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Tata 4SPCR BSVI Engine

EMS Service Routine Manual

©copyright, Confidential, Tata Motors Limited

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Revision Control

This document’s revision control is managed by issue date.

Issue Date Prepared by Revision Reason/Changes

12/12/2020 Abhinav Thiyagarajan 1.0 Initial Document

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Contents

S. no. Fault Description Page

1 EGRH Actuator Clean and Learn Test Routine 4
2 VGTH Actuator Clean and Learn Test Routine 5
3 ETV Actuator Clean and Learn Test Routine 6
4 Reset EGRH Actuator Learn Value 7
5 Reset VGTH Actuator Learn Value 8
6 Reset ETV Actuator Learn Value 9
7 EGRH Actuator Functionality Test Routine [0%, 50%, and 100%] 10
8 VGTH Actuator Functionality Test Routine [0%, 50%, and 100%] 11
9 ETV Actuator Functionality Test Routine [0%, 50%, and 100%] 12
10 Reset DPF Soot Values Routine 13
11 Reset DP Sensor Values Routine 14
12 Reset SCR Values Routine 15
13 Reset PFM Sensor Learn Values Routine 16
14 Reset Injector Trim Values Routine 17
15 Reset IMV Values Routine 18
16 Reset APS Values Routine 19
17 Injector 1 Shut Off Test Routine 20
18 Injector 2 Shut Off Test Routine 21
19 Injector 3 Shut Off Test Routine 22
20 Injector 4 Shut Off Test Routine 23
21 Injector 4 Buzzing Test Routine 24
22 Injector 4 Buzzing Test Routine 25
23 Injector 4 Buzzing Test Routine 26
24 Injector 4 Buzzing Test Routine 27
25 SPCs Test Routine 28
26 Hydraulic Test Routine 29
27 Compression Test Routine 30
28 Power Balance Test Routine 31
29 Rail Pressure Test Routine 32
30 IMV Test Routine 37
31 IMV Buzzing Test Routine 38
32 Regeneration at Idle Test Routine 39

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EGRH Actuator Clean and Learn Test Routine

Purpose:
For performing forced EGRH valve cleaning & learning

When to Perform?

 If the actuator/valve is replaced.

 If the actuator learned value is in-correct.
 If the actuator values are reset.

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Coolant temperature: more than 75 deg. C
 Battery Voltage: > 12V
 No Electrical Faults of EGRH Registered.

Observations (during and after the test):

 Before performing this test, reset the actuator values through Reset EGRH Learn Value Test routine.
 Then start EGRH Actuator Clean and Learn Routine. Once the test is started, wait for 30 sec in key
ON condition for the test to get completed.
 After the completion of 30 sec, switch off the ignition and check whether: HP EGR Learned ADC is
between 123 to 286 ADCnt from vehicle parameter list in TDS tool at key ON condition.
 If the learned value is out of the mentioned above limits, replace the valve.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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VGTH Actuator Clean and Learn Test Routine

Purpose:
For performing forced VGTH valve cleaning & learning

When to Perform?

 If the actuator/valve is replaced.

 If the actuator learned value is in-correct.
 If the actuator values are reset.

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Coolant temperature: more than 75 deg. C
 Battery Voltage: > 12V
 No Electrical Faults of VGTH Registered.

Observations (during and after the test):

 Before performing this test, reset the actuator values through Reset VGTH Learn Value Test routine.
 Then start VGTH Actuator Clean and Learn Routine. Once the test is started, wait for 30 sec in key
ON condition for the test to get completed.
 After the completion of 30 sec, switch off the ignition and check whether: HP VGT Learned ADC is
between 593 to 859 ADCnt from vehicle parameter list in TDS tool at key ON condition.
 If the learned value is out of the mentioned above limits, replace the valve.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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ETV Actuator Clean and Learn Test Routine

Purpose:
For performing forced ETV valve cleaning & learning

When to Perform?

 If the actuator/valve is replaced.

 If the actuator learned value is in-correct.
 If the actuator values are reset.

