Automotive Sector

Index
1. Accelerator pedal module (APP1)
2. Accelerator pedal module (APP2)
3. ADC monitoring
4. Atmospheric pressure sensor
5. Battery
6. Brake switch
7. Clutch switch
8. Camshaft sensor
9. Communication monitoring
10. Controller and TPU monitoring
11. Coolant overheat lamp – power stage
12. Coolant temperature sensor
13. Incremental speed sensor
14. ECU monitoring
15. EEPROM monitoring
16. Error path for coolant temperature output
17. Error path for offset between cam and crankshaft sensor
18. Fuel temperature sensor
19. High temperature indication
20. injector power stage
21. K line
22. Main relay
23. Metering unit pump – power stage
24. MIL lamp – power stage fault status
25. Monitoring module communication monitoring
26. Power stage monitoring
27. power stage voltage monitoring
28. Rail pressure sensor
29. Sensor supply monitoring 1
30. Sensor supply monitoring 2
31. Terminal 15
32. Vehicle speed sensor
33. Resistance values

LCV CRDe Service Manual 1

 P-0123
P-0122
P-1120
Automotive Sector
1) Accelerator Pedal Module (APP 1)
Description: The Accelerator pedal module (APM) mounts in place of accelerator
pedal and is connected to the ECU by wires. The APM sensor is a variable resistor
(potentiometer) whose resistance changes according to the pedal position. ECU
applies a reference voltage to the APM sensor and then measures the voltage that is
present on the APM sensor signal circuit. The ECU uses the APM sensor signal for
further calculation of fuelling & other engine operational parameters.

DTC Diagnostic item

P-0123 Voltage above upper limit
P-0122 Voltage below lower limit.
P-1120 Plausibility with APP2 violated

DTC detection condition Probable cause

Normal Operation
• The Accelerator pedal module (APM) outputs • Open or shorted
a voltage, which is proportional to the Accelerator pedal
Position of accelerator pedal. module circuits, loose
• The ECU checks whether the voltage output or wrong connections.
by the Accelerator pedal module is within a • Accelerator pedal
specified range. module failed or
In addition, it checks that the voltage output maladjusted.
does not become too large while the engine is
in idling.
Proper Performance
• Sensor output voltage has continued to
between 0 to 5V, varying accelerator pedal
position.
Malfunction; out-of-range
• With the changing Accelerator pedal position,
the sensor output voltage has continued to be
5V or 0V.
Reaction:
• The engine speed not varying with changing
accelerator pedal position. (Constant 1200
rpm) The system lamp is continuously on.

LCV CRDe Service Manual 2

 P-0123
P-0122
P-1120
Automotive Sector

ECU

K45 K09 K30 K46 K31 K08

Gr-B
G-R
R-W Sb
P W-R

5-GND
2 4-O/P 3-GND 1 6-O/P

Vcc Vcc

APP1 APP2

LCV CRDe Service Manual 3

 P-0123
P-0122
P-1120
Automotive Sector

Test Procedure APP1

1. Connect the diagnostic tester

2. Turn Ignition Switch ON
3. Verify either P0123 or P122 or P1120 are present.

• Turn Ignition switch OFF & disconnect Accelerator pedal connector.

• Turn the Ignition ON & measure voltage between terminal 2 & terminal 3 of
the APP1 (from the APP1 connector side.)
• It should be 5 ± 0.3 V
• Is it?

Yes No

Turn Ignition OFF

Measure the continuity between terminal Measure the continuity between
K09 in ECU and Terminal 4 of K45 & 2 ( Voltage)
connector K30 and 3 ( ground)
Continuity is OK? (resistance below 1 Repair the damaged line/ connection
Ω)
Clear code

LCV CRDe Service Manual 4

 P-0123
P-0122
P-1120
Automotive Sector
Verify that the complaint has been
eliminated.

Yes No

Reconnect. Before reconnection check Repair the damaged line/ connection

that the pins are not bent or oxidation
has not taken place.
Clear the codes Clear code
Does the problem persist? Verify that the complaint has been
eliminated.

Yes No
Check the APP 1 resistance in both the
state 0% & 100%
Is it within the specifications

Yes No
Clear code. Replace the Accelerator pedal Module
Verify that the complaint has been eliminated.

LCV CRDe Service Manual 5

 P-0223
P-0222
Automotive Sector P-1220
P-1221
2) Accelerator Pedal Module (APP2)

Description: The Accelerator pedal module (APM) mounts in place of accelerator

pedal and is connected to the ECU by wires. The APM sensor is a variable resistor
(potentiometer) whose resistance changes according to the pedal position. ECU
applies a reference voltage to the APM sensor and then measures the voltage that is
present on the APM sensor signal circuit. The ECU uses the APM sensor signal for
further calculation of fuelling & other engine operational parameters.

DTC Diagnostic item

P-0223 Voltage above upper limit
P-0222 Voltage below lower limit.
P-1220 Plausibility with APP1 violated
P-1221 Accelerator Pedal signal not plausible with brake

DTC detection condition Probable cause

Proper Performance
Sensor output voltage has continued to between 0 • Open or shorted
to 2.5V, with varying accelerator pedal position. Accelerator pedal module
circuits, loose or wrongs
Malfunction; out-of-range connections.
• With the fully pressed Accelerator pedal
module, the sensor output voltage has • Accelerator pedal module
continued to be 2.5V or 0 for 4 sec. failed or maladjusted.

Reaction
• The engine speed not varying with changing
accelerator pedal position. (Constant 1200
rpm)
• The system lamp is continuously on.

LCV CRDe Service Manual 6

 P-0223
P-0222
Automotive Sector P-1220
P-1221

ECU

K45 K09 K30 K46 K31 K08

Gr-
G-R B
R-W Sb
P W-
R

4-O/P 1 6-O/P 5-GND

2 3-GND
Vcc Vcc

APP1 APP2

LCV CRDe Service Manual 7

 P-0223
P-0222
P-1220
Automotive Sector
P-1221

Test Procedure APP2

4. Connect the diagnostic tester

5. Turn Ignition Switch ON
6. Verify that either P0223/P0222/P1220 / or P1221 is present.

• Turn Ignition switches OFF & disconnect Accelerator pedal connector.

• Turn the Ignition ON & measure voltage between terminal 2 & terminal 3 of
the APP2 (from the APP2 connector side.)
• It should be 2.5 ± 0.15 V
• Is it?

Yes No

Turn Ignition OFF

Measure the continuity between terminal Measure the continuity between
K31 in ECU and Terminal 6 of K46 & 1 ( Voltage)
connector K08 and 5 ( ground)

LCV CRDe Service Manual 8

 P-0223
P-0222
P-1220
P-1221
Automotive Sector
Continuity is OK? (resistance below 1 Repair the damaged line/ connection
Ω)
Clear code
Verify that the complaint has been
eliminated.

