Diagnostic Manual DI3200 BSIII

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

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
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

P0236 Manifold Pressure sensor fault - plausibility Calculated Boost pressure is not in the expected range.
RECOVERY MODE
1 None
TO CHECK TO RECTIFY
ECU CONNECTIONS
COOLANT TEMPERATURE SIGNAL FAULTS:- 44

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.
2 IN_FUEL_TEMPERATURE deg C
SMC_STOPPED,SMC_CRANKING,
4 SMC_ENGINE_STATE SMC_RUNNING,SMC_STALLING.
7 ICV_VEHICLE_SPEED Km/hr
RECOVERY MODE
1 Turns Check engine lamp ON
TO CHECK TO RECTIFY
1.Coolant sensor connection 1.Remove and connect again
4.Coolant Sensor malfunctioning 4.Change sensor
ECU CONNECTIONS
COOLANT TEMPERATURE SIGNAL FAULT:- 55

P0115 Coolant temperature signal-Generic. General Fault- occurs when a coolant sensor fault occurs.
RECOVERY MODE
1 Disables RVD on all injectors
TO CHECK TO RECTIFY
1.Coolant sensor connection 1.Remove and connect again
4.Coolant Sensor malfunctioning 4.Change sensor
ECU CONNECTIONS
RAIL PRESSURE SIGNAL FAULT:- 6 6

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.
1 IN_RAIL_PRESSURE_FEEDBACK bar
4 P_L_VEXT1_RAW Volt
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
4.Wiring connector breakage 4.Change connector
5.Rail Pressure Sensor malfunctioing 5.Change Rail + Sensor
ECU CONNECTIONS
RAIL PRESSURE CALIBRATION FAULT:- 7 7

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)
RECOVERY MODE
2 Disables RVD
3 Disable cylinder balancing
4 Disables SPC
TO CHECK TO RECTIFY
1.Rail Sensor connection 1.Remove and connect again
4.Wiring connector breakage 4.Change connector
5.Rail Pressure Sensor malfunctioing 5.Change Rail + Sensor
ECU CONNECTIONS
RAIL PRESSURE ERROR 88

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

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

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
4 RPC_IM_CRT_DMND Volt
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
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.
1 SMC-ENGINE_STATE SMC_RUNNING,SMC_STALLING.
3 IN_IGNITION_SWITCH OFF,ON
RECOVERY MODE
1 None
TO CHECK TO RECTIFY
1.Relay connection 1.Remove and connect again
4.Relay functioning 4. Replace relay
ECU CONNECTIONS
ECU - RELAY OPEN 12 12

P1685 ECU -Relay Stuck open. Supply Relay Open Circuit-unexpected.
1 SMC-ENGINE_STATE SMC_RUNNING,SMC_STALLING.
RECOVERY MODE
None
TO CHECK TO RECTIFY
1.Relay connection 1.Remove and connect again
4.Relay functioning 4. Replace relay
ECU CONNECTIONS
INJECTOR COMBUSTION - TOO LOW 1313

P0263 Cylinder 1- Combustion Imbalance Combustion Imbalance in cyl 1
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

P0201 Open circuit fault - Injector Cyl 1 Injector Cyl 1 Open Circuit.
RECOVERY MODE
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

P0261 Short circuit HSD to LSD (Injector Cyl 1) Short circuit HSD to LSD (Injector Cyl 1)
7 IN_VEHICLE_SPEED Km/hr
RECOVERY MODE
3 Disable SPC strategy
4 Deactivates ISO test for injector
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

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.
6 RPC_IM_CRT_DMND %
RECOVERY MODE
2 Engine stops after delay
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
4. IMV electrical resistance on HP pump (5.3 max) 4.Change IMV
ECU CONNECTIONS
CAM SIGNAL FAULT 17 17

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.
7 IN_VEHICLE_SPEED Km/hr
RECOVERY MODE
TO CHECK TO RECTIFY
1.CAM sensor connection 1.Remove and connect again
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

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
RECOVERY MODE
TO CHECK TO RECTIFY
1. Crank Sensor connection 1.Remove and connect again
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

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
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

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.
1 IN_BATTERY_VOLTAGE volt
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

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.
RECOVERY MODE
1 Disables Pilot and Post injection
2 Engine stop after delay
3 Disables RVD
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

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.
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

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.
5 P_L_BATTERY_RAW Volt
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

P2269 Water in Fuel fault. Water in fuel detected.
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

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

P2147 Injector bank 1 fault Injector bank 1 fault - shorted to GND
P2148 Injector bank 1 fault Injector bank 1 fault - shorted to VBATT
RECOVERY MODE
2 Disables Cylinder Balancing
4 Disable IM trim calculations
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

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
1 IN_BATTERY_VOLTAGE V
3 IN_INLET_AIR_TEMPRATURE deg C
5 P_L_VEXT1_RAW V
RECOVERY MODE
1 Torque Reduction
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

P1107 ATMOSPHERIC PRESSURE FAULT Global Atmospheric pressure fault
4 P_L_BATTERY_RAW V
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

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
RECOVERY MODE
1 Torque Reduction
TO CHECK TO RECTIFY
ECU Replace ECU
ECU CONNECTIONS
INTERNAL TO ECU
PEDAL TRACK FAULT 30
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)
2 IN_VEHICLE_SPEED Kmph
3 P_L_VEXT2_RAW V
5 P_L_VEXT1_RAW V
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

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

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

P0503 VEHICLE SPEED OVERRUN FAULT Vehicle speed sensor fault (speed too high)
5 IN_GEAR_RATIO
RECOVERY MODE
none
TO CHECK TO RECTIFY
continuity is ok
ECU CONNECTIONS
VEHICLE SPEED SIGNAL LOSS FAULT 34

P0502 VEHICLE SPEED SIGNAL LOSS FAULT Vehicle speed sensor fault (signal lost)
5 IN_GEAR_RATIO
RECOVERY MODE
none
TO CHECK TO RECTIFY
continuity is ok
ECU CONNECTIONS
VEHICLE SPEED FAULT 35

P0500 VEHICLE SPEED FAULT Vehicle speed fault(global)
4 IN_GEAR_RATIO
5 P_L_COOLANT_TEMPERATURE V
RECOVERY MODE
1 Disables SPC
2 Torque reduction
TO CHECK TO RECTIFY
continuity is ok
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

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
None
RECOVERY MODE
None
TO CHECK TO RECTIFY
1 Read I2C / I3C from ECU Enter correct I2C / I3C values
CHECK ENGINE LAMP FAULT 37

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)
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

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
6 P_L_BATTERY_RAW Volt
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)

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Mahindra DI 3200 BS III

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

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CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

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CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

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

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

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CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

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1. Correct Electrical Problem

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

SENSOR 5 V SUPPLY FAULT(Vext 2) 22

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

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

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

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

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

ECU Replace ECU

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

ECU Replace ECU

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

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

1 Pedal sensor connection 1.Remove and connect again

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

1 Pedal sensor connection 1.Remove and connect again

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CHECK ENGINE LAMP FAULT 37

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

CODE FAULT NAME DIAGNOSTIC TOOL DESCRIPTION

Disconnect IMV connector from UPCR

Connect Dummy IMV in Wiring harness

Connect clear plastic tubes (supplied

Close venturi connection pipe with plug

Crank for 5 seconds only

Measure length of fuel collected in cm

Replace injector whose value is more

Repeat test if individual injectors are

Start & Warm up engine > 65 deg C

Connect all containers to injector back

Close venturi connection pipe with plug

Start the engine & Set diagnostic tool

Run the engine at idle for “X” seconds

Once leak detection cycle is over, stop