx Sensor Circuit - Voltage Below Normal or
Shorted to Low Source.
Actual meaning of Fault Code: Voltage supplied to the after treatment outlet NOx sensor is below 18V
or Zero, either wire cut or rub and ground.
1. Nox sensor 4 pin connector is available in NOX ECU fitted in right side of chassis long member or over
3rd cross member. It’s having 4 pin.
2. Terminating resistor near Nox ECU
Terminating resistor
A) Check Nox sensor and its coupler physically for any damages.
B) Check Nox sensor fuse (20 Amp.)
C) Check supply voltage on pin number 1 of Nox sensor harness.
D) Check continuity of pin no. 3 of NOx Sensor and 7 no. pin of J1 connector.
E) Check continuity of pin no. 2 of NOx Sensor and 22 no. pin of J1 connector.
F) Check CAN wire for any physical damages.
G) Check and ensure proper fitment of terminating resistor fitted near NOx ECU.
H) Supply voltage on can high wire (yellow) and can low wire (Green)-(Can high-2.4 to 2.6, Can low- 1.7
to 1.9).
24V
7
3
30
45
2
30
22
45
A) Check the after treatment outlet NOx sensor circuit.

B) Check CAN wires and its supply voltage.
C) Ensure proper fitment of terminating resistor
Fault Code: 2771
Fault Description (As per INSITE): After treatment Outlet NOx Sensor - Abnormal Update Rate.
Actual meaning of Fault Code: NOx sensor is not receiving power.
Sensor & connector location in vehicle: NOX ECU
A) Check 24volt supply across pin 1 & 4 of NOX ECU connector.
B) Check and ensure proper fitment of CAN terminating resistor fitted one near NOx ECU and other near
engine ECU.
C) Check no pin back out from 34 pin interface connector fitted in left side of chassis long member near
gear box & ensure proper fitment.
D) Check Engine CAN interface of W/H engine & OEM W/H.
E) Supply voltage on can high wire (yellow) and can low wire (Green)-(Can high-2.4 to 2.6,Can low- 1.7 to
1.9).
F) Open/loose connection of J1939 data link circuit between the engine ECM and after treatment outlet
NOx sensor.
G) A damaged engine ECM.
H) Check and ensure no leakage from EGP.

24V
A) Check the after treatment outlet NOx sensor circuit
B) Check CAN wires and its supply voltage.
C) Ensure proper fitment of terminating resistor.
D) No loose connection of J1939 data link circuit between the engine ECM and after treatment outlet
NOx sensor.
E) If all parameter checked and found OK then ECM calibration required.
F) After recalibration again FC become active then change EGP unit.
Fault Code: 2772
Fault Description (As per INSITE): After treatment Outlet NOx - Data Valid but above Normal Operating
Range - Least Severe Level. The engine NOx output is higher than recommended levels.
Actual meaning of Fault Code: ECU detects NOx output reading higher than recommended levels. No
Electrical fault in system
Sensor & connector location in vehicle: NOX ECU

A) DEF quality is not within specification or expired/contaminated.
B) Check any external leakages in the DEF dosing unit and/or DEF lines.
C) After treatment nozzle has malfunctioned/chocked/plugged.
D) After treatment DEF dosing unit has malfunctioned or damaged.
E) Low Quality fuel being used - Adultrated fuel.
F) After treatment SCR catalyst is damaged or missing.
G) Check DEF air supply lines.
H) Check and ensure no leakage from EGP
A) Performed the DOT test.

B) Checked the concentration of AUS-32 if concentration not ok then filled recommended AUS -32.
C) If all parameter checked and found OK then ECM calibration required.
D) After recalibration again FC become active then change EGP unit.
Fault Code: 2773
Fault Description (As per INSITE): After treatment Outlet NOx - Data Valid but Above Normal Operating
Range - Most Severe Level. The engine NOx output is higher than recommended levels.
Actual meaning of Fault Code: ECU detects NOx output reading higher than recommended levels. No
Electrical fault in system.
A) DEF quality is not within specification or expired/contaminated.
B) Check any external leakages in the DEF dosing unit and/or DEF lines.
C) After treatment nozzle has malfunctioned/chocked/plugged.
D) After treatment DEF dosing unit has malfunctioned or damaged.
E) Low Quality fuel being used - Adultrated fuel.
F) After treatment SCR catalyst is damaged or missing.
G) Check DEF air supply lines.