Yes No

Reconnect. Before reconnection check Repair the damaged line/ connection

that the pins are not bent or oxidation
has not taken place.
Clear the codes Clear code
Does the problem persist? Verify that the complaint has been
eliminated.

Yes No
Check the APP 2 resistance in both the
state 0% & 100%
Is it within the specifications

Yes No
Replace the Accelerator pedal Module
Clear code.
Verify that the complaint has been eliminated.

LCV CRDe Service Manual 9

 P-1600
P-1601
P-1602
Automotive Sector P-1603

3) ADC Monitoring

Description: Analog to Digital converter inside the ECU is not working properly

DTC Diagnostic item

P-1600 ADC monitoring : SRC-High error of ADC reference voltage
P-1601 ADC monitoring : SRC-Low error of ADC reference voltage
P-1602 ADC monitoring : Test impulse error
P-1603 ADC monitoring : ADC queue error

Reaction: The System Check lamp will be continuously ON.

Test Procedure:

1. Switch ON Ignition
2. Using diagnostic tester, clear the ECU faults
3. Switch OFF Ignition key and wait for 2 minutes
4. Switch ON Ignition
5. Using diagnostic tester check whether any of the above mentioned fault is
present
6. If fault is still present, switch OFF ignition
7. Replace the ECU with a new one and repeat steps 4 & 5
8. If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M

LCV CRDe Service Manual 10

 P-0108
P-0107
Automotive Sector

4) Atmospheric pressure sensor

DTC Diagnostic item

P-0108 Voltage above upper limit
P-0107 Voltage below lower limit

DTC detection condition Probable cause

Normal Operation
• The atmospheric pressure sensor outputs a • Failed atmospheric
voltage, which corresponds to atmospheric pressure sensor.
pressure.

Normal Operation
• Ignition switch: ON
• Malfunction lamp: OFF after 2 Sec
• Battery voltage is 8V to 12V.
• No error reported in error memory.

Malfunction
• The sensor output voltage has continued to
be 5V or higher.
• The sensor output voltage has continued to
be 0V or lower.

Reaction
• System lamp will blink.
• Engine will run with default atmospheric
Pressure of 800hPa

LCV CRDe Service Manual 11

 P-0108
P-0107

Automotive Sector

1. Connect the diagnostic tester

2. Turn Ignition Switch ON
3. Verify that either P0108 or P0107 is present.

• Check the battery voltage.

• Clear the error codes.
• Verify if the error has been cleared.

Yes No

Repeat the clear error, for 3 times.

Replace the ECU

LCV CRDe Service Manual 12

 P-0563
Automotive Sector P-0562
5) Battery

Description:
The system voltage has to guarantee to perform diagnosis functions. The
Electronic Control Unit (ECU) monitors battery voltage. If this code is set, the
System Lamp is off.

DTC Diagnostic item

P-0563 Voltage above upper limit
P-0562 Voltage below lower limit.

DTC detection condition Probable cause

Detecting Condition
• Battery voltage <8 V • Charging system not
Enable Condition working.
- No main relay failure • Wiring harness to ECU
faulty.
• Battery voltage > 16V
Enable Condition
- No main relay failure

Test Procedure Battery

• Check charging system

• Check charging system (including battery) for proper operation.
• Refer the charging system section in the Electrical.
• Charging system OK. ( Voltage during cranking should be 8 to 16 Volts)

Yes No

Check the ECU, problem procedure. Repair or replace.

LCV CRDe Service Manual 13

 P-1792
Automotive Sector
P-1791
6) Brake switch

Description:
The function acquires and processes the information via the brake contact and the
redundant brake contact. The status message of the brake position is the output.

DTC Diagnostic item

P-1792 Brake signal is defective
P-1791 Brake signals not plausible

DTC detection condition Probable cause

Principle
• The brake switch outputs a voltage, which • Open, shorted, loose or
corresponds to the brake position. wrong connections of
• The ECU checks whether this voltage is brake switch Wiring.
within a specified range (0 or 12V). • Brake switch damage or
faulty
Normal Operation • Brake switch failed or
• Ignition switch: ON maladjusted.
• System lamp: OFF after 2 Sec .
• Battery voltage is 8V –16V.

Malfunction
• The sensor output voltage has continued to
be 0V in spite of brake pedal being
pressed/not pressed
• The sensor output voltage has continued to
12V in spite of brake pedal being
pressed/not pressed
• Main or redundant switch is not working.
Reaction
• System lamp will be off.

LCV CRDe Service Manual 14

 P-1792
P-1791
Automotive Sector

Stop lamp
Br G 15A
K 17

K80
R
P-B
ECU G

LCV CRDe Service Manual 15

 P-1792
Automotive Sector
P-1791

Test Procedure Brake switch

Codes: P-01792, P-1791

7. Connect the diagnostic tester

8. Turn Ignition Switch ON
9. Verify that either P1791 or P1792 are present.

• Disconnect the brake switch connector.

• Turn Ignition ON and check the supply voltage to brake switch tow point
connector.
• It should be 12 V when Ignition ON
• Is it?

Yes No

Turn the Ignition OFF Check the 15 Amp fuse after the main
relay
Connect the brake connector Check the supply to K01 & K05
(Fuses of K01 & K05)
Check the voltage at K80 of ECU input Repair connections as necessary
pin when the brake is in released
position

When the brake pedal is pressed then it

should be checked at K17
It should be 12 V Clear codes & verify.
Is it?

Yes No

LCV CRDe Service Manual 16

 P-1792
P-1791
Automotive Sector

Replace the brake switch with known Turn Ignition OFF

good component
Check for error Remove brake switch connection &
check continuity between terminal K17
& K80 with brake switch connector
Clear the error memory Is it OK?

No Yes

Repair the connection as necessary. Replace the brake switch with known
good component
Clear the error and verify.

LCV CRDe Service Manual 17

 P-0704

Automotive Sector

7) Clutch switch

DTC Diagnostic item

P-0704 Clutch signal is not plausible

Description
The clutch signal is acquired as a hardware signal. The signal is checked for
plausibility using gear information. Error is detected, if there is a valid gear change
without the clutch being pressed during the time that elapsed since the last gear
change.

DTC detection condition Probable cause

Normal Operation
• The clutch switch outputs a voltage, which • Open, shorted, loose or
corresponds to the clutch position. wrong connections of
• The ECU checks whether this voltage is brake switch Wiring.
within a specified range (0 or 12V). • Clutch switch failed or
maladjusted.
Normal Operating Requirements: • Clutch switch damage or
• Ignition switch: ON faulty.
• Malfunction lamp: OFF after 2 Sec
• Battery voltage is 8V –16V.

Malfunction
• The sensor output voltage has continued to
be 0V in spite of clutch pedal being
pressed/not pressed.
• The sensor output voltage has continued to
12V in spite of clutch pedal being
pressed/not pressed.
Reaction:
• System lamp will be off.