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Coolant temperature: more than 75 deg. C
 Battery Voltage: > 12V
 No Electrical Faults of ETV Registered.

Observations (during and after the test):

 Before performing this test, reset the actuator values through Reset ETV Learn Value Test routine.
 Then start ETV Actuator Clean and Learn Routine. Once the test is started, wait for 30 sec in key ON
condition for the test to get completed.
 After the completion of 30 sec, switch off the ignition and then check whether: ETV Learned ADC is
between 102 to 184 ADCnt from vehicle parameter list in TDS tool at key ON condition.
 If the learned value is out of the mentioned above limits, replace the valve.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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Reset EGRH Learn Test Routine

Purpose:
For resetting EGR learned values.

When to Perform?

 If the actuator/valve is replaced.

 If the actuator learned value is in-correct.

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Coolant temperature: more than 75 deg. C
 Battery Voltage: > 12V
 No Electrical Faults of EGRH Registered.

Procedure and Observations (during and after the test):

 Execute the test through Reset EGRH Learn Value Test routine.
 After the completion of test, give a power latch.
 Then, execute: EGRH Actuator Clean and Learn Value Test routine.
 Wait for 30 sec to get test completed and then switch off the ignition. Then check whether: HP EGR
Learned ADC is between 123 to 286 ADCnt from vehicle parameter list in TDS tool.
 If the learned value is out of the mentioned above limits, replace the valve.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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Reset VGTH Learn Test Routine

Purpose:
For resetting VGTH learned values.

When to Perform?

 If the actuator/valve is replaced.

 If the actuator learned value is in-correct.

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Coolant temperature: more than 75 deg. C
 Battery Voltage: > 12V
 No Electrical Faults of VGTH Registered.

Procedure and Observations (during and after the test):

 Execute the test through Reset VGTH Learn Value Test routine.
 After the completion of test, give a power latch.
 Then, execute: VGTH Actuator Clean and Learn Value Test routine.
 Wait for 30 sec to get test completed and then switch off the ignition. Then check whether: HP VGT
Learned ADC is between 593 to 859 ADCnt from vehicle parameter list in TDS tool.
 If the learned value is out of the mentioned above limits, replace the valve.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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Reset ETV Learn Test Routine

Purpose:
For resetting ETV learned values.

When to Perform?

 If the actuator/valve is replaced.

 If the actuator learned value is in-correct.

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Coolant temperature: more than 75 deg. C
 Battery Voltage: > 12V
 No Electrical Faults of ETV Registered.

Procedure and Observations (during and after the test):

 Execute the test through Reset ETV Learn Value Test routine.
 After the completion of test, give a power latch.
 Then, execute: ETV Actuator Clean and Learn Value Test routine.
 Wait for 30 sec to get test completed and then switch off the ignition. Then check whether: ETV
Learned ADC is between 102 to 184 ADCnt from vehicle parameter list in TDS tool.
 If the learned value is out of the mentioned above limits, replace the valve.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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EGRH Actuator Functionality Test Routine

Purpose:
For taking direct control of EGR demand. Can be used in EOL or Field to check the actuator functioning.

When to Perform?

 In case of faults: P0403-73 (EGRH valve Stuck Fault), P0400-7C (EGR valve Actuation Response - Slow
Fault), P0400-9B (EGR Excessive Flow Detected Fault), and P0400-9C (EGR Insufficient Flow Detected
Fault).
 If the actuator/valve is replaced.
 After EGRH Actuator Clean and Learn Test

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Coolant temperature: more than 75 deg. C
 Battery Voltage: > 12V
 No Electrical Faults of EGRH Registered.

Procedure and Observations (during and after the test):

 Execute the test through EGRH Actuator Functionality Test [0%, 50%, and 100%] routine.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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VGTH Actuator Functionality Test Routine

Purpose:
For taking direct control of VGTH demand. Can be used in EOL or Field to check the actuator functioning.

When to Perform?