H) Verify the priming cycle of the diesel exhaust fluid (DEF) dosing unit through INSITE (in all parameter
tab)
I) Check the DEF lines and fittings for restriction and contamination.
A) Check the after treatment catalyst system.

B) Verify the priming cycle of the diesel exhaust fluid (DEF) dosing unit
C) Check the DEF dosing unit air supply system.
D) Check the DEF lines and fittings for restriction and contamination.
E) Perform the DEF Doser Pump Override Test.
F) If all parameter checked and found OK then ECM calibration required.
G) After recalibration again FC become active then change EGP unit.
Fault Code: 3142
Fault Description (As per INSITE): After treatment SCR Intake Temperature Sensor Circuit - Voltage
above Normal or Shorted to High Source. High signal voltage detected at the SCR intake temperature
sensor circuit.
Actual meaning of Fault Code: High signal voltage detected at SCR intake temperature sensor circuit.
Sensor & connector location in vehicle: SCR Temperature Sensor mounted on Exhaust tail pipe (EGP)
A) Check SCR temp sensor & w/h connecter fitted properly, no pin back out.
B) Check proper fitment of J2 connector in ECM.

C) Check ECU pin no 24 & 45 of J2 connector in ENGINE ECU for terminal bend.
D) Check terminal back out of J2 connector for pin no 24 & 45
E) Check continuity of ECU pin no 24 to SCR temp sensor pin no-1.
F) Check continuity of ECU pin no 45 to SCR temp sensor pin no-2.
45
24
28
45
24
28
1 2
2
4
28
4 1 2
5
28
A. Check the SCR inlet temperature sensor and circuit.

B. Check the ECM and OEM harness.
C. Replace SCR temperature sensor if all above found OK
Fault Code: 3143
Fault Description (As per INSITE): After treatment SCR Intake Temperature Sensor Circuit - Voltage
below Normal or Shorted to Low Source. Low signal voltage detected at the SCR intake temperature
sensor circuit
Actual meaning of Fault Code: Signal voltage detected at SCR intake temperature sensor circuit.
Sensor & connector location in vehicle: (EGP) SCR Temperature Sensor mounted on Exhaust tail pipe
(EGP) and its connector near Dozer unit
A) Check temp sensor connection physically for any damage, loose and bent.
B) Check thermistor probe available on EGP, any bend or not.
C) Check continuity from pin no.2 of temp sensor to 45 no. pin of J2 (Black/brown wire of temp sensor).
D) Checked continuity from pin no.1 of temp sensor to 24 no. pin of J2 (white/black wire of temp
sensor.)
45 1 2
2
1 2
24
A) Check the SCR inlet temperature sensor and circuit.

B) Check the ECM and OEM harness.
C)
2 Replace SCR temperature sensor if all above found OK
Action Taken/To be taken

C) Replace SCR temperature sensor if all above found OK
Fault Code: 3144
Fault Description (As per INSITE): After treatment SCR Intake Temperature - Data Erratic, Intermittent,
or Incorrect.. The SCR intake temperature sensor is not changing with engine operating conditions.
Actual meaning of Fault Code: Incorrect/Intermittent Exhaust temperature has been detected.
and its connector near Dozer unit

A) Check temp Sensor connection physically for any damage, loose and bent.
B) Check thermistor probe available on EGP, any bend or not.
C) Check continuity from pin no.2 of temp sensor to 45 no. pin of J2 (Black/brown wire of temp sensor)
D) Checked continuity from pin no.1 of temp sensor to 24 no. pin of J2 (white/black wire of temp
sensor.)
4 1 2
5
1 2
2
4
2

C) Replace SCR temperature sensor if all above found OK
D) ECM needs to be calibrated.
Fault Code: 3164
Fault Description (As per INSITE): After treatment SCR Intake Temperature - Data Valid but above
Normal Operating Range - Least Severe Level. High selective catalytic reduction (SCR) intake
temperature has been detected.
Actual meaning of Fault Code: High SCR intake temperature has been detected.
and its connector near Dozer unit
A) Check the charge air cooler, clamps, hoses, and piping.
B) Inspect turbocharger compressor and turbine blades.
C) Check temp.sensor which was mounted on EGP for any damaged.
A. Check the air handling system for correct operation.