LCV CRDe Service Manual 18

 P-0704

Automotive Sector

IC Main 14PFT

15 Amp
1 Br-B
K58
4
R G Br-B

Clutch switch ECU

(normally closed)

LCV CRDe Service Manual 19

 P-0704

Automotive Sector

Test Procedure Clutch switch

10.Connect the diagnostic tester

11.Turn Ignition Switch ON
12.Verify that error P0704 is present.

Verify that no error related to vehicle speed that (vehicle speed sensor related) is
present. If present, first attend to those complaints then verify if the error P0704 is
present and then proceed.

Disconnect clutch switch connector

Turn the ignition ON
Checks supply voltage to clutch switch on connector.
It should be 12 V, when Ignition is ON. Is it?

Yes No

Turn Ignition OFF Check the 15 Amp fuse after the main
relay ( this fuse also controls EGR &
Brake switch)
Connect the clutch switch connector Check the supply to K01 & K05
Check the voltage at K 58 of the ECU Repair the connections as necessary
pin, when the clutch is in released
condition.
It should be 12 V Clear codes & verify
Is it?

Yes No

Clear the codes & verify. Turn Ignition OFF

LCV CRDe Service Manual 20

 P-0704

Automotive Sector
If the problem persist, replace with a Remove clutch switch connection &
known good switch check continuity between terminal K58
with clutch switch connector.
Clear the codes & verify Is it OK?

No Yes

Repair the connection as necessary. Replace the clutch switch with known
good component
Clear the error memory & verify

LCV CRDe Service Manual 21

 P-0340
P-0341
Automotive Sector

8) Camshaft speed sensor

DTC Diagnostic item

P-0340 No camshaft signal
P-0341 Wrong camshaft signal

Description
The Hall effect camshaft position sensor senses the Top dead center (TDC) point
of the # 1 cylinder in the compression stroke. Which allows the ECU to determine
when to start the injection.

DTC detection condition Probable cause

Normal Operation
• When the engine is running, the Camshaft • Open or shorted
Position sensor outputs a pulse signal. camshaft position
• The ECU checks whether the pulse signal is sensor circuits, loose
input. or wrong connection.
• Camshaft Position
Malfunction sensor malfunction.
• Normal signal pattern has not been input for
cylinder identification from the camshaft
position sensor signal for 4 sec. (Engine
should be cranked to check this error).

Reaction
• Engine will not start
• System lamp will be continuously on.

LCV CRDe Service Manual 22

 P-0340
P-0341
Automotive Sector

Sensor R-L ECU

3 A 11
Vs
Vs
2 R-G
A50

Signal
1 G A20

GND.

Vs= Supply voltage- 5V

LCV CRDe Service Manual 23

 P-0340
P-0341
Automotive Sector

Codes: P-0340, P-0341

13.Connect the diagnostic tester

14.Turn Ignition Switch ON
15.Verify that either P0340 or P0341 are present.

• Switch off the Ignition

• Disconnect the camshaft sensor connector.
• Turn ON the Ignition.
• Measure the voltage between the A11 (supply)& A 20 (ground).
• It should be 5 ± 0.3 Volts
• Is it?

Yes No

Turn the Ignition OFF Repair the wire.

Disconnect ECU connector A Clear the error codes & verify
Measure the continuity of Ground
(between sensor pin no 1 & ECU
terminal A20) in the camshaft phase
sensor harness.
Is it OK?

LCV CRDe Service Manual 24

 P-0340
P-0341
Automotive Sector
Yes No

Measure the continuity of signal Repair the connection.

(between sensor pin no 2 & ECU
terminal A50) in the camshaft phase
sensor harness.
Is it OK? Clear the error codes & verify

Yes No

Check for physical damage to pins or Repair the connection.

oxidation.
Also check if the connectors are moving Clear the error codes & verify
backwards when inserted.
Is it OK?

Yes No

Replace the camshaft phase sensor Repair the connection.

Clear the error codes & verify Clear the error codes & verify

LCV CRDe Service Manual 25

 P-162A

Automotive Sector

9) Communication Monitoring

Description: Communication between controller and power stage inside the ECU
is not OK

DTC Diagnostic item

P-162A Communication error of CJ940

Reaction: The System Check lamp will be continuously ON.

Test Procedure:

9. Switch ON Ignition
10. Using diagnostic tester, clear the ECU faults
11. Switch OFF Ignition key and wait for 2 minutes
12. Switch ON Ignition
13. Using diagnostic tester check whether any of the above mentioned fault is
present
14. If fault is still present, switch OFF ignition
15. Replace the ECU with a new one and repeat steps 4 & 5
16. If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M

LCV CRDe Service Manual 26

 P-1659

Automotive Sector

10) Controller and TPU Monitoring

Description: Controller and Time processing unit out of sync

DTC Diagnostic item

P-1659 Deviation between TPU and system time

Reaction: The System Check lamp will be continuously ON.

Test Procedure:

17. Switch ON Ignition

18.Using diagnostic tester, clear the ECU faults
19.Switch OFF Ignition key and wait for 2 minutes
20.Switch ON Ignition
21.Using diagnostic tester check whether any of the above mentioned fault is
present
22.If fault is still present, switch OFF ignition
23.Replace the ECU with a new one and repeat steps 4 & 5
24.If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M

LCV CRDe Service Manual 27

 P-165E
P-165F
P-1660
Automotive Sector P-1661
11) Coolant overheat Lamp -power stage

DTC Diagnostic item

P-165E Short Circuit to Battery
P-165F Short Circuit to Battery
P-1660 No Load
P-1661 Excess Temperature

DTC detection condition Probable cause

Normal operation
• When ignition is ON coolant overheat lamp
will be ON & OFF after 2 sec. • Open short circuit to
• When coolant temperature crosses the set battery or ground.
value lamp will glow. • Wrong connection for
coolant overheats lamp
Malfunction circuit.
• Coolant overheat lamp will not respond,
during the lamp test.
• Show wrong display.

LCV CRDe Service Manual 28

 P-165E
P-165F
P-1660
Automotive Sector
P-1661

LCV CRDe Service Manual 29

 P-165E
P-165F
Automotive Sector P-1660
P-1661
16.Connect the diagnostic tester
17.Turn Ignition Switch ON
18.Verify that either P1660 or P1661 or P165E or P165F is present.

• Switch off the Ignition

• Check the connections to the coolant overheat lamp.
• Check the continuity between ECU terminal K94 with overheat lamp.
• Is it OK?

Yes No

Switch ON the Ignition Repair the connection

Check if the supply is coming to the Clear codes and verify that the overheat
overheat lamp lamp is working correctly.
Is it OK

Yes No

Lamp failure. Repair the connection.