 In case of faults: P22CA-73 (Variable Geometry Turbocharger Stuck Fault), P0045-7C (Turbocharger
Actuation Response to Build Demanded - Slow Fault), P0234-00 (Excessive Boost Pressure Detected
Fault), and P0299-00 (Insufficient Boost Pressure Detected Fault).
 If the actuator/valve is replaced.
 After VGTH Actuator Clean and Learn Test

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Battery Voltage: > 12V
 No Electrical Faults of VGTH Registered.

Procedure and Observations (during and after the test):

 Execute the test through VGTH Actuator Functionality Test [0%, 50%, and 100%] routine.
 Also, if possible, while executing the test, check physically whether the actuator lever is moving.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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ETV Actuator Functionality Test Routine

Purpose:
For taking direct control of ETV demand. Can be used in EOL or Field to check the actuator functioning.

When to Perform?

 In case of faults: P04D3-1C (Exhaust Throttle Valve Stuck Fault).

 If the actuator/valve is replaced.
 After ETV Actuator Clean and Learn Test

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Battery Voltage: > 12V
 No Electrical Faults of ETV Registered.

Procedure and Observations (during and after the test):

 Execute the test through ETV Actuator Functionality Test [0%, 50%, and 100%] routine.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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Reset DPF Soot Values Routine

Purpose:
Resetting of DPF soot values (strictly use only if DPF brick is replaced)

When to Perform?

 If the DPF is replaced.

 In case of faults: P24A4-00 (DPF Overloaded Fault)

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Battery Voltage: > 12V
 No Faults other than Overloaded DPF is registered.

Procedure and Observations (during and after the test):

 Execute the test through reset DPF soot values routine.
 After the completion of this routine, perform Regeneration at Idle before dispatching the vehicle.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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Reset DP Sensor Values Routine

Purpose:
Resetting of DP sensor values (strictly use only if DP sensor is replaced or DPF brick is replaced).

When to Perform?

 If the DP sensor or DPF brick is replaced.



Preconditions:
 Engine state: Ignition ON and Engine OFF
 Battery Voltage: > 12V
 No Faults other than Overloaded DPF is registered.

Procedure and Observations (during and after the test):

 Execute the test through Reset DP Sensor Values routine.
 After the completion of this routine, perform Regeneration at Idle before dispatching the vehicle.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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Reset SCR Values Routine

Purpose:
Resetting of SCR values (strictly use only if SCR brick is replaced)

When to Perform?

 If the SCR brick is replaced.

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Battery Voltage: > 12V
 No Faults other than Overloaded DPF is registered.

Procedure and Observations (during and after the test):

 Execute the test through Reset SCR valves test routine.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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Reset PFM Sensor Learn Values Routine

Purpose:
For resetting PFM learnt value. To be used when replacing PFM sensor

When to Perform?

 If the PFM sensor is replaced.

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Battery Voltage: > 12V
 No electrical faults of PFM sensor registered.

Procedure and Observations (during and after the test):

 Execute the test through Reset PFM Sensor Learn Value test routine.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between

Failure actions:
 Make sure enabling conditions are met and start again

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Reset Injector Trim Values Routine

Purpose:
For resetting injector trims. To be used when injectors are replaced

When to Perform?

 If the Injector is replaced.

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Battery Voltage: > 12V
 No electrical faults of Injectors are registered.

Procedure and Observations (during and after the test):

 Execute the test through Reset Injector Trim Value test routine.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.

Failure actions:
 Make sure enabling conditions are met and start again

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Reset IMV Values Routine

Purpose:
For resetting IMV. To be used when IMV are replaced

When to Perform?

 If the IMV is replaced.

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Battery Voltage: > 12V
 No electrical faults of IMV are registered.

Procedure and Observations (during and after the test):

 Execute the test through Reset IMV Value test routine.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.

Failure actions:
 Make sure enabling conditions are met and start again

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Reset APS Values Routine

Purpose:
For resetting APS trims.

When to Perform?

 If the CAM gear/ trigger wheel is replaced.