B. Inspect the SCR inlet temperature sensor.
Fault Code: 3559
Fault Description (As per INSITE): After treatment 1 Diesel Exhaust Fluid Dosing Unit - Voltage below
Normal or Shorted to Low Source. Low signal voltage detected at the after treatment diesel exhaust
fluid dosing unit.
Actual meaning of Fault Code: Low signal voltage detected at dosing unit. DEF power wire
cut/damage/rub or ground.
Sensor & connector location in vehicle: DEF return valve - 14 pin round connector located at back side
of dozer unit.
DEF Return valve -14 pin round connector
A) Check the DEF tank filter for any blockage and damaged.
B) Check supply voltage on Pin number-E of 14 pin rounder connector located back side of dozer unit (24
Volt)
C) Check continuity from Pin E of doser unit of 14 pin round coupler to Pin number 30 of J2 connector.
D) Check proper fitment of J2 connector in ECM.
E) Check both 34 pin interface connector one at left side of chassis long member and other located at
radiator side (34 pin connector in cowl vehicle & 16-16-2 pin connector in CAB vehicle)
F) Check no terminal back out from both interface connectors.
2
30
A. Check and correct wiring harness engine for 24 V power supply at Dozer unit.
B. Check ECM pin no.30 for bent/damage
Fault Code: 3568
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid (DEF) Dosing Valve - Mechanical
System Not responding or Out of Adjustment. The DEF dosing valve has been detected to be stuck
closed.
Actual meaning of Fault Code: Dozer pump internal mechanical parts sticky or malfunctioning.
2. No electrical fault in system.
A) Checked the concentration of AUS-32 if concentration not ok then filled recommended AUS -32.
B) Dosing valve stuck closed internally.
C) Dosing valve restricted
D) Malfunctioning DEF pressure sensor.
A. Perform the Diesel Exhaust Fluid Doser Pump Override Test.

B. Check Doser unit connector as per loose connection, Pin damaged, Mating pert damaged of
doser unit.
C. Check ECM calibration if any updated calibration available then calibrated the ECU.
D. 4. Change Dozer unit.
Fault Code: 3571
Fault Description (As per INSITE): After treatment 1 Diesel Exhaust Fluid (DEF) Pressure Sensor -
Voltage above Normal or Shorted to High Source. High signal voltage detected at the after treatment
DEF pressure sensor circuit
Actual meaning of Fault Code:
A) High signal voltage detected at DEF pressure sensor circuit.

B) Either sensor wire open/short to supply line
of dozer unit
A) Check pressure sensor signal wire for open circuit/ short to supply line.
B) ECM Malfunctioning.
C) Check Doser unit 14 pin round connector for loose connection, rust formation, Pin Back-out etc.
D) Check 34 pin interface connector fitted in left side of long member near gear box for any loose
fitment or water entry.
E) Check the voltage on Pin number E of 14 pin round connector (It must be 24 volt).
F) Check the sensor supply voltage on Pin number "P" of 14 pin round connector (It's become 4.75 to
5.25).
G) Check Continuity from Pin number "P" of 14 pin round connector to Pin number 22 of J2 connector.
H) Check continuity from Pin number "V" of 14 pin round connector to pin number 66 of J2 connector.
I) Check pin no. 22 & 66 of J2 connector for any bent/damage/terminal back out
24
5
V
22
66
22
2
A. the after treatment diesel exhaust fluid (DEF) pressure sensor and circuit
B. Check the engine control module (ECM) and original equipment manufacturer (OEM) harness.
Fault Code: 3572
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid Pressure Sensor - Voltage Below
Normal or Shorted to Low Source. Low signal voltage detected at the diesel exhaust fluid pressure
sensor circuit.
Actual meaning of Fault Code:
A) Low signal voltage detected at DEF pressure sensor circuit.

B) Either sensor wire open/shorted to ground
of dozer unit.
A) Check pressure sensor signal wire for open circuit/ short to supply line.
B) Malfunctioning ECM.
C) Check Doser unit 14 pin round connector for loose connection, rust formation, Pin Back-out etc.
D) Check 34 pin interface connector fitted in left side of long member near gear box for any loose
fitment or water entry.
E) Check the voltage on Pin number E of 14 pin round connector (It must be 24 volt).
F) Check the sensor supply voltage on Pin number "P" of 14 pin round connector (It's become 4.75 to
5.25).
G) Check Continuity from Pin number "P" of 14 pin round connector to pin number 22 of J2 connector.
H) Check continuity from Pin number "V" of 14 pin round connector to pin number 66 of J2 connector.
I) Check continuity from Pin number "E" of 14 pin round connector to pin number 30 of J2 connector.
J) Check pin no. 22, 30 & 66 of J2 connector for any bent/damage/terminal back out
24
5
22
66
30
66
22
28
A) Check the after treatment diesel exhaust fluid (DEF) pressure sensor and circuit.
B) Check the sensor supply voltage and return circuit
C) Check the ECM and original equipment manufacturer (OEM) harness
Fault Code: 3574
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid Pressure Sensor - Data Valid but
below Normal Operating Range - Moderately Severe Level. Low diesel exhaust fluid pressure has been
detected in the dosing unit.
Actual meaning of Fault Code: Low DEF pressure has been detected in the dosing unit.
of dozer unit.