Change the lamp Check the 15 Amp fuse ( cluster lamp
fuse)
Clear codes and verify that the coolant overheat lamp is working properly

LCV CRDe Service Manual 30

 P-0118
P-0117
Automotive Sector
12) Coolant Temperature Sensor

Description: The Water temperature sensor (WTF) is located in a coolant passage

of the cylinder head. The WTF sensor is a variable resistor whose resistance
changes as the temperature of the engine coolant flowing past the sensor changes.
When the coolant temperature is low, the sensor resistance is high; when the
coolant temperature is high, the sensor resistance is low. The ECU checks WTF
voltage and uses the information to help smooth the engine operation.

DTC Diagnostic item

P-0118 Voltage above upper limit
P-0117 Voltage below lower limit

DTC detection condition Probable cause

Background
• The engine coolant temperature sensor • Open or shorted
converts the engine coolant temperature to a Engine Coolant
voltage and outputs it. Temperature sensor
• The ECU checks whether the voltage is circuit, or loose or
within a specified range. In addition, it checks wrong connection
that the engine coolant temperature (signal) • Engine Coolant
does not drop while the engine is warming up. Temperature sensor
failed.
Malfunction; out-of-range
• Sensor output voltage has continued to be 5V
or higher for 4 sec.
• Sensor output voltage has continued to be
0.1V or lower for 4 sec.

Reaction:
• System lamp will be on.
• Engine will continue to run with water
temperature of 120 deg C.

LCV CRDe Service Manual 31

 P-0118
P-0117
Automotive Sector

ECU
A 58 A41

W-R R-G

2
1

Coolant Temperature Sensor

LCV CRDe Service Manual 32

 P-0118
P-0117
Automotive Sector

Test Procedure Coolant Temperature Sensor

Codes: P-0118, P-0117,

19.Connect the diagnostic tester
20.Turn Ignition Switch ON

• Verify DTC P0118 or P0117 are present.

• Turn the Ignition OFF
• Disconnect the CTS connector.
• Turn Ignition ON and check the voltage between CTS’ signal terminal 1 and
ground.
• It should be 5 V when Ignition ON
• Is it?

LCV CRDe Service Manual 33

 P-0118
P-0117
Automotive Sector

Yes No

Turn the Ignition OFF Open or short between CTS signal

terminal 1 and ECU
Measure continuity between A 58 of Repair as necessary.
ECU & connector terminal 1
Measure continuity between A 41 of
ECU & connector terminal 2
Is it OK

Yes No

Connect CTS connector Open or short between CTS signal

terminal 1 and ECU
Turn Ignition ON Repair as necessary.
Check the voltage of CTS
Is it as per specification

Yes No

Poor terminal contact due to oxidation, Temporarily install a known good CTS
bent or misplaced terminal and check for proper operation.
Repair as necessary If problem is corrected, replace CTS.

• Return vehicle to original condition. Clear all DTC.

• Verify by driving vehicle with Diagnostic tester connected and monitor for
error codes.

LCV CRDe Service Manual 34

 P-0335
P-0336
Automotive Sector

13) Incremental speed sensor

DTC Diagnostic item

P-0335 No crankshaft signal
P-0336 Wrong crankshaft signal

Description
In order that the ECU can control the engine at all, the position of the crankshaft
must be known so that the cylinder in compression and the timing of the next fuel
injection can be calculated. The CKP is an inductive pulse generator, which scans
protrusions on the flywheel. Two teeth are missing, and this gap is situated at 90°
before TDC.

DTC detection condition Probable cause

Background
• When the engine is running, the Crankshaft • Open, shorted or
Position sensor outputs a pulse signal. wrong connection
• The ECU checks whether the pulse signal is crankshaft position
input while the engine is cranking. sensor circuit.
• Failed or damaged
Normal Operating condition crankshaft position
• Engine is being cranked. sensor.

Malfunction
• Normal signal pattern has not been input for
cylinder identification from the crankshaft
position sensor signal for 4 sec.
• No synchronization between crankshaft &
camshaft signal.

Reaction
• System lamp continuously on.
• Engine will not start.
• If engine is running & this fault occurs,
engine will stop immediately.

LCV CRDe Service Manual 35

 P-0335
P-0336
Automotive Sector

ISS (Incremental speed sensor/ Crankshaft speed sensor)

Sensor ECU

N S
Y
1 A 27
Positive

2 A 12
Negative

Shield
3
B-R A 21

LCV CRDe Service Manual 36

 P-0335
P-0336
Automotive Sector

Test Procedure ISS

21.Connect the diagnostic tester

22.Turn Ignition Switch ON
23.Verify that either P0335 or P0336 are present. Please verify after cranking the
engine.

• Turn the Ignition switch OFF.

• Disconnect the crankshaft position connector and also the connector at ECU.
• Measure the continuity between the sensor terminal 1 and ECU terminal A 27
• Is it OK?

Yes No

Measure all terminals for short to GND Repair the wire.

Is it OK Clear code & verify the CKP sensor is

within normal parameters.

Yes No

Check if the sensor is damaged. If so Repair the connection.

change sensor with a known good
component.
Clear code & verify the CKP sensor is within normal parameters.

LCV CRDe Service Manual 37

 P-1638

Automotive Sector

14) ECU Monitoring

Description: Monitoring module inside ECU reports a defect

DTC Diagnostic item

P-1638 Set, if error-counter of Watchdog or controller are not plausible or
the system must shut down

Reaction: The System Check lamp will be continuously ON.

Engine will shut down

Test Procedure:

25. Switch ON Ignition

26.Using diagnostic tester, clear the ECU faults
27.Switch OFF Ignition key and wait for 2 minutes
28.Switch ON Ignition
29.Using diagnostic tester check whether any of the above mentioned fault is
present
30.If fault is still present, switch OFF ignition
31.Replace the ECU with a new one and repeat steps 4 & 5
32.If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M

LCV CRDe Service Manual 38

 P-162B
Automotive Sector P-162C
15) EEPROM Monitoring P-162D

Description: EEPROM storage device inside ECU is not OK

DTC Diagnostic item

P-162B EEPROM: error during last read operation
P-162C EEPROM: error during last write operation
P-162D EEPROM: default value used

Reaction: The System Check lamp will be continuously ON.

Test Procedure:

33. Switch ON Ignition

34.Using diagnostic tester, clear the ECU faults
35.Switch OFF Ignition key and wait for 2 minutes
36.Switch ON Ignition
37.Using diagnostic tester check whether any of the above mentioned fault is
present
38.If fault is still present, switch OFF ignition
39.Replace the ECU with a new one and repeat steps 4 & 5
40.If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M

LCV CRDe Service Manual 39

 P1608
P1609
P160A
Automotive Sector P160B
16) Error path of coolant temperature output

Description
The component driver for the coolant temperature outputs the variable as a PWM
signal to the power stage. (Output on the cluster) In normal operation, the PWM
power stage is tested for short circuit to battery, to ground, open circuit and excess
temperature.

