Version: 1.

0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Table of Contents
P0299-00: Boost pressure is too low fault....................................................................................................................... 12
P0234-00: Over Boost Pressure Fault .............................................................................................................................. 16
P0403-08: EGR Actuator - Internal Communication failure in ECU ................................................................................. 20
P0403-4B: EGR Actuator - Internal temperature error in ECU ........................................................................................ 23
P0403-79: EGR Actuator - Return spring broken error.................................................................................................... 26
P0403-7C: EGR Actuator - Slow response fault ............................................................................................................... 29
P0403-71: EGR Actuator - Stuck fault .............................................................................................................................. 32
P2457-00: EGR Cooler - Efficiency very low .................................................................................................................... 35
P0403-A1: EGR Actuator - Controller system voltage error ............................................................................................ 38
P0403-F2: EGR Actuator - Negative Pin - Short to Battery .............................................................................................. 41
P0403-F3: EGR Actuator - Negative Pin - Short to Ground.............................................................................................. 44
P0403-13: EGR Actuator - Open load error ..................................................................................................................... 47
P0403-F5: EGR Actuator - Over Current in Negative Pin ................................................................................................. 50
P0403-F4: EGR Actuator - Over Current in Positive Pin ................................................................................................... 53
P0403-F0: EGR Actuator - Positive Pin - Short to Battery................................................................................................ 56
P0403-F1: EGR Actuator - Positive Pin - Short to Ground ............................................................................................... 59
P0400-9B: EGR Flow is too high ....................................................................................................................................... 62
P0400-9C: EGR Flow is too low ........................................................................................................................................ 66
P040A-11: EGR Cooler temperature sensor - Short to Ground ..................................................................................... 69
P040A-12: EGR Cooler temperature sensor - Short to Battery or open ......................................................................... 72
P040A-64: EGR Cooler temperature sensor - Signal not valid based on reference sensors ........................................... 75
P0409-14: EGR Actuator position sensor - Short to Ground or Open failure ................................................................. 78
P0409-12: EGR Actuator position sensor - Short to battery............................................................................................ 81
P0403-54: EGR Actuator - 1st learning failed / Value out of range ................................................................................. 84
P0403-99: EGR Actuator - Learning exceeded wear limit ............................................................................................... 87
P26C5-08: Exhaust Throttle Valve - Internal Communication failure in ECU .................................................................. 90
P26C5-4B: Exhaust Throttle Valve - Internal temperature error in ECU ......................................................................... 93

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-79: Exhaust Throttle Valve - Slow response fault ................................................................................................ 96

P26C5-71: Exhaust Throttle Valve - Stuck fault ............................................................................................................... 99
P26C5-F0: Exhaust Throttle Valve - Negative Pin - Short to Battery ............................................................................. 102
P26C5-F2: Exhaust Throttle Valve - Negative Pin - Short to Ground ............................................................................. 105
P26C5-F5: Exhaust Throttle Valve - Negative Pin Currrent High ................................................................................... 108
P26C5-13: Exhaust Throttle Valve - Open load error .................................................................................................... 111
P26C5-F3: Exhaust Throttle Valve - Positive Pin - Short to Battery ............................................................................... 114
P26C5-F1: Exhaust Throttle Valve - Positive Pin - Short to Ground .............................................................................. 117
P26C5-F4: Exhaust Throttle Valve - Positive Pin Currrent High ..................................................................................... 120
P26C5-A1: Exhaust Throttle Valve - Return spring broken............................................................................................ 123
P2BF4-2F: Exhaust Throttle Valve position sensor - Improper signal........................................................................... 126
P2BF4-14: Exhaust Throttle Valve position sensor - Short to Ground.......................................................................... 129
P2BF4-12: Exhaust Throttle Valve position sensor - Short to battery Or Open ............................................................ 132
P26C5-54: Exhaust Throttle Valve - 1st learning failed / Value out of range ................................................................ 135
P26C5-99: Exhaust Throttle Valve - Learning exceeded wear limit............................................................................... 138
P0243-08: Turbo E-Wastegate - Internal Communication failure in ECU ..................................................................... 141
P0243-4B: Turbo E-Wastegate - Internal temperature error in ECU ............................................................................ 145
P0243-71: Turbo E-Wastegate - Actuator Stuck fault ................................................................................................... 149
P0243-13: Turbo E-Wastegate - Drive Open load error ................................................................................................ 153
P0243-F2: Turbo E-Wastegate - Negative Pin - Short to Battery .................................................................................. 157
P0243-F3: Turbo E-Wastegate - Negative Pin - Short to Ground .................................................................................. 161
P0243-F5: Turbo E-Wastegate - Over Current in Negative Pin ..................................................................................... 165
P0243-F4: Turbo E-Wastegate - Over Current in Positive Pin ....................................................................................... 169
P0243-F0: Turbo E-Wastegate - Positive Pin - Short to Battery .................................................................................... 173
P0243-F1: Turbo E-Wastegate - Positive Pin - Short to Ground .................................................................................... 177
P2AB7-14: Turbo E-Wastegate position sensor - Short to Ground or Open ................................................................ 181
P2AB7-12: Turbo E-Wastegate position sensor - Short to battery ................................................................................ 185
P0243-54: Turbo E-Wastegate - 1st learning failed / Value out of range ..................................................................... 189
P0243-99: Turbo E-Wastegate - Learning exceeded wear limit .................................................................................... 193
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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2226-64: Barometric Pressure Sensor - Signal not valid ............................................................................................. 197

P0070-15: Ambient temperature sensor - Short to battery or Open ............................................................................ 200
P0070-11: Ambient temperature sensor - Short to ground .......................................................................................... 203
P0070-64: Ambient temperature sensor - Signal not valid based on reference sensors .............................................. 206
P0235-29: PFM Sensor - Boost pressure sensor signal error ........................................................................................ 209
P0235-64: PFM Sensor - Boost pressure signal not valid (Compared against other sensor) ........................................ 213
P0110-15: Inlet air temperature sensor - Short to Battery or Open ............................................................................. 217
P0110-11: Inlet air temperature sensor - Short to Ground ........................................................................................... 220
P0110-64: Inlet air temperature sensor - Signal not valid based on reference sensors ............................................... 223
P0105-12: Intake Manifold Pressue sensor - Short to Battery ...................................................................................... 226
P0105-14: Intake Manifold Pressue sensor - Short to Ground or Open........................................................................ 230
P0105-64: Intake Manifold Pressue sensor - Signal not valid based on reference sensors .......................................... 234
P00E8-15: Intake Manifold temperature sensor - Short to Battery or Open ................................................................ 238
P00E8-11: Intake Manifold temperature sensor - Short to Ground.............................................................................. 242
P00E8-64: Intake Manifold temperature sensor - Signal not valid based on reference sensors .................................. 246
P026A-00: Intercooler Performance - Low efficiency error .......................................................................................... 250
P006A-9B: PFM Sensor - Signal drift error (High) .......................................................................................................... 254
P006A-9C: PFM Sensor - Signal drift error (Low) ........................................................................................................... 258
P0100-29: PFM Sensor - Signal error ............................................................................................................................. 262
P007A-29: Intercooler out temperature - Sensor signal error ..................................................................................... 266
P007A-64: Intercooler out temperature - Signal not valid based on reference sensors.............................................. 270
P0100-81: PFM Sensor - SENT 1 data error ................................................................................................................... 274
P0100-86: PFM Sensor - SENT 1 global message error ................................................................................................. 278
P010A-81: PFM Sensor - SENT 2 data error ................................................................................................................... 282
P010A-86: PFM Sensor - SENT 2 global message error ................................................................................................. 286
U0155-00: Lost Communication with Instrument Cluster............................................................................................. 290
U007B-00: Communication Error - Private CAN Bus Off or Passive Error ..................................................................... 292
U007A-00: Communication Error - Public CAN Bus Off or Passive Error....................................................................... 297
U010E-00: Lost Communication with DCU .................................................................................................................... 301
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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

U0619-00: Lost Communication with DEF Urea Level Sensor ....................................................................................... 305
P0340-99: Cam Sensor - Learning failure ...................................................................................................................... 309
P0340-78: Cam Sensor - Signal drift error ..................................................................................................................... 312
P0340-2F: Cam Sensor - Signal erratic error.................................................................................................................. 315
P0340-31: Cam Sensor - Signal Lost fault ...................................................................................................................... 318
P0340-39: Cam Sensor - Signal Missing error ................................................................................................................ 321
P0016-00: CRANK Sensor - Invalid gap between consecutive signals ........................................................................... 324
P0335-27: CRANK Sensor - Signal Early Detection Error ............................................................................................... 327
P0335-31: CRANK Sensor - Signal Lost fault .................................................................................................................. 330
P0335-1F: CRANK Sensor - Signal Missing ..................................................................................................................... 333
P2226-04: Barometric Pressure Sensor - Sensor internal failure .................................................................................. 336
P2226-08: Barometric Pressure Sensor - Sensor signal failure ..................................................................................... 339
P2226-1C: Barometric Pressure Sensor - Sensor signal out of range ............................................................................ 342
P0641-08: ECU 5V channel communication failure ....................................................................................................... 345
P0641-4B: ECU 5V supply system thermal shutdown .................................................................................................. 348
P0641-00: ECU External supply Channel1 failure .......................................................................................................... 351
P0651-00: ECU External supply Channel2 failure .......................................................................................................... 354
P0697-00: ECU External supply Channel3 failure .......................................................................................................... 357
P06D6-00: ECU Internal 3V supply channel failure ....................................................................................................... 360
P06D2-00: ECU Internal 5V Supply channel failure ....................................................................................................... 363
P268A-54: Injector Codes corrupted or not written properly ....................................................................................... 366
P020A-00: ECU - Internal injection timing fault ............................................................................................................ 369
P020C-00: ECU - Internal injection timing fault ............................................................................................................. 372
P020D-00: ECU - Internal injection timing fault ............................................................................................................ 375
P020B-00: ECU - Internal injection timing fault ............................................................................................................. 378
P060B-00: ECU - Internal memory failure ..................................................................................................................... 381
P060A-48: ECU - Internal memory failure ..................................................................................................................... 384
P060C-43: ECU - Internal memory failure ..................................................................................................................... 387
P0607-44: ECU - Internal memory failure ..................................................................................................................... 390
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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0607-05: ECU - Internal memory failure ..................................................................................................................... 393

P060C-44: ECU - Internal memory failure ..................................................................................................................... 396
P060C-05: ECU - Internal memory failure ..................................................................................................................... 399
P060C-49: ECU - Internal memory failure ..................................................................................................................... 402
P060C-42: ECU - Internal memory failure ..................................................................................................................... 405
P060C-45: ECU - Internal memory failure ..................................................................................................................... 408
P0607-04: ECU - Internal memory failure ..................................................................................................................... 411
P060A-49: ECU - Internal memory failure ..................................................................................................................... 414
P060A-42: ECU - Internal memory failure ..................................................................................................................... 417
P060A-45: ECU - Internal memory failure ..................................................................................................................... 420
P060C-47: ECU - Internal memory failure ..................................................................................................................... 423
P060C-00: ECU Internal Memory Failure ....................................................................................................................... 426
P060C-08: ECU Internal Memory Failure ....................................................................................................................... 429
P060C-92: ECU Internal Memory Failure ....................................................................................................................... 432
P062F-00: ECU Non volatile memory error ................................................................................................................... 435
P060C-00: Engine Safety Module - Memory Flash failure ............................................................................................. 438
P0201-56: Cylinder 1 - Injector codes not written / Missing ......................................................................................... 441
P0202-56: Cylinder 2 - Injector codes not written / Missing ......................................................................................... 444
P0203-56: Cylinder 3 - Injector codes not written / Missing ......................................................................................... 447
P0204-56: Cylinder 4 - Injector codes not written / Missing ......................................................................................... 450
P0607-51: EDP (Engine Data Plate) data writing error .................................................................................................. 453
P0607-55: Variant coding not written ........................................................................................................................... 456
P0630-55: Vehicle Identification Number is not written............................................................................................... 459
P0115-15: Engine Coolant temperature sensor - Short to Battery or Open ................................................................. 462
P0115-11: Engine Coolant temperature sensor - Short to Ground ............................................................................... 465
P0115-64: Engine Coolant temperature sensor - Signal not valid based on reference sensors ................................... 468
P0115-2A: Engine Coolant temperature sensor - Signal Stuck at very low ................................................................... 471
P0128-71: Engine Coolant Thermostat stuck fault ........................................................................................................ 474
P0480-9E: E-Viscous FAN - Disengagement failure ....................................................................................................... 477
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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0480-13: E-Viscous FAN - Drive open .......................................................................................................................... 480

P0480-12: E-Viscous FAN - Drive Short to Battery ........................................................................................................ 483
P0480-11: E-Viscous FAN - Drive Short to Ground ........................................................................................................ 486
P0480-9F: E-Viscous FAN - Engagement failure ............................................................................................................ 489
P0526-38: E-Viscous FAN - Speed Signal error .............................................................................................................. 492
P0526-29: E-Viscous FAN - Speed Signal invalid error................................................................................................... 495
P0520-15: Engine Oil pressure is too high / Switch not present in the engine ............................................................. 498
P0524-00: Engine Oil pressure is too low ...................................................................................................................... 501
P0217-00: Engine Over heating fault............................................................................................................................. 504
P0219-00: Engine Over speed fault ............................................................................................................................... 508
P2269-00: Water in fuel fault ........................................................................................................................................ 510
P2264-15: Water In fuel sensor - Short to Battery or Open .......................................................................................... 513
P2264-11: Water in fuel sensor - Short to Ground........................................................................................................ 516
P2031-62: DOC inlet temperature sensor - Signal not valid based on Model .............................................................. 519
P1542-00: DPF Regeneration system fault from DCU ................................................................................................... 522
P0263-00: Cylinder 1 - Injector balance low fault ......................................................................................................... 524
P0201-13: Cylinder 1 - Injector Circuit open ................................................................................................................. 528
P0201-2B: Cylinder 1 - Injector Short circuit error ........................................................................................................ 531
P0266-00: Cylinder 2 - Injector balance low fault ......................................................................................................... 534
P0202-13: Cylinder 2 - Injector Circuit Open ................................................................................................................. 538
P0202-2B: Cylinder 2 - Injector Short circuit error ........................................................................................................ 541
P0269-00: Cylinder 3 - Injector balance low fault ......................................................................................................... 544
P0203-13: Cylinder 3 - Injector Circuit Open ................................................................................................................. 548
P0203-2B: Cylinder 3 - Injector Short circuit error ........................................................................................................ 551
P0272-00: Cylinder 4 - Injector balance low fault ......................................................................................................... 554
P0204-13: Cylinder 4 - Injector Circuit Open ................................................................................................................. 558
P0204-2B: Cylinder 4 - Injector Short circuit error ........................................................................................................ 561
P062D-08: Injector Bank 0 - Internal Communication fault .......................................................................................... 564
P062D-04: Injector Bank 0 - Internal Communication fault .......................................................................................... 567
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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2146-12: Injector Bank 0 - Short to Battery fault ........................................................................................................ 570

P2146-11: Injector Bank 0 - Short to Ground fault ........................................................................................................ 573
P062E-08: Injector Bank 1 - Internal Communication fault ........................................................................................... 576
P062E-04: Injector Bank 1 - Internal Communication fault ........................................................................................... 579
P2149-12: Injector Bank 1 - Short to Battery fault ....................................................................................................... 582
P2149-11: Injector Bank 1 - Short to Ground fault ........................................................................................................ 585
P00C6-7B: Rail pressure not bulit at Low tank level during engine cranking ................................................................ 588
P00C6-00: Rail pressure not bulit at normal tank level during engine cranking ........................................................... 591
P0180-15: Fuel temperature sensor - Short to Battery or Open ................................................................................... 594
P0180-11: Fuel temperature sensor - Short to Ground ................................................................................................ 597
P0180-29: Fuel temperature sensor - Signal not valid based on reference sensors ..................................................... 600
P0090-13: HPV - Circuit Open ........................................................................................................................................ 603
P228D-00: HPV - Controller correction High error ........................................................................................................ 606
P228C-00: HPV - Controller correction Low error ......................................................................................................... 609
P0090-1B: HPV - Current control error (High) ............................................................................................................... 612
P0090-1A: HPV - Current control error (Low)................................................................................................................ 615
P0090-19: HPV - Feedback Current High error .............................................................................................................. 618
P0090-18: HPV - Feedback Current Low error............................................................................................................... 621
P0090-F0: HPV High side pin - Short to Battery ............................................................................................................ 624
P0090-F1: HPV High side pin - Short to Ground ............................................................................................................ 627
P0090-F2: HPV Low side pin - Short to Battery ............................................................................................................. 630
P0090-F3: HPV Low side pin - Short to Ground ............................................................................................................. 633
P0088-92: HPV - Over pressure fault ............................................................................................................................. 636
P0001-9B: IMV - Controller correction High error......................................................................................................... 639
P0001-9C: IMV - Controller correction Low error ......................................................................................................... 642
P0001-1B: IMV - Current control error (High) ............................................................................................................... 645
P0001-1A: IMV - Current control error (Low) ................................................................................................................ 648
P0001-19: IMV - Feedback Current High error .............................................................................................................. 651
P0001-18: IMV - Feedback Current Low error............................................................................................................... 654
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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0001-13: IMV - Open Circuit ........................................................................................................................................ 657

P0001-F0: IMV High side pin - Short to Battery............................................................................................................. 660
P0001-F1: IMV High side pin - Short to Ground ............................................................................................................ 663
P0001-F2: IMV Low side pin - Short to Battery ............................................................................................................. 666
P0001-F3: IMV Low side pin - Short to Ground ............................................................................................................. 669
P0088-94: IMV - Over pressure fault ............................................................................................................................. 672
P0325-00: Accelerometer sensor 1 failure .................................................................................................................... 675
P0330-00: Accelerometer sensor 2 failure .................................................................................................................... 678
P016E-00: Rail Pressure Control - Negative Error ......................................................................................................... 681
P016F-00: Rail Pressure Control - Positive Error ........................................................................................................... 684
P0190-11: Rail pressure sensor - Short to Ground ....................................................................................................... 687
P0190-12: Rail pressure sensor - Short to Battery or Open .......................................................................................... 690
P0088-22: Rail pressure sensor - Signal too high .......................................................................................................... 693
P0087-00: Rail pressure sensor - Signal too Low ........................................................................................................... 696
P2BA7-00: DEF Level Empty Indication ......................................................................................................................... 699
P203F-00: DEF Level Low Indication .............................................................................................................................. 702
P203F-7B: DEF Level Near Empty Indication ................................................................................................................. 705
P203F-21: DEF Level very Low Indication ...................................................................................................................... 708
P2BAA-00: Inducement - DEF Consumption fault ......................................................................................................... 711
P2BA8-00: Inducement - DEF Dosing Stopped Fault ..................................................................................................... 713
P2BA9-00: Inducement - DEF Quality fault.................................................................................................................... 715
P2BAE-00: Inducement - DEF SCR System fault............................................................................................................. 717
P0645-13: AC relay - Open Circuit ................................................................................................................................. 719
P0645-12: AC relay - Short to Battery ........................................................................................................................... 722
P0645-11: AC relay - Short to Ground ........................................................................................................................... 725
P2138-00: Accelerator foot pedal correlation error...................................................................................................... 728
P2120-29: Accelerator foot Pedal Limph fault .............................................................................................................. 731
P2120-71: Accelerator foot Pedal Stuck fault................................................................................................................ 734
P2120-15: Accelerator Foot Pedal track1 sensor - Short to Battery or Open ............................................................... 737
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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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P2120-11: Accelerator Foot Pedal track1 sensor - Short to Ground ............................................................................. 740
P2125-15: Accelerator Foot Pedal track2 sensor - Short to Battery or Open ............................................................... 743
P2125-11: Accelerator Foot Pedal track2 sensor - Short to Ground ............................................................................. 746
P0560-A3: Battery supply Voltage high fault ................................................................................................................ 749
P0560-A2: Battery supply Voltage Low fault ................................................................................................................. 752
P2141-A3: Battery Voltage - Channel 2 voltage high failure ......................................................................................... 755
P2141-A2: Battery Voltage - Channel 2 voltage low failure .......................................................................................... 758
P0703-12: Brake Safety Switch - Short to Battery ......................................................................................................... 761
P0504-64: Brake Switch & Safety Brake switch signals are not matching .................................................................... 764
P083F-00: Clutch top & bottom switch signals are not coherent ................................................................................. 767
P0830-29: Clutch Top Switch Signal Invalid ................................................................................................................... 770
P1801-13: DPF Inhibit switch lamp - Open circuit failure.............................................................................................. 773
P1801-12: DPF Inhibit switch lamp - Short to Battery failure ....................................................................................... 776
P1801-11: DPF Inhibit switch lamp - Short to Ground failure ....................................................................................... 779
P25BA-9E: DPF Regeneration Request Switch - Stuck fault ......................................................................................... 782
P260E-13: DPF Regeneration Request switch lamp - Open circuit failure .................................................................... 785
P260E-12: DPF Regeneration Request switch lamp - Short to Battery failure .............................................................. 788
P260E-11: DPF Regeneration Request switch lamp - Short to Ground failure.............................................................. 791
P0685-13: ECU Power relay electrical fault - Open Circuit ............................................................................................ 794
P0685-73: ECU Power relay stuck fault ......................................................................................................................... 797
P0380-13: Glow plug - Circuit Open ............................................................................................................................. 800
P0380-12: Glow plug - Short to Battery......................................................................................................................... 803
P0380-11: Glow plug - Short to Ground ........................................................................................................................ 806
P0650-13: MIL lamp - Open Circuit............................................................................................................................... 809
P0650-12: MIL lamp - Short to Battery .......................................................................................................................... 812
P0650-11: MIL lamp - Short to Ground ......................................................................................................................... 815
P081D-24: Neutral Gear Switch signal stuck close fault ................................................................................................ 818
P081D-23: Neutral Gear Switch signal Stuck open fault ............................................................................................... 821
P0615-13: Start relay - Circuit Open .............................................................................................................................. 824
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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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P0615-F2: Start relay - Short to Battery ........................................................................................................................ 827

P0615-F3: Start relay - Short to Ground ........................................................................................................................ 830
P0500-31: Vehicle speed sensor - Signal loss during vehicle driving ............................................................................ 833
P0500-01: Vehicle speed sensor - Signal not valid / Sensor not connected ................................................................. 836
P2226-04: ECU Barometric Sensor Failure .................................................................................................................... 839
P2226-34: ECU Barometric Sensor Failure (Value out of Range- High) ......................................................................... 841
P2226-33: ECU Barometric Sensor Failure (Value out of Range- Low).......................................................................... 843
P0641-08: Failure of Microcontroller inside ECU for Injector ....................................................................................... 845
P16D2-01: Failure of Microcontroller inside ECU .......................................................................................................... 847
P1697-01: Failure of Microcontroller inside ECU .......................................................................................................... 849
P16A3-01: Failure of Microcontroller inside ECU .......................................................................................................... 851
P0641-01: Failure of Microcontroller inside ECU .......................................................................................................... 853
P06D2-00: Failure of Microcontroller inside ECU .......................................................................................................... 855
P1641-01: Failure of Microcontroller inside ECU .......................................................................................................... 857
P1651-01: Failure of Microcontroller inside ECU .......................................................................................................... 859
P0641-01: ECU 5 Voltage Supply Issue For Channel 1 Sensors ..................................................................................... 861
P0651-01: ECU 5 Voltage Supply Issue For Channel 2 Sensors ..................................................................................... 863
P0697-01: ECU 5 Voltage Supply Issue For Channel 3 Sensors ..................................................................................... 865
P16D2-75: Thermal shutdown due to ECU Microcontroller Failure.............................................................................. 867
P1697-75: Thermal shutdown due to ECU Microcontroller Failure .............................................................................. 869
P16A3-75: Thermal shutdown due to ECU Microcontroller Failure .............................................................................. 871
P1641-75: Thermal shutdown due to ECU Microcontroller Failure .............................................................................. 873
P1651-75: Thermal shutdown due to ECU Microcontroller Failure .............................................................................. 875
P0641-75: Thermal shutdown due to ECU Microcontroller Failure .............................................................................. 877
P0651-75: Thermal shutdown due to ECU Microcontroller Failure .............................................................................. 879
P0697-75: Thermal shutdown due to ECU Microcontroller Failure .............................................................................. 881
P0520-12: Engine oil pressure sensor short to battery ................................................................................................. 883
P0520-14: Engine oil pressure sensor short to ground or open.................................................................................... 885
P0195-15: Engine Oil temp Sensor short to battery or open ........................................................................................ 887
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P0195-11: Engine Oil temp sensor short to ground ...................................................................................................... 889

P2CEF-13: Oil Thermostat Open circuit Fault ................................................................................................................ 891
P2CEF-11: Oil Thermostat short circuit to ground ........................................................................................................ 893
P2CEF-12: Oil Thermostat short circuit to battery ........................................................................................................ 895

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P0299-00: Boost pressure is too low fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wastegate actuator/PFM electrical failures