connector
A) Check DEF Level in DEF tank.
B) Check Dosing unit supply line (transfer pipe) for blockage, restriction, frozen, or broken.
C) Check DEF tank filter for any blockage/restriction/chock.
D) Check external leakages of DEF from Dozer unit.
E) Check open pipe of DEF dosing unit supply line
F) Check Pin no." E" and pin no. "P" of 14 pin round connector for terminal back out or Open circuit in
the wiring harness.
G) Check loose fitment of Dosing unit connector and any damaged of PIN.
H) Check 34 pin Interface connector fitted near chassis long member for any damaged.
I) Check any water ingress inside the 34 pin interface connector fitted at chassis long member.
J) Check DEF injector and transfer line for any crystallization
K) Malfunctioning or slow DEF dosing unit pump motor / Purge valve stuck open/Internal leakage in
Dozer unit.
A) Perform the DEF doser pump override test; if test found Not OK then go ahead with 2nd option.
B) Check & Inspect the DEF dosing unit. If found any abnormalities change Dozer unit.
Fault Code: 3575
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid Pressure Sensor - Data Valid but
above Normal Operating Range - Moderately Severe Level. High pressure has been detected in the
diesel exhaust fluid path in the dosing unit.
Actual meaning of Fault Code: High DEF pressure has been detected in the dosing unit
of dozer unit

A) Check Pin no." E" and pin no. "P" of 14 pin round connector for terminal back out or Open circuit in
the wiring harness.
B) Check loose fitment of Dosing unit connector and any damaged of PIN.
C) Check 34 pin Interface connector fitted near chassis long member for any damaged.
D) Check supply voltage on Pin number E of 14 pin round connector
E) Check continuity from pin no." E"of 14 pin round connector to pin no. 30 of J2 connector.
F) Perform the DOT test and ASOV click test.
24V
30
2
A) Check the after treatment diesel exhaust fluid (DEF) dosing unit and circuit
B) Perform the Diesel Exhaust Fluid Doser Pump Override Test
C) IF Doser Pump Override Test is found failed after all corrective action, change Dozer unit and do
ECM calibration.
Fault Code: 3577
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid (DEF) Return Valve - Voltage
above Normal or Shorted to High Source. High signal voltage detected at the after treatment DEF return
valve.
Actual meaning of Fault Code: High signal voltage detected at the after treatment DEF return valve or
pin no.E of 14 pin round connector either open/short.
of dozer unit.

A) Check supply voltage on Pin number E of 14 pin round connector (24 V)
B) Check continuity from Pin "E" of 14 pin round connector to pin number 30 of J2 connector or any
damages/terminal back out.
C) Check 34 pin interface connector for any loose fitment/ open or water ingress/terminal back out.
D) Check injector and transfer line for crystallization.
E) Perform the Diesel Exhaust Fluid Doser Pump Override Test.
24V
30
2
A) Check the after treatment diesel exhaust fluid (DEF) dosing unit and circuit.
B) Check the engine control module (ECM) and original equipment manufacturer (OEM) harness.
C) Perform the Diesel Exhaust Fluid Doser Pump Override Test. 4. IF Doser Pump Override Test is
found failed after all corrective action, change Dozer unit and perform ECM calibration.
Fault Code: 3578
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid (DEF) Return Valve - Voltage
below Normal or Shorted to Low Source. Low signal voltage detected at the DEF return valve.
Actual meaning of Fault Code: Low signal voltage detected at DEF return valve.
of dozer unit.
A) Check supply voltage on Pin number E of 14 pin round connector.
B) Check continuity from Pin no. E of 14 pin round connector to pin no. 30 of J2 connector.
C) Check for any damaged or Bent of PIN number 30 & 13 of J2 connector.