DTC Diagnostic item

P-1608 Short circuit to battery
P-1609 Short circuit to ground
P-160A No load
P-160B Excess temperature

DTC detection condition Probable cause

Normal Operation • Open or shorted
• The coolant temperature output voltage, Engine Coolant
which is given to the cluster from ECU as an Temperature output
output. sensor circuit, or
• The ECU checks whether this voltage is loose or wrong
within a specified range (0 or 5V). connection.

Normal Operating Conditions

• Ignition switch: ON
• System lamp: OFF after 2 Sec

Malfunction
• No indication of water temperature on the
instrument cluster.

LCV CRDe Service Manual 40

 P1608
P1609
P160A
Automotive Sector P160B

Test Procedure Coolant temperature output

24.Connect the diagnostic tester

25.Turn Ignition Switch ON
26.Verify that the either of the error codes P1608 or P1609 or P160A or P160B is
present.

Turn the Ignition OFF

• Remove the cluster connections of the coolant temperature indicator.

• Check the continuity between coolant temperature output connector with K29
of the ECU.
• Is it OK?

LCV CRDe Service Manual 41

 P1608
P1609
P160A
Automotive Sector
P160B

Yes No

Check the cluster lamp fuse Open or short between coolant

temperature output & ECU K29
Check the temperature value in Repair as necessary
diagnostic tester .Compare it with
physical measurements

Check the output at K29 when Ignition

is ON
Is it OK Clear the error & verify.

Yes No

Replace the instrument cluster Clear codes & verify.

Verify DTC with coolant temperature
output

LCV CRDe Service Manual 42

 P-1340

Automotive Sector
17) Error path of offset between camshaft and crankshaft

DTC Diagnostic item

P-1340 Offset between camshaft and crankshaft

DTC detection condition Probable cause

Normal operation
• Engine is being cranked & started. • Mounting of phase
sensor, speed sensor or
Malfunction flywheel is loose.
• Normal signal pattern has not been input for • Manufacturing defect.
cylinder identification from the crankshaft • Sensors faulty or
position sensor signal and camshaft position damaged.
sensor signal for 4 sec.
• No synchronization between crankshaft &
camshaft signal.

Reaction
• Engine is not being cranked.
• System lamp will continuously ON.

LCV CRDe Service Manual 43

 P-1340

Automotive Sector

Segment Speed Sensor (camshaft sensor)

Sensor R-L ECU

3 A 11
Vs
Vs
2 R-G
A50

Signal
1 G A20

GND.

Vs= Supply voltage- 5V

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 P - 1340

Automotive Sector
27.Connect the diagnostic tester
28.Turn Ignition Switch ON
29.Verify that P1340 is present.

Turn the Ignition OFF.

Disconnect the camshaft & also the crankshaft sensors.
Is it OK?

Yes No

Check the flywheel mounting Correct the mounting

Check the wiring harness continuity Clear codes & verify that the signal is
between the cam sensor to ECU & also within limit
the cranks sensor to ECU
Flywheel mounting is OK

Yes No

Check for any manufacturing defects Correct the mounting.

Clear codes & verify that the signal is Clear codes & verify that the signal is
within limit within limit
If it is not in limit, change the
corresponding sensor

LCV CRDe Service Manual 45

 P-0182
P-0183
Automotive Sector
18) Fuel Temperature Sensor
DTC Diagnostic item
P-0182 Voltage above upper limit
P-0183 Voltage below lower limit

Description:
Fuel temperature sensor acquires the raw value of the fuel temperature. The raw
value is linearised and monitored for compliance with the signal range.

DTC detection condition Probable cause

Background
• The fuel temperature sensor converts the • Open or shorted Engine
engine fuel temperature to a voltage and fuel temperature sensor
outputs it. circuit, loose or wrong
• The ECU checks whether the voltage is connection
within a specified range. • Fuel temperature sensor
failed.
Malfunction; out-of-range
• Sensor output voltage has continued to be 5V
or higher for 4 sec.
• Sensor output voltage has continued to be
0.1V or lower for 4 sec.
Reaction
• System lamp will blink continuously.
• Engine will run with default fuel temp of 20
Deg C.

LCV CRDe Service Manual 46

 P – 0182
P – 0183
Automotive Sector

ECU

A 52 A51

W G

1 2

Fuel Temperature Sensor

LCV CRDe Service Manual 47

 P-0182
Automotive Sector
P-0183

Test Procedure Fuel Temperature Sensor

Codes: P-0182, P-0183

30.Connect the diagnostic tester

31.Turn the Ignition Switch ON
32.Verify that either P0182 or P0183 are present.

• Turn the Ignition OFF

• Disconnect the FTS connector.
• Turn the Ignition ON and check the voltage between FTS’ signal terminal 1 and
ground.
• It should be 5 V ± 0.3 when Ignition ON
• Is it?

Yes No

Turn the Ignition OFF Open or short between FTS signal

terminal 1 and ECU
Measure continuity between A 52 of Repair as necessary.
ECU & connector terminal 1
Measure continuity between A 51 of
ECU & connector terminal 2
Is it OK

Yes No

Connect FTS connector Open or short between FTS signal

terminal 1 and ECU
Turn Ignition ON Repair as necessary.
Check the voltage of FTS ( at A51 &

LCV CRDe Service Manual 48

 P-0182
P-0183
Automotive Sector
A52)
Is it as per specification

Yes No

Poor terminal contact due to oxidation, Temporarily install a known good FTS
bent or misplaced terminal and check for proper operation.
Repair as necessary If problem is corrected, replace FTS.

• Return vehicle to original condition. Clear all DTC.

• Verify by driving vehicle with diagnostic tester connected and monitor for error
codes.

LCV CRDe Service Manual 49

 P – 1608
P – 1609
Automotive Sector
P – 160A
P – 160B
19) High Temperature Indication

Code Description
P-1608 Short circuit to battery- coolant temperature
output to cluster
P-1609 Short circuit to ground- coolant temperature
output to cluster
P-160A No load- coolant temperature output to cluster
P-160B Excess temp- coolant temperature output to
cluster
Description
The component driver for the coolant temperature outputs the variable as a PWM
signal to the power stage. (Output on the cluster) In normal operation, the PWM
power stage is tested for short circuit to battery, to ground, open circuit and excess
temperature.

Normal Failure
When the engine is witched ON the The system lamp status in the event
light will glow ON and then switch of the fault: OFF.
OFF ( The light is at the end of the
temperature band

LCV CRDe Service Manual 50

 P - 1608
P - 1609
Automotive Sector P - 160A
Test Procedure High Temperature Indication P-160B

• Verify DTC P-0704 as being present.

• Turn the Ignition OFF
• Remove the cluster connection of coolant temperature indication.
• Check the continuity between coolant temperature output connector with K 29
of ECU
• Is it OK?