Fault Code P0299-00 2. Intake path air leakages
3. Air filter choke
4. Intercooler Blockage /Leakage in intercooler
5. ATS/DPF clogging or Cracking Issues
6. ETV related issues
Engine emission may go high
MIL ON for 15 secs 7. Turbo hardware failure
Vehicle run with poor pickup
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_UNDERBOOST_APV

System Actuators EGR/ETV/Turbo / Boost pressure monitoring

OBD Inducement Non-Inducement

SPN & FMI 1127 / 18

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check for Turbo wastegate/PFM/ETV electrical errors.If found any, rectify Perform service regeneration at IDLE after issue
1
and drive vehicle for 10 Kms in highway and check for DTC rectification
Air filter choke
Air filter to compressor, compressor to intercooler,
Intercooler to PFM, PFM to Intake manifold, EGR cooler to
Check for intake path air leakages. If found any, rectify and drive vehicle
2 intake manifold lines
for 10 Kms in highway and check for DTC
Perform service regeneration at IDLE after issue
rectification
Check for air filter choke. If found any, rectify and drive vehicle for 10 Perform service regeneration at IDLE after issue
3
Kms in highway and check for DTC rectification
Check for intercooler puncture / Blockages. If found any, rectify and drive Perform service regeneration at IDLE after issue
4
vehicle for 10 Kms in highway and check for DTC rectification
If still issue persists, check DPF/ATS clogging (Like Urea deposition or DPF
cracking).
If urea deposition found, perform service regeneration once or twice to
Perform service regeneration at IDLE after issue
5 remove deposits. If still issue present, replace SCR system/ATS.
rectification
If DPF craking found, replace DPF /ATS system.
After issue rectification, drive vehicle for 10 Kms in highway and check
for DTC
Perform following Actuator tests :
1. Exhaust throttle Actuation - 0%, 50% & 100%
After test error between demand & feedback should be
If still issue persists, Check wheter ETV is functioning well or not by doing
6 less than 4%
actuator test and drive vehicle for 10 Kms in highway and check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET VGTH Values Test
If still issue persists, Replace turbo actuator/ turbocharger assembly and 2. Turbo Actuator learning Test
7
drive vehicle for 10 Kms in highway and check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
8 If still issue persists, Replace ECU. ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0234-00: Over Boost Pressure Fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Restriction nearby positive air charge path to

Fault Code P0234-00 engine
2. Boost pressure sensor malfunction
3. Turbo Waste gate actuator faulty / stuck
4. Turbo Internal HW failure
MIL ON for 15 secs 5. Fuel Injectors failure 1. Dynamic Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_OVERBOOST_APV

System Actuators EGR/ETV/Turbo / Boost pressure monitoring

OBD Inducement Non-Inducement

SPN & FMI 1127 / 16

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check for blockage in intake air path (turbo to intake manifold). If found Perform service regeneration at IDLE after issue
1
any, rectify and drive vehicle for 10 Kms in highway and check for DTC rectification
Check for boost pressure sensor related errors.If found any, rectify and Perform service regeneration at IDLE after issue
2
drive vehicle for 10 Kms in highway and check for DTC rectification
Acceptable difference : +/- 5 kPa.
Check boost pressure value at Key ON and compare against Manifold Perform following routine after component Replacement:
pressure sensor and Ambient pressure sensor. If difference is too much, Reset PFM sensor Learning
3
Replace PFM sensor. Drive vehicle for 10 Kms in highway and check for
DTC Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET VGTH Values Test
Check Turbocharger Waste gate for physical damage / Stuck. If found
2. Turbo Actuator learning Test
4 any, Replace turbo actuator/ turbocharger assembly. Drive vehicle for 10
Kms in highway and check for DTC
Perform service regeneration at IDLE after issue
rectification
Write new Injector I3C codes through TDS.
Check for excessive fuel injection. If found any, Replace fuel injectors.
5
Drive vehicle for 10 Kms in highway and check for DTC Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
6 If still issue persists, Re-flash ECU dataset and check for DTC again
rectification
Perform following routine after component Replacement:
1. RESET VGTH Values Test
If still issue persists, Replace turbo actuator/ turbocharger assembly and 2. Turbo Actuator learning Test
7
check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
8 If still issue persists, Replace ECU. ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-08: EGR Actuator - Internal Communication failure in ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-08

1. harness issues
MIL ON 2. EGR Actuator internal failures 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_DIG_COM_APV

System Actuators EGR/ETV/Turbo / EGR Component monitoring

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 5838 / 19

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
2 1. Pin back out checks (ECU side and EGR connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Perform following routine after component Replacement:
3 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-4B: EGR Actuator - Internal temperature error in ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-4B

1. harness issues
MIL ON 2. EGR Actuator internal failures 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_DIG_THE_APV

System Actuators EGR/ETV/Turbo / EGR Component monitoring

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 5764 / 16

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
2 1. Pin back out checks (ECU side and EGR connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Perform following routine after component Replacement:
3 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-79: EGR Actuator - Return spring broken error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-79

1. Stuck EGR valve
2. Mechanical failure of EGR
MIL ON Engine emission may go high
3. Malfunction of ECU
2. OBD Inducement reaction. Refer table
SCR Lamp ON
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_SPR_BROKEN_APV

System Actuators EGR/ETV/Turbo / EGR Component monitoring

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 5838 / 07

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
1 1. Pin back out checks (ECU side and EGR connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Perform following services in TDS:
Perform Actuator Demand check through TDS. Check for Demand and
1. Test Actuators - EGR actuator demand check[0%, 50% &
feedback position. If there is too much difference between demand and
2 100%]
measured value, Connect one new EGR actuator assembly externally and
perform necessary services through TDS.
Acceptable deviation : +/- 3%
Perform following services in TDS:
Do Key OFF, wait for 20 secs. Perform Actuator Demand check through 1. Test Actuators - EGR actuator demand check[0%, 50% &
3 TDS. Check Demand and feedback position difference. If difference is 100%]
found OK, start engine and wait for 30 secs. Check for DTC
Acceptable deviation : +/- 3%
Perform following routine after component Replacement:
If there is no DTC, Fix new EGR in the vehicle and perform necessary
4 1. RESET EGRH values Test
services through TDS and check for DTC
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-7C: EGR Actuator - Slow response fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-7C

1. Faulty EGR valve
MIL ON Engine emission may go high
2. Faulty ECU
2. OBD Inducement reaction. Refer table
SCR Lamp ON
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_SLOW_RESP_INC_APV

System Actuators EGR/ETV/Turbo / EGR Component monitoring

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 5838 / 09

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram.
Check Voltages between pins during ignition ON as well as
Check EGR actuator electrical failures. If found any issue, rectify and engine ON
check for DTC 5V : Pin 2&6, Pin 6& ground
1 1. Pin back out checks (ECU side and EGR connector side) 2.5V : Pin 1&ground,5&ground
2. Connector/Sensor physical damage 0V : Pin 1&5, Pin 2&ground
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Test Actuators - EGR actuator demand check[0%, 50% &
Perform Actuator Demand check through TDS. Check for Demand and 100%]
feedback position. If there is too much difference between demand and
2
measured value, Connect one new EGR actuator assembly externally and Acceptable deviation : +/- 3%
perform necessary services through TDS.
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Test Actuators - EGR actuator demand check[0%, 50% &
100%]
Do Key OFF, wait for 20 secs. Perform Actuator Demand check through
3 TDS. Check Demand and feedback position difference. If difference is
Acceptable deviation : +/- 3%
found OK, start engine and wait for 30 secs. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET EGRH values Test
If there is no DTC, Fix new EGR in the vehicle and perform necessary 2. EGR valve learning Test
4
services through TDS and check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU. ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-71: EGR Actuator - Stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-71

1. EGR actuator wiring harness
MIL ON 2. Faulty EGR actuator 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_POS_APV

System Actuators EGR/ETV/Turbo / EGR Component monitoring

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 5838 / 31

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram.
Check Voltages between pins during ignition ON as well as
Check EGR actuator electrical failures. If found any issue, rectify and engine ON
check for DTC 5V : Pin 2&6, Pin 6& ground
1 1. Pin back out checks (ECU side and EGR connector side) 2.5V : Pin 1&ground,5&ground
2. Connector/Sensor physical damage 0V : Pin 1&5, Pin 2&ground
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Test Actuators - EGR actuator demand check[0%, 50% &
Perform Actuator Demand check through TDS. Check for Demand and 100%]
feedback position. If there is too much difference between demand and
2
measured value, Connect one new EGR actuator assembly externally and Acceptable deviation : +/- 3%
perform necessary services through TDS.
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Test Actuators - EGR actuator demand check[0%, 50% &
100%]
Do Key OFF, wait for 20 secs. Perform Actuator Demand check through
3 TDS. Check Demand and feedback position difference. If difference is
Acceptable deviation : +/- 3%
found OK, start engine and wait for 30 secs. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET EGRH values Test
If there is no DTC, Fix new EGR actuator in the vehicle and perform 2. EGR valve learning Test
4
necessary services through TDS and check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU. ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 33 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2457-00: EGR Cooler - Efficiency very low

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2457-00

1.Faulty T_EGR Sensor
2.Faulty EGR cooler Engine emission may go high & Vehicle may
MIL ON
run with poor pickup

Fault System Summary:

Development Fault code F_M_EGRH_COOL_PERF_LO_APV

System Actuators EGR/ETV/Turbo / EGR Cooler monitoring

OBD Inducement Non-Inducement

SPN & FMI 4752 / 07

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
Check EGR temperature sensor electrical failures. If found any issue, T_EGR Pin 1 - ECU Pin 73
rectify and check for DTC T_EGR Pin 2 - ECU Pin 09
1 1. Pin back out checks (ECU side and EGR temperature sensor side)
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures) Perform service regeneration at IDLE after issue
rectification
If found any issues in EGR temperature sensor, Replace sensor. Drive Perform service regeneration at IDLE after issue
2
vehicle for 10 Kms in highway and check for DTC rectification
If problem persists check water supply connection of EGR cooler. If found
Perform service regeneration at IDLE after issue
3 any issues, rectify it. Drive vehicle for 10 Kms in highway and check for
rectification
DTC
If still issue persists, Replace EGR Cooler. Drive vehicle for 10 Kms in Perform service regeneration at IDLE after issue
4
highway and check for DTC rectification
Perform service regeneration at IDLE after issue
5 If still issue persists, Replace ECU.
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-A1: EGR Actuator - Controller system voltage error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-A1

1. EGR actuator voltage out of range
MIL ON 2. Mechanical failure of ETV 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_VOLTAGE_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 3058 / 14

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
2 1. Pin back out checks (ECU side and EGR actuator connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-F2: EGR Actuator - Negative Pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-F2

1. EGR motor negative pin S2G (pin E68)
MIL ON 2. harness issues 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_S2V_NEG_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 5928 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
2 1. Pin back out checks (ECU side and EGR actuator connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 42 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 43 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-F3: EGR Actuator - Negative Pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-F3

1. EGR motor negative pin S2G (pin E68)
MIL ON 2. harness issues 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_S2G_NEG_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 5928 / 04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 44 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
2 1. Pin back out checks (ECU side and EGR actuator connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 46 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-13: EGR Actuator - Open load error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-13

1. Harness issues
MIL ON 2. Exhaust throttle actuator hardware issues 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_OL_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 2791 / 05

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
2 1. Pin back out checks (ECU side and EGR connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 48 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 49 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-F5: EGR Actuator - Over Current in Negative Pin

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-F5

1. EGR Actuator motor failure (over current on
pin E68)
MIL ON 2. Faulty Wiring harness 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_OC_NEG_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 5928 / 06

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
2 1. Pin back out checks (ECU side and EGR connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 51 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-F4: EGR Actuator - Over Current in Positive Pin

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-F4

1. EGR Actuator motor failure (over current on
pin E89)
MIL ON 2. Faulty wiring harness 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_OC_POS_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 2791 / 06

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
2 1. Pin back out checks (ECU side and EGR connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 54 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 55 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-F0: EGR Actuator - Positive Pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-F0

1. EGR motor positive pin S2V (pin E89)
MIL ON 2. harness issues 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_S2V_POS_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 2791 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 56 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
2 1. Pin back out checks (ECU side and EGR actuator connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 57 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 58 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-F1: EGR Actuator - Positive Pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-F1

1. EGR motor positive pin S2G (pin E89)
MIL ON 2. harness issues 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_S2G_POS_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 2791 / 04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
2 1. Pin back out checks (ECU side and EGR actuator connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 60 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 61 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0400-9B: EGR Flow is too high

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0400-9B 1. Intake air leakage

2. Faulty PFM sensor
3. Faulty EGR Valve
MIL ON 1. Regeneration Inhibition
4. Faulty ECU
2. Engine emission may go high & Vehicle
may run with poor pickup

Fault System Summary:

Development Fault code F_M_EGRH_HFLOW_APV

System Actuators EGR/ETV/Turbo / EGR Flow Monitoring

OBD Inducement Non-Inducement

SPN & FMI 2659 / 16

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Air filter choke
Air filter to compressor, compressor to intercooler,
Intercooler to PFM, PFM to Intake manifold, EGR cooler to
Check for Intake air system leakages/Air filter choke in vehicle. If found
intake manifold lines, Check all gaskets in above said
1 any, rectify it. Drive vehicle for 10 Kms, monitor labels mentioned in
joints
specification 2 and check for DTC
Perform service regeneration at IDLE after issue
rectification

Check following labels during all steps:

1. EGR Flow correction (Range should be 0.7 to 1.7)
Air flow difference b/w actual and estimated should be
less than 2 g/s.
If still issue persists, Check any errors related to PFM sensor & EGR valve
TDS Label name :
2 actuator. If found any rectify it. Drive vehicle for 10 Kms, monitor labels
* Air Flow_Measured
mentioned in specification 2 and check for DTC
* Air Flow_Modelled

Perform service regeneration at IDLE after issue

rectification
If still issue persists, check PFM sensor orientation as per design
Perform service regeneration at IDLE after issue
3 specification. If found any issues, rectify it . Drive vehicle for 10 Kms,
rectification
monitor labels mentioned in specification 2 and check for DTC
Perform following routines:
If still issue persists, Replace PFM sensor, perform component 1. RESET PFM values Test
4 replacement service. Drive vehicle for 10 Kms, monitor labels mentioned
in specification 2 and check for DTC Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. Test Actuators - EGR actuator demand check[0%, 50% &
Perform Actuator Demand check through TDS. Check for Demand and 100%]
feedback position. If there is too much difference between demand and
5
measured value, Connect one new EGR actuator assembly externally and Acceptable deviation : +/- 3%
perform necessary services through TDS.
Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET EGRH values Test
Replace that new EGR actuator assembly in vehicle. Drive vehicle for 10 2. EGR valve learning Test
6
Kms, monitor labels mentioned in specification 2 and check for DTC
Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
7 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 65 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0400-9C: EGR Flow is too low

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0400-9C 1. Intake/Exhaust leakage

2. Faulty PFM sensor
3. Faulty EGR Valve
MIL ON Engine emission may go high
4. Faulty ECU
2. OBD Inducement reaction. Refer table
SCR Lamp ON
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_LOW_FLOW_1_APV

System Actuators EGR/ETV/Turbo / EGR Flow Monitoring

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 2659 / 18

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Air filter choke
Air filter to compressor, compressor to intercooler,
Intercooler to PFM, PFM to Intake manifold, EGR cooler to
Check for leakages in Intake air system leakages/EGR path/Exhaust lines
intake manifold lines, Check all gaskets in above said
1 in the vehicle. If found any, rectify it. Drive vehicle for 10 Kms, monitor
joints
labels mentioned in specification 2 and check for DTC
Perform service regeneration at IDLE after issue
rectification

Check following labels during all steps:

1. EGR Flow correction (Range should be 0.7 to 1.7)
Air flow difference b/w actual and estimated should be
less than 2 g/s.
If still issue persists, Check any errors related to PFM sensor & EGR valve
TDS Label name :
2 actuator. If found any rectify it. Drive vehicle for 10 Kms, monitor labels
* Air Flow_Measured
mentioned in specification 2 and check for DTC
* Air Flow_Modelled

Perform service regeneration at IDLE after issue

rectification

Perform following routines:

1. RESET PFM values Test
If still issue persists, perform PFM reset service & EGR learning service
2. EGR valve learning Test
3 once. Drive vehicle for 10 Kms, monitor labels mentioned in specification
2 and check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET EGRH values Test
If still issue persists, Replace EGR actuator assembly. Drive vehicle for 10 2. EGR valve learning Test
4
Kms, monitor labels mentioned in specification 2 and check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
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Date: 31-01-2023

P040A-11: EGR Cooler temperature sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P040A-11 1. Wiring harness issue (Short circuit)

No Vehicle reaction
2. Faulty T_EGR sensor
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_EGRH_INTAK_T_LO_APV

System Actuators EGR/ETV/Turbo / EGR intake temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 412 / 04

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
T_EGR Pin 1 - ECU Pin 73
Check EGR temperature sensor electrical failures. If found any issue,
T_EGR Pin 2 - ECU Pin 09
rectify and check for DTC
For Resistance checks, Kepp sensor outside (Open to air)
1 1. Pin back out checks (ECU side and EGR temperature sensor side)
0degC : 29846ohms, 20degC : 12868ohms, 25degC:
2. Connector/Sensor physical damage
10584ohms, 40degC: 6091ohms
3.Continuity checks (Open / Short circuit failures)
Measured resistance has to be compared against local
ambient temperature
2 If still issue persists, Re-flash ECU dataset and check for DTC again
3 If still issue persists, Replace EGR temperature sensor and check for DTC
4 If still issue persists, Replace ECU

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Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P040A-12: EGR Cooler temperature sensor - Short to Battery or open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P040A-12 1. Wiring harness issue (Connector open / pin

back out /Short circuit) No Vehicle reaction
2. Faulty sensor
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_EGRH_INTAK_T_HI_APV

System Actuators EGR/ETV/Turbo / EGR intake temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 412 / 03

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
T_EGR Pin 1 - ECU Pin 73
Check EGR temperature sensor electrical failures. If found any issue,
T_EGR Pin 2 - ECU Pin 09
rectify and check for DTC
For Resistance checks, Kepp sensor outside (Open to air)
1 1. Pin back out checks (ECU side and EGR temperature sensor side)
0degC : 29846ohms, 20degC : 12868ohms, 25degC:
2. Connector/Sensor physical damage
10584ohms, 40degC: 6091ohms
3.Continuity checks (Open / Short circuit failures)
Measured resistance has to be compared against local
ambient temperature
2 If still issue persists, Replace EGR temperature sensor and check for DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
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Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P040A-64: EGR Cooler temperature sensor - Signal not valid based on

reference sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P040A-64 1.Faulty wiring harness

2.Faulty sensor No Vehicle reaction
3.Faulty ECU
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_EGRH_IN_TEMP_XC_APV

System Actuators EGR/ETV/Turbo / EGR intake temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 412 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
T_EGR Pin 1 - ECU Pin 73
Check EGR temperature sensor electrical failures. If found any issue,
T_EGR Pin 2 - ECU Pin 09
rectify it and check for DTC
For Resistance checks, Kepp sensor outside (Open to air)
1 1. Pin back out checks (ECU side and sensor side)
0degC : 29846ohms, 20degC : 12868ohms, 25degC:
2. Connector/Sensor physical damage
10584ohms, 40degC: 6091ohms
3.Continuity checks (Open / Short circuit failures)
Measured resistance has to be compared against local
ambient temperature
After rectification of step 1, connect EGR temp. sensor externally and Reference sensors :
2 keep it in ambient with wiring connected. Like that keep reference 1. Coolant temperature sensor
sensors as well. Check temp. difference across all sensors 2. Intake manifold temperature sensor (TMAP)

3 If difference found within specification, Fit back all 3 sensors into engine. Temperature difference threshold : +/20 deg C

If still issue persists, connect one new EGR temp. sensor externally and Reference sensors :
4 keep it in ambient with wiring connected. Like that keep reference 1. Coolant temperature sensor
sensors as well. Check temp. difference across all sensors 2. Intake manifold temperature sensor (TMAP)
If difference found within specification, Fit new EGR temp. sensor into
5 Temperature difference threshold : +/20 deg C
engine and connect other sensors also
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0409-14: EGR Actuator position sensor - Short to Ground or Open failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0409-14

1. harness issues
MIL ON 2. EGR Actuator internal failures 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_FDB_LO_APV

System Actuators EGR/ETV/Turbo / EGR Position feedback sensor

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 27 / 04

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
2 1. Pin back out checks (ECU side and EGR connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Perform following routine after component Replacement:
3 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0409-12: EGR Actuator position sensor - Short to battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0409-12

1. harness issues
MIL ON 2. EGR Actuator internal failures 1. Regeneration Inhibition
SCR Lamp ON 3. Faulty ECU 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_FDB_HI_APV

System Actuators EGR/ETV/Turbo / EGR Position feedback sensor

EGR Inducement Group

OBD Inducement
25% Trq Reduction after 36 Hrs; 20 KmpH Spd Limitation after 100 Hrs

SPN & FMI 27 / 03

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Refer circuit diagram.
Check EGR actuator electrical failures. If found any issue, rectify and
Check Voltages between pins during ignition ON as well as
check for DTC
engine ON
2 1. Pin back out checks (ECU side and EGR connector side)
5V : Pin 2&6, Pin 6& ground
2. Connector/Sensor physical damage
2.5V : Pin 1&ground,5&ground
3.Continuity checks (Open / Short circuit failures)
0V : Pin 1&5, Pin 2&ground
Perform following routine after component Replacement:
3 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
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Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-54: EGR Actuator - 1st learning failed / Value out of range

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-54 1. 1st learning not performed at EOL

2. Faulty EGR actuator
3. Faulty ECU
MIL ON Engine emission may go high

Fault System Summary:

Development Fault code F_M_EGRH_LRN_1ST_CL_APV

System Actuators EGR/ETV/Turbo / EGR Position Learning Monitor

OBD Inducement Non-Inducement

SPN & FMI 3058 / 13

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Do Ignition OFF and wait for 20 secs and Do Key ON. Clear DTC & Check
1
for DTC.
If still issue persists, Check for any errors related to EGR actuator. If
2
found any, rectify it and check for DTC
If still issue persists, Clear DTC and perform actuator reset & learning Perform following routine after component Replacement:
3 service through TDS. Do Key off, wait for 20 secs and do key ON. Clear 1. RESET EGRH values Test
DTC & Check for DTC again 2. EGR valve learning Test
Perform following services in TDS:
Perform Actuator Demand check through TDS. Check for Demand and
1. Test Actuators - EGR actuator demand check[0%, 50% &
feedback position. If there is too much difference between demand and
4 100%]
measured value, Connect one new EGR actuator assembly externally and
perform necessary services through TDS.
Acceptable deviation : +/- 3%
Select dataset based on Vehicle Identification
5 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
6 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0403-99: EGR Actuator - Learning exceeded wear limit

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-99 1. EGR actuator wear limit reached

2. Faulty EGR actuator
3. Faulty ECU
MIL ON Engine emission may go high

Fault System Summary:

Development Fault code F_M_EGRH_LRN_CL_LGDV_APV

System Actuators EGR/ETV/Turbo / EGR Position Learning Monitor

OBD Inducement Non-Inducement

SPN & FMI 5829 / 16

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1. RESET EGRH values Test
Check EGR actuator for any physical damage. If found any, rectify / 2. EGR valve learning Test
1
Replace component. Clear DTC & Check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
2 If still issue persists, Re-flash ECU dataset and check for DTC again
rectification
Select dataset based on Vehicle Identification
number(VIN)
3 If still issue persists, Replace EGR actuator assembly and check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET EGRH values Test
2. EGR valve learning Test
4 If still issue persists, Replace ECU.
Perform service regeneration at IDLE after issue
rectification

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Circuit Schematic Diagram:

Location and Component Image:

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-08: Exhaust Throttle Valve - Internal Communication failure in ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-08

MIL ON
1. harness issues 1. 50% Torque reduction
2. Exhaust throttle actuator internal failures
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_DIG_COM_APV

System Actuators EGR/ETV/Turbo / ETV Component monitoring

OBD Inducement Non-Inducement

SPN & FMI 8322 / 19

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Exhaust throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Perform following routine after component Replacement:
3 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
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Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-4B: Exhaust Throttle Valve - Internal temperature error in ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-4B

MIL ON
1. harness issues 1. 50% Torque reduction
2. Exhaust throttle actuator internal failures
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_DIG_THE_APV

System Actuators EGR/ETV/Turbo / ETV Component monitoring

OBD Inducement Non-Inducement

SPN & FMI 5627 / 17

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Exhaust throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Perform following routine after component Replacement:
3 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-79: Exhaust Throttle Valve - Slow response fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-79

1. Stuck of Exhaust throttle valve
MIL ON 2. Mechanical failure of ETV 1. 50% Torque reduction
3. Malfunction of ECU 2. Engine emission go high & Vehicle run
CEL ON with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_SPR_BRKN_APV