D) Measure the resistance between SUPPLY pin" T" and RETURN pin "B" of 14 pin round connector (it
must be 10 to 12 ohms.)
E) Check any loose connection of SCR harness and interface connectors.
24
30
2
30
13
12
A) Check the after treatment diesel exhaust fluid (DEF) dosing unit and circuit.
B) Check the engine control module (ECM) and original equipment manufacturer (OEM) harness.
C) Perform the Diesel Exhaust Fluid Doser Pump Override Test.
D) IF Doser Pump Override Test is found failed after all corrective action, change Dozer unit and
perform ECM calibration.
Fault Code: 3681
Fault Description (As per INSITE): After treatment outlet NOx sensor power supply - Data erratic,
intermittent, or incorrect. The after treatment outlet NOx sensor indicates that the power supply to the
sensor is incorrect
Actual meaning of Fault Code: NOx sensor indicates that power supply to the sensor is incorrect.
Sensor & connector location in vehicle: Nox sensor connector near NOX ECU and this is 4 pin connector
A) Inspect after treatment outlet NOx sensor and connector pins for any damaged/terminal back
out/open wire in circuit.
B) Check supply voltage on pin number 1 of Nox sensor. (24 volt).
C) Check the Nox sensor
D) Check the battery connection or terminal connection.
E) Check Battery voltage.( 24 volt)
F) Internal malfunction of the outlet NOx sensor.

24V
A) Check the after treatment outlet NOx sensor circuit and change if found any abnormalities.
B) Check the OEM harness.
Fault Code: 4157
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid (DEF) Return Valve - Mechanical
System Not Responding or Out of Adjustment. The purge valve has been detected to be stuck closed.
Actual meaning of Fault Code: Dozer unit internally defective or malfunctioning, No Electrical fault in
system.
A) Malfunctioning DEF return valve.
B) Plugged or restricted DEF circuit.
A) Perform the DEF doser leak test.

Fault Code: 4172
Fault Description (As per INSITE): After treatment Selective Catalytic Reduction Dosing Air Assist
Absolute Pressure Sensor - Voltage above Normal or Shorted to Low Source. High signal voltage
detected at the dosing air assist pressure sensor circuit.
Actual meaning of Fault Code: High signal voltage detected at the dosing air assist pressure sensor
circuit.
A. ASOV 2 pole connector fitted back side of Dozer unit.