Preconditions:
 Engine state: Ignition ON and Engine OFF
 Battery Voltage: > 12V
 No electrical faults of IMV are registered.

Procedure and Observations (during and after the test):

 Execute the test through Reset APS Value test routine.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.

Failure actions:
 Make sure enabling conditions are met and start again

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Injector 1 Shut Off Test Routine

Purpose:
The aim of this test is to check injector. Disables Cylinder 1 injector

When to Perform?
 Associated faults triggered
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:

 Engine state = Idle running

 Engine speed (Min/Max) = (700/3100)
 Brake Switch = Not pressed
 Clutch switch = Not pressed
 Vehicle speed (Min/Max) = (0/0) km/h
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/0) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

The engine noise will get changed during the test.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.

Failure actions:
 Make sure enabling conditions are met and start again

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Injector 2 Shut Off Test Routine

Purpose:
The aim of this test is to check injector. Disables Cylinder 2 injector

When to Perform?
 Associated faults triggered
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:

 Engine state = Idle running

 Engine speed (Min/Max) = (700/3100)
 Brake Switch = Not pressed
 Clutch switch = Not pressed
 Vehicle speed (Min/Max) = (0/0) km/h
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/0) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

The engine noise will get changed during the test.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.

Failure actions:
 Make sure enabling conditions are met and start again

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Injector 3 Shut Off Test Routine

Purpose:
The aim of this test is to check injector. Disables Cylinder 3 injector

When to Perform?
 Associated faults triggered
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:

 Engine state = Idle running

 Engine speed (Min/Max) = (700/3100)
 Brake Switch = Not pressed
 Clutch switch = Not pressed
 Vehicle speed (Min/Max) = (0/0) km/h
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/0) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

The engine noise will get changed during the test.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.

Failure actions:
 Make sure enabling conditions are met and start again

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Injector 4 Shut Off Test Routine

Purpose:
The aim of this test is to check injector. Disables Cylinder 4 injector

When to Perform?
 Associated faults triggered
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:

 Engine state = Idle running

 Engine speed (Min/Max) = (700/3100)
 Brake Switch = Not pressed
 Clutch switch = Not pressed
 Vehicle speed (Min/Max) = (0/0) km/h
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/0) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

The engine noise will get changed during the test.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.

Failure actions:
 Make sure enabling conditions are met and start again

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Injector 1 Buzzing Test Routine

Purpose:
The aim of this test is to check Cylinder 1 injector solenoid function and unjamming.

When to Perform?
 Associated faults triggered
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:
 Engine state = Idle running
 Engine speed (Min/Max) = (700/3100)
 Brake Switch = Not pressed
 Clutch switch = Not pressed
 Vehicle speed (Min/Max) = (0/0) km/h
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/0) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test)

When this routine is launched, it makes the injector control valve to move faster which creates a buzzing
sound. If the buzzing sound is heard, then the injector control valve is in good condition else the control valve
is stuck.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.

Failure actions:
 Make sure enabling conditions are met and start again

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Injector 2 Buzzing Test Routine

Purpose:
The aim of this test is to check Cylinder 2 injector solenoid function and unjamming

When to Perform?
 Associated faults triggered
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:
 Engine state = Idle running
 Engine speed (Min/Max) = (700/3100)
 Brake Switch = Not pressed
 Clutch switch = Not pressed
 Vehicle speed (Min/Max) = (0/0) km/h
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/0) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

When this routine is launched, it makes the injector control valve to move faster which creates a buzzing
sound. If the buzzing sound is heard, then the injector control valve is in good condition else the control valve
is stuck.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.

Failure actions:
 Make sure enabling conditions are met and start again

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Injector 3 Buzzing Test Routine

Purpose:
The aim of this test is to check Cylinder 3 injector solenoid function and unjamming

When to Perform?
 Associated faults triggered
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:
 Engine state = Idle running
 Engine speed (Min/Max) = (700/3100)
 Brake Switch = Not pressed
 Clutch switch = Not pressed
 Vehicle speed (Min/Max) = (0/0) km/h
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/0) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

When this routine is launched, it makes the injector control valve to move faster which creates a buzzing
sound. If the buzzing sound is heard, then the injector control valve is in good condition else the control valve
is stuck.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.