Yes No

Check coolant temperature and voltage Open or short between coolant

using the diagnostic tester temperature output & K 29 in ECU
Check the output at K29 when Ignition Repair as necessary.
is ON ( 180 to 4975mV)
Is it OK

Yes No

Related to Coolant Temperature Sensor. Follow the test procedure for CTS

• Return vehicle to original condition. Clear all DTC.

• Verify by driving vehicle with diagnostic tester connected and monitor for
error codes.

LCV CRDe Service Manual 51

 P-1210
P-1211
P-1212
Automotive Sector P-1213
P-1214
P-1215
20) Injector power stage- chip specific errors P-1216
P-1217
Description: Injector power stage inside ECU defective
DTC Diagnostic item
P-1210 Chip-specific errors : CY33X internal reset / clock loss / under
voltage
P-1211 Chip-specific errors: CY33X is unlocked / CY33X in it error
P-1212 Chip-specific errors:CY33X is in Test mode
P-1213 Chip-specific errors: CY33X SPI communication error
/checksum/read back
P-1214 Chip-specific errors ->CY33X internal parity error
P-1215 Chip-specific errors ->CY33X internal program flow error
P-1216 Chip-specific errors ->CY33X check of inv. YSEL during ON
failed
P-1217 Chip-specific errors ->CY33X ON timeout for at least 1 cylinder

Reaction: The System Check lamp will be continuously ON.

Engine stops.

Test Procedure:

41. Switch ON Ignition

42.Using diagnostic tester, clear the ECU faults
43.Switch OFF Ignition key and wait for 2 minutes
44.Switch ON Ignition
45.Using diagnostic tester check whether any of the above mentioned fault is
present
46.If fault is still present, switch OFF ignition
47.Replace the ECU with a new one and repeat steps 4 & 5
48.If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M

LCV CRDe Service Manual 52

Automotive Sector
21) K line: Diagnostic connector

• Connect the diagnostic tester to the DLC.

• Turn the Ignition ON.
• Check for the connection on the Simputer
• Is it OK?

No Yes

Remove the diagnostic tester from the Diagnostic connector is OK.

connector
Switch on the Ignition
Check the voltage of the pin no 4/5 & 7
of the connector (It should show 12
Volts when Ignition is ON and show 0
Volts when Ignition is switched OFF.
Is it OK?

No Yes

Check connectivity between K25 and Check the voltage between the
diagnostic connector pin no 7 connector pins10 & pin 4/5. It should
show 12 V continuously
If is not OK, then repair If it is not showing , repair the
connection
Check the voltage Otherwise it indicates
less/poor/intermittent contact
Is it OK Repair

Yes No

LCV CRDe Service Manual 53

Automotive Sector

Connect diagnostic tester & confirm Diagnostic hardware is faulty.

Change the hardware

LCV CRDe Service Manual 54

 P121A
P121B
Automotive Sector
22) Main relay

DTC Diagnostic item

P-121A Main relay does not open in time
P-121B Main relay opens too early

DTC detection condition Probable cause

Normal operation
• While cranking engine will start properly. • Open, shorted or wrong
connection of main relay.
Malfunction • Main relay fuse is blown.
• Supply will not come to ECU input. • Relay is not working

Reaction
• Engine will not start.
• No communication with diagnostic tester.

LCV CRDe Service Manual 55

 P121A
P121B

Automotive Sector

Engine not cranking- diagnostic tester not responding.

Turn the Ignition OFF.

Check battery voltage. It should be greater than 8 Volts
Check the 30 Amp fuse

33.Connect the diagnostic tester

34.Turn Ignition Switch ON
35.Verify that either P121A or P121B is present.

• Ensure that the main relay is inserted properly in the connector

• Remove relay.
• Check the relay externally

LCV CRDe Service Manual 56

 P121A
P121B
Automotive Sector
• Give 12 Volts to terminal 86 and Ground the terminal 85.
• A clicking sound should be heard.
• If the sound is not heard, replace the relay.
• Check if 12 Volts is available at terminal 30,86 & 85.
• With respect to ground, terminal 87 should show 0 Volts
• Is it OK?

Yes No

Switch ON the Ignition Check the wiring harness

Measure at terminal K72 of ECU or Repair the main relay connections (
terminal 85 of the relay. check the 30 Amp fuse)
Is it showing 0 Volts Clear codes & verify that the main relay
is working properly

Yes No

Measure the voltage at ECU terminal Check that the terminal K 28 of ECU is
K05/K01. Or at terminal 87 of the relay showing 12 Volts. If not repair the
connection.
It should show 12 Volts

Yes No

Clear codes and verify that the main Replace the relay with a known good
relay is working properly component.
Clear codes and verify that the main
relay is working properly

LCV CRDe Service Manual 57

 P-1252
P-1253
Automotive Sector P-1250
P-1251
23) Metering unit pump -Power stage

DTC Diagnostic item

P-1252 Short Circuit to Battery
P-1253 Short Circuit to Ground
P-1250 No Load
P-1251 Excess Temperature

DTC detection condition Probable cause

Normal operation
• When ignition is ON pump is getting supply • Open, shorted or wrong
from ECU connection of pump
• Engine is starting properly. circuit.

Malfunction
• When ignition is ON pump is not getting PWM
signal from ECU.

Reaction
• Engine is not starting & error is recorded in ECU
error memory.
• Fuel output is not available from pump.
• System lamp will remain ON.

LCV CRDe Service Manual 58

 P-1252
P-1253
Automotive Sector P-1250
P-1251
High Pressure Pump (with fuel metering unit)

ECU

A19 A 49

W
Y

2 1
Twisted pair wires

LCV CRDe Service Manual 59

 P-1252
Automotive Sector P-1253
P-1250
P-1251
36.Connect the diagnostic tester
37.Turn Ignition Switch ON
38.Verify that either P-1252 or P-1253 or P-1250 or P-1251 is present.

• Check the connections to the pump.

• Check that the connections are connected correctly; and that it is not connected
in reverse way.
• Disconnect the pump and ECU connectors.
• Check the continuity between the ECU terminal A19 and pump terminal 2
• Check the continuity between the ACY terminal A49 with pump terminal 1
• Is it OK?

Yes No

Check the continuity of ECU connector Check for terminal contamination.

terminal A49 and A19 with Battery +ve Repair the connection.
and Ground.
Is it OK? Clear codes and verify that the error has
been eliminated.

No Yes

Error observed due to loose/ intermittent There is a possibility of short circuit of

battery to ground
Ensure that the connections are proper Repair the connections
Clear codes and verify the error Clear codes & verify.

LCV CRDe Service Manual 60

 P-1654
P-1655
P-1656
Automotive Sector P-1657

24) MIL lamp -Power Stage fault status

DTC Diagnostic item

P-1654 Short Circuit to Battery
P-1655 Short Circuit to Battery
P-1656 No Load
P-1657 Excess Temperature

DTC detection condition Probable cause

Normal Operation
• When Ignition is switched ON the system lamp • Open, shorted or wrong
will glow ON for 2 sec. connection of system
• It will switch OFF if no error is set. lamp circuit.