B. DEF Return valve -14 pin round connector fitted back side of dozer unit

A) Inspect Air solenoid valve as per loose fitment, damaged, rust, Broken, Moisture, water entry.
B) Check 14 pin round connector fitted back side of dozer unit for any back out pin/loose connection.
C) Check and change ECM calibration if any update is available.
D) Perform DOT test and checked fault code
E) Perform ASOV click test
F) Check Continuity from pin no. 1 of ASOV connector to pin no. 13 of J2 connector.
G) Check supply voltage (24V) on 2nd pin of ASOV.
H) Malfunctioning dosing air assist pressure sensor.
I) Malfunctioning ECM.
1 2
13
2
A) Check the after treatment diesel exhaust fluid (DEF) dosing air assist pressure sensor and circuit.
B) Check the ECM and original equipment manufacturer (OEM) harness.
C) Change ASOV unit or repair/ change wiring harness in case of damage.
D) DO ECM Calibration.
E) Change ECM in case of AC active after all necessary checkups as per guideline provided.
Fault Code: 4173
Fault Description (As per INSITE): After treatment Selective Catalytic Reduction Dosing Air Assist
Absolute Pressure Sensor - Voltage below Normal or Shorted to Low Source. Low signal voltage detected
at the dosing air assist pressure sensor circuit
Actual meaning of Fault Code: Low signal voltage detected at the dosing air assist pressure sensor
circuit
Sensor & connector location in vehicle: ASOV 2 pole connector fitted back side of Dozer unit
A) Check ASOV wiring connection as per physical damaged, rusty, pin back-out, Moisture, Dirty.
B) Check the voltage on Pin no. P (5V) of 14 pin round connector.
B) Check the continuity from pin no."P" of 14 pin round connector to pin no. "22" of J2 connector.
C) Check supply voltage on ASOV Solenoid. (On supply wire is 24 volt and signal wire having 12 volt.)
D) Check continuity from pin no. 1 of ASOV connector to pin no. 13 of J 2 connector.
E) Check any open connector & terminal back out from 34 pin interface connectors.
F) Check battery voltage.
G) Check supply wire (ASOV connector pin no.1) for open circuit/short to ground.
H) Malfunctioning dosing air assist pressure sensor
I) Malfunctioning ECM.
5
22
12V 24V
1 2
1
3
A) Check the after treatment diesel exhaust fluid (DEF) dosing air assist pressure sensor and circuit.
B) Check the ECM and original equipment manufacturer (OEM) harness.
C) Change ASOV unit or repair/ change wiring harness in case of damage.
D) DO ECM Calibration.
E) Change ECM in case of AC active after all necessary checkups as per guidelines provided.
Fault Code: 4174
Fault Description (As per INSITE): After treatment Selective Catalytic Reduction (SCR) 1 Dosing Reagent
Temperature Sensor - Voltage above Normal or Shorted to High Source. High signal voltage detected at
the diesel exhaust fluid temperature sensor circuit.
Actual meaning of Fault Code: High signal voltage detected at DEF temperature sensor
Sensor & connector location in vehicle: SCR Temperature Sensor fitted on EGP and its connector fitted
over cross member
A) Check 34 pin interface connectors for pin push back/ loose/water ingress /short to ground.
B) Check SIGNAL wire for shorted to ground/rubbing/open circuit.
C) Malfunctioning dosing air assist pressure sensor
D) Malfunctioning ECM.
A) Check the after treatment diesel exhaust fluid (DEF) pressure sensor and circuit.
B) Check the ECM and engine harness.
C) ECM recalibration to be done in case of active FC & check FC after recalibration.
Change Dozer unit if FC become Active after checking all mentioned parameters.
Fault Code: 4175
Fault Description (As per INSITE): After treatment 1 Selective Catalytic Reduction (SCR) Dosing Reagent
Temperature Sensor - Voltage below Normal or Shorted to Low Source. Low signal voltage detected at
the diesel exhaust fluid temperature sensor circuit.
Actual meaning of Fault Code: Low signal voltage detected at DEF temperature sensor circuit
Sensor & connector location in vehicle: Temperature Sensor fitted on EGP and its sensor connector
fitted over cross member
A) Check DEF temperature sensor and its wiring harness for any damages.
B) Check 34 pin interface connectors for pin push back/ loose/water ingress /short to ground.
C) Malfunctioning of ECM.
D) Check continuity from pin no. 2 of temperature sensor connector to pin no. 45 of J2 connector
(Black/brown wire of temp sensor).
D) Check continuity from pin no. 2 of temperature sensor connector to pin no.21 of 34 pin interface
connector.
E) Perform DOT test and ASOV click test and checked Fault code.
4 1 2
5
2
1 2
A) Check the after treatment selective catalyst reduction (SCR) dosing air assists valve and
circuit.
B) Check the engine control module (ECM) and original equipment manufacturer (OEM)
harness.
C) Change Temperature sensor and wiring harness, if found damage
D) ECM recalibration.
E) Finally change ECM if FC become active
Fault Code: 4176
Fault Description (As per INSITE): After treatment 1 Selective Catalytic Reduction (SCR) Dosing Air Assist
Valve - Voltage above Normal or Shorted to Low Source. High signal voltage detected at the dosing air
assist valve circuit.
Actual meaning of Fault Code: High signal voltage detected at the dosing air assist valve circuit
Sensor & connector location in vehicle: ASOV coupler fitted on back side of Dozer unit
ASOV 2 pole
A) Check ASOV connecter fitted properly in dosing pump, no pin back out.
B) Check ASOV solenoid Pin and sleeve for any damaged or rusty, bend and back-out.
C) Malfunctioning of ECM, Check with new one or ECM recalibration
3) Malfunctioning dosing air assist valve. Change ASOV unit
A) Check the after treatment selective catalyst reduction (SCR) dosing air assists valve and
circuit.
B) Check the engine control module (ECM) and original equipment manufacturer (OEM)
harness.
C) Change ASOV unit.
Fault Code: 4177
Fault Description (As per INSITE): After treatment 1 Selective Catalytic Reduction (SCR) Dosing Air Assist
Valve - Voltage below Normal or Shorted to Low Source. Low signal voltage detected at the dosing air
assist valve circuit
Actual meaning of Fault Code: Low signal voltage detected at ASOV coupler due to open
circuit/wire/short to ground
A) Check ASOV connecter fitted properly in dosing pump, no pin back out.
B) Check 5A fuse for ASOV in fuse box is in ok condition.
C) Check 24v supply in ASOV connector pin no-2 & 12 V in pin no.1
D) Check proper fitment of engine ECU J2 connector in ECM.
E) Check ECU pin no 13 in for terminal bend/water entry/Bent.
F) Check terminal back out of ECU (J2) connector for pin no 13.
G) Check continuity from ECU pin no 13 to ASOV connector pin no-1.