Failure actions:
 Make sure enabling conditions are met and start again

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Injector 4 Buzzing Test Routine

Purpose:
The aim of this test is to check Cylinder 4 injector solenoid function and unjamming.

When to Perform?
 Associated faults triggered
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:
 Engine state = Idle running
 Engine speed (Min/Max) = (700/3100)
 Brake Switch = Not pressed
 Clutch switch = Not pressed
 Vehicle speed (Min/Max) = (0/0) km/h
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/0) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

When this routine is launched, it makes the injector control valve to move faster which creates a buzzing
sound. If the buzzing sound is heard, then the injector control valve is in good condition else the control valve
is stuck.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.

Failure actions:
 Make sure enabling conditions are met and start again

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SPCs Test Routine

Purpose:
The aim of the test is to perform MDP correction on the injectors.

When to Perform?
 Faults : P268A-F0 / F1/F2 Minimum Delivery Injector Pulse - Not Updated Fault
 Injectors are replaced or injector coding routine is done on the vehicle

Preconditions:
 Engine state = Idle running
 Engine speed (Min/Max) = (700/3100)
 Brake Switch = Not pressed
 Clutch switch = Not pressed
 Vehicle speed (Min/Max) = (0/0) km/h
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/0) %
 DOC in temperature is more than 280 deg. C
 DPF out temperature is more than 300 deg. C
 Combustion mode= 0.

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

 Variation in engine rpm and rail pressure demand
 MDP value update at the end of the routine test.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.

Failure actions:
 Make sure enabling conditions are met and start again

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Hydraulic Test Routine

Purpose:
The aim of the test is to check if the high pressure system works without trouble and if the global static leak
of the injectors is acceptable (speed of pressure decrease not too high).

When to Perform?
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:
 Battery voltage (Min/Max) = (10/16) V
 Coolant temperature (Min/Max) = (50/105) deg. C
 Engine state = Stopped
 Brake Switch = Not pressed
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/3) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

The Vehicle should be cranked continuously until it stops.
A hydraulic test result is computed when the test is finished. It can take 5 different values:
0: Test is not finished (In progress).
1: OK
2: NOK, Engine speed under starter is too low.
3: NOK, Average of pressure feedback during the average state is too low.
4: NOK, Both engine speed under starter and average of pressure feedback are too low.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.
 When engine is not cranked within 10 seconds of starting the test.

Failure actions:
 Make sure enabling conditions are met and start again.

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Compression Test Routine

Purpose:
The compression test consists of measure cylinder specific rotational speed for detect if a problem of
compression exists. No fuel injection is allowed (no engine start possible). The measure are realized during
cranking speed.

When to Perform?
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:
 Battery voltage (Min/Max) = (10/16) V
 Coolant temperature (Min/Max) = (50/105) deg. C
 Engine state = Stopped
 Brake Switch = Not pressed
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/3) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

The Vehicle should be cranked continuously until it stops.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.
 When engine is not cranked within 10 seconds of starting the test.

Failure actions:
 Make sure enabling conditions are met and start again.

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Power Balance Test Routine

Purpose:
This Test is used to check that the Engine has been correctly mounted and there is no defective
components that unbalance the engine firing.

When to Perform?
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:
 Engine state = Idle running
 Vehicle speed (Min/Max) = (0/0) km/h
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/0) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

 Engine speed is set to 1600 rpm. Next, after 15 sec time, pedal position will be set to 0%.
 This working point will be maintained during 13 sec, then the engine speed and injection delta speed
for each cylinder are recorded as reference is reached.
 After 10 sec, this state is terminated, the Injector shut off sequence will start.
 During this step, each cylinder will be shut off one by one for 4.5 sec.
 Then engine speed and injection delta speed will be recorded for each cylinder after 5 sec
 Once shut off time is elapsed, each cylinder will be turned on in next 5sec
 Once each cylinder have been shut off once, the test sequence is complete and results are available.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.
 When engine is not cranked within 10 seconds of starting the test.