System Actuators EGR/ETV/Turbo / ETV Component monitoring

OBD Inducement Non-Inducement

SPN & FMI 8322 / 10

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram.
Check Voltages between pins during ignition ON as well as
Check Exhaust throttle actuator electrical failures. If found any issue,
engine ON
rectify and check for DTC
5V : Pin 1&2, Pin 1& ground
1 1. Pin back out checks (ECU side and Exhaust throttle connector side)
0V : Pin 2&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Test Actuators - Exhaust throttle demand check[0%,
Perform Actuator Demand check through TDS. Check for Demand and 50% & 100%]
feedback position. If there is too much difference between demand and
2
measured value, Connect one new Exhaust throttle assembly externally Acceptable deviation : +/- 3%
and perform necessary services through TDS.
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Test Actuators - Exhaust throttle demand check[0%,
50% & 100%]
Do Key OFF, wait for 20 secs. Perform Actuator Demand check through
3 TDS. Check Demand and feedback position difference. If difference is
Acceptable deviation : +/- 3%
found OK, start engine and wait for 30 secs. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET Exhaust brake Values Test
If there is no DTC, Fix new Exhaust throttle in the vehicle and perform 2. Exhaust throttle valve learning Test
4
necessary services through TDS and check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 98 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-71: Exhaust Throttle Valve - Stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-71

1. Exhaust throttle actuator wiring harness open
MIL ON
circuit 1. 50% Torque reduction
2. Faulty ETV actuator
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_POS_APV

System Actuators EGR/ETV/Turbo / ETV Component monitoring

OBD Inducement Non-Inducement

SPN & FMI 8322 / 07

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 99 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram.
Check Voltages between pins during ignition ON as well as
Check Exhaust throttle actuator electrical failures. If found any issue,
engine ON
rectify and check for DTC
5V : Pin 1&2, Pin 1& ground
1 1. Pin back out checks (ECU side and Exhaust throttle connector side)
0V : Pin 2&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Test Actuators - Exhaust throttle demand check[0%,
Perform Actuator Demand check through TDS. Check for Demand and 50% & 100%]
feedback position. If there is too much difference between demand and
2
measured value, Connect one new Exhaust throttle assembly externally Acceptable deviation : +/- 3%
and perform necessary services through TDS.
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Test Actuators - Exhaust throttle demand check[0%,
50% & 100%]
Do Key OFF, wait for 20 secs. Perform Actuator Demand check through
3 TDS. Check Demand and feedback position difference. If difference is
Acceptable deviation : +/- 3%
found OK, start engine and wait for 30 secs. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET Exhaust brake Values Test
If there is no DTC, Fix new Exhaust throttle in the vehicle and perform 2. Exhaust throttle valve learning Test
4
necessary services through TDS and check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 100 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 101 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-F0: Exhaust Throttle Valve - Negative Pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-F0

1. Exhaust throttle motor negative pin S2V (pin
MIL ON E26) 1. 50% Torque reduction
2. harness issues 2. Regeneration Inhibition
3. Faulty ECU
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_S2V_NEG_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 11792 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 102 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Exhaust throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 103 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 104 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-F2: Exhaust Throttle Valve - Negative Pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-F2

1. Exhaust throttle motor negative pin S2G (pin
MIL ON E26) 1. 50% Torque reduction
2. harness issues 2. Regeneration Inhibition
3. Faulty ECU
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_S2G_NEG_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 11796 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 105 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Exhaust throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 106 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 107 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-F5: Exhaust Throttle Valve - Negative Pin Currrent High

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-F5

1. Exhaust Throttle Actuator motor failure (over
MIL ON
current on pin E26) 1. 50% Torque reduction
2. Faulty Wiring harness
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_OC_NEG_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 11796 / 06

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 108 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Exhaust throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 109 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 110 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-13: Exhaust Throttle Valve - Open load error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-13

MIL ON
1. Harness issues 1. 50% Torque reduction
2. Exhaust throttle actuator hardware issues
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_OL_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 8322 / 05

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 111 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 112 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 113 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-F3: Exhaust Throttle Valve - Positive Pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-F3

1. Exhaust throttle motor positive pin S2V (pin
MIL ON E47) 1. 50% Torque reduction
2. harness issues 2. Regeneration Inhibition
3. Faulty ECU
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_S2V_POS_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 11796 / 04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 114 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Exhaust throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 115 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 116 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-F1: Exhaust Throttle Valve - Positive Pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-F1

1. Exhaust throttle motor positive pin S2G (pin
MIL ON E47) 1. 50% Torque reduction
2. harness issues 2. Regeneration Inhibition
3. Faulty ECU
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_S2G_POS_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 11792 / 04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 117 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Exhaust throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 118 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 119 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-F4: Exhaust Throttle Valve - Positive Pin Currrent High

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-F4

1. Exhaust Throttle Actuator motor failure (over
MIL ON
current on pin E47) 1. 50% Torque reduction
2. Faulty wiring harness
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_OC_POS_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 11792 / 06

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 120 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Exhaust throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 121 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 122 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-A1: Exhaust Throttle Valve - Return spring broken

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-A1

MIL ON
1. Exhaust Throttle actuator voltage out of range 1. 50% Torque reduction
2. Mechanical failure of ETV
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_VOLTAGE_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 8322 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 123 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Exhaust throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
4 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 124 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 125 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2BF4-2F: Exhaust Throttle Valve position sensor - Improper signal

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BF4-2F 1. harness issues

2. Exhaust throttle actuator internal failures
3. Faulty ECU Engine emission go high & Vehicle may run
with poor pickup

Fault System Summary:

Development Fault code F_M_EXH_BRK_FDB_NOI_APV

System Actuators EGR/ETV/Turbo / ETV Position feedback sensor

OBD Inducement Non-Inducement

SPN & FMI 5625 / 02

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Exhaust throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Perform following routine after component Replacement:
3 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2BF4-14: Exhaust Throttle Valve position sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BF4-14

MIL ON
1. harness issues 1. 50% Torque reduction
2. Exhaust throttle actuator internal failures
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_FDB_LO_APV

System Actuators EGR/ETV/Turbo / ETV Position feedback sensor

OBD Inducement Non-Inducement

SPN & FMI 5625 / 04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 129 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Exhaust throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Perform following routine after component Replacement:
3 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 130 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2BF4-12: Exhaust Throttle Valve position sensor - Short to battery Or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BF4-12

MIL ON
1. harness issues 1. 50% Torque reduction
2. Exhaust throttle actuator internal failures
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_FDB_HI_APV

System Actuators EGR/ETV/Turbo / ETV Position feedback sensor

OBD Inducement Non-Inducement

SPN & FMI 5625 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 132 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Exhaust throttle actuator electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Exhaust throttle connector side) engine ON
2. Connector/Sensor physical damage 2.5V : Pin 4&ground, Pin 6& ground
3.Continuity checks (Open / Short circuit failures) 0V : Pin 6&4
Perform following routine after component Replacement:
3 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 133 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-54: Exhaust Throttle Valve - 1st learning failed / Value out of range
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-54 1. 1st learning not performed at EOL

2. Faulty Exhaust Throttle
3. Faulty ECU
MIL ON Engine emission may go high

Fault System Summary:

Development Fault code F_M_EXH_BRK_LN1ST_CL_APV

System Actuators EGR/ETV/Turbo / ETV Position Learning Monitor

OBD Inducement Non-Inducement

SPN & FMI 5625 / 13

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Do Ignition OFF and wait for 20 secs and Do Key ON. Clear DTC & Check
1
for DTC.
If still issue persists, Check for any errors related to Exhaust Throttle. If
2
found any, rectify it and check for DTC
If still issue persists, Clear DTC and perform actuator reset & learning Perform following routine after component Replacement:
3 service through TDS. Do Key off, wait for 20 secs and do key ON. Clear 1. RESET Exhaust brake Values Test
DTC & Check for DTC again 2. Exhaust throttle valve learning Test
Perform following services in TDS:
Perform Actuator Demand check through TDS. Check for Demand and
1. Test Actuators - Exhaust throttle demand check[0%,
feedback position. If there is too much difference between demand and
4 50% & 100%]
measured value, Connect one new Exhaust throttle assembly externally
and perform necessary services through TDS.
Acceptable deviation : +/- 3%
Select dataset based on Vehicle Identification
5 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
6 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 136 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P26C5-99: Exhaust Throttle Valve - Learning exceeded wear limit

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-99 1. Exhaust throttle actuator wear limit reached

2. Faulty Exhaust Throttle
3. Faulty ECU
MIL ON Engine emission may go high

Fault System Summary:

Development Fault code F_M_EXH_BRK_LNCL_LDV_APV

System Actuators EGR/ETV/Turbo / ETV Position Learning Monitor

OBD Inducement Non-Inducement

SPN & FMI 8322 / 09

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1. RESET Exhaust brake Values Test
Check Exhaust throttle actuator for any physical damage. If found any, 2. Exhaust throttle valve learning Test
1
rectify / Replace component. Clear DTC & Check for DTC
Perform service regeneration at IDLE after issue
rectification
2 If still issue persists, Re-flash ECU dataset and check for DTC again
Select dataset based on Vehicle Identification
number(VIN)
3 If still issue persists, Replace Exhaust throttle assembly and check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
4 If still issue persists, Replace ECU
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
If still issue persists, detach / disconnect ATS from ETV pipe & check
2. Read & Write proper injector codes (I3C) from Old
indicated torque in Low Idle & high Idle. If torque found within
5 ECU/Engine
specification, then DPF might be having issues. Remove/Replace DPF &
3. All actuator learning services [EGR / Exhaust Throttle /
check for DTC
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

If still issue persists, Check Vehicle speed sensor electrical failures. If

found any issue, rectify it and check for DTC
6 1. Pin back out checks (ECU side and Actuator side)
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0243-08: Turbo E-Wastegate - Internal Communication failure in ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-08 1. harness issues

2. Wastegate actuator internal failures
MIL ON for 15 secs 3. Faulty ECU 1. Dynamic Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_DIG_COM_APV

System Actuators EGR/ETV/Turbo / Turbocharger Component monitoring

OBD Inducement Non-Inducement

SPN & FMI 646 / 19

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Circuit diagram & Component images

Author: ERC Page 141 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Turbocharger connector electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Turbo connector side) engine ON
2. Connector/Sensor physical damage Pin 1&2 - 5V ; Pin 1 & ground - 5V
3.Continuity checks (Open / Short circuit failures) Pin 2 & ground - 0V
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
3 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 142 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 143 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0243-4B: Turbo E-Wastegate - Internal temperature error in ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-4B 1. harness issues

2. Wastegate actuator internal failures
MIL ON for 15 secs 3. Faulty ECU 1. Dynamic Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_DIG_THE_APV

System Actuators EGR/ETV/Turbo / Turbocharger Component monitoring

OBD Inducement Non-Inducement

SPN & FMI 5788 / 15

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Circuit diagram & Component images

Author: ERC Page 145 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Turbocharger connector electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Turbo connector side) engine ON
2. Connector/Sensor physical damage Pin 1&2 - 5V ; Pin 1 & ground - 5V
3.Continuity checks (Open / Short circuit failures) Pin 2 & ground - 0V
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
3 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 146 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 147 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Author: ERC Page 148 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0243-71: Turbo E-Wastegate - Actuator Stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-71 1.Waste gate actuator/motor stuck inside

2.Wastegate flap damage
3.Wastegate link damage Engine emission go high
MIL ON for 15 secs
Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_VGTH_HB_POS_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 7381 / 07

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Circuit diagram & Component images

Author: ERC Page 149 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram.
Check Voltages between pins during ignition ON as well as
Check Turbocharger connector electrical failures. If found any issue,
engine ON
rectify and check for DTC
Pin 1&2 - 5V ; Pin 1 & ground - 5V
1 1. Pin back out checks (ECU side and Turbo connector side)
Pin 2 & ground - 0V
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Test Actuators - Turbo charger demand check[0%, 50%
Perform Actuator Demand check through TDS. Check for Demand and
& 100%]
feedback position. If there is too much difference between demand and
2 2. Acceptable deviation : +/- 3%
measured value, Connect one new turbocharger assembly externally and
perform necessary services through TDS.
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. Test Actuators - Turbo charger demand check[0%, 50%
Do Key OFF, wait for 20 secs. Perform Actuator Demand check through & 100%]
3 TDS. Check Demand and feedback position difference. If difference is 2. Acceptable deviation : +/- 3%
found OK, start engine and wait for 30 secs. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET VGTH Values Test
If there is no DTC, Fix new turbocharger in the vehicle and perform 2. Turbo Actuator learning Test
4
necessary services through TDS and check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU. ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 151 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0243-13: Turbo E-Wastegate - Drive Open load error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-13 1. Harness issues

2. Wastegate actuator hardware issues
MIL ON for 15 secs 3. Faulty ECU 1. Dynamic Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_OL_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 5451 / 05

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Circuit diagram & Component images

Author: ERC Page 153 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Turbocharger connector electrical failures. If found any issue,
rectify and check for DTC
2 1. Pin back out checks (ECU side and Turbo connector side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
4 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 154 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 155 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0243-F2: Turbo E-Wastegate - Negative Pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-F2 1. Wastegate Actuator motor failure (over

current on pin E21)
2. harness issues
MIL ON for 15 secs 3. Faulty ECU 1. Dynamic Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_S2V_NEG_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 6294 / 03

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Circuit diagram & Component images

Author: ERC Page 157 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Turbocharger connector electrical failures. If found any issue,
rectify and check for DTC
2 1. Pin back out checks (ECU side and Turbo connector side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
4 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 158 of 896

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0243-F3: Turbo E-Wastegate - Negative Pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-F3 1. Wastegate Actuator motor failure (over

current on pin E21)
2. harness issues
MIL ON for 15 secs 3. Faulty ECU 1. Dynamic Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_S2G_NEG_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 6294 / 04

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 161 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Turbocharger connector electrical failures. If found any issue,
rectify and check for DTC
2 1. Pin back out checks (ECU side and Turbo connector side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
4 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 162 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 163 of 896

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0243-F5: Turbo E-Wastegate - Over Current in Negative Pin

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-F5 1. Wastegate Actuator motor failure (over

current on pin E21)
2. harness issues
MIL ON for 15 secs 3. Faulty ECU 1. Dynamic Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_OC_NEG_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 6294 / 06

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 165 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Turbocharger connector electrical failures. If found any issue,
rectify and check for DTC
2 1. Pin back out checks (ECU side and Turbo connector side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
4 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 166 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 167 of 896

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0243-F4: Turbo E-Wastegate - Over Current in Positive Pin

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-F4 1. Wastegate Actuator motor failure (over

current on pin E42)
2. harness issues
MIL ON for 15 secs 3. Faulty ECU 1. Dynamic Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_OC_POS_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 5421 / 06

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Circuit diagram & Component images

Author: ERC Page 169 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Turbocharger connector electrical failures. If found any issue,
rectify and check for DTC
2 1. Pin back out checks (ECU side and Turbo connector side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
4 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 170 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 171 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0243-F0: Turbo E-Wastegate - Positive Pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-F0 1. Wastegate Actuator motor failure (over

current on pin E42)
2. harness issues
MIL ON for 15 secs 3. Faulty ECU 1. Dynamic Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_S2V_POS_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 5421 / 03

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 173 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Turbocharger connector electrical failures. If found any issue,
rectify and check for DTC
2 1. Pin back out checks (ECU side and Turbo connector side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
4 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 174 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 175 of 896

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0243-F1: Turbo E-Wastegate - Positive Pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-F1 1. Wastegate Actuator motor failure (over

current on pin E42)
2. harness issues
MIL ON for 15 secs 3. Faulty ECU 1. Dynamic Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_S2G_POS_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 5421 / 04

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Circuit diagram & Component images

Author: ERC Page 177 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Turbocharger connector electrical failures. If found any issue,
rectify and check for DTC
2 1. Pin back out checks (ECU side and Turbo connector side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Select dataset based on Vehicle Identification
3 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
4 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 178 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 179 of 896

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2AB7-14: Turbo E-Wastegate position sensor - Short to Ground or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2AB7-14 1. harness issues

2. Wastegate actuator internal failures
MIL ON for 15 secs 3. Faulty ECU 1. Dynamic Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_FDB_LO_APV

System Actuators EGR/ETV/Turbo / Turbocharger Position feedback sensor

OBD Inducement Non-Inducement

SPN & FMI 1188 / 04

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Circuit diagram & Component images

Author: ERC Page 181 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Turbocharger connector electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Turbo connector side) engine ON
2. Connector/Sensor physical damage Pin 1&2 - 5V ; Pin 1 & ground - 5V
3.Continuity checks (Open / Short circuit failures) Pin 2 & ground - 0V
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
3 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 182 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 183 of 896

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2AB7-12: Turbo E-Wastegate position sensor - Short to battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2AB7-12 1. harness issues

2. Wastegate actuator internal failures
MIL ON for 15 secs 3. Faulty ECU 1. Dynamic Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_FDB_HI_APV

System Actuators EGR/ETV/Turbo / Turbocharger Position feedback sensor

OBD Inducement Non-Inducement

SPN & FMI 1188 / 03

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Circuit diagram & Component images

Author: ERC Page 185 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16 – 32 V
check for DTC
Check Turbocharger connector electrical failures. If found any issue, Refer circuit diagram.
rectify and check for DTC Check Voltages between pins during ignition ON as well as
2 1. Pin back out checks (ECU side and Turbo connector side) engine ON
2. Connector/Sensor physical damage Pin 1&2 - 5V ; Pin 1 & ground - 5V
3.Continuity checks (Open / Short circuit failures) Pin 2 & ground - 0V
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
3 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 186 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 187 of 896

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0243-54: Turbo E-Wastegate - 1st learning failed / Value out of range

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-54 1. 1st learning not performed at EOL

2. Faulty Turbocharger No Vehicle reaction
3. Faulty ECU
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_VGTH_HB_LN1ST_CL_APV

System Actuators EGR/ETV/Turbo / Turbocharger Position Learning Monitor

OBD Inducement Non-Inducement

SPN & FMI 1188 / 13

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Do Ignition OFF and wait for 20 secs and Do Key ON. Clear DTC & Check
1
for DTC.
If still issue persists, Check for any errors related to Turbocharger. If
2
found any, rectify it and check for DTC
If still issue persists, Clear DTC and perform actuator reset & learning Perform following routine after component Replacement:
3 service through TDS. Do Key off, wait for 20 secs and do key ON. Clear 1. RESET VGTH Values Test
DTC & Check for DTC again 2. Turbo Actuator learning Test
Perform following services in TDS:
1. Test Actuators - Turbo charger demand check[0%, 50%
If problem resolved, Perform Actuator Demand check.If test is passed,
4 & 100%]
release the vehicle
Acceptable deviation : +/- 3%
Select dataset based on Vehicle Identification
5 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
6 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 190 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 191 of 896

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0243-99: Turbo E-Wastegate - Learning exceeded wear limit

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-99 1. Turbocharger actuator wear limit reached

2. Faulty Turbocharger No Vehicle reaction
3. Faulty ECU
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_VGTH_HB_LNCL_LDV_APV

System Actuators EGR/ETV/Turbo / Turbocharger Position Learning Monitor

OBD Inducement Non-Inducement

SPN & FMI 1188 / 07

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1. RESET VGTH Values Test
Check E Waste gate actuator for any physical damage. If found any, 2. Turbo Actuator learning Test
1
rectify / Replace component. Clear DTC & Check for DTC
Perform service regeneration at IDLE after issue
rectification
Check E Waste gate actuator for any physical damage. If found any, Perform service regeneration at IDLE after issue
2
rectify / Replace component. Clear DTC & Check for DTC rectification
Select dataset based on Vehicle Identification
number(VIN)
3 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET VGTH Values Test
If still issue persists, Replace turbo actuator/ turbocharger assembly and 2. Turbo Actuator learning Test
4
check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU. ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 195 of 896

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2226-64: Barometric Pressure Sensor - Signal not valid

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2226-64 1.Faulty wiring harness

2.Faulty sensor
MIL ON for 15 secs 3.Faulty ECU 1. 30% Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_ATMOS_P_XC_APV

System Air Intake System / Ambient Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 108 / 02

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Reference sensors :
At Key ON condition, check all 3 sensors pressure values. If ambient 1. PFM Boost pressure sensor
1
pressure value is out of specification, Replace ECU 2. TMAP/Intake manifold pressure sensor
Pressure difference threshold : +/- 8 kPa
Reference sensors :
If any other sensor's pressure value is out of specification, Replace that
1. PFM Boost pressure sensor
2 sensor. check all 3 sensors pressure values. Check pressure differences
2. TMAP/Intake manifold pressure sensor
against specification.
Temperature difference threshold : +/20 deg C
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0070-15: Ambient temperature sensor - Short to battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0070-15 1. Wiring harness issue (Connector open / pin

back out /Short circuit) No Vehicle reaction
2. Faulty sensor
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_EXT_AIR_TEMP_HI_APV

System Air Intake System / Ambient Temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 171 / 03

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
Outside Amibent temp.(OAT) Pin 1 - ECU Pin E57
Check Ambient sensor electrical failures. If found any issue, rectify and Outside Amibent temp.(OAT) Pin 2 - ECU Pin E51
check for DTC For Resistance checks, Kepp sensor outside (Open to air)
1 1. Pin back out checks (ECU side and sensor side) 10degC : 5970ohms, 15degC : 4714ohms, 20degC:
2. Connector/Sensor physical damage 3748ohms, 25degC: 2998ohms, 30degC-2418ohms,
3.Continuity checks (Open / Short circuit failures) 35degC: 1962, 40degC: 1604ohms
Measured resistance has to be compared against local
ambient temperature
If still issue persists, Replace Ambient temperature sensor and check for
2
DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0070-11: Ambient temperature sensor - Short to ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0070-11 1. Wiring harness issue (Short circuit)

No Vehicle reaction
2. Faulty sensor
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_EXT_AIR_TEMP_LO_APV

System Air Intake System / Ambient Temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 171 / 04

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
Outside Amibent temp.(OAT) Pin 1 - ECU Pin E57
Check Ambient sensor electrical failures. If found any issue, rectify and Outside Amibent temp.(OAT) Pin 2 - ECU Pin E51
check for DTC For Resistance checks, Kepp sensor outside (Open to air)
1 1. Pin back out checks (ECU side and sensor side) 10degC : 5970ohms, 15degC : 4714ohms, 20degC:
2. Connector/Sensor physical damage 3748ohms, 25degC: 2998ohms, 30degC-2418ohms,
3.Continuity checks (Open / Short circuit failures) 35degC: 1962, 40degC: 1604ohms
Measured resistance has to be compared against local
ambient temperature
If still issue persists, Replace Ambient temperature sensor and check for
2 Select dataset as per Vehicle configuration(VC)
DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0070-64: Ambient temperature sensor - Signal not valid based on reference

sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0070-64 1.Faulty wiring harness

2.Faulty sensor No Vehicle reaction
3.Faulty ECU
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_EXT_AIR_TEMP_XC_APV

System Air Intake System / Ambient Temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 171 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
Outside Amibent temp.(OAT) Pin 1 - ECU Pin E57
Check Ambient sensor electrical failures. If found any issue, rectify and Outside Amibent temp.(OAT) Pin 2 - ECU Pin E51
check for DTC For Resistance checks, Kepp sensor outside (Open to air)
1 1. Pin back out checks (ECU side and sensor side) 10degC : 5970ohms, 15degC : 4714ohms, 20degC:
2. Connector/Sensor physical damage 3748ohms, 25degC: 2998ohms, 30degC-2418ohms,
3.Continuity checks (Open / Short circuit failures) 35degC: 1962, 40degC: 1604ohms
Measured resistance has to be compared against local
ambient temperature
After rectification of step 1, connect Ambient temp. sensor externally Reference sensors :
2 and keep it in ambient with wiring connected. Like that keep reference 1. Inlet Air temperature sensor (IAT)
sensors as well. Check temp. difference across all sensors 2. Intercooler out temperature sensor (PFM)

3 If difference found within specification, Fit back all 3 sensors into engine. Temperature difference threshold : +/20 deg C

If still issue persists, connect one new Ambient temp. sensor externally Reference sensors :
4 and keep it in ambient with wiring connected. Like that keep reference 1. Inlet Air temperature sensor (IAT)
sensors as well. Check temp. difference across all sensors 2. Intercooler out temperature sensor (PFM)
If difference found within specification, Fit new Ambient temp. sensor
5 Temperature difference threshold : +/20 deg C
into engine and connect other sensors also
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0235-29: PFM Sensor - Boost pressure sensor signal error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0235-29

1.Faulty wiring harness
MIL ON 2.Faulty sensor 1. Regeneration Inhibition
3.Faulty ECU 2. Urea dosing will be stopped
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_BOOSTP_SENT_FDAT_APV