12V 24V
13
13
2
1 2
1
3
A) Check the after treatment selective catalyst reduction (SCR) dosing air assist valve and
circuit.
B) 2. Check the engine control module (ECM) and original equipment manufacturer (OEM)
harness.
C) Change ASOV unit.
Fault Code: 4238
Fault Description (As per INSITE): After treatment 1 SCR Dosing Air Assist Absolute Pressure - Data Valid
but below Normal Operating Range - Moderately Severe Level. Low dosing air assist pressure has been
detected in the dosing unit.
Actual meaning of Fault Code: Low air pressure has been detected in dosing unit during dosing cycle

A) Check 12 V & 24 V supply on ASOV 2 pin coupler fitted on back side of Dozer unit.
B) Check resistance of ASOV solenoid (It should be 10 Ohm).
C) Check air supply line for blockage/restriction.
D) Check any physical damage of air supply line.
E) Check DEF and air mixture transfer line for any leakages/physical damage.
F) Insufficient air pressure built up from the vehicle air supplier system.
G) Check the after treatment SCR dosing air assist valve and the air supply and transfer lines.
A) Check after treatment SCR dosing air assist valve and circuit.
B) Check the engine control module (ECM) and original equipment manufacturer
C) (OEM) harness.
D) 3. Clean the transfer line and Dozer nozzle and perform the DEF doser pump override
test.
Fault Code: 4239
Fault Description (As per INSITE): After treatment 1 SCR Dosing Air Assist Absolute Pressure - Data Valid
but above Normal Operating Range - Moderately Severe Level. High air pressure has been detected in
the dosing unit during dosing mode...
Actual meaning of Fault Code: High air pressure has been detected in dosing unit during dosing cycle
Sensor & connector location in vehicle: ASOV unit fitted on back side of Dozer unit

A) Check air supply line from auxiliary port.
B) Check restricted and blockage of DEF and air mixture transfer line.
C) Check Dozer nozzle for blockage/crystallization.
D) Malfunctioning air pressure regulator.
E) Check air solenoid and diesel exhaust fluid (DEF) line.
F) Check air solenoid (ASOV) and diesel exhaust fluid (DEF) line
A) Perform the Diesel Exhaust Fluid Doser Pump Override Test.

B) Replace Dozer unit if still FC become active if all parameters found OK
Fault Code: 4271
Fault Description (As per INSITE): After treatment 1 SCR Dosing Air Assist Valve - Mechanical System
Not Responding or Out of Adjustment. High air pressure has been detected in the diesel exhaust fluid
dosing unit during prime when dosing air assist valve is closed
Actual meaning of Fault Code: High air pressure has been detected in dosing unit during priming cycle
Sensor & connector location in vehicle: ASOV unit fitted on back side of Dozer unit

A) Check air connection for any kink formation /damaged.
B) Check air connection from Air oil separator to dosing unit
C) Check air supply from DDU port number 24
D) Check transfer line DEF injection
E) Clean transfer line by hot water
F) Flash dosing unit by hot water
G) Do click test by insite
H) Check supply voltage on pin number 26 of interface connector.
I) Check ASOV unit.
A) Check the air solenoid.

B) 2. Inspect the DEF lines.
C) 3. Inspect the after treatment nozzle
D) 4. Perform the DEF Doser Pump Override Test.
Fault Code: 3558
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid Dosing Valve - Current Below
Normal or Open Circuit
Actual meaning of Fault Code: Dosing Valve circuit open
of dozer unit
DEF Return valve -14 pin

round connector
A) Check proper connection of dosing unit connector and circuit
B) Check 24 volt supply on pin number “E" of 14 pin round connector.
C) Check 5 volt supply on pin number "P" of 14 pin round connector.
D) Check continuity from Pin "E" of 14 pin round connector to pin number 30 of J2 connector or any
E) Measure the resistance between the DEF return valve SUPPLY pin" T" and RETURN pin "B" at 14 pin
round connector (it must be 10 to 12 ohms.)
24V
5V
30
57
2
74
72
2
22
47
76
2
66
79
2
48
A) Check the air solenoid.