Malfunction
• When ignition is switched ON the system lamp
does not glow ON.

LCV CRDe Service Manual 61

 P-1654
P-1655
Automotive Sector P-1656
P-1657

LCV CRDe Service Manual 62

 P-1654
Automotive Sector P-1655
39.Connect the diagnostic tester P-1656
P-1657
40.Turn Ignition Switch ON
41.Verify that either P1654 or P1655 or P1666 or P1667 is present.

• Switch off the Ignition

• Disconnect the camshaft sensor connector.
• The connections to the system lamp.
• Check the continuity between the ECU terminal K71 with system lamp
• Is it OK?

Yes No

Turn the Ignition OFF Check the fuse.

Disconnect ECU connector A Repair the wire.
Measure the continuity of Ground Clear the error codes & verify
(between sensor pin no 1 & ECU
terminal A20) in the camshaft phase
sensor harness.
Is it OK?

Yes No

Lamp failure Repair the connection.

Replace lamp Clear codes and verify that the system
lamp is working properly.
Clear codes and verify that the system
lamp is working properly.

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 P-1664

Automotive Sector

25) Monitoring module communication Monitoring

Description: Communication failure with monitoring module.

DTC Diagnostic item
P-1664 The fault path contains the supervision of the SPI-Handler
Set, if SPI-communication failed

Reaction: The System Check lamp will be continuously ON.

Test Procedure:

49. Switch ON Ignition

50.Using diagnostic tester, clear the ECU faults
51.Switch OFF Ignition key and wait for 2 minutes
52.Switch ON Ignition
53.Using diagnostic tester check whether any of the above mentioned fault is
present.
54.If fault is still present, switch OFF ignition
55.Replace the ECU with a new one and repeat steps 4 & 5
56.If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M

LCV CRDe Service Manual 64

 P-1641
P-1642
Automotive Sector P-1643

26) Power Stage Monitoring

Description: Controller not able to control power stage

DTC Diagnostic item
P-1641 Test of redundant shut off paths during initialization: Watch dog
switch off path defect
P-1642 Test of redundant shut off paths during initialization: Voltage
monitoring upper limit shut off path defect
P-1643 Test of redundant shut off paths during initialization: Voltage
monitoring lower limit shut off path defect

Reaction: The System Check lamp will be continuously ON.

Test Procedure:

57. Switch ON Ignition

58.Using diagnostic tester, clear the ECU faults
59.Switch OFF Ignition key and wait for 2 minutes
60.Switch ON Ignition
61.Using diagnostic tester check whether any of the above mentioned fault is
present
62.If fault is still present, switch OFF ignition
63.Replace the ECU with a new one and repeat steps 4 & 5
64.If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M

LCV CRDe Service Manual 65

 P-1631
P-1632
Automotive Sector

27) Power stage voltage Monitoring

Description: Over / Under voltage to power stage detected

DTC Diagnostic item
P-1631 (Hardware) CJ940 upper limit: internal supply voltage upper limit
P-1632 (Hardware) CJ940 lower limit: internal supply voltage lower limit

Reaction: The System Check lamp will be continuously ON.

Test Procedure:

65. Switch ON Ignition

66.Using diagnostic tester, clear the ECU faults
67.Switch OFF Ignition key and wait for 2 minutes
68.Switch ON Ignition
69.Using diagnostic tester check whether any of the above mentioned fault is
present
70.If fault is still present, switch OFF ignition
71.Replace the ECU with a new one and repeat steps 4 & 5
72.If fault is not present in the new ECU, then the old ECU is defective and has to
be sent back to M&M.

LCV CRDe Service Manual 66

 P-0193
P-0192
Automotive Sector
28) Rail Pressure Sensor

DTC Diagnostic item

P-0193 Voltage above upper limit.
P-0192 Voltage below lower limit.

DTC detection condition Probable cause

Normal operation • Open, shorted or wrong
• When ignition is ON rail pressure sensor getting connection of rail
supply from ECU. pressure sensor circuit.
• ECU reads the rail pressure in terms of voltage. • Rail pressure sensor
• Engine is starting properly. failed.
• Building pressure in rail.

Malfunction
• Rail pressure output voltage is below

Reaction
• When ignition is ON system lamp is glowing.
Engine is not starting & error is set in ECU
Error memory.

LCV CRDe Service Manual 67

 P-0193
P-0192
Automotive Sector

ECU

A28 A43 A08

O-B R O

3 2 1

V cc V out GND

Rail Pressure Sensor

LCV CRDe Service Manual 68

Automotive Sector

4. Connect the diagnostic tester

5. Turn Ignition Switch ON
6. Verify that either P-0193 or P-0192 is present.

• Switch off the Ignition

• Disconnect the camshaft sensor connector.
• Turn ON the Ignition.
• Measure the voltage between the supply and the ground of the Rail pressure
sensor (Pin no 1 & 3 of the RPS connector).
• It should be 5 ± 0.3 Volts
• Is it?

LCV CRDe Service Manual 69

Automotive Sector

Yes No

Check the continuity between the ECU Repair the wire.

terminal A28 & pin no 3 of the RPS.

Continuity between the ECU terminal

A43 & pin no 2 of the RPS
Is it OK? Clear the error codes & verify

Yes No

Connect the rail pressure sensor Repair the wire.

connector to sensor. (Check for pins contamination)
Switch ON the Ignition Clear the error codes & verify
Check the output of the RPS ( Should be
in range of 500 to 700 mVolts
Is it?

Yes No

Change the engine speed and check the Rail pressure sensor has failed.
corresponding increase in RPS value

( This can be done using the live data in Change the Rail assembly ( RPS is not
the diagnostic tester) serviced separately)
Is there a change in the RPS Clear codes & verify

LCV CRDe Service Manual 70

Automotive Sector

Yes No

Clear codes & verify Replace rail.

Clear codes & verify.

LCV CRDe Service Manual 71

 P-1644
P-1645
Automotive Sector

29) Sensor supply monitoring 1

DTC Diagnostic item

P-1644 Voltage above upper limit
P-1645 Voltage below lower limit

DTC detection condition Probable cause

Normal Operation
The ECU monitors the supply voltage to camshaft
phase sensor, and accelerator pedal ( APP1)

Malfunction
The voltages are beyond the range.

Reactions

System lamp status for this error is ON.

LCV CRDe Service Manual 72

 P-1644
P-1645
Automotive Sector

LCV CRDe Service Manual 73

 P-1644
P-1645
Automotive Sector

7. Connect the diagnostic tester

8. Turn Ignition Switch ON
9. Verify that either P-1644 or P-1645 is present.

• This is related to the cam shaft sensor supply & also APP1 supply voltage
• Check the connection of the cam shaft sensor supply & accelerator pedal
connector
• Is it OK?