Failure actions:
 Make sure enabling conditions are met and start again.

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Rail Pressure Test Routine

Purpose:
The aim of this test is to check injector back leak

When to Perform?
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:
 Battery voltage (Min/Max) = (10/16) V
 Coolant temperature (Min/Max) = (50/105) deg. C
 Engine state = Running
 Engine speed (Min/Max) = (600/2500)
 Brake & Clutch Switch = Not pressed
 Vehicle speed (Min/Max) = (0/0) km/h
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/3) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

 Raising and falling of engine rpm

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Routine Interrupt conditions:

 When any of the pre-conditions fail in between.
 When engine is not cranked within 10 seconds of starting the test.

Failure actions:
 Make sure enabling conditions are met and start again.

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IMV Test Routine

Purpose:
The objective of the test is to check that the Inlet Metering Valve works without trouble by monitoring the
rail pressure error during an acceleration.

When to Perform?
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:
 Battery voltage (Min/Max) = (10/16) V
 Coolant temperature (Min/Max) = (50/105) deg. C
 Engine state = Running
 Engine speed (Min/Max) = (600/2500)
 Brake & Clutch Switch = Not pressed
 Vehicle speed (Min/Max) = (0/0) km/h
 Gear ratio (Min/Max) = (0/0)
 Accelerator pedal position (Min/Max) = (0/3) %

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

The engine is ramped up five times to repeat the sequence.
The IMV test final result is computed when the test is finished
0: OK
1: FAILED, at least one of the accelerations is with high pressure variation and high pressure error (above
the 200 bar).

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.
 When engine is not cranked within 10 seconds of starting the test.

Failure actions:
 Make sure enabling conditions are met and start again.

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IMV Buzzing Test Routine

Purpose:
The aim of this test is to check IMV solenoid function and unjamming

When to Perform?
 Associated faults triggered
 To confirm the functioning of IMV control valve
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:
 Ignition = ON
 Engine state = OFF/Stopped
 Vehicle speed = 0 km/h
 Battery voltage (Min/Max) = (10/16) V
 Gear = Neutral
 Accelerator pedal position = 0 %
 The Rail pressure information is correct (no fault) and the value is not too high

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

When this routine is launched, it makes the IMV control valve to move faster.

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.
 When engine is not cranked within 10 seconds of starting the test.

Failure actions:
 Make sure enabling conditions are met and start again.

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Regeneration at Idle Test Routine

Purpose:
For performing Service DPF Regeneration

When to Perform?
 Associated faults triggered
 To confirm the functioning of IMV control valve
 Engine won’t start or difficult to start
 Engine stalls while running
 Lack of power and dashboard warning lamps light: the recovery mode may lead to engine stop

Preconditions:
 Warm up the vehicle more than 85 deg. C coolant temperature preferably by vehicle running.
 Bring the vehicle to idle and ensure that engine is in ON state for more than 10 min before starting
this service.
 Confirm Gear: Neutral, Accelerator Pedal: 0%, Clutch Sate: Engaged and Brake Switch: False
 No fault other than Overloaded fault.

Precautions:
 Check fuel lines for leakage/Pinch/Cut.
 Check ECU pins for oxidation, bending & damage.
 Check and ensure rail pressure feed-back values whether these values follow the demand
continuously during cranking or idling (Rail Pressure demand, Rail Pressure feedback). There should
not be major difference in values.

Procedure and Observations (during and after the test):

 Raised engine rpm from Idle (2500 rpm)
 Smoke from tail pipe
 Heat up time 300 sec

Routine Interrupt conditions:

 When any of the pre-conditions fail in between.
 When engine is not cranked within 10 seconds of starting the test.

Failure actions:
 Make sure enabling conditions are met and start again.

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