System Air Intake System / Boost pressure monitoring

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 5541 / 19

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram &
Check voltages between points When Ignition ON as well
Check PFM sensor electrical failures. If found any issue, rectify it and
as engine ON
check for DTC
5V : Pin 1&3, 3&4, 2&3, 1&ground, 2&ground, 4&ground
1 1. Pin back out checks (ECU side and sensor side)
0V : 1&2, 1&4, 2&4, 3&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
Damage of sensor/ Broken Sensor
Perform following services in TDS:
Check any physical damage of PFM Sensor. If found any issues, 1. RESET PFM Sensor Learning
2
rectify/replace it and check for DTC
Perform service regeneration at IDLE after issue
rectification
Air flow threshold : 25-35 g/s
Boost pressure : Based on present altitude
Perform following services in TDS:
Check the air mass flow during idling through Diagnostic Tester. If its out
3 1. RESET PFM Sensor Learning
of specification, Replace sensor & check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
5 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
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Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0235-64: PFM Sensor - Boost pressure signal not valid (Compared against
other sensor)
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0235-64

1.Faulty wiring harness
MIL ON 2.Faulty sensor 1. Regeneration Inhibition
3.Faulty ECU 2. Urea dosing will be stopped
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_BOOST_P_XC_APV

System Air Intake System / Boost pressure monitoring

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 5541 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram &
Check voltages between points When Ignition ON as well
Check PFM/Boost pressure sensor electrical failures. If found any issue,
as engine ON
rectify it and check for DTC
5V : Pin 1&3, 3&4, 2&3, 1&ground, 2&ground, 4&ground
1 1. Pin back out checks (ECU side and sensor side)
0V : 1&2, 1&4, 2&4, 3&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
Reference sensors :
1. Ambient pressure sensor
After rectification of step 1, connect PFM sensor externally and keep it in
2. TMAP/Intake manifold pressure sensor
2 ambient with wiring connected. Like that keep reference sensors as well.
Check pressure difference across all sensors
Perform service regeneration at IDLE after issue
rectification
Pressuree difference threshold : +/- 8 kPa
If difference found within specification, Fit PFM sensor into engine and
3
connect other sensors as well. Perform service regeneration at IDLE after issue
rectification
Reference sensors :
1. Ambient pressure sensor
If still issue persists, connect one new PFM sensor externally and keep it
2. TMAP/Intake manifold pressure sensor
4 in ambient with wiring connected. Like that keep reference sensors as
well. Check pressure difference across all sensors
Perform service regeneration at IDLE after issue
rectification
Pressuree difference threshold : +/- 8 kPa
Perform following services in TDS:
If difference found within specification, Fit new PFM sensor into engine 1. RESET PFM Sensor Learning
5
and connect other sensors also
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0110-15: Inlet air temperature sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0110-15 1. Wiring harness issue (Connector open / pin

back out /Short circuit) No Vehicle reaction
2. Faulty sensor
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_INLET_AIR_HI_APV

System Air Intake System / Inlet Air temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 172 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
Inlet air temp.(IAT) Pin 1 - ECU Pin E57
Check Inlet Air temp. sensor electrical failures. If found any issue, rectify Inlet air temp.(IAT) Pin 2 - ECU Pin E62
and check for DTC For Resistance checks, Kepp sensor outside (Open to air)
1 1. Pin back out checks (ECU side and sensor side) 0degC : 5712ohms, 10degC : 3684ohms, 20degC:
2. Connector/Sensor physical damage 2437ohms, 25degC: 2000ohms, 30degC-1651ohms,
3.Continuity checks (Open / Short circuit failures) 40degC: 1143ohms
Measured resistance has to be compared against local
ambient temperature
If still issue persists, Replace Inlet Air temperature sensor and check for
2
DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0110-11: Inlet air temperature sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0110-11 1. Wiring harness issue (Short circuit)

No Vehicle reaction
2. Faulty sensor
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_INLET_AIR_LO_APV

System Air Intake System / Inlet Air temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 172 / 04

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
Inlet air temp.(IAT) Pin 1 - ECU Pin E57
Check Inlet Air temp. sensor electrical failures. If found any issue, rectify Inlet air temp.(IAT) Pin 2 - ECU Pin E62
and check for DTC For Resistance checks, Kepp sensor outside (Open to air)
1 1. Pin back out checks (ECU side and sensor side) 0degC : 5712ohms, 10degC : 3684ohms, 20degC:
2. Connector/Sensor physical damage 2437ohms, 25degC: 2000ohms, 30degC-1651ohms,
3.Continuity checks (Open / Short circuit failures) 40degC: 1143ohms
Measured resistance has to be compared against local
ambient temperature
If still issue persists, Replace Inlet Air temperature sensor and check for
2
DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0110-64: Inlet air temperature sensor - Signal not valid based on reference
sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0110-64 1.Faulty wiring harness

2.Faulty sensor No Vehicle reaction
3.Faulty ECU
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_INLET_AIR_TEMP_XC_APV

System Air Intake System / Inlet Air temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 172 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
Inlet air temp.(IAT) Pin 1 - ECU Pin E57
Check Inlet Air temperature sensor electrical failures. If found any issue, Inlet air temp.(IAT) Pin 2 - ECU Pin E62
rectify it and check for DTC For Resistance checks, Kepp sensor outside (Open to air)
1 1. Pin back out checks (ECU side and sensor side) 0degC : 5712ohms, 10degC : 3684ohms, 20degC:
2. Connector/Sensor physical damage 2437ohms, 25degC: 2000ohms, 30degC-1651ohms,
3.Continuity checks (Open / Short circuit failures) 40degC: 1143ohms
Measured resistance has to be compared against local
ambient temperature
After rectification of step 1, connect Inlet Air temp. sensor externally and Reference sensors :
2 keep it in ambient with wiring connected. Like that keep reference 1. Ambient temperature sensor
sensors as well. Check temp. difference across all sensors 2. Intercooler out temperature sensor(PFM)

3 If difference found within specification, Fit back all 3 sensors into engine. Temperature difference threshold : +/20 deg C

If still issue persists, connect one new Inlet Air temp. sensor externally Reference sensors :
4 and keep it in ambient with wiring connected. Like that keep reference 1. Ambient temperature sensor
sensors as well. Check temp. difference across all sensors 2. Intercooler out temperature sensor
If difference found within specification, Fit new Inlet air temp. sensor
5 Temperature difference threshold : +/20 deg C
into engine and connect other sensors also
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0105-12: Intake Manifold Pressue sensor - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0105-12

1. Wiring harness issue (Short circuit)
2. Faulty sensor Engine emission go high
MIL ON for 15 secs
Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_MAP_SENSOR_HI_APV

System Air Intake System / Intake Manifold pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 3563 / 04

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
TMAP Pin 1 - ECU Pin E11
Check TMAP/Intake manifold pressure sensor electrical failures. If found
TMAP Pin 2 - ECU Pin E96
any issue, rectify and check for DTC
TMAP Pin 3 - ECU Pin E53
1 1. Pin back out checks (ECU side and sensor side)
TMAP Pin 4 - ECU Pin E74
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
If still issue persists, ReplaceTMAP/Intake manifold pressure sensor and Perform service regeneration at IDLE after issue
2
check for DTC rectification
Select dataset as per Vehicle configuration(VC)
3 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
4 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0105-14: Intake Manifold Pressue sensor - Short to Ground or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0105-14 1. Wiring harness issue (Connector open / pin

back out /Short circuit)
2. Faulty sensor Engine emission go high
MIL ON for 15 secs
Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_MAP_SENSOR_LO_APV

System Air Intake System / Intake Manifold pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 102 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
TMAP Pin 1 - ECU Pin E11
Check TMAP/Intake manifold pressure sensor electrical failures. If found
TMAP Pin 2 - ECU Pin E96
any issue, rectify and check for DTC
TMAP Pin 3 - ECU Pin E53
1 1. Pin back out checks (ECU side and sensor side)
TMAP Pin 4 - ECU Pin E74
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
If still issue persists, ReplaceTMAP/Intake manifold pressure sensor and Perform service regeneration at IDLE after issue
2
check for DTC rectification
Select dataset as per Vehicle configuration(VC)
3 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
4 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0105-64: Intake Manifold Pressue sensor - Signal not valid based on

reference sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0105-64 1.Faulty wiring harness

2.Faulty sensor
3.Faulty ECU Engine emission go high
MIL ON for 15 secs
Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_MAP_XC_APV

System Air Intake System / Intake Manifold pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 3563 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
TMAP Pin 1 - ECU Pin E11
Check TMAP/Intake manifold pressure sensor electrical failures. If found
TMAP Pin 2 - ECU Pin E96
any issue, rectify it and check for DTC
TMAP Pin 3 - ECU Pin E53
1 1. Pin back out checks (ECU side and sensor side)
TMAP Pin 4 - ECU Pin E74
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
Reference sensors :
1. Ambient pressure sensor
After rectification of step 1, connect TMAP sensor externally and keep it
2. PFM/Boost pressure sensor
2 in ambient with wiring connected. Like that keep reference sensors as
well. Check pressure difference across all sensors
Perform service regeneration at IDLE after issue
rectification
Pressuree difference threshold : +/- 8 kPa
If difference found within specification, Fit TMAP sensor into engine and
3
connect other sensors as well. Perform service regeneration at IDLE after issue
rectification
Reference sensors :
1. Ambient pressure sensor
If still issue persists, connect one new TMAP sensor externally and keep it
2. PFM/Boost pressure sensor
4 in ambient with wiring connected. Like that keep reference sensors as
well. Check pressure difference across all sensors
Perform service regeneration at IDLE after issue
rectification
Pressuree difference threshold : +/- 8 kPa
If difference found within specification, Fit new TMAP sensor into engine
5
and connect other sensors also Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P00E8-15: Intake Manifold temperature sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P00E8-15 1. Wiring harness issue (Connector open / pin

back out /Short circuit)
2. Faulty sensor Engine emission may go high
MIL ON for 15 secs
Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_IP_TEMP_HI_APV

System Air Intake System / Intake Manifold temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 105 / 03

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:

TMAP Pin 1 - ECU Pin E11
TMAP Pin 2 - ECU Pin E96
TMAP Pin 3 - ECU Pin E53
Check TMAP/Intake manifold temp. sensor electrical failures. If found TMAP Pin 4 - ECU Pin E74
any issue, rectify and check for DTC For Resistance checks, Kepp sensor outside (Open to air)
1 1. Pin back out checks (ECU side and sensor side) 15degC : 3068ohms, 20degC : 2499ohms, 25degC:
2. Connector/Sensor physical damage 2056ohms, 30degC: 1706ohms, 35degC : 1411ohms
3.Continuity checks (Open / Short circuit failures) Measured resistance has to be compared against local
ambient temperature

Perform service regeneration at IDLE after issue

rectification

If still issue persists, Replace TMAP/Intake manifold temperature sensor Perform service regeneration at IDLE after issue
2
and check for DTC rectification
Select dataset as per Vehicle configuration(VC)
3 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
4 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P00E8-11: Intake Manifold temperature sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P00E8-11

1. Wiring harness issue (Short circuit)
2. Faulty sensor Engine emission go high
MIL ON for 15 secs
Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_IP_TEMP_LO_APV

System Air Intake System / Intake Manifold temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 105 / 04

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:

TMAP Pin 1 - ECU Pin E11
TMAP Pin 2 - ECU Pin E96
TMAP Pin 3 - ECU Pin E53
Check TMAP/Intake manifold temp. sensor electrical failures. If found TMAP Pin 4 - ECU Pin E74
any issue, rectify and check for DTC For Resistance checks, Kepp sensor outside (Open to air)
1 1. Pin back out checks (ECU side and sensor side) 15degC : 3068ohms, 20degC : 2499ohms, 25degC:
2. Connector/Sensor physical damage 2056ohms, 30degC: 1706ohms, 35degC : 1411ohms
3.Continuity checks (Open / Short circuit failures) Measured resistance has to be compared against local
ambient temperature

Perform service regeneration at IDLE after issue

rectification

If still issue persists, Replace TMAP/Intake manifold temperature sensor Perform service regeneration at IDLE after issue
2
and check for DTC rectification
Select dataset as per Vehicle configuration(VC)
3 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
4 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P00E8-64: Intake Manifold temperature sensor - Signal not valid based on

reference sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P00E8-64 1.Faulty wiring harness

2.Faulty sensor
3.Faulty ECU Engine emission go high
MIL ON for 15 secs
Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_INTAKE_PLEN_TEMP_XC_APV

System Air Intake System / Intake Manifold temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 105 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:

TMAP Pin 1 - ECU Pin E11
TMAP Pin 2 - ECU Pin E96
TMAP Pin 3 - ECU Pin E53
Check TMAP/Intake manifold temp. sensor electrical failures. If found TMAP Pin 4 - ECU Pin E74
any issue, rectify it and check for DTC For Resistance checks, Kepp sensor outside (Open to air)
1 1. Pin back out checks (ECU side and sensor side) 15degC : 3068ohms, 20degC : 2499ohms, 25degC:
2. Connector/Sensor physical damage 2056ohms, 30degC: 1706ohms, 35degC : 1411ohms
3.Continuity checks (Open / Short circuit failures) Measured resistance has to be compared against local
ambient temperature

Perform service regeneration at IDLE after issue

rectification

Reference sensors :
1. EGR intake temperature sensor
After rectification of step 1, connect TMAP sensor externally and keep it
2. Intercooler out temperature sensor(PFM)
2 in ambient with wiring connected. Like that keep reference sensors as
well. Check temp. difference across all sensors
Perform service regeneration at IDLE after issue
rectification
Temperature difference threshold : +/20 deg C
3 If difference found within specification, Fit back all 3 sensors into engine.
Perform service regeneration at IDLE after issue
rectification
Reference sensors :
1. EGR intake temperature sensor
If still issue persists, connect one new TMAP sensor externally and keep it
2. Intercooler out temperature sensor(PFM)
4 in ambient with wiring connected. Like that keep reference sensors as
well. Check temp. difference across all sensors
Perform service regeneration at IDLE after issue
rectification
Temperature difference threshold : +/20 deg C
If difference found within specification, Fit new TMPA sensor into engine
5
and connect other sensors also Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P026A-00: Intercooler Performance - Low efficiency error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Electrical errors of PFM sensor/E-Viscous FAN

2. Blockages in the front air passage
Fault Code P026A-00
3. Intake air leakages
4. Faulty intercooler
5. Faulty E-Viscous FAN
6. Faulty PFM sensor Engine emission go high
MIL ON
Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_INTERCOOLER_PERF_LO_APV

System Air Intake System / Intercooler performance Monitor

OBD Inducement Non-Inducement

SPN & FMI 5285 / 07

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check E-Viscous FAN/PFM sensor electrical failures. If found any issue,
rectify it and check for DTC
Perform service regeneration at IDLE after issue
1 1. Pin back out checks (ECU side and sensor side)
rectification
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
If anything found in step 1, after rectification drive vehicle for 10 Kms in Perform service regeneration at IDLE after issue
2
highway and check for DTC rectification
If still issue persists, Check Blockages near by intercooler side/front
Perform service regeneration at IDLE after issue
3 Bonnet. If found any, rectify the same. Drive vehicle for 10 Kms and
rectification
check for DTC
If still issue persists, Check Intake air leakage / Air filter related issues. If Perform service regeneration at IDLE after issue
4
found any, rectify the same. Drive vehicle for 10 Kms and check for DTC rectification
If still issue persists, Replace intercooler. Drive vehicle for 10 Kms in Perform service regeneration at IDLE after issue
5
highway and check for DTC rectification
Perform service regeneration at IDLE after issue
6 If still issue persists, Replace E-vsicus FAN and check for DTC
rectification
Perform following services in TDS:
1. RESET PFM Sensor Learning
7 If still issue persists, Replace PFM sensor and check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
8 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P006A-9B: PFM Sensor - Signal drift error (High)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P006A-9B

1. Intake air leakage / Blockage
2. Faulty PFM sensor
MIL ON 3. Faulty TMAP sensor 1. Regeneration Inhibition
4. Faulty ECU 2. Urea dosing will be stopped
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_AMF_CORR_HI_FFR_APV

System Air Intake System / PFM Air Mass flow Monitor

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 132 / 20

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Air filter choke
Air filter to compressor, compressor to intercooler,
Intercooler to PFM, PFM to Intake manifold, EGR cooler to
Check Intake air leakage / Air filter related issues. If found any, rectify the
1 intake manifold lines
same. Drive vehicle for 10 Kms and check for DTC
Perform service regeneration at IDLE after issue
rectification

Refer circuit diagram &

Check voltages between points When Ignition ON as well
Check PFM/TMAP sensor electrical failures. If found any issue, rectify it
as engine ON
and check for DTC
5V : Pin 1&3, 3&4, 2&3, 1&ground, 2&ground, 4&ground
2 1. Pin back out checks (ECU side and sensor side)
0V : 1&2, 1&4, 2&4, 3&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
If anything found in step1, after rectification drive vehicle for 10 Kms and Perform service regeneration at IDLE after issue
3
check for DTC rectification
Damage of sensor/ Broken Sensor
Perform following services in TDS: (If PFM is changed)
Check any physical damage of PFM & TMAP Sensor.If found any, replace
4 1. RESET PFM Sensor Learning
respective sensor. Drive vehicle for 10 Kms and check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
Check the air mass flow during idling through Diagnostic Tester. If its out
1. RESET PFM Sensor Learning
5 of specification, Replace PFM sensor. Drive vehicle for 10 Kms and check
Perform service regeneration at IDLE after issue
for DTC
rectification
If still issue persists, Replace TMAP sensor. Check the air mass flow
Perform service regeneration at IDLE after issue
6 during idling through Diagnostic Tester. Drive vehicle for 10 Kms and
rectification
check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
7 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P006A-9C: PFM Sensor - Signal drift error (Low)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P006A-9C

1. Intake air leakage / Blockage
2. Faulty PFM sensor
MIL ON 3. Faulty TMAP sensor 1. Regeneration Inhibition
4. Faulty ECU 2. Urea dosing will be stopped
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_AMF_CORR_LO_FFR_APV

System Air Intake System / PFM Air Mass flow Monitor

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 132 / 21

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Air filter choke
Air filter to compressor, compressor to intercooler,
Intercooler to PFM, PFM to Intake manifold, EGR cooler to
Check Intake air leakage / Air filter related issues. If found any, rectify the
1 intake manifold lines
same. Drive vehicle for 10 Kms and check for DTC
Perform service regeneration at IDLE after issue
rectification

Refer circuit diagram &

Check voltages between points When Ignition ON as well
Check PFM/TMAP sensor electrical failures. If found any issue, rectify it
as engine ON
and check for DTC
5V : Pin 1&3, 3&4, 2&3, 1&ground, 2&ground, 4&ground
2 1. Pin back out checks (ECU side and sensor side)
0V : 1&2, 1&4, 2&4, 3&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
If anything found in step1, after rectification drive vehicle for 10 Kms and Perform service regeneration at IDLE after issue
3
check for DTC rectification
Damage of sensor/ Broken Sensor
Perform following services in TDS: (If PFM is changed)
Check any physical damage of PFM & TMAP Sensor.If found any, replace
4 1. RESET PFM Sensor Learning
respective sensor. Drive vehicle for 10 Kms and check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
Check the air mass flow during idling through Diagnostic Tester. If its out
1. RESET PFM Sensor Learning
5 of specification, Replace PFM sensor. Drive vehicle for 10 Kms and check
Perform service regeneration at IDLE after issue
for DTC
rectification
If still issue persists, Replace TMAP sensor. Check the air mass flow
Perform service regeneration at IDLE after issue
6 during idling through Diagnostic Tester. Drive vehicle for 10 Kms and
rectification
check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
7 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 260 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Author: ERC Page 261 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0100-29: PFM Sensor - Signal error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0100-29

1.Faulty wiring harness
MIL ON 2.Faulty sensor 1. Regeneration Inhibition
3.Faulty ECU 2. Urea dosing will be stopped
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_AMF_SENT_FDAT_APV

System Air Intake System / PFM Air Mass flow Monitor

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 132 / 19

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 262 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram &
Check voltages between points When Ignition ON as well
Check PFM sensor electrical failures. If found any issue, rectify it and as engine ON
check for DTC 5V : Pin 1&3, 3&4, 2&3, 1&ground, 2&ground, 4&ground
1 1. Pin back out checks (ECU side and sensor side) 0V : 1&2, 1&4, 2&4, 3&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Damage of sensor/ Broken Sensor

Perform following services in TDS:
Check any physical damage of PFM Sensor. If found any issues, 1. RESET PFM Sensor Learning
2
rectify/replace it and check for DTC
Perform service regeneration at IDLE after issue
rectification
Air flow threshold : 25-35 g/s
Perform following services in TDS:
1. RESET PFM Sensor Learning
Check the air mass flow during idling through Diagnostic Tester. If its out
3
of specification, Replace sensor & check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)

4 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
5 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 263 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 264 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Author: ERC Page 265 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P007A-29: Intercooler out temperature - Sensor signal error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P007A-29

1.Faulty wiring harness
MIL ON 2.Faulty sensor 1. Regeneration Inhibition
3.Faulty ECU 2. Urea dosing will be stopped
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_IC_SENT_FDATA_APV

System Air Intake System / PFM Intercooler outlet temperature sensor

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 2630 / 09

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 266 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram &
Check voltages between points When Ignition ON as well
Check PFM sensor electrical failures. If found any issue, rectify it and as engine ON
check for DTC 5V : Pin 1&3, 3&4, 2&3, 1&ground, 2&ground, 4&ground
1 1. Pin back out checks (ECU side and sensor side) 0V : 1&2, 1&4, 2&4, 3&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Damage of sensor/ Broken Sensor

Perform following services in TDS:
Check any physical damage of PFM Sensor. If found any issues, 1. RESET PFM Sensor Learning
2
rectify/replace it and check for DTC
Perform service regeneration at IDLE after issue
rectification

Air flow threshold : 25-35 g/s

Intercooler temp. @ Key ON : ~25 to 35 degC (Keep
sensor outside from engine and check)
Perform following services in TDS:
Check the air mass flow during idling through Diagnostic Tester. If its out
3 1. RESET PFM Sensor Learning
of specification, Replace sensor & check for DTC

Perform service regeneration at IDLE after issue

rectification
Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
5 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 267 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 268 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Author: ERC Page 269 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P007A-64: Intercooler out temperature - Signal not valid based on reference

sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P007A-64

1.Faulty wiring harness
MIL ON 2.Faulty sensor 1. Regeneration Inhibition
3.Faulty ECU 2. Urea dosing will be stopped
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_IC_OUT_TEMP_XC_APV

System Air Intake System / PFM Intercooler outlet temperature sensor

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 2630 / 02

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 270 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram &
Check voltages between points When Ignition ON as well
Check PFM/Intercooler out temp. sensor electrical failures. If found any
as engine ON
issue, rectify it and check for DTC
5V : Pin 1&3, 3&4, 2&3, 1&ground, 2&ground, 4&ground
1 1. Pin back out checks (ECU side and sensor side)
0V : 1&2, 1&4, 2&4, 3&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
Reference sensors :
1. Inlet Air temperature (IAT) sensor
After rectification of step 1, connect PFM sensor externally and keep it in
2. Intake manifold temperature sensor (TMAP)
2 ambient with wiring connected. Like that keep reference sensors as well.
Check temp. difference across all sensors
Perform service regeneration at IDLE after issue
rectification
Temperature difference threshold : +/20 deg C
3 If difference found within specification, Fit back all 3 sensors into engine.
Perform service regeneration at IDLE after issue
rectification
Reference sensors :
1. Inlet Air temperature (IAT) sensor
If still issue persists, connect one new PFM temp. sensor externally and
2. Intake manifold temperature sensor (TMAP)
4 keep it in ambient with wiring connected. Like that keep reference
sensors as well. Check temp. difference across all sensors
Perform service regeneration at IDLE after issue
rectification
Temperature difference threshold : +/20 deg C
If difference found within specification, Fit new PFM sensor into engine
5
and connect other sensors also Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 271 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 272 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Author: ERC Page 273 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0100-81: PFM Sensor - SENT 1 data error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0100-81

1.Faulty wiring harness
MIL ON 2.Faulty sensor 1. Regeneration Inhibition
3.Faulty ECU 2. Urea dosing will be stopped
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_SENT1_SENSR_FDAT_APV

System Air Intake System / PFM Sensor

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 516200 / 02

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 274 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram &
Check voltages between points When Ignition ON as well
Check PFM sensor electrical failures. If found any issue, rectify it and
as engine ON
check for DTC
5V : Pin 1&3, 3&4, 2&3, 1&ground, 2&ground, 4&ground
1 1. Pin back out checks (ECU side and sensor side)
0V : 1&2, 1&4, 2&4, 3&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
Damage of sensor/ Broken Sensor
Perform following services in TDS:
Check any physical damage of PFM Sensor. If found any issues, 1. RESET PFM Sensor Learning
2
rectify/replace it and check for DTC
Perform service regeneration at IDLE after issue
rectification
Air flow threshold : 25-35 g/s
Perform following services in TDS:
Check the air mass flow during idling through Diagnostic Tester. If its out 1. RESET PFM Sensor Learning
3
of specification, Replace sensor & check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
5 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 275 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 276 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Author: ERC Page 277 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0100-86: PFM Sensor - SENT 1 global message error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0100-86