Yes No

Remove the sensor connections of the Repair the connection

camshaft sensor & the Accelerator pedal
Clear the error Clear codes and verify.
If the error heals then the problem may
be due to poor connection
Does it heal?

No Yes

Clear the codes & verify. Check the continuity between the ECU
connector A11 and the camshaft
terminal 3

Between ECU connector K 45 and

Accelerator pedal Terminal 2

Repair the connection

If the error is still present, then the ECU Reconnect everything
is suspect.

LCV CRDe Service Manual 74

Automotive Sector
Replace ECU with a known good one. Clear codes and check cam phase sensor
Clear codes & verify. and Accelerator pedal is working
properly.

LCV CRDe Service Manual 75

 P-1646
P-1647
Automotive Sector
30) Sensor supply monitoring 2

DTC Diagnostic item

P-1646 Voltage above upper limit
P-1647 Voltage below lower limit

DTC detection condition Probable cause

Normal Operation
The ECU monitors the supply voltage to Rail
pressure sensor and accelerator pedal (APP 2)

Malfunction
The voltages are beyond the range.

Reactions

System lamp status for this error is ON. The ECU

LCV CRDe Service Manual 76

 P-1646
P-1647

Automotive Sector

10.Connect the diagnostic tester

11.Turn Ignition Switch ON
12.Verify that either P-1646 or P-1647 is present.

• This is related to the rail pressure sensor and APP2 supply voltage
• Check the connection of the rail pressure sensor & accelerator pedal connector
• Is it OK?

Yes No

Remove the sensor connections of the Repair the connection

LCV CRDe Service Manual 77

 P – 1646
P – 1647
Automotive Sector
Rail pressure sensor & the Accelerator
pedal
Clear the error Clear codes and verify.
If the error heals then the problem may
be due to poor connection.
Does it heal?

No Yes

Clear the codes & verify. Check the continuity between the Rail
pressure connector terminal 3 and
terminal A14 of the ECU
Check the continuity of between
terminal 1 of the Accelerator pedal
(APP2) and K 46 of the ECU

Repair the connection

If the error is still present, then the ECU Reconnect everything
is suspect.
Replace ECU with a known good one. Clear codes and verify.
Clear codes & verify.

LCV CRDe Service Manual 78

 P-1658

Automotive Sector
31) Terminal 15 (Ignition) – contains plausibility error (Sig) of T15

DTC Diagnostic item

P-1658 No Terminal T15 signals detected

DTC detection condition Probable cause

Normal operation
• When ignition is ON relay coil will get • Open, shorted or wrong
energized. connection of T15
• Engine being started. circuit.

Malfunction
• When ignition is ON supply is not coming to
ECU.
• Main relay coil will not get energized.
• Engine will not start.

Connect the diagnostic tester

42.Turn Ignition Switch ON
43.Verify that P-1658 is present.

• Check that the main relay is getting energized

• To check that the relay is getting energized, hear for the clicking sound from the
main relay when the Ignition is switched ON.
• Is it OK

Yes No

Turn the Ignition OFF Follow the Main relay fault finding
procedure.
Measure the continuity of the wire Clear the error codes & verify
between the K28 terminal of the ECU

LCV CRDe Service Manual 79

Automotive Sector
and the Ignition switch

Is it OK?

Yes No

Check for loose or intermittent Repair the connection.

connection also
Repair the connection Clear the codes and verify that the
vehicle is working perfectly
Clear the codes and verify that the
vehicle is working perfectly

LCV CRDe Service Manual 80

 P-0503
P-0500
Automotive Sector P-0501
32) Vehicle speed sensing

DTC Diagnostic item

P-0503 Exceeding of the maximum vehicle speed
P-0500 HW signal for vehicle speed not valid
P-0501 Vehicle speed not plausible with injection mass and engine speed

DTC detection condition Probable cause

Normal Operation
• The vehicle speed sensor outputs a pulse • Failed vehicle speed
signal while the vehicle is driven. sensor.
• The ECU checks whether the pulse signal is • Open shorted vehicle-
present. speed sensor circuit,
loose or wrong
connection.
Malfunction
• Sensor output voltage has not changed (No
pulse signal) for 4 sec.

LCV CRDe Service Manual 81

 P-0503
P-0500
Automotive Sector P-0501

LCV CRDe Service Manual 82

 P-0503
P-0500
Automotive Sector P-0501

44.Connect the diagnostic Tester

45.Turn Ignition Switch ON
46.Verify that either P0503 or P0500 or P0501 is present.

• Drive the vehicle

• Does the speedometer show the correct value? (Compare the values of
speedometer with the value visible in the diagnostic tester- use the live data tab
in diagnostic tester.)
• Is it OK?

Yes No

Turn the Ignition OFF Repair the cable ( from the pin no 1 to
pin no 5 of the instrument cluster socket-
C24)
Inspect the interface between the VSS Clear the error codes & verify
and the speedometer gear in the Gearbox
Is it OK?

Yes No

Disconnect VSS Repair the interface between he

speedometer & the VSS
Disconnect ECU connector Clear codes & verify that VSS signal is
within limit.
Measure the continuity between the
ECU terminal K75 and sensor terminal
3
Is it OK?

LCV CRDe Service Manual 83

 P-0503
P-0500
Automotive Sector P-0501

Yes No

Check the open circuit between the Repair the wire between VSS connector
sensor Ground & positive supply & ECU terminal
Is it OK Clear codes & verify that VSS signal is
within limit.

Yes No

Verify that the ECU connections are OK Repair short circuit to Ground or
another circuit in wire between VSS
harness connector
If OK replace VSS with a known good Clear codes and verify that the VSS
VSS signal is within range.
Clear codes and verify that the VSS
signal is within range.
If problem persist- replace ECU

LCV CRDe Service Manual 84

Automotive Sector

33) Resistance Values

Coolant temperature Sensor/ Fuel Temperature sensor

Temperature Resistance Min kΏ Resistance Max kΏ

10 8.244 10.661
20 2.262 2.76
80 0.304 0.342
100 0.178 0.196

Accelerator pedal

Poti 1 Poti 2
Accelerator pedal:- 0% 2.160KOhm, 2.672KOhm
Accelerator pedal :-100% 1.321KOhm 2.112KOhm
Poti 1 1.2 kΏ ± 0.4 1.7 kΏ ± 0.4

Injector Solenoid coil

Nominal value: 0.255 Ohm

Min: 0.215 Ohm,
Max: 0.295 Ohm
Measured at 20-70 degrees centigrade.

MPROP coil resistance

Between Minimum: 2.60 Ohm & Maximum: 3.15 Ohm

Measured at 20 degrees centigrade.

LCV CRDe Service Manual 85