B) 2. Inspect the DEF lines.
C) 3. Inspect the after treatment nozzle
D) 4. Perform the DEF Doser Pump Override Test.
Fault Code: 3567
Fault Description (As per INSITE): After treatment Diesel Exhaust Fluid Dosing Valve - Current below
Normal or Open Circuit
Actual meaning of Fault Code: Dosing Valve circuit open
of dozer unit
DEF Return valve
A) Check proper connection of dosing unit connector and circuit
B) Check 24 volt supply on pin number “E" of 14 pin round connector.
C) Check 5 volt supply on pin number "P" of 14 pin round connector.
D) Check continuity from Pin "E" of 14 pin round connector to pin number 30 of J2 connector or any
E) Measure the resistance between the DEF return valve SUPPLY pin" T" and RETURN pin "B" at 14 pin
round connector (it must be 10 to 12 ohms.)
24V
5V
30
12 Ohms
A) Check the after treatment diesel exhaust dosing valve and circuit.
B) Check the after treatment diesel exhaust dosing valve resistance
Fault Code: 1117
Fault Description (As per INSITE): Power Supply Lost with Ignition On - Data erratic, intermittent or
incorrect
Actual meaning of Fault Code: supply cut off during inanition ON condition
A) Check 30 Amp fuse between battery to ECM (ECM pin 1,3,5)near battery.
B) Check 60 Amp Maxi fuse beside the radiator (Yellow colour)

C) Check 5 Amp EMS fuse
D) Check 10 Amp fuse coming from ECM 15 number pin to Ignition switch
E) Check Neutral relay (Yellow) & Starter lock out relay (Green).
F) Check battery voltage and power connectors.
G) Check netural switch earthing fitted on 3rd cross member.
H) Check interface connectors for any loose fitment.
I) Ensure welding operation to be performed after opening of battery cables and interface connectors
during body building.
J) Check ECM pins for any physical damages/water ingress
A) ECM recalibration
B) Change ECM with New one

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Fault Code: 1668

Sensors & Connectors identification and location in BSIV vehicle

Diagnostic Steps/Troubleshooting guidelines:

A) Ensure connector properly tight & no pin terminal back out.

Fault Code: 1669

Sensors & Connectors identification and location in BSIV vehicle

Diagnostic Steps/Troubleshooting guidelines:

Action Taken/to be taken:

A) Ensure connector properly tight & no pin terminal back out.

Fault Code: 1671

B) Check pins of DEF sensor of 4 pole connector.

D) Check ECU pin no. 91 for any bent/damaged

E) Check ECM calibration

Action Taken/to be taken:

B) If still FC is active then calibrate the ECM

Fault Code: 1673

Diagnostic Steps/Troubleshooting guidelines:

A) DEF tank is empty.

Action Taken/to be taken:

A) Fill DEF tank fully.

C) If still FC is active then calibrate the ECM

Sensors & Connectors identification and location in BSIV vehicle

Diagnostic Steps/Troubleshooting guidelines:

A) Ensure connector properly tight & no pin terminal back out.

Fault Code: 1678

Sensors & Connectors identification and location in BSIV vehicle

Diagnostic Steps/Troubleshooting guidelines:

Action Taken/to be taken:

Fault Code: 1682

Sensor & connector location in vehicle:

Sensors & Connectors identification and location in BSIV vehicle

DEF Return valve -14 pin round

Diagnostic Steps/Troubleshooting guidelines:

A) Low DEF level in the DEF tank.

B) DEF supply to Dozer nozzle line blocked/ restricted.

D) DEF tank filter chocked/ restricted or plugged.

E) Dozing unit filter chocked/ restricted or plugged.

F) Check battery connection (ensure series connection).

Action Taken/to be taken:

A) Check the after treatment DEF dosing unit.

Fault Code: 1694

Sensors & Connectors identification and location in BSIV vehicle

Nox sensor connector

Diagnostic Steps/Troubleshooting guidelines:

C) Heavy carbon deposition on the tip of the sensor.

D) Check fuel Quality (No adulteration).

E) Nox sensor position and height also need to check.

F) Nox sensor loose fitment or an incorrectly installed in Exhaust system.

Action Taken/to be taken:

A) Check Exhaust system and Nox sensor position properly in EGP.

Fault Code: 1887

2. Terminating resistor near Nox ECU

Sensors & Connectors identification and location in BSIV vehicle

Nox sensor connector

B) Check Nox sensor fuse (20 Amp.)

C) Check supply voltage on pin number 1 of Nox sensor harness.

F) Check CAN wire for any physical damages.

Action Taken/to be taken:

A) Check the after treatment outlet NOx sensor circuit.

Actual meaning of Fault Code: NOx sensor is not receiving power.

Sensor & connector location in vehicle: NOX ECU

Sensors & Connectors identification and location in BSIV vehicle

Nox sensor connector