1.Faulty wiring harness
MIL ON 2.Faulty sensor 1. Regeneration Inhibition
3.Faulty ECU 2. Urea dosing will be stopped
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_SENT1_SENSOR_APV

System Air Intake System / PFM Sensor

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 516200 / 19

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 278 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram &
Check voltages between points When Ignition ON as well
Check PFM sensor electrical failures. If found any issue, rectify it and
as engine ON
check for DTC
5V : Pin 1&3, 3&4, 2&3, 1&ground, 2&ground, 4&ground
1 1. Pin back out checks (ECU side and sensor side)
0V : 1&2, 1&4, 2&4, 3&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
Damage of sensor/ Broken Sensor
Perform following services in TDS:
Check any physical damage of PFM Sensor. If found any issues, 1. RESET PFM Sensor Learning
2
rectify/replace it and check for DTC
Perform service regeneration at IDLE after issue
rectification
Air flow threshold : 25-35 g/s
Perform following services in TDS:
Check the air mass flow during idling through Diagnostic Tester. If its out 1. RESET PFM Sensor Learning
3
of specification, Replace sensor & check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
5 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 279 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 280 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Author: ERC Page 281 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P010A-81: PFM Sensor - SENT 2 data error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P010A-81

1.Faulty wiring harness
MIL ON 2.Faulty sensor 1. Regeneration Inhibition
3.Faulty ECU 2. Urea dosing will be stopped
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_SENT2_SENSR_FDAT_APV

System Air Intake System / PFM Sensor

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 516201 / 02

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 282 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram &
Check voltages between points When Ignition ON as well
Check PFM sensor electrical failures. If found any issue, rectify it and
as engine ON
check for DTC
5V : Pin 1&3, 3&4, 2&3, 1&ground, 2&ground, 4&ground
1 1. Pin back out checks (ECU side and sensor side)
0V : 1&2, 1&4, 2&4, 3&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
Damage of sensor/ Broken Sensor
Perform following services in TDS:
Check any physical damage of PFM Sensor. If found any issues, 1. RESET PFM Sensor Learning
2
rectify/replace it and check for DTC
Perform service regeneration at IDLE after issue
rectification
Air flow threshold : 25-35 g/s
Perform following services in TDS:
Check the air mass flow during idling through Diagnostic Tester. If its out 1. RESET PFM Sensor Learning
3
of specification, Replace sensor & check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
5 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 283 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 284 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Author: ERC Page 285 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P010A-86: PFM Sensor - SENT 2 global message error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P010A-86

1.Faulty wiring harness
MIL ON 2.Faulty sensor 1. Regeneration Inhibition
3.Faulty ECU 2. Urea dosing will be stopped
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_SENT2_SENSOR_APV

System Air Intake System / PFM Sensor

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 516201 / 19

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 286 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram &
Check voltages between points When Ignition ON as well
Check PFM sensor electrical failures. If found any issue, rectify it and
as engine ON
check for DTC
5V : Pin 1&3, 3&4, 2&3, 1&ground, 2&ground, 4&ground
1 1. Pin back out checks (ECU side and sensor side)
0V : 1&2, 1&4, 2&4, 3&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
Damage of sensor/ Broken Sensor
Perform following services in TDS:
Check any physical damage of PFM Sensor. If found any issues, 1. RESET PFM Sensor Learning
2
rectify/replace it and check for DTC
Perform service regeneration at IDLE after issue
rectification
Air flow threshold : 25-35 g/s
Perform following services in TDS:
Check the air mass flow during idling through Diagnostic Tester. If its out 1. RESET PFM Sensor Learning
3
of specification, Replace sensor & check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
5 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 287 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 288 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Author: ERC Page 289 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

U0155-00: Lost Communication with Instrument Cluster

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness Faulty
2. Following components CAN lines might be
Fault Code U0155-00 No Vehicle reaction
faulty
V ECU, ECU, DCU & ABS

Fault System Summary:

Development Fault code F_M_J1939_DD_TIMEOUT_APV

System CAN Errors / Instrument Cluster / VECU

OBD Inducement Non-Inducement

SPN & FMI 516206 / 19

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check communication / wiring continuity between CAN high & low pins
Refer circuit diagram
1 across components mentioned in the specification. If found any issue,
Components : V ECU, ECU, DCU & ABS
rectify it and check for DTC
If still issue persists, remove components one by one in the network.
Refer circuit diagram
2 Clear DTC and check for DTC. If DTC not appearing for removal of any one
Components : V ECU, ECU, DCU & ABS
component, Replace that particular component and check for DTC
If still persists, Replace complete private CAN network wiring harness and
3
check for DTC

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

U007B-00: Communication Error - Private CAN Bus Off or Passive Error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code U007B-00 1. Wiring harness/Terminals are faulty

2. CAN High and Low terminals short each other
in any one of the CAN network (NOx
sensors/Urea quality sensor/ECU/DCU)
MIL ON 3. Any one of the above devices in the CAN 1. 1500 rpm Engine speed limitation
SCR Lamp ON network is faulty 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_BUS_OFF_CAN2_APV

System CAN Errors / Network

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 516233 / 19

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram
CAN High pins : EMS ECU V77-DCU 214
Check CAN High connection wiring continuity between components
Components : ECU, DCU, NOx sensors & Quality sensor
mentioned in specification. Also check resistance between devices. If
1 Refer Specification 8 for wiring harness routing
resistance found out of specification, Check for open circuit / terminal
loose contact in the line. If found any rectify it and check for DTC
Perform service regeneration at IDLE after issue
rectification
Refer circuit diagram
If still issue persists, Check CAN Low connection wiring continuity CAN High pins : EMS ECU V78-DCU 215
between components mentioned in specification. Also check resistance Components : ECU, DCU, NOx sensors & Quality sensor
2 between devices. If resistance found out of specification, Check for open Refer Specification 8 for wiring harness routing
circuit / terminal loose contact in the line. If found any rectify it and
check for DTC Perform service regeneration at IDLE after issue
rectification
Resistance between any 2 points : < 1 ohm
If still issue persists, Check resistance between CAN High & Low
Refer Specification 8 for wiring harness routing
3 resistance on EMS ECU & DCU. While checking resistance disconnect ECU
& ensure remaining all connections are connected
Perform service regeneration at IDLE after issue
rectification

Expected Resistance threshold : 120 ohms

Check points :
1. EMS ECU V77 - V78
If resistance found higher than 10K ohms, check proper connections for
4 terminating resistor in the line. If found any issue rectify it and check for
Refer Specification 8 for wiring harness routing
DTC
Perform service regeneration at IDLE after issue
rectification

Check for open mouth, deformed terminals, loose

crimping
If resistance found lesser than 20 ohms, CAN High and Low connections
5 are short each other. Repair short circuit. If require, replace wiring Refer Specification 8 for wiring harness routing
harness and check for DTC
Perform service regeneration at IDLE after issue
rectification
Other devices in the line :
DCU, NOx sensors & Quality sensor
If still issue persists, remove devices one by one and check for DTC. While
6 removing any one device if fault didn't occur, replace that particular Refer Specification 8 for wiring harness routing
device or rectify that particular wiring related issues
Perform service regeneration at IDLE after issue
rectification

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Date: 31-01-2023

Other devices in the line :

DCU, NOx sensors & Quality sensor
If still issue persists (which means not able communicate with EMS ECU),
then check for communication with other devices in CAN network. If
7 Refer Specification 8 for wiring harness routing
other devices communication found OK, check EMS ECU power supply
lines, fuses, etc., If found any issues, rectify it and check for DTC
Perform service regeneration at IDLE after issue
rectification

5L ULTRA Platform- Front Chassis Harness, IP-Harness,EGP

Harness
5L Signa Platform- Engine Harness,Aftertreatment
harness,EGP harness
5L Cowl Platform- Main harness,Engine
If still persists, Replace private CAN network wiring harness one by one
8 harness,Aftertreatment harness,EGP harness
(mentioned in the specification) and check for DTC.
5L Bus- Panel harness,Aftertreatment harness,EGP
harness

Perform service regeneration at IDLE after issue

rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

U007A-00: Communication Error - Public CAN Bus Off or Passive Error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness/Terminals are Faulty
2. CAN High and Low terminals short each other
in any one of the CAN network (VECU, ECU, DCU
Fault Code U007A-00 No Vehicle reaction
& ABS)
3. Any one of the above devices in the CAN
network is faulty

Fault System Summary:

Development Fault code F_M_BUS_OFF_CAN1_APV

System CAN Errors / Network

OBD Inducement Non-Inducement

SPN & FMI 516234 / 19

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram
Check CAN High connection wiring continuity between EMS ECU, VECU &
CAN High pins : EMS ECU V81-VECU F4-DCU 211
DCU. Also check resistance between devices. If resistance found out of
1 Components : VECU, ECU, DCU & ABS
specification, Check for open circuit / terminal loose contact in the line. If
found any rectify it and check for DTC
Refer Specification 9 for wiring harness routing
Refer circuit diagram
If still issue persists, Check CAN Low connection wiring continuity
CAN High pins : EMS ECU V80-VECU E4-DCU 212
between EMS ECU, VECU & DCU. Also check resistance between devices.
2 Components : VECU, ECU, DCU & ABS
If resistance found out of specification, Check for open circuit / terminal
loose contact in the line. If found any rectify it and check for DTC
Refer Specification 9 for wiring harness routing
If still issue persists, Check resistance between CAN High & Low Resistance between any 2 points : < 1 ohm
3 resistance on EMS ECU & DCU. While checking resistance disconnect ECU
& ensure remaining all connections are connected Refer Specification 9 for wiring harness routing
Expected Resistance threshold : 60 ohms
Check points :
If resistance found higher than 10K ohms, check proper connections for
1. EMS ECU V81 - V80
4 terminating resistor in the line. If found any issue rectify it and check for
2. DCU V211 - 212
DTC
Refer Specification 9 for wiring harness routing
Check for open mouth, deformed terminals, loose
If resistance found lesser than 20 ohms, CAN High and Low connections
crimping
5 are short each other. Repair short circuit. If require, replace wiring
harness and check for DTC
Refer Specification 9 for wiring harness routing
Other devices in the line :
If still issue persists, remove devices one by one and check for DTC. While
VECU, DCU & ABS
6 removing any one device if fault didn't occur, replace that particular
device or rectify that particular wiring related issues
Refer Specification 9 for wiring harness routing
If still issue persists (which means not able communicate with EMS ECU), Other devices in the line :
then check for communication with other devices in CAN network. If VECU, DCU & ABS
7
other devices communication found OK, check EMS ECU power supply
lines, fuses, etc., If found any issues, rectify it and check for DTC Refer Specification 9 for wiring harness routing
Other devices in the line :
If still issue persists, check for diagnostic CAN circuits. If found any issues, VECU, DCU & ABS
8
rectify it. If required, replace wiring harnessss and check for DTC
Refer Specification 9 for wiring harness routing
5L ULTRA Platform- Front Chassis Harness, IP-Harness
5L Signa Platform- Engine Harness,Aftertreatment
If still persists, Replace public CAN network wiring harness one by one harness
9
(mentioned in the specification) and check for DTC. 5L Cowl Platform- Main harness,Engine
harness,Aftertreatment harness
5L Bus-Panel harness,Retarder harness,ABS harness

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Date: 31-01-2023

Circuit Schematic Diagram:

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Date: 31-01-2023

Location and Component Image:

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

U010E-00: Lost Communication with DCU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code U010E-00

1. Wiring harness/Terminals are faulty
2. CAN High and Low terminals short each other
in any one of the CAN network (NOx
MIL ON sensors/Urea quality sensor/ECU/DCU) 1. 30% Torque reduction
3. Any one of the above devices in the CAN
SCR Lamp ON 2. 1500 rpm Engine speed limitation
network is faulty
3. Engine emissions go high
4. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_J1939_TMLPM8_TMO_APV

System CAN Errors / Private CAN DCU

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 516229 / 19

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check CAN High connection wiring continuity between components Refer circuit diagram
mentioned in specification. Also check resistance between devices. If CAN High pins : EMS ECU V77-DCU 214
1
resistance found out of specification, Check for open circuit / terminal Components : ECU, DCU, NOx sensors & Quality sensor
loose contact in the line. If found any rectify it and check for DTC Refer Specification 8 for wiring harness routing
If still issue persists, Check CAN Low connection wiring continuity
Refer circuit diagram
between components mentioned in specification. Also check resistance
CAN High pins : EMS ECU V78-DCU 215
2 between devices. If resistance found out of specification, Check for open
Components : ECU, DCU, NOx sensors & Quality sensor
circuit / terminal loose contact in the line. If found any rectify it and
Refer Specification 8 for wiring harness routing
check for DTC
If still issue persists, Check resistance between CAN High & Low Resistance between any 2 points : < 1 ohm
3 resistance on EMS ECU & DCU. While checking resistance disconnect ECU
& ensure remaining all connections are connected Refer Specification 8 for wiring harness routing
Expected Resistance threshold : 120 ohms
If resistance found higher than 10K ohms, check proper connections for Check points :
4 terminating resistor in the line. If found any issue rectify it and check for 1. EMS ECU V77 - V78
DTC
Refer Specification 8 for wiring harness routing
Check for open mouth, deformed terminals, loose
If resistance found lesser than 20 ohms, CAN High and Low connections
crimping
5 are short each other. Repair short circuit. If require, replace wiring
harness and check for DTC
Refer Specification 8 for wiring harness routing
Other devices in the line :
If still issue persists, remove devices one by one and check for DTC. While
DCU, NOx sensors & Quality sensor
6 removing any one device if fault didn't occur, replace that particular
device or rectify that particular wiring related issues
Refer Specification 8 for wiring harness routing
If still issue persists (which means not able communicate with EMS ECU), Other devices in the line :
then check for communication with other devices in CAN network. If DCU, NOx sensors & Quality sensor
7
other devices communication found OK, check EMS ECU power supply
lines, fuses, etc., If found any issues, rectify it and check for DTC Refer Specification 8 for wiring harness routing
5L ULTRA Platform- Front Chassis Harness, IP-Harness,EGP
Harness
5L Signa Platform- Engine Harness,Aftertreatment
If still persists, Replace private CAN network wiring harness one by one harness,EGP harness
8
(mentioned in the specification) and check for DTC. 5L Cowl Platform- Main harness,Engine
harness,Aftertreatment harness,EGP harness
5L Bus- Panel harness,Aftertreatment harness,EGP
harness

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Date: 31-01-2023

Circuit Schematic Diagram:

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Date: 31-01-2023

Location and Component Image:

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

U0619-00: Lost Communication with DEF Urea Level Sensor

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness/Terminals are faulty
2. CAN High and Low terminals short each other
in any one of the CAN network (NOx
Fault Code U0619-00 No Vehicle reaction
sensors/Urea quality sensor/ECU/DCU)
3. Any one of the above devices in the CAN
network is faulty

Fault System Summary:

Development Fault code F_M_J1939_AT1T1I1_TMO_APV

System CAN Errors / Urea Quality Sensor

OBD Inducement Non-Inducement

SPN & FMI 3517 / 19

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check CAN High connection wiring continuity between components Refer circuit diagram
mentioned in specification. Also check resistance between devices. If CAN High pins : EMS ECU V77-DCU 214
1
resistance found out of specification, Check for open circuit / terminal Components : ECU, DCU, NOx sensors & Quality sensor
loose contact in the line. If found any rectify it and check for DTC Refer Specification 8 for wiring harness routing
If still issue persists, Check CAN Low connection wiring continuity
Refer circuit diagram
between components mentioned in specification. Also check resistance
CAN High pins : EMS ECU V78-DCU 215
2 between devices. If resistance found out of specification, Check for open
Components : ECU, DCU, NOx sensors & Quality sensor
circuit / terminal loose contact in the line. If found any rectify it and
Refer Specification 8 for wiring harness routing
check for DTC
If still issue persists, Check resistance between CAN High & Low Resistance between any 2 points : < 1 ohm
3 resistance on EMS ECU & DCU. While checking resistance disconnect ECU
& ensure remaining all connections are connected Refer Specification 8 for wiring harness routing
Expected Resistance threshold : 120 ohms
If resistance found higher than 10K ohms, check proper connections for Check points :
4 terminating resistor in the line. If found any issue rectify it and check for 1. EMS ECU V77 - V78
DTC
Refer Specification 8 for wiring harness routing
Check for open mouth, deformed terminals, loose
If resistance found lesser than 20 ohms, CAN High and Low connections
crimping
5 are short each other. Repair short circuit. If require, replace wiring
harness and check for DTC
Refer Specification 8 for wiring harness routing
Other devices in the line :
If still issue persists, remove devices one by one and check for DTC. While
DCU, NOx sensors & Quality sensor
6 removing any one device if fault didn't occur, replace that particular
device or rectify that particular wiring related issues
Refer Specification 8 for wiring harness routing
If still issue persists (which means not able communicate with EMS ECU), Other devices in the line :
then check for communication with other devices in CAN network. If DCU, NOx sensors & Quality sensor
7
other devices communication found OK, check EMS ECU power supply
lines, fuses, etc., If found any issues, rectify it and check for DTC Refer Specification 8 for wiring harness routing
5L ULTRA Platform- Front Chassis Harness, IP-Harness,EGP
Harness
5L Signa Platform- Engine Harness,Aftertreatment
If still persists, Replace private CAN network wiring harness one by one harness,EGP harness
8
(mentioned in the specification) and check for DTC. 5L Cowl Platform- Main harness,Engine
harness,Aftertreatment harness,EGP harness
5L Bus- Panel harness,Aftertreatment harness,EGP
harness

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Date: 31-01-2023

Circuit Schematic Diagram:

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Date: 31-01-2023

Location and Component Image:

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0340-99: Cam Sensor - Learning failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue

2. Faulty Sensor
Fault Code P0340-99 3. Air gap is out of specification
No Vehicle reaction
4. Tightening torques on trigger wheel
5. Faulty ECU
6. Faulty trigger wheel / Backlash
CEL ON

Fault System Summary:

Development Fault code F_M_APS_CAM_LEARNING_APV

System Crank/Cam Sensor / Cam Sensor

OBD Inducement Non-Inducement

SPN & FMI 636 / 13

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Cam sensor electrical failures. If found any issue, rectify and check Refer circuit diagram &
for DTC When Ignition ON as well as engine ON, check voltage
1 1. Pin back out checks (ECU side and CAM connector side) between points:
2. Connector/sensor physical damage 0V : Pin 1&2, Pin 3&ground
3.Continuity checks (Open / Short circuit failures) 5V : Pin1&3, Pin 2&3, Pin1&ground, Pin 2&ground
If still issue persists, Perform Reset APS service through TDS. Do Key off
2 Routine name : RESET APS values
and wait for 20 secs and Do Key ON. Start engine and check for DTC
Check air gap between cam sensor and trigger wheel as per specification.
3 0.65 to 1.35 mm
If found any issue, rectify it. Start engine and check for DTC
Perform following routine after component Replacement:
4 Replace CAM sensor. Start engine and check for DTC
1. RESET APS values

Check for trigger wheel mounting bolts torque. If torque is out of 1 Kg-m for 8.8 class
5
specification, rectify it. Start engine and check for DTC 1.5 Kg-m for 10.9 class

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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Circuit Schematic Diagram:

Location and Component Image:

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Date: 31-01-2023

P0340-78: Cam Sensor - Signal drift error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue

2. Faulty Sensor
Fault Code P0340-78 3. Air gap is out of specification
No Vehicle reaction
4. Tightening torques on trigger wheel
5. Faulty ECU
6. Faulty trigger wheel / Backlash
CEL ON

Fault System Summary:

Development Fault code F_M_APS_CAM_DRIFT_APV

System Crank/Cam Sensor / Cam Sensor

OBD Inducement Non-Inducement

SPN & FMI 636 / 09

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Cam sensor electrical failures. If found any issue, rectify and check Refer circuit diagram &
for DTC When Ignition ON as well as engine ON, check voltage
1 1. Pin back out checks (ECU side and CAM connector side) between points:
2. Connector/sensor physical damage 0V : Pin 1&2, Pin 3&ground
3.Continuity checks (Open / Short circuit failures) 5V : Pin1&3, Pin 2&3, Pin1&ground, Pin 2&ground
If still issue persists, Perform Reset APS service through TDS. Do Key off
2 Routine name : RESET APS values
and wait for 20 secs and Do Key ON. Start engine and check for DTC
Check air gap between cam sensor and trigger wheel as per specification.
3 0.65 to 1.35 mm
If found any issue, rectify it. Start engine and check for DTC
Perform following routine after component Replacement:
4 Replace CAM sensor. Start engine and check for DTC
1. RESET APS values

Check for trigger wheel mounting bolts torque. If torque is out of 1 Kg-m for 8.8 class
5
specification, rectify it. Start engine and check for DTC 1.5 Kg-m for 10.9 class

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
Check any physical damage Cam Trigger wheel. Check for backlash of
7 gears. Replace component, if found faulty. Start engine and check for
DTC

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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Circuit Schematic Diagram:

Location and Component Image:

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P0340-2F: Cam Sensor - Signal erratic error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue

2. Faulty Sensor
Fault Code P0340-2F 3. Air gap is out of specification
No Vehicle reaction
4. Tightening torques on trigger wheel
5. Faulty ECU
6. Faulty trigger wheel / Backlash
CEL ON

Fault System Summary:

Development Fault code F_M_APS_CAM_ERRATIC_APV

System Crank/Cam Sensor / Cam Sensor

OBD Inducement Non-Inducement

SPN & FMI 636 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Cam sensor electrical failures. If found any issue, rectify and check Refer circuit diagram &
for DTC When Ignition ON as well as engine ON, check voltage
1 1. Pin back out checks (ECU side and CAM connector side) between points:
2. Connector/sensor physical damage 0V : Pin 1&2, Pin 3&ground
3.Continuity checks (Open / Short circuit failures) 5V : Pin1&3, Pin 2&3, Pin1&ground, Pin 2&ground
If still issue persists, Perform Reset APS service through TDS. Do Key off
2 Routine name : RESET APS values
and wait for 20 secs and Do Key ON. Start engine and check for DTC
Check air gap between cam sensor and trigger wheel as per specification.
3 0.65 to 1.35 mm
If found any issue, rectify it. Start engine and check for DTC
Perform following routine after component Replacement:
4 Replace CAM sensor. Start engine and check for DTC
1. RESET APS values

Check for trigger wheel mounting bolts torque. If torque is out of 1 Kg-m for 8.8 class
5
specification, rectify it. Start engine and check for DTC 1.5 Kg-m for 10.9 class

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
Check any physical damage Cam Trigger wheel. Check for backlash of
7 gears. Replace component, if found faulty. Start engine and check for
DTC

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0340-31: Cam Sensor - Signal Lost fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue

2. Faulty Sensor
Fault Code P0340-31 3. Air gap is out of specification
No Vehicle reaction
4. Tightening torques on trigger wheel
5. Faulty ECU
6. Faulty trigger wheel / Backlash
CEL ON

Fault System Summary:

Development Fault code F_M_APS_CAM_LOST_APV

System Crank/Cam Sensor / Cam Sensor

OBD Inducement Non-Inducement

SPN & FMI 636 / 11

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 318 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Cam sensor electrical failures. If found any issue, rectify and check Refer circuit diagram &
for DTC When Ignition ON as well as engine ON, voltage between
1 1. Pin back out checks (ECU side and CAM connector side) points:
2. Connector/sensor physical damage 0V : Pin 1&2, Pin 3&ground
3.Continuity checks (Open / Short circuit failures) 5V : Pin1&3, Pin 2&3, Pin1&ground, Pin 2&ground
If still issue persists, Perform Reset APS service through TDS. Do Key off
2 Routine name : RESET APS values
and wait for 20 secs and Do Key ON. Start engine and check for DTC
Perform following routine after component Replacement:
3 Replace CAM sensor. Start engine and check for DTC
1. RESET APS values

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 320 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0340-39: Cam Sensor - Signal Missing error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue

2. Faulty Sensor
Fault Code P0340-39 3. Air gap is out of specification
No Vehicle reaction
4. Tightening torques on trigger wheel
5. Faulty ECU
6. Faulty trigger wheel / Backlash
CEL ON

Fault System Summary:

Development Fault code F_M_APS_CAM_MISSING_APV

System Crank/Cam Sensor / Cam Sensor

OBD Inducement Non-Inducement

SPN & FMI 636 / 08

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Cam sensor electrical failures. If found any issue, rectify and check Refer circuit diagram &
for DTC When Ignition ON as well as engine ON, check voltage
1 1. Pin back out checks (ECU side and CAM connector side) between points:
2. Connector/sensor physical damage 0V : Pin 1&2, Pin 3&ground
3.Continuity checks (Open / Short circuit failures) 5V : Pin1&3, Pin 2&3, Pin1&ground, Pin 2&ground
If still issue persists, Perform Reset APS service through TDS. Do Key off
2 Routine name : RESET APS values
and wait for 20 secs and Do Key ON. Start engine and check for DTC
Check air gap between cam sensor and trigger wheel as per specification.
3 0.65 to 1.35 mm
If found any issue, rectify it. Start engine and check for DTC
Perform following routine after component Replacement:
4 Replace CAM sensor. Start engine and check for DTC
1. RESET APS values

Check for trigger wheel mounting bolts torque. If torque is out of 1 Kg-m for 8.8 class
5
specification, rectify it. Start engine and check for DTC 1.5 Kg-m for 10.9 class

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
Check any physical damage Cam Trigger wheel. Check for backlash of
7 gears. Replace component, if found faulty. Start engine and check for
DTC

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0016-00: CRANK Sensor - Invalid gap between consecutive signals

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue

2. Burr deposits in sensor
Fault Code P0016-00 3. Air gap is out of specification
No Vehicle reaction
4. Faulty sensor
5. Faulty ECU
6. Faulty flywheel
CEL ON

Fault System Summary:

Development Fault code F_M_APS_INVALID_GAP_APV

System Crank/Cam Sensor / Crank Sensor

OBD Inducement Non-Inducement

SPN & FMI 190 / 10

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Crank sensor electrical failures. If found any issue, rectify and Refer circuit diagram &
check for DTC When Ignition ON as well as engine ON, check voltage
1 1. Pin back out checks (ECU side and crank sensor side) between points:
2. Connector/sensor physical damage 0V : Pin 1&2
3.Continuity checks (Open / Short circuit failures) 2.5V : Pin 1&ground, Pin 2&ground
Check burr deposition on crank sensor tip, clean the burrs if noticed.
2
Start engine and check for DTC
Check gap between crank sensor and trigger wheel as per specification. If
3 0.75 to 1.3 mm
found any issue, rectify it. Start engine and check for DTC
4 Replace crank sensor. Start engine and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
6 Replace flywheel. Start engine and check for DTC

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0335-27: CRANK Sensor - Signal Early Detection Error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue

Fault Code P0335-27 2. Burr deposits in sensor
3. Air gap is out of specification
4. Faulty sensor
5. Faulty ECU
CEL ON 6. Faulty flywheel 1. 50% Torque reduction
2. 1700 rpm Engine speed limitation

Fault System Summary:

Development Fault code F_M_APS_CRANK_EARLY_APV

System Crank/Cam Sensor / Crank Sensor

OBD Inducement Non-Inducement

SPN & FMI 190 / 08

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Circuit diagram & Component images

Author: ERC Page 327 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Crank sensor electrical failures. If found any issue, rectify and Refer circuit diagram &
check for DTC When Ignition ON as well as engine ON, check voltage
1 1. Pin back out checks (ECU side and crank sensor side) between points:
2. Connector/sensor physical damage 0V : Pin 1&2
3.Continuity checks (Open / Short circuit failures) 2.5V : Pin 1&ground, Pin 2&ground
Check burr deposition on crank sensor tip, clean the burrs if noticed.
2
Start engine and check for DTC
Check gap between crank sensor and trigger wheel as per specification. If
3 0.75 to 1.3 mm
found any issue, rectify it. Start engine and check for DTC
4 Replace crank sensor. Start engine and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
6 Replace flywheel. Start engine and check for DTC

Author: ERC Page 328 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 329 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0335-31: CRANK Sensor - Signal Lost fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue

Fault Code P0335-31 2. Burr deposits in sensor
3. Air gap is out of specification
4. Faulty sensor
5. Faulty ECU
CEL ON 6. Faulty flywheel 1. 50% Torque reduction
2. 1700 rpm Engine speed limitation

Fault System Summary:

Development Fault code F_M_APS_CRANK_LOST_APV

System Crank/Cam Sensor / Crank Sensor

OBD Inducement Non-Inducement

SPN & FMI 190 / 11

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Circuit diagram & Component images

Author: ERC Page 330 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Crank sensor electrical failures. If found any issue, rectify and Refer circuit diagram &
check for DTC When Ignition ON as well as engine ON, check voltage
1 1. Pin back out checks (ECU side and crank sensor side) between points:
2. Connector/sensor physical damage 0V : Pin 1&2
3.Continuity checks (Open / Short circuit failures) 2.5V : Pin 1&ground, Pin 2&ground
Check burr deposition on crank sensor tip, clean the burrs if noticed.
2
Start engine and check for DTC
Check gap between crank sensor and trigger wheel as per specification. If
3 0.75 to 1.3 mm
found any issue, rectify it. Start engine and check for DTC
4 Replace crank sensor. Start engine and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
6 Replace flywheel. Start engine and check for DTC

Author: ERC Page 331 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0335-1F: CRANK Sensor - Signal Missing

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue

Fault Code P0335-1F 2. Burr deposits in sensor
3. Air gap is out of specification
4. Faulty sensor
5. Faulty ECU
CEL ON 6. Faulty flywheel 1. 50% Torque reduction
2. 1700 rpm Engine speed limitation

Fault System Summary:

Development Fault code F_M_APS_CRANK_MISS_APV

System Crank/Cam Sensor / Crank Sensor

OBD Inducement Non-Inducement

SPN & FMI 190 / 02

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Circuit diagram & Component images

Author: ERC Page 333 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Crank sensor electrical failures. If found any issue, rectify and Refer circuit diagram &
check for DTC When Ignition ON as well as engine ON, check voltage
1 1. Pin back out checks (ECU side and crank sensor side) between points:
2. Connector/sensor physical damage 0V : Pin 1&2
3.Continuity checks (Open / Short circuit failures) 2.5V : Pin 1&ground, Pin 2&ground
Check burr deposition on crank sensor tip, clean the burrs if noticed.
2
Start engine and check for DTC
Check gap between crank sensor and trigger wheel as per specification. If
3 0.75 to 1.3 mm
found any issue, rectify it. Start engine and check for DTC
4 Replace crank sensor. Start engine and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
6 Replace flywheel. Start engine and check for DTC

Author: ERC Page 334 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2226-04: Barometric Pressure Sensor - Sensor internal failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2226-04

1. Faulty Barometric Sensor
MIL ON for 15 secs 1. 30% Torque reduction
2. Faulty ECU
2. Vehicle may run with low pickup, high
CEL ON
smoke, frequent DPF regen & misfire issues

Fault System Summary:

Development Fault code F_M_BARO_FAILURE_APV

System ECU Internal/Memory / Ambient Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 108 / 12

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

1 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 337 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2226-08: Barometric Pressure Sensor - Sensor signal failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2226-08

1. Faulty Barometric Sensor
MIL ON for 15 secs 1. 30% Torque reduction
2. Faulty ECU
2. Vehicle may run with low pickup, high
CEL ON
smoke, frequent DPF regen & misfire issues

Fault System Summary:

Development Fault code F_M_BARO_SPI_APV

System ECU Internal/Memory / Ambient Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 108 / 19

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

1 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2226-1C: Barometric Pressure Sensor - Sensor signal out of range

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2226-1C

1. Faulty Barometric Sensor
MIL ON for 15 secs 1. 30% Torque reduction
2. Faulty ECU
2. Vehicle may run with low pickup, high
CEL ON
smoke, frequent DPF regen & misfire issues

Fault System Summary:

Development Fault code F_M_BARO_OOR_APV

System ECU Internal/Memory / Ambient Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 108 / 09

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

1 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 343 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0641-08: ECU 5V channel communication failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0641-08

1. Sensor not connected / Wiring harness
CEL BLINK 2. Sensor is faulty 1. No Pedal Response
3. Faulty ECU
2. Engine speed increased to 1300 rpm
3. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_VEXT_SPI_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3509 / 19

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

16-32V
Check the battery voltage. If battery voltage is out of range, rectify it and
1
check for DTC Perform service regeneration at IDLE after issue
rectification
Sensors need to be checked :
1. Accelerator Pedal Sensor
Check mentioned sensor electrical failures. If found any issue, rectify and
2. Fan Speed sensor
check for DTC
3. Turbocharger position sensor
2 1. Pin back out checks (ECU side and sensor side)
4. Exhaust throttle sensor
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification
Remove sensors mentioned in step 2, one by one. If fault gets resolved, Perform service regeneration at IDLE after issue
3
Replace particular sensor. Start engine and check for DTC rectification
Select dataset as per Vehicle configuration(VC)
4 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0641-4B: ECU 5V supply system thermal shutdown

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0641-4B

CEL BLINK 1. ECU Supply Voltage short circuit 1. No Pedal Response

2. Faulty ECU
2. Engine speed increased to 1300 rpm
3. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_VEXT_THERMAL_SHT_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3509 / 07

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Circuit diagram & Component images

Author: ERC Page 348 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

16-32V
Check the battery voltage. If battery voltage is out of range, rectify it and
1
check for DTC Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
2 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
3 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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Date: 31-01-2023

P0641-00: ECU External supply Channel1 failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0641-00

CEL BLINK 1. ECU Supply Voltage short circuit 1. No Pedal Response

2. Faulty ECU
2. Engine speed increased to 1300 rpm
3. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_VEXT1_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3509 / 12

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

16-32V
Check the battery voltage. If battery voltage is out of range, rectify it and
1
check for DTC Perform service regeneration at IDLE after issue
rectification
Check mentioned sensor electrical failures. If found any issue, rectify and Sensors need to be checked :
check for DTC 1. Accelerator Pedal Sensor
2 1. Pin back out checks (ECU side and sensor side) 2. Fan Speed sensor
2. Connector/Sensor physical damage 3. Turbocharger position sensor
3.Continuity checks (Open / Short circuit failures) 4. Exhaust throttle sensor
Remove sensors mentioned in step 2, one by one. If fault gets resolved,
3
Replace particular sensor. Start engine and check for DTC
4 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0651-00: ECU External supply Channel2 failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0651-00

CEL BLINK 1. ECU Supply Voltage short circuit 1. No Pedal Response

2. Faulty ECU
2. Engine speed increased to 1300 rpm
3. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_VEXT2_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3510 / 12

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

16-32V
Check the battery voltage. If battery voltage is out of range, rectify it and
1
check for DTC Perform service regeneration at IDLE after issue
rectification
Sensors need to be checked :
Check mentioned sensor electrical failures. If found any issue, rectify and
1. Accelerator Pedal Sensor
check for DTC
2. Vehicle Speed Sensor
2 1. Pin back out checks (ECU side and sensor side)
3. EGR Position Sensor
2. Connector/Sensor physical damage
4. TMAP Sensor
3.Continuity checks (Open / Short circuit failures)
5. PFM Sensor
Remove sensors mentioned in step 2, one by one. If fault gets resolved,
3
Replace particular sensor. Start engine and check for DTC
4 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0697-00: ECU External supply Channel3 failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0697-00

1. ECU Supply Voltage short circuit
CEL BLINK 2. Faulty ECU 1. No Pedal Response
2. Engine speed increased to 1300 rpm

Fault System Summary:

Development Fault code F_M_VEXT3_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3511 / 12

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

16-32V
Check the battery voltage. If battery voltage is out of range, rectify it and
1
check for DTC Perform service regeneration at IDLE after issue
rectification
Check mentioned sensor electrical failures. If found any issue, rectify and
check for DTC Sensors need to be checked :
2 1. Pin back out checks (ECU side and sensor side) 1. Rail pressure Sensor
2. Connector/Sensor physical damage 2. CAM sensor
3.Continuity checks (Open / Short circuit failures)
Remove sensors mentioned in step 2, one by one. If fault gets resolved,
3
Replace particular sensor. Start engine and check for DTC
4 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P06D6-00: ECU Internal 3V supply channel failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P06D6-00

1. ECU Supply Voltage short circuit
CEL BLINK
2. Faulty ECU 1. No Pedal Response
2. Engine speed increased to 1300 rpm

Fault System Summary:

Development Fault code F_M_VEXT_VCCLBUCK_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3514 / 12

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

16-32V
1 Check the battery voltage. If voltage out of range, correct battery.
Perform service regeneration at IDLE after issue
rectification
2 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 361 of 896

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P06D2-00: ECU Internal 5V Supply channel failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P06D2-00

1. ECU Supply Voltage short circuit
CEL BLINK
2. Faulty ECU 1. No Pedal Response
2. Engine speed increased to 1300 rpm

Fault System Summary:

Development Fault code F_M_VEXT_VCC_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3513 / 12

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

16-32V
1 Check the battery voltage. If voltage out of range, correct battery.
Perform service regeneration at IDLE after issue
rectification
2 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 364 of 896

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P268A-54: Injector Codes corrupted or not written properly

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P268A-54

1. ECU memory error
CEL BLINK 2. Faulty ECU 1. No Pedal Response
2. Engine speed increased to 1300 rpm

Fault System Summary:

Development Fault code F_M_C2I_RAM_INTEGRITY_APV

System ECU Internal/Memory / Hardware

OBD Inducement Non-Inducement

SPN & FMI 2797 / 13

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

16-32V
1 Check fault code related C3I.If found any, rectify it and check for DTC
Perform service regeneration at IDLE after issue
rectification
2 Rewrite C3I injector again. Clear DTC and Check for DTC Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 Re-flash ECU dataset and check for DTC again 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4 If still issue persists, Replace ECU

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P020A-00: ECU - Internal injection timing fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P020A-00

1. Faulty CAM/Crank Sensor
2. Faulty ECU Vehicle may run with poor pickup, high
MIL ON for 15 secs
smoke

Fault System Summary:

Development Fault code F_M_ETC_TMNG_CHECK_0_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 7384 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform service regeneration at IDLE after issue
1 Replace Crank sensor and Clear DTC. Start engine and check for DTC
rectification
2 Replace Cam sensor and Clear DTC. Start engine and check for DTC
3 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P020C-00: ECU - Internal injection timing fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P020C-00

1. Faulty CAM/Crank Sensor
2. Faulty ECU Vehicle may run with poor pickup, high
MIL ON for 15 secs
smoke or starting issues

Fault System Summary:

Development Fault code F_M_ETC_TMNG_CHECK_1_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 7386 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform service regeneration at IDLE after issue
1 Replace Crank sensor and Clear DTC. Start engine and check for DTC
rectification
2 Replace Cam sensor and Clear DTC. Start engine and check for DTC
3 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P020D-00: ECU - Internal injection timing fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P020D-00

1. Faulty CAM/Crank Sensor
2. Faulty ECU Vehicle may run with poor pickup, high
MIL ON for 15 secs
smoke or starting issues

Fault System Summary:

Development Fault code F_M_ETC_TMNG_CHECK_2_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 7387 / 02

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform service regeneration at IDLE after issue
1 Replace Crank sensor and Clear DTC. Start engine and check for DTC
rectification
2 Replace Cam sensor and Clear DTC. Start engine and check for DTC
3 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 376 of 896

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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P020B-00: ECU - Internal injection timing fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P020B-00

1. Faulty CAM/Crank Sensor
2. Faulty ECU Vehicle may run with poor pickup, high
MIL ON for 15 secs
smoke or starting issues

Fault System Summary:

Development Fault code F_M_ETC_TMNG_CHECK_3_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 7385 / 02

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform service regeneration at IDLE after issue
1 Replace Crank sensor and Clear DTC. Start engine and check for DTC
rectification
2 Replace Cam sensor and Clear DTC. Start engine and check for DTC
3 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 379 of 896

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060B-00: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060B-00
Stop Engine 1. Faulty ECU No Vehicle reaction
BLINK
Lamp

Fault System Summary:

Development Fault code F_M_ESM_ADC_MON_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516172 / 12

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060A-48: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060A-48
Stop Engine 1. Faulty ECU No Vehicle reaction
BLINK
Lamp

Fault System Summary:

Development Fault code F_M_ESM_CLOCK_MON_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516209 / 12

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060C-43: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-43
Stop Engine 1. Faulty ECU No Vehicle reaction
BLINK
Lamp

Fault System Summary:

Development Fault code F_M_ESM_FUNC_SAFE_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516210 / 12

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
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Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0607-44: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0607-44
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_L2_PRIME_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516211 / 12

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0607-05: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0607-05
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_LOCK_MON_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516212 / 12

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 394 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060C-44: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-44
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_MEM_CFG_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516213 / 12

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 397 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060C-05: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-05
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_MEM_PROTECT_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516214 / 12

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 400 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060C-49: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-49
Stop Engine 1. Faulty ECU No Vehicle reaction
BLINK
Lamp

Fault System Summary:

Development Fault code F_M_ESM_MEM_RAM_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516215 / 12

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 403 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060C-42: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-42
Stop Engine 1. Faulty ECU No Vehicle reaction
BLINK
Lamp

Fault System Summary:

Development Fault code F_M_ESM_MM_QUERY_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516216 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 406 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060C-45: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-45
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_PFC_FAIL_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516217 / 12

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 409 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0607-04: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0607-04
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_RESET_MON_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516218 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 412 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060A-49: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060A-49
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_SOP_OUTEN_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516219 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 415 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060A-42: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060A-42
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_SOP_TEST_FC_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516220 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 418 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060A-45: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060A-45
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_SOP_TEST_MM_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516221 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 421 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060C-47: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-47
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_WATCHDOG_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516222 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 424 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060C-00: ECU Internal Memory Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-00 1. Faulty ECU No Vehicle reaction

Fault System Summary:

Development Fault code F_M_C3MIO_CONFIG_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516224 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 426 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 427 of 896

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060C-08: ECU Internal Memory Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-08 1. Faulty ECU No Vehicle reaction

Fault System Summary:

Development Fault code F_M_C3MIO_SPI_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516223 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 430 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060C-92: ECU Internal Memory Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-92 1. Faulty ECU No Vehicle reaction

Fault System Summary:

Development Fault code F_M_C3MIO_STATE_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516225 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 432 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P062F-00: ECU Non volatile memory error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P062F-00
CEL BLINK 1.Faulty ECU 1. No Pedal Response
2. Engine speed increased to 1300 rpm

Fault System Summary:

Development Fault code F_M_P_L_NVM_DEVICE_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516226 / 12

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P060C-00: Engine Safety Module - Memory Flash failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-00
Stop Engine 1. Faulty ECU No Vehicle reaction
BLINK
Lamp

Fault System Summary:

Development Fault code F_M_ESM_MEM_FLASH_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516224 / 12

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0201-56: Cylinder 1 - Injector codes not written / Missing

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0201-56 1. Injector correction code not written

2. Faulty ECU
CEL BLINK 1. No Pedal Response

Fault System Summary:

Development Fault code F_M_C2I_DATA_APV_0

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 651 / 13

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Enter Injector codes Manually
Write I3C code in Cylinder No 1, key off for 30 sec. Clear DTC and Check
1
for DTC Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
2 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3 If still issue persists, Replace ECU
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Perform service regeneration at IDLE after issue

rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0202-56: Cylinder 2 - Injector codes not written / Missing

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0202-56 1. Injector correction code not written

2. Faulty ECU
CEL BLINK 1. No Pedal Response

Fault System Summary:

Development Fault code F_M_C2I_DATA_APV_3

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 652 / 13

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Enter Injector codes Manually
Write I3C code in Cylinder No 1, key off for 30 sec. Clear DTC and Check
1
for DTC Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
2 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3 If still issue persists, Replace ECU
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Perform service regeneration at IDLE after issue

rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0203-56: Cylinder 3 - Injector codes not written / Missing

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0203-56 1. Injector correction code not written

2. Faulty ECU
CEL BLINK 1. No Pedal Response

Fault System Summary:

Development Fault code F_M_C2I_DATA_APV_1

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 653 / 13

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Enter Injector codes Manually
Write I3C code in Cylinder No 1, key off for 30 sec. Clear DTC and Check
1
for DTC Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
2 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3 If still issue persists, Replace ECU
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Perform service regeneration at IDLE after issue

rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0204-56: Cylinder 4 - Injector codes not written / Missing

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0204-56 1. Injector correction code not written

2. Faulty ECU
CEL BLINK 1. No Pedal Response

Fault System Summary:

Development Fault code F_M_C2I_DATA_APV_2

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 654 / 13

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Enter Injector codes Manually
Write I3C code in Cylinder No 1, key off for 30 sec. Clear DTC and Check
1
for DTC Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
2 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3 If still issue persists, Replace ECU
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Perform service regeneration at IDLE after issue

rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0607-51: EDP (Engine Data Plate) data writing error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0607-51
1. Engine variant coding data not written
CEL BLINK 1. No Pedal Response

Fault System Summary:

Development Fault code F_M_EDP_WRITE_APV

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 516205 / 13

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Write parameter file. Select parameter file based on
1 Re-Write vehicle parameters. Clear error& check for DTC
Vehicle configuration
2 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0607-55: Variant coding not written

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0607-55
Variant Coding not written
CEL BLINK 1. No Pedal Response

Fault System Summary:

Development Fault code F_M_VARIANT_CODING_WRITE_APV

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 516204 / 13

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Write parameter file. Select parameter file based on
1 Re-Write vehicle parameters. Clear error& check for DTC
Vehicle configuration
2 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0630-55: Vehicle Identification Number is not written

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0630-55 VIN not written No Vehicle reaction

Fault System Summary:

Development Fault code F_M_VIN_ID_VIRG_APV

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 237 / 13

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Write parameter file. Select parameter file based on
1 Re-Write vehicle parameters. Clear error& check for DTC
Vehicle configuration
2 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0115-15: Engine Coolant temperature sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0115-15 1. Wiring harness issue (Connector open / pin

back out /Short circuit)
2. Faulty sensor
MIL ON for 15 secs Vehicle runs with poor pickup

Fault System Summary:

Development Fault code F_M_COOLANT_HI_APV

System Engine Protection / Coolant temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 110 / 03

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram and
Coolant Sesnor Pin 1 - ECU Pin E38
Check Coolant temperature sensor electrical failures. If found any issue,
Coolant Sesnor Pin 2 - ECU Pin E17
rectify and check for DTC
When Ignition ON & Engine running condition, check
1 1. Pin back out checks (ECU side and sensor side)
voltage between points:
2. Connector/Sensor physical damage
5V : 1& 2, 1&ground
3.Continuity checks (Open / Short circuit failures)
0V : 2&ground
Perform Specification 2
For Resistance checks, Kepp sensor outside (Open to air)
10degC : 3791ohms, 20degC : 2500ohms, 25degC:
If still issue persists, Replace coolant temperature sensor and check for
2 2057ohms, 30degC: 1706ohms, 40degC: 1174ohms
DTC
Measured resistance has to be compared against local
ambient temperature
3 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0115-11: Engine Coolant temperature sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0115-11 1. Sensor connector Pin short to Ground

2. Faulty sensor
MIL ON for 15 secs Vehicle runs with poor pickup

Fault System Summary:

Development Fault code F_M_COOLANT_LO_APV

System Engine Protection / Coolant temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 110 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Coolant temperature sensor electrical failures. If found any issue, Refer circuit diagram and
rectify and check for DTC When Ignition ON & Engine running condition, check
1 1. Pin back out checks (ECU side and sensor side) voltage between points:
2. Connector/Sensor physical damage 5V : 1& 2, 1&ground
3.Continuity checks (Open / Short circuit failures) 0V : 2&ground
If still issue persists, Replace coolant temperature sensor and check for
2
DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0115-64: Engine Coolant temperature sensor - Signal not valid based on

reference sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0115-64 1.Faulty wiring harness

2.Faulty sensor
3.Faulty ECU
MIL ON for 15 secs Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_COOLANT_TEMP_XC_APV

System Engine Protection / Coolant temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 110 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram and
Coolant Sesnor Pin 1 - ECU Pin E38
Check Coolant temp. sensor electrical failures. If found any issue, rectify
Coolant Sesnor Pin 2 - ECU Pin E17
it and check for DTC
When Ignition ON & Engine running condition, check
1 1. Pin back out checks (ECU side and sensor side)
voltage between points:
2. Connector/Sensor physical damage
5V : 1& 2, 1&ground
3.Continuity checks (Open / Short circuit failures)
0V : 2&ground
Perform Specification 2

Reference sensors :
1. Ambient temperature sensor
2. Fuel temperature sensor
After rectification of step 1, connect Coolant temp. sensor externally and
2 keep it in ambient with wiring connected. Like that keep reference For Resistance checks, Kepp sensor outside (Open to air)
sensors as well. Check temp. difference across all sensors 10degC : 3791ohms, 20degC : 2500ohms, 25degC:
2057ohms, 30degC: 1706ohms, 40degC: 1174ohms
Measured resistance has to be compared against local
ambient temperature

3 If difference found within specification, Fit back all 3 sensors into engine. Temperature difference threshold : +/20 deg C

If still issue persists, connect one new Coolant temp. sensor externally Reference sensors :
4 and keep it in ambient with wiring connected. Like that keep reference 1. Ambient temperature sensor
sensors as well. Check temp. difference across all sensors 2. Fuel temperature sensor
If difference found within specification, Fit new Coolant temp. sensor
5 Temperature difference threshold : +/20 deg C
into engine and connect other sensors also
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0115-2A: Engine Coolant temperature sensor - Signal Stuck at very low

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0115-2A 1. Wiring harness

2. Faulty sensor
MIL ON for 15 secs Vehicle runs with poor pickup

Fault System Summary:

Development Fault code F_M_COOLANT_SIR_LO_APV

System Engine Protection / Coolant temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 110 / 01

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram and
Coolant Sesnor Pin 1 - ECU Pin E38
Check Coolant temperature sensor electrical failures. If found any issue,
Coolant Sesnor Pin 2 - ECU Pin E17
rectify and check for DTC
When Ignition ON & Engine running condition, check
1 1. Pin back out checks (ECU side and sensor side)
voltage between points:
2. Connector/Sensor physical damage
5V : 1& 2, 1&ground
3.Continuity checks (Open / Short circuit failures)
0V : 2&ground
Perform Specification 2
For Resistance checks, Kepp sensor outside (Open to air)
10degC : 3791ohms, 20degC : 2500ohms, 25degC:
If still issue persists, Replace coolant temperature sensor and check for
2 2057ohms, 30degC: 1706ohms, 40degC: 1174ohms
DTC
Measured resistance has to be compared against local
ambient temperature
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0128-71: Engine Coolant Thermostat stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0128-71 1. Faulty Thermostat

2. Faulty Coolant Temperature Sensor
MIL ON for 15 secs Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_COOLANT_TH_APV

System Engine Protection / Coolant thermostat

OBD Inducement Non-Inducement

SPN & FMI 1659 / 07

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check fault codes related to coolant temperature sensor. If found any,
1
rectify it and check for DTC

If still issue persists, start engine and check coolant temperature at Idle.
2
Coolant temperature should reach minimum 65 deg C within 30 mins.

3 If temp. not increased, Replace thermostat and repeat step 2

When Ignition ON, voltage between points:

If still issue persists, Replace coolant temperature sensor and repeat step 1 and 2 - 5V
4
2 1 and ground- 5V
2 and ground- 0V

5 If still issue persists, Replace coolant thermostat and repeat step 2 Hot water temperature range – 80-100 deg C.
6 If still issue persists, Replace ECU

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0480-9E: E-Viscous FAN - Disengagement failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0480-9E 1. Faulty E Viscous fan

No Vehicle reaction
2. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FAN_CLUTCH_STUCK_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 11

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
Check E-Viscous FAN electrical failures. If found any issue, rectify it and
E-Viscous FAN Pin A - Battery +24V
check for DTC
E-Viscous FAN Pin C - ECU Pin E59
1 1. Pin back out checks (ECU side and Actuator connector side)
E-Viscous FAN Pin D - ECU Pin E39
2. Connector/Sensor physical damage
E-Viscous FAN Pin E - ECU Pin E13
3.Continuity checks (Open / Short circuit failures)
E-Viscous FAN Pin F - ECU Pin E99
If still issue persists, Start engine and raise engine speed to flyup. Check
FAN speed. After 1 min, FAN speed should lesser than 500 rpm if coolant.
2
temp. lesser than 88 deg C. If not, Replace E-Viscous FAN assembly and
check for DTC
3 If still issue persists, Replace E-Viscous FAN assembly and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0480-13: E-Viscous FAN - Drive open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0480-13 1. Wiring harness issue

2. Faulty E-Viscous FAN No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FAN1_DRIVE_OC_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 05

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
Check E-Viscous FAN electrical failures. If found any issue, rectify it and
E-Viscous FAN Pin A - Battery +24V
check for DTC
E-Viscous FAN Pin C - ECU Pin E59
1 1. Pin back out checks (ECU side and Actuator side)
E-Viscous FAN Pin D - ECU Pin E39
2. Connector/Sensor physical damage
E-Viscous FAN Pin E - ECU Pin E13
3.Continuity checks (Open / Short circuit failures)
E-Viscous FAN Pin F - ECU Pin E99
2 If still issue persists, Replace E-Viscous FAN relay and check for DTC
3 If still issue persists, Replace E-Viscous FAN assembly and check for DTC
If still issue persists, Replace E-Viscous FAN wiring harness and check for
4
DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0480-12: E-Viscous FAN - Drive Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0480-12 1. Wiring harness issue

2. Faulty E-Viscous FAN No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FAN1_DRIVE_SC2V_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
Check E-Viscous FAN electrical failures. If found any issue, rectify it and
E-Viscous FAN Pin A - Battery +24V
check for DTC
E-Viscous FAN Pin C - ECU Pin E59
1 1. Pin back out checks (ECU side and Actuator side)
E-Viscous FAN Pin D - ECU Pin E39
2. Connector/Sensor physical damage
E-Viscous FAN Pin E - ECU Pin E13
3.Continuity checks (Open / Short circuit failures)
E-Viscous FAN Pin F - ECU Pin E99
2 If still issue persists, Replace E-Viscous FAN relay and check for DTC
3 If still issue persists, Replace E-Viscous FAN assembly and check for DTC
If still issue persists, Replace E-Viscous FAN wiring harness and check for
4
DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0480-11: E-Viscous FAN - Drive Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0480-11 1. Wiring harness issue

2. Faulty E-Viscous FAN No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FAN1_DRIVE_SC2G_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
Check E-Viscous FAN electrical failures. If found any issue, rectify it and
E-Viscous FAN Pin A - Battery +24V
check for DTC
E-Viscous FAN Pin C - ECU Pin E59
1 1. Pin back out checks (ECU side and Actuator side)
E-Viscous FAN Pin D - ECU Pin E39
2. Connector/Sensor physical damage
E-Viscous FAN Pin E - ECU Pin E13
3.Continuity checks (Open / Short circuit failures)
E-Viscous FAN Pin F - ECU Pin E99
2 If still issue persists, Replace E-Viscous FAN relay and check for DTC
3 If still issue persists, Replace E-Viscous FAN assembly and check for DTC
If still issue persists, Replace E-Viscous FAN wiring harness and check for
4
DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0480-9F: E-Viscous FAN - Engagement failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0480-9F 1. Faulty E Viscous fan

No Vehicle reaction
2. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FAN_CLUTCH_SLIP_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 07

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram:
Check E-Viscous FAN electrical failures. If found any issue, rectify it and
E-Viscous FAN Pin A - Battery +24V
check for DTC
E-Viscous FAN Pin C - ECU Pin E59
1 1. Pin back out checks (ECU side and Actuator connector side)
E-Viscous FAN Pin D - ECU Pin E39
2. Connector/Sensor physical damage
E-Viscous FAN Pin E - ECU Pin E13
3.Continuity checks (Open / Short circuit failures)
E-Viscous FAN Pin F - ECU Pin E99
2 If still issue persists, Replace E-Viscous FAN assembly and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 490 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0526-38: E-Viscous FAN - Speed Signal error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Engine over speed due to improper gear shift

Fault Code P0526-38 2. Wiring harness issue
No Vehicle reaction
3. Faulty E-Viscous FAN
4. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FAN_SENSOR_PERIOD_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check errors related to Engine over speed. If found any, check over
1 speed counters and understand the real cause of engine over speed.
Clear DTC, drive vehicle for 5 Kms and Check for DTC
Refer circuit diagram:
If still issue persists, Check E-Viscous FAN electrical failures. If found any
E-Viscous FAN Pin A - Battery +24V
issue, rectify it and check for DTC
E-Viscous FAN Pin C - ECU Pin E59
2 1. Pin back out checks (ECU side and Actuator connector side)
E-Viscous FAN Pin D - ECU Pin E39
2. Connector/Sensor physical damage
E-Viscous FAN Pin E - ECU Pin E13
3.Continuity checks (Open / Short circuit failures)
E-Viscous FAN Pin F - ECU Pin E99
3 If still issue persists, Replace E-Viscous FAN assembly and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0526-29: E-Viscous FAN - Speed Signal invalid error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Engine over speed due to improper gear shift

Fault Code P0526-29 2. Wiring harness issue
No Vehicle reaction
3. Faulty E-Viscous FAN
4. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FAN_SENSOR_SPEED_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 10

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check errors related to Engine over speed. If found any, check over
1 speed counters and understand the real cause of engine over speed.
Clear DTC, drive vehicle for 5 Kms and Check for DTC
Refer circuit diagram:
If still issue persists, Check E-Viscous FAN electrical failures. If found any
E-Viscous FAN Pin A - Battery +24V
issue, rectify it and check for DTC
E-Viscous FAN Pin C - ECU Pin E59
2 1. Pin back out checks (ECU side and Actuator connector side)
E-Viscous FAN Pin D - ECU Pin E39
2. Connector/Sensor physical damage
E-Viscous FAN Pin E - ECU Pin E13
3.Continuity checks (Open / Short circuit failures)
E-Viscous FAN Pin F - ECU Pin E99
3 If still issue persists, Replace E-Viscous FAN assembly and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0520-15: Engine Oil pressure is too high / Switch not present in the engine
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0520-15

1. Switch is not fitted
No Vehicle reaction
Oil Pres. 2. Engine oil pressure is high
ON
Lamp

Fault System Summary:

Development Fault code F_M_OIL_PRES_CAL_HI_STP_APV

System Engine Protection / Oil Pressure switch

OBD Inducement Non-Inducement

SPN & FMI 100 / 03

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Oil pressure switch electrical failures. If found any issue, rectify it
and check for DTC
Refer circuit diagram:
1 1. Pin back out checks (ECU side and sensor side)
Oil pressure switch Pin 1 - ECU Pin E77
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
If still issue persists, Check oil level. If found high oil level, remove excess
2 oil and maintain proper oil level. Drive vehicle for 5 Kms and stop engine
and check for DTC
3 If still issue persists, Replace oil pressure switch

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0524-00: Engine Oil pressure is too low

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0524-00
Oil Pres.
ON Engine oil pressure is low 1. 30% Torque reduction
Lamp
2. 1500 rpm Engine speed limitation

Fault System Summary:

Development Fault code F_M_OIL_PRES_CAL_LO_RUN_APV

System Engine Protection / Oil Pressure switch

OBD Inducement Non-Inducement

SPN & FMI 100 / 01

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Coolant temp. sensor electrical failures. If found any issue, rectify
it and check for DTC
Refer circuit diagram:
1 1. Pin back out checks (ECU side and sensor side)
Oil pressure switch Pin 1 - ECU Pin E77
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
If still issue persists, Check oil level. If found low oil level, fill oil and
2 maintain proper oil level. Drive vehicle for 5 Kms and stop engine and
check for DTC
If still issue persists, check presence of oil pressure switch in the engine.
3 Or Replace oil pressure switch. Drive vehicle for 5 Kms and stop engine
and check for DTC

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0217-00: Engine Over heating fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Low coolant level

Fault Code P0217-00 2. Mechanical failure of E viscous fan, Coolant
sensor No Vehicle reaction
3. Low coolant level
4. Failure of poly V belt
CEL ON

Fault System Summary:

Development Fault code F_M_ENG_OVER_HEAT_APV

System Engine Protection / Over Heat Monitor

OBD Inducement Non-Inducement

SPN & FMI 5100 / 31

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

1 Check coolant level in expansion tank. If found low, fill up to max level
Check Coolant temp. sensor & E-Viscous FAN electrical failures. If found
any issue, rectify it and check for DTC
2 1. Pin back out checks (ECU side and sensor side)
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
If still issue persists, Check E-Viscous FAN HW related errors & physical
3
function of FAN. If found any issues, rectify it.
If still issue persists, Check coolant pump V-belt condition. If found any Put thermostat in hot water and check for its function.
4
issues, Replace it Hot water temperature range – 80-100 degC
Check coolant thermostat functionality and related errors. If found any
5
issues, rectify it
6 Check water pump impeller for any defect. If found defective, Replace it.
Check Coolant color, if found black check EGR Cooler & measure the
7
cylinder compression pressure.
If nothing is found, It might be genuine error. Clear DTC and release
8
vehicle.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

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 Version: 1.0
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Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0219-00: Engine Over speed fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Engine Speed above 2600 rpm, due to
Fault Code P0219-00 abnormal gear change No Vehicle reaction
2. Faulty Crank sensor

Fault System Summary:

Development Fault code F_M_ENGINE_OVERSPD_APV

System Engine Protection / Over Speed Monitor

OBD Inducement Non-Inducement

SPN & FMI 2812 / 31

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check errors related to Crank sensor. If found any, rectify it and run
1
vehicle for 15 mins and check for DTC
Check Engine over speed data (Speed, gear ratio, vehicle speed, etc.,). If
2 any abnormal gear shift found, inform driver, not to perform improper 2400 ± 50 rpm
gearshifts

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2269-00: Water in fuel fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Water collected in Filter

Fault Code P2269-00 2. found fluid other than diesel
3. Faulty harness
4. Faulty sensor
5. Faulty ECU
WIF Lamp ON 1. 50% Torque reduction

Fault System Summary:

Development Fault code F_M_WATER_IN_FUEL_APV

System Engine Protection / Water in fuel Sensor

OBD Inducement Non-Inducement

SPN & FMI 97 / 31

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Remove WIF sensor from fuel filter and drain water/other fluid. If found
1
any. Drive vehicle for 5 Kms and check for DTC
If foundddd any other fluid other than diesel, check fuel tank. Drain
2 complete fuel and Replace it with proper diesel, Replace filters as well if
required. Drive vehicle for 5 Kms and check for DTC
Check WIF sensor electrical failures. If found any issue, rectify it and
check for DTC Refer circuit diagram
3 1. Pin back out checks (ECU side and sensor side) WIF Sensor Pin 1 - ECU Pin E66
2. Connector/Sensor physical damage WIF Sensor Pin 2 - ECU Pin E40
3.Continuity checks (Open / Short circuit failures)
If still issue persists, Replace WIF sensor. Drive vehicle for 5 Kms and
4
check for DTC
If still issue persists, Replace prefilter element. Drive vehicle for 5 Kms
5
and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2264-15: Water In fuel sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2264-15 1. Water in Fuel sensor short to ground

2. Faulty sensor
3. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_WIF_SENSOR_SC2V_APV

System Engine Protection / Water in fuel Sensor

OBD Inducement Non-Inducement

SPN & FMI 97 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check WIF sensor electrical failures. If found any issue, rectify it and
check for DTC Refer circuit diagram
1 1. Pin back out checks (ECU side and sensor side) WIF Sensor Pin 1 - ECU Pin E66
2. Connector/Sensor physical damage WIF Sensor Pin 2 - ECU Pin E40
3.Continuity checks (Open / Short circuit failures)
Remove WIF sensor from fuel filter and drain water/other fluid. If found
2
any. Drive vehicle for 5 Kms and check for DTC
If foundddd any other fluid other than diesel, check fuel tank. Drain
3 complete fuel and Replace it with proper diesel, Replace filters as well if
required. Drive vehicle for 5 Kms and check for DTC
If still issue persists, Replace WIF sensor. Drive vehicle for 5 Kms and
4
check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2264-11: Water in fuel sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2264-11 1. Water in Fuel sensor short to ground

2. Faulty sensor
3. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_WIF_SENSOR_SC2G_APV

System Engine Protection / Water in fuel Sensor

OBD Inducement Non-Inducement

SPN & FMI 97 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check WIF sensor electrical failures. If found any issue, rectify it and
check for DTC Refer circuit diagram
1 1. Pin back out checks (ECU side and sensor side) WIF Sensor Pin 1 - ECU Pin E66
2. Connector/Sensor physical damage WIF Sensor Pin 2 - ECU Pin E40
3.Continuity checks (Open / Short circuit failures)
Remove WIF sensor from fuel filter and drain water/other fluid. If found
2
any. Drive vehicle for 5 Kms and check for DTC
If foundddd any other fluid other than diesel, check fuel tank. Drain
3 complete fuel and Replace it with proper diesel, Replace filters as well if
required. Drive vehicle for 5 Kms and check for DTC
If still issue persists, Replace WIF sensor. Drive vehicle for 5 Kms and
4
check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2031-62: DOC inlet temperature sensor - Signal not valid based on Model
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2031-62

1. Deviation in temperature signal between
sensor and Modelled value
MIL ON 1. Regeneration Inhibition
2. Faulty sensor
2. Engine emission may go high & Vehicle
may run with poor pickup

Fault System Summary:

Development Fault code F_M_DOC_IN_TEMP_PLAU_APV

System Exhaust System / DOC Upstream temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 4765 / 09

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Exhaust / Intake air leakage in the system. If anything found, Perform service regeneration at IDLE after issue
1
please rectify and run vehicle around 10 Kms and check for DTCs rectification
Check DTCs related to PFM,ETV, Turbo Wastegate actuator. If found any, Perform service regeneration at IDLE after issue
2
rectify the same and drive vehicle for 10 Kms and check for DTCs rectification
Perform service regeneration at IDLE after issue
3 If No leakages / DTCs found, Replace sensor with new one
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P1542-00: DPF Regeneration system fault from DCU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P1542-00
DPF system faults are inhibiting Regeneration
1. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_DUC_EMS_REACT12_APV

System Exhaust System / Regeneration System fault

OBD Inducement Non-Inducement

SPN & FMI 3700 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Rectify other system faults in ECU & DCU.Perform service regeneration
1
and check for DTC

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0263-00: Cylinder 1 - Injector balance low fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0263-00 1. Other system errors (Rail

pressure/EGR/ETV/Intake air system) No Vehicle reaction
2. Injector 1 is faulty
CEL ON

Fault System Summary:

Development Fault code F_M_FCI_INJ_BAL_LOW_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 651 / 09

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Other system errors :
EGR Electrical / funcation fault codes
Check indicated torque at engine low idle & high idle . If torque found Rail pressure sensor errors
out of specifcation, then injector balance fault triggered because of other Exhaust throttle electrical / stuck closed
system failures, check specification for more details. If found any issues, Intake air system related errors like PFM/Intake manifold
1
rectify it and start engine. pressue/temperatures
After rectification,Raise engine speed to 1500-1700 rpm and keep it for 2 DPF related failures
mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

2. Indicated torque range :
Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
If no faults observed, remove after ETV pipe & check whether ETV is
3. Perform ETV Actuator test in TDS-ECU (Test Actuator
stuck closed physically by performing actuator tests (0%,50%&100%). If
Tab- 0%,50% & 100%)
actuator is not moving, relpace ETV & perform tests mentioned in
2 3. ETV error allowed during actuator test : +/- 5%
specification.
4. Perform ETV Actuator learning test through TDS-ECU if
After rectification,Raise engine speed to 1500-1700 rpm and keep it for 2
ETV replaced
mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

If still issue persists, detach / disconnect ATS from ETV pipe & check 2. Indicated torque range :
indicated torque in Low Idle & high Idle. If torque found within Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
specification, then DPF might be having issues. Remove/Replace DPF & 3. Perform DPF replacement service through TDS-DCU if
3
check for DTC. DPF is replaced
After rectification,Raise engine speed to 1500-1700 rpm and keep it for 2
mins. Check for DTC. Perform service regeneration at IDLE after issue
rectification

Refer circuit diagram. Check connection between EMS

ECU & Injector pigtail connector (Inj.)
If still issue persists, Check Injector pigtail connector related issues. If
Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
found any issue, rectify it and start engine. Raise engine speed to 1500-
Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
1700 rpm and keep it for 2 mins. Check for DTC.
4 Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
1. Pin back out checks (ECU side and Injector connector sensor side)
Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
2. Connector/sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
1.7V : Ground & Inj. Pins 1,2,3,10
If no issues found in step2 , check for voltages across different Injector 4.5V : Ground & Inj. Pins 4,5,8,9
5 pigtail pins. If found any issues, rectify it (If required Replace wiring
harness/Replace injector) and check for DTC If injector changed, Write proper injector codes (I3C) in
ECU after reading it from new Injector

Perform service regeneration at IDLE after issue

rectification

Perform following services in TDS:

1. Injector shut off test
If no issues found in step 3, Conduct Injector actuator test through 2. Injector Buzz test
diagnostic tool. If found any issues, replace particular injector/wiring 3. If injector changed, Write proper injector codes (I3C) in
6
harness based on finding & start engine. Raise engine speed to 1500- ECU after reading it from new Injector
1700 rpm and keep it for 2 mins. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Raise engine
7
speed to 1500-1700 rpm and keep it for 2 mins. Check for DTC Perform service regeneration at IDLE after issue
rectification
1. Ensure Injector back leak should not exceed 160ml with
If still issue persists, Perform injector back leak test. If back leak found
all injectors
out of specification, Remove & Refit injector along with quill & quill nut.
8
Apply proper tightening torque. Start engine, Raise engine speed to
Perform service regeneration at IDLE after issue
1500-1700 rpm and keep it for 2 mins. Check for DTC
rectification
Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace Injector1 & write I3C code. Start engine,
from new Injector
9 Raise engine speed to 1500-1700 rpm and keep it for 2 mins. Check for
DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
10 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0201-13: Cylinder 1 - Injector Circuit open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0201-13

1. Wiring harness issue
2. Injector 1 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_OC_INJ_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 651 / 05

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram. Check connection between EMS
ECU & Injector pigtail connector (Inj.)
If still issue persists, Check Injector pigtail connector related issues. If Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
found any issue, rectify it and check for DTC Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
1 1. Pin back out checks (ECU side and Injector connector sensor side) Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
2. Connector/sensor physical damage Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
1.7V : Ground & Inj. Pins 1,2,3,10
If no issues found in step1 , check for voltages across different Injector 4.5V : Ground & Inj. Pins 4,5,8,9
2 pigtail pins. If found any issues, rectify it (If required Replace wiring
harness/Replace injector) and check for DTC If injector changed, Write proper injector codes (I3C) in
ECU after reading it from new Injector

Perform service regeneration at IDLE after issue

rectification

Perform following services in TDS:

1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
3 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
4 If still issue persists, Replace ECU
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Perform service regeneration at IDLE after issue

rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0201-2B: Cylinder 1 - Injector Short circuit error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0201-2B

1. Wiring harness issue
2. Injector 1 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_SC_INJ_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 651 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram. Check connection between EMS
ECU & Injector pigtail connector (Inj.)
If still issue persists, Check Injector pigtail connector related issues. If Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
found any issue, rectify it and check for DTC Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
1 1. Pin back out checks (ECU side and Injector connector sensor side) Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
2. Connector/sensor physical damage Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
1.7V : Ground & Inj. Pins 1,2,3,10
If no issues found in step1 , check for voltages across different Injector 4.5V : Ground & Inj. Pins 4,5,8,9
2 pigtail pins. If found any issues, rectify it (If required Replace wiring
harness/Replace injector) and check for DTC If injector changed, Write proper injector codes (I3C) in
ECU after reading it from new Injector

Perform service regeneration at IDLE after issue

rectification

Perform following services in TDS:

1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
3 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
4 If still issue persists, Replace ECU
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Perform service regeneration at IDLE after issue

rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0266-00: Cylinder 2 - Injector balance low fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0266-00 1. Other system errors (Rail

pressure/EGR/ETV/Intake air system) No Vehicle reaction
2. Injector 2 is faulty
CEL ON

Fault System Summary:

Development Fault code F_M_FCI_INJ_BAL_LOW_APV_3

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 652 / 09

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 534 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Other system errors :
EGR Electrical / funcation fault codes
Check indicated torque at engine low idle & high idle . If torque found Rail pressure sensor errors
out of specifcation, then injector balance fault triggered because of other Exhaust throttle electrical / stuck closed
system failures, check specification for more details. If found any issues, Intake air system related errors like PFM/Intake manifold
1
rectify it and start engine. pressue/temperatures
After rectification,Raise engine speed to 1500-1700 rpm and keep it for 2 DPF related failures
mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

2. Indicated torque range :
Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
If no faults observed, remove after ETV pipe & check whether ETV is
3. Perform ETV Actuator test in TDS-ECU (Test Actuator
stuck closed physically by performing actuator tests (0%,50%&100%). If
Tab- 0%,50% & 100%)
actuator is not moving, relpace ETV & perform tests mentioned in
2 3. ETV error allowed during actuator test : +/- 5%
specification.
4. Perform ETV Actuator learning test through TDS-ECU if
After rectification,Raise engine speed to 1500-1700 rpm and keep it for 2
ETV replaced
mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

If still issue persists, detach / disconnect ATS from ETV pipe & check 2. Indicated torque range :
indicated torque in Low Idle & high Idle. If torque found within Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
specification, then DPF might be having issues. Remove/Replace DPF & 3. Perform DPF replacement service through TDS-DCU if
3
check for DTC. DPF is replaced
After rectification,Raise engine speed to 1500-1700 rpm and keep it for 2
mins. Check for DTC. Perform service regeneration at IDLE after issue
rectification

Refer circuit diagram. Check connection between EMS

ECU & Injector pigtail connector (Inj.)
If still issue persists, Check Injector pigtail connector related issues. If
Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
found any issue, rectify it and start engine. Raise engine speed to 1500-
Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
1700 rpm and keep it for 2 mins. Check for DTC.
4 Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
1. Pin back out checks (ECU side and Injector connector sensor side)
Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
2. Connector/sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 535 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
1.7V : Ground & Inj. Pins 1,2,3,10
If no issues found in step2 , check for voltages across different Injector 4.5V : Ground & Inj. Pins 4,5,8,9
5 pigtail pins. If found any issues, rectify it (If required Replace wiring
harness/Replace injector) and check for DTC If injector changed, Write proper injector codes (I3C) in
ECU after reading it from new Injector

Perform service regeneration at IDLE after issue

rectification

Perform following services in TDS:

1. Injector shut off test
If no issues found in step 3, Conduct Injector actuator test through 2. Injector Buzz test
diagnostic tool. If found any issues, replace particular injector/wiring 3. If injector changed, Write proper injector codes (I3C) in
6
harness based on finding & start engine. Raise engine speed to 1500- ECU after reading it from new Injector
1700 rpm and keep it for 2 mins. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Raise engine
7
speed to 1500-1700 rpm and keep it for 2 mins. Check for DTC Perform service regeneration at IDLE after issue
rectification
1. Ensure Injector back leak should not exceed 160ml with
If still issue persists, Perform injector back leak test. If back leak found
all injectors
out of specification, Remove & Refit injector along with quill & quill nut.
8
Apply proper tightening torque. Start engine, Raise engine speed to
Perform service regeneration at IDLE after issue
1500-1700 rpm and keep it for 2 mins. Check for DTC
rectification
Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace Injector1 & write I3C code. Start engine,
from new Injector
9 Raise engine speed to 1500-1700 rpm and keep it for 2 mins. Check for
DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
10 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 536 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 537 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0202-13: Cylinder 2 - Injector Circuit Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0202-13

1. Wiring harness issue
2. Injector 2 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_OC_INJ_APV_3

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 652 / 05

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 538 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram. Check connection between EMS
ECU & Injector pigtail connector (Inj.)
If still issue persists, Check Injector pigtail connector related issues. If Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
found any issue, rectify it and check for DTC Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
1 1. Pin back out checks (ECU side and Injector connector sensor side) Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
2. Connector/sensor physical damage Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
1.7V : Ground & Inj. Pins 1,2,3,10
If no issues found in step1 , check for voltages across different Injector 4.5V : Ground & Inj. Pins 4,5,8,9
2 pigtail pins. If found any issues, rectify it (If required Replace wiring
harness/Replace injector) and check for DTC If injector changed, Write proper injector codes (I3C) in
ECU after reading it from new Injector

Perform service regeneration at IDLE after issue

rectification

Perform following services in TDS:

1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
3 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
4 If still issue persists, Replace ECU
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 539 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 540 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0202-2B: Cylinder 2 - Injector Short circuit error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0202-2B

1. Wiring harness issue
2. Injector 2 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_SC_INJ_APV_3

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 652 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 541 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram. Check connection between EMS
ECU & Injector pigtail connector (Inj.)
If still issue persists, Check Injector pigtail connector related issues. If Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
found any issue, rectify it and check for DTC Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
1 1. Pin back out checks (ECU side and Injector connector sensor side) Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
2. Connector/sensor physical damage Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
1.7V : Ground & Inj. Pins 1,2,3,10
If no issues found in step1 , check for voltages across different Injector 4.5V : Ground & Inj. Pins 4,5,8,9
2 pigtail pins. If found any issues, rectify it (If required Replace wiring
harness/Replace injector) and check for DTC If injector changed, Write proper injector codes (I3C) in
ECU after reading it from new Injector

Perform service regeneration at IDLE after issue

rectification

Perform following services in TDS:

1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
3 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
4 If still issue persists, Replace ECU
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 542 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 543 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0269-00: Cylinder 3 - Injector balance low fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0269-00 1. Other system errors (Rail

pressure/EGR/ETV/Intake air system) No Vehicle reaction
2. Injector 3 is faulty
CEL ON

Fault System Summary:

Development Fault code F_M_FCI_INJ_BAL_LOW_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 653 / 09

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 544 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Other system errors :
EGR Electrical / funcation fault codes
Check indicated torque at engine low idle & high idle . If torque found Rail pressure sensor errors
out of specifcation, then injector balance fault triggered because of other Exhaust throttle electrical / stuck closed
system failures, check specification for more details. If found any issues, Intake air system related errors like PFM/Intake manifold
1
rectify it and start engine. pressue/temperatures
After rectification,Raise engine speed to 1500-1700 rpm and keep it for 2 DPF related failures
mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

2. Indicated torque range :
Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
If no faults observed, remove after ETV pipe & check whether ETV is
3. Perform ETV Actuator test in TDS-ECU (Test Actuator
stuck closed physically by performing actuator tests (0%,50%&100%). If
Tab- 0%,50% & 100%)
actuator is not moving, relpace ETV & perform tests mentioned in
2 3. ETV error allowed during actuator test : +/- 5%
specification.
4. Perform ETV Actuator learning test through TDS-ECU if
After rectification,Raise engine speed to 1500-1700 rpm and keep it for 2
ETV replaced
mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

If still issue persists, detach / disconnect ATS from ETV pipe & check 2. Indicated torque range :
indicated torque in Low Idle & high Idle. If torque found within Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
specification, then DPF might be having issues. Remove/Replace DPF & 3. Perform DPF replacement service through TDS-DCU if
3
check for DTC. DPF is replaced
After rectification,Raise engine speed to 1500-1700 rpm and keep it for 2
mins. Check for DTC. Perform service regeneration at IDLE after issue
rectification

Refer circuit diagram. Check connection between EMS

ECU & Injector pigtail connector (Inj.)
If still issue persists, Check Injector pigtail connector related issues. If
Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
found any issue, rectify it and start engine. Raise engine speed to 1500-
Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
1700 rpm and keep it for 2 mins. Check for DTC.
4 Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
1. Pin back out checks (ECU side and Injector connector sensor side)
Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
2. Connector/sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 545 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
1.7V : Ground & Inj. Pins 1,2,3,10
If no issues found in step2 , check for voltages across different Injector 4.5V : Ground & Inj. Pins 4,5,8,9
5 pigtail pins. If found any issues, rectify it (If required Replace wiring
harness/Replace injector) and check for DTC If injector changed, Write proper injector codes (I3C) in
ECU after reading it from new Injector

Perform service regeneration at IDLE after issue

rectification

Perform following services in TDS:

1. Injector shut off test
If no issues found in step 3, Conduct Injector actuator test through 2. Injector Buzz test
diagnostic tool. If found any issues, replace particular injector/wiring 3. If injector changed, Write proper injector codes (I3C) in
6
harness based on finding & start engine. Raise engine speed to 1500- ECU after reading it from new Injector
1700 rpm and keep it for 2 mins. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Raise engine
7
speed to 1500-1700 rpm and keep it for 2 mins. Check for DTC Perform service regeneration at IDLE after issue
rectification
1. Ensure Injector back leak should not exceed 160ml with
If still issue persists, Perform injector back leak test. If back leak found
all injectors
out of specification, Remove & Refit injector along with quill & quill nut.
8
Apply proper tightening torque. Start engine, Raise engine speed to
Perform service regeneration at IDLE after issue
1500-1700 rpm and keep it for 2 mins. Check for DTC
rectification
Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace Injector1 & write I3C code. Start engine,
from new Injector
9 Raise engine speed to 1500-1700 rpm and keep it for 2 mins. Check for
DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
10 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 546 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 547 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0203-13: Cylinder 3 - Injector Circuit Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0203-13

1. Wiring harness issue
2. Injector 3 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_OC_INJ_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 653 / 05

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 548 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram. Check connection between EMS
ECU & Injector pigtail connector (Inj.)
If still issue persists, Check Injector pigtail connector related issues. If Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
found any issue, rectify it and check for DTC Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
1 1. Pin back out checks (ECU side and Injector connector sensor side) Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
2. Connector/sensor physical damage Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
1.7V : Ground & Inj. Pins 1,2,3,10
If no issues found in step1 , check for voltages across different Injector 4.5V : Ground & Inj. Pins 4,5,8,9
2 pigtail pins. If found any issues, rectify it (If required Replace wiring
harness/Replace injector) and check for DTC If injector changed, Write proper injector codes (I3C) in
ECU after reading it from new Injector

Perform service regeneration at IDLE after issue

rectification

Perform following services in TDS:

1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
3 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
4 If still issue persists, Replace ECU
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 549 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 550 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0203-2B: Cylinder 3 - Injector Short circuit error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0203-2B

1. Wiring harness issue
2. Injector 3 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_SC_INJ_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 653 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 551 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram. Check connection between EMS
ECU & Injector pigtail connector (Inj.)
If still issue persists, Check Injector pigtail connector related issues. If Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
found any issue, rectify it and check for DTC Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
1 1. Pin back out checks (ECU side and Injector connector sensor side) Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
2. Connector/sensor physical damage Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
1.7V : Ground & Inj. Pins 1,2,3,10
If no issues found in step1 , check for voltages across different Injector 4.5V : Ground & Inj. Pins 4,5,8,9
2 pigtail pins. If found any issues, rectify it (If required Replace wiring
harness/Replace injector) and check for DTC If injector changed, Write proper injector codes (I3C) in
ECU after reading it from new Injector

Perform service regeneration at IDLE after issue

rectification

Perform following services in TDS:

1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
3 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
4 If still issue persists, Replace ECU
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 552 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 553 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0272-00: Cylinder 4 - Injector balance low fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0272-00 1. Other system errors (Rail

pressure/EGR/ETV/Intake air system) No Vehicle reaction
2. Injector 4 is faulty
CEL ON

Fault System Summary:

Development Fault code F_M_FCI_INJ_BAL_LOW_APV_2

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 654 / 09

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Other system errors :
EGR Electrical / funcation fault codes
Check indicated torque at engine low idle & high idle . If torque found Rail pressure sensor errors
out of specifcation, then injector balance fault triggered because of other Exhaust throttle electrical / stuck closed
system failures, check specification for more details. If found any issues, Intake air system related errors like PFM/Intake manifold
1
rectify it and start engine. pressue/temperatures
After rectification,Raise engine speed to 1500-1700 rpm and keep it for 2 DPF related failures
mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

2. Indicated torque range :
Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
If no faults observed, remove after ETV pipe & check whether ETV is
3. Perform ETV Actuator test in TDS-ECU (Test Actuator
stuck closed physically by performing actuator tests (0%,50%&100%). If
Tab- 0%,50% & 100%)
actuator is not moving, relpace ETV & perform tests mentioned in
2 3. ETV error allowed during actuator test : +/- 5%
specification.
4. Perform ETV Actuator learning test through TDS-ECU if
After rectification,Raise engine speed to 1500-1700 rpm and keep it for 2
ETV replaced
mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

If still issue persists, detach / disconnect ATS from ETV pipe & check 2. Indicated torque range :
indicated torque in Low Idle & high Idle. If torque found within Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
specification, then DPF might be having issues. Remove/Replace DPF & 3. Perform DPF replacement service through TDS-DCU if
3
check for DTC. DPF is replaced
After rectification,Raise engine speed to 1500-1700 rpm and keep it for 2
mins. Check for DTC. Perform service regeneration at IDLE after issue
rectification

Refer circuit diagram. Check connection between EMS

ECU & Injector pigtail connector (Inj.)
If still issue persists, Check Injector pigtail connector related issues. If
Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
found any issue, rectify it and start engine. Raise engine speed to 1500-
Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
1700 rpm and keep it for 2 mins. Check for DTC.
4 Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
1. Pin back out checks (ECU side and Injector connector sensor side)
Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
2. Connector/sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
1.7V : Ground & Inj. Pins 1,2,3,10
If no issues found in step2 , check for voltages across different Injector 4.5V : Ground & Inj. Pins 4,5,8,9
5 pigtail pins. If found any issues, rectify it (If required Replace wiring
harness/Replace injector) and check for DTC If injector changed, Write proper injector codes (I3C) in
ECU after reading it from new Injector

Perform service regeneration at IDLE after issue

rectification

Perform following services in TDS:

1. Injector shut off test
If no issues found in step 3, Conduct Injector actuator test through 2. Injector Buzz test
diagnostic tool. If found any issues, replace particular injector/wiring 3. If injector changed, Write proper injector codes (I3C) in
6
harness based on finding & start engine. Raise engine speed to 1500- ECU after reading it from new Injector
1700 rpm and keep it for 2 mins. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Raise engine
7
speed to 1500-1700 rpm and keep it for 2 mins. Check for DTC Perform service regeneration at IDLE after issue
rectification
1. Ensure Injector back leak should not exceed 160ml with
If still issue persists, Perform injector back leak test. If back leak found
all injectors
out of specification, Remove & Refit injector along with quill & quill nut.
8
Apply proper tightening torque. Start engine, Raise engine speed to
Perform service regeneration at IDLE after issue
1500-1700 rpm and keep it for 2 mins. Check for DTC
rectification
Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace Injector1 & write I3C code. Start engine,
from new Injector
9 Raise engine speed to 1500-1700 rpm and keep it for 2 mins. Check for
DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
10 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0204-13: Cylinder 4 - Injector Circuit Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0204-13

1. Wiring harness issue
2. Injector 4 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_OC_INJ_APV_2

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 654 / 05

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram. Check connection between EMS
ECU & Injector pigtail connector (Inj.)
If still issue persists, Check Injector pigtail connector related issues. If Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
found any issue, rectify it and check for DTC Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
1 1. Pin back out checks (ECU side and Injector connector sensor side) Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
2. Connector/sensor physical damage Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
1.7V : Ground & Inj. Pins 1,2,3,10
If no issues found in step1 , check for voltages across different Injector 4.5V : Ground & Inj. Pins 4,5,8,9
2 pigtail pins. If found any issues, rectify it (If required Replace wiring
harness/Replace injector) and check for DTC If injector changed, Write proper injector codes (I3C) in
ECU after reading it from new Injector

Perform service regeneration at IDLE after issue

rectification

Perform following services in TDS:

1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
3 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
4 If still issue persists, Replace ECU
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Perform service regeneration at IDLE after issue

rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0204-2B: Cylinder 4 - Injector Short circuit error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0204-2B

1. Wiring harness issue
2. Injector 4 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_SC_INJ_APV_2

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 654 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram. Check connection between EMS
ECU & Injector pigtail connector (Inj.)
If still issue persists, Check Injector pigtail connector related issues. If Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
found any issue, rectify it and check for DTC Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
1 1. Pin back out checks (ECU side and Injector connector sensor side) Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
2. Connector/sensor physical damage Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
1.7V : Ground & Inj. Pins 1,2,3,10
If no issues found in step1 , check for voltages across different Injector 4.5V : Ground & Inj. Pins 4,5,8,9
2 pigtail pins. If found any issues, rectify it (If required Replace wiring
harness/Replace injector) and check for DTC If injector changed, Write proper injector codes (I3C) in
ECU after reading it from new Injector

Perform service regeneration at IDLE after issue

rectification

Perform following services in TDS:

1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
3 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
4 If still issue persists, Replace ECU
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Perform service regeneration at IDLE after issue

rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P062D-08: Injector Bank 0 - Internal Communication fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P062D-08
1. Faulty ECU Engine emission may go high
MIL ON
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_DIAG_READ_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2797 / 19

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P062D-04: Injector Bank 0 - Internal Communication fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P062D-04
1. Faulty ECU Engine emission may go high
MIL ON
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_DIAG_RESET_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2797 / 12

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2146-12: Injector Bank 0 - Short to Battery fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2146-12

1. Injector Bank 0 (Cylinder 1 or Cylinder 4) high
side pins short to battery
MIL ON 1. Engine speed increased to 1200 rpm
2. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_BANK_SC2VBAT_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2797 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

16 – 32 V
Check electrical errors related to Battery voltage. If found any issues,
1
rectify it and check for DTC Perform service regeneration at IDLE after issue
rectification
Refer circuit diagram. Check connection between EMS
ECU & Injector pigtail connector (Inj.)
Check Injector pigtail connector related issues. If found any issue, rectify Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
and check for DTC Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
2 1. Pin back out checks (ECU side and Injector connector sensor side) Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
2. Connector/sensor physical damage Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
If no issues found in step2 , check for voltages across different Injector
1.7V : Ground & Inj. Pins 1,2,3,10
3 pigtail pins. If found any issues, rectify it (If required Replace wiring
4.5V : Ground & Inj. Pins 4,5,8,9
harness/Replace injector) and check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace specific injector(1 or 4 or both) and check from new Injector(s)
5
for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2146-11: Injector Bank 0 - Short to Ground fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2146-11

1. Injector Bank 0 (Cylinder 1 or Cylinder 4) high
side pins short to ground
MIL ON 1. Engine speed increased to 1200 rpm
2. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_BANK_SC2GND_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2797 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

16 – 32 V
Check electrical errors related to Battery voltage. If found any issues,
1
rectify it and check for DTC Perform service regeneration at IDLE after issue
rectification
Refer circuit diagram. Check connection between EMS
ECU & Injector pigtail connector (Inj.)
Check Injector pigtail connector related issues. If found any issue, rectify Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
and check for DTC Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
2 1. Pin back out checks (ECU side and Injector connector sensor side) Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
2. Connector/sensor physical damage Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
If no issues found in step2 , check for voltages across different Injector
1.7V : Ground & Inj. Pins 1,2,3,10
3 pigtail pins. If found any issues, rectify it (If required Replace wiring
4.5V : Ground & Inj. Pins 4,5,8,9
harness/Replace injector) and check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace specific injector(1 or 4 or both) and check from new Injector(s)
5
for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 575 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P062E-08: Injector Bank 1 - Internal Communication fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P062E-08
1. Faulty ECU Engine emission may go high
MIL ON
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_DIAG_READ_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2798 / 19

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 577 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P062E-04: Injector Bank 1 - Internal Communication fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P062E-04
1. Faulty ECU Engine emission may go high
MIL ON
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_DIAG_RESET_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2798 / 12

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
2 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2149-12: Injector Bank 1 - Short to Battery fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2149-12

1. Injector Bank 1 (Cylinder 2 or Cylinder 3) high
side pins short to battery
MIL ON 1. Engine speed increased to 1200 rpm
2. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_BANK_SC2VBAT_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2798 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

16 – 32 V
Check electrical errors related to Battery voltage. If found any issues,
1
rectify it and check for DTC Perform service regeneration at IDLE after issue
rectification
Refer circuit diagram. Check connection between EMS
ECU & Injector pigtail connector (Inj.)
Check Injector pigtail connector related issues. If found any issue, rectify Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
and check for DTC Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
2 1. Pin back out checks (ECU side and Injector connector sensor side) Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
2. Connector/sensor physical damage Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
If no issues found in step2 , check for voltages across different Injector
1.7V : Ground & Inj. Pins 1,2,3,10
3 pigtail pins. If found any issues, rectify it (If required Replace wiring
4.5V : Ground & Inj. Pins 4,5,8,9
harness/Replace injector) and check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace specific injector(2 or 3 or both) and check from new Injector(s)
5
for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2149-11: Injector Bank 1 - Short to Ground fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2149-11

1. Injector Bank 0 (Cylinder 2 or Cylinder 3) high
side pins short to ground
MIL ON 1. Engine speed increased to 1200 rpm
2. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_BANK_SC2GND_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2798 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

16 – 32 V
Check electrical errors related to Battery voltage. If found any issues,
1
rectify it and check for DTC Perform service regeneration at IDLE after issue
rectification
Refer circuit diagram. Check connection between EMS
ECU & Injector pigtail connector (Inj.)
Check Injector pigtail connector related issues. If found any issue, rectify Inj1: ECU pin E87-Inj.Pin 4; ECU pin E22-Inj. Pin 1
and check for DTC Inj2: ECU pin E24- Inj.Pin 8; ECU pin E23-Inj. Pin 3
2 1. Pin back out checks (ECU side and Injector connector sensor side) Inj3: ECU pin E86- Inj.Pin 9; ECU pin E43-Inj. Pin 10
2. Connector/sensor physical damage Inj4: ECU pin E45- Inj.Pin 5; ECU pin E44-Inj. Pin 2
3.Continuity checks (Open / Short circuit failures)
Perform service regeneration at IDLE after issue
rectification

Check voltages between Injector connector pins when

ignition ON,
2.8V : 1&4, 3&8, 9&10, 2&5
If no issues found in step2 , check for voltages across different Injector
1.7V : Ground & Inj. Pins 1,2,3,10
3 pigtail pins. If found any issues, rectify it (If required Replace wiring
4.5V : Ground & Inj. Pins 4,5,8,9
harness/Replace injector) and check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace specific injector(2 or 3 or both) and check from new Injector(s)
5
for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P00C6-7B: Rail pressure not bulit at Low tank level during engine cranking
Overview:

Fault Code Description Cause Effect on Vehicle

1. Fuel tank level is low
2. Issues in Low pressure line
3. Fuel filter is clogged
4. HPV return line leakage (Common rail is
Fault Code P00C6-7B No Vehicle reaction
faulty)
5. High injector back leak (Injector fitment issue)
6. Faulty Injector
7. Faulty IMV/HP Pump

Fault System Summary:

Development Fault code F_M_RPC_BUILD_LOWTK_APV

System Fuel Injection System / Fuel tank level monitor

OBD Inducement Non-Inducement

SPN & FMI 5585 / 17

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Press the hand primer 150 times to reach fuel near
Check fuel level in the tank. If diesel level is low, refill fuel. Crank the
1 transfer pump inlet. Ensure no leakage or no air trap in
engine and check for rail pressure buildup. Check for DTC
low-pressure circuit.
If still issue persists, check for low pressure fuel lines. If found any issues, Press the hand primer 150 times to reach fuel near
2 rectify it. Crank the engine and check for rail pressure buildup. Check for transfer pump inlet. Ensure no leakage or no air trap in
DTC low-pressure circuit.
If still issue persists, check for whether fuel filter is clogged. If its clogged, Press the hand primer 150 times to reach fuel near
3 replace it with new one lines. Crank the engine and check for rail transfer pump inlet. Ensure no leakage or no air trap in
pressure buildup. Check for DTC low-pressure circuit.
If still issue persists, open rail pressure return line from HPV. During
cranking there should not be any fuel flow in the line. If found any, If component replaced, perform
4
replace HPV/Common Rail. Crank the engine and check for rail pressure 1. RESET HP Pump values test
buildup. Check for DTC
If still issue persists, conduct Injector back leak test during cranking. If
collected quantity is out of specification, refit injectors along with Quil &
5 Back leak should be < 10 ml @ cranking duration 8-10 secs
Quil nut assemply. Crank the engine and check for rail pressure buildup.
Check for DTC
If still issue persists, perform injector buzz test. If found any issues, Perform following services in TDS:
6 Replace respective injector. Crank the engine and check for rail pressure 1. Write proper injector codes (I3C) in ECU after reading it
buildup. Check for DTC from new Injector
Perform following services in TDS:
If still issue persists, Replace HP pump. Crank the engine and check for
7 1. RESET IMV values test
rail pressure buildup. Check for DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
8 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P00C6-00: Rail pressure not bulit at normal tank level during engine cranking
Overview:

Fault Code Description Cause Effect on Vehicle

1. Fuel tank level is low
2. Issues in Low pressure line
3. Fuel filter is clogged
Fault Code P00C6-00 4. HPV return line leakage (Common rail is
No Vehicle reaction
faulty)
5. High injector back leak (Injector fitment issue)
6. Faulty Injector
CEL ON 7. Faulty IMV/HP Pump

Fault System Summary:

Development Fault code F_M_RPC_BUILD_NRMTK_APV

System Fuel Injection System / Fuel tank level monitor

OBD Inducement Non-Inducement

SPN & FMI 5585 / 01

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Press the hand primer 150 times to reach fuel near
Check fuel level in the tank. If diesel level is low, refill fuel. Crank the
1 transfer pump inlet. Ensure no leakage or no air trap in
engine and check for rail pressure buildup. Check for DTC
low-pressure circuit.
If still issue persists, check for low pressure fuel lines. If found any issues, Press the hand primer 150 times to reach fuel near
2 rectify it. Crank the engine and check for rail pressure buildup. Check for transfer pump inlet. Ensure no leakage or no air trap in
DTC low-pressure circuit.
If still issue persists, check for whether fuel filter is clogged. If its clogged, Press the hand primer 150 times to reach fuel near
3 replace it with new one lines. Crank the engine and check for rail transfer pump inlet. Ensure no leakage or no air trap in
pressure buildup. Check for DTC low-pressure circuit.
If still issue persists, open rail pressure return line from HPV. During
cranking there should not be any fuel flow in the line. If found any, If component replaced, perform
4
replace HPV/Common Rail. Crank the engine and check for rail pressure 1. RESET HP Pump values test
buildup. Check for DTC
If still issue persists, conduct Injector back leak test during cranking. If
collected quantity is out of specification, refit injectors along with Quil &
5 Back leak should be < 10 ml @ cranking duration 8-10 secs
Quil nut assemply. Crank the engine and check for rail pressure buildup.
Check for DTC
If still issue persists, perform injector buzz test. If found any issues, Perform following services in TDS:
6 Replace respective injector. Crank the engine and check for rail pressure 1. Write proper injector codes (I3C) in ECU after reading it
buildup. Check for DTC from new Injector
Perform following services in TDS:
If still issue persists, Replace HP pump. Crank the engine and check for
7 1. RESET IMV values test
rail pressure buildup. Check for DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
8 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0180-15: Fuel temperature sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0180-15 1. Wiring harness issue (Connector open / pin

back out /Short circuit) No Vehicle reaction
2. Faulty sensor
CEL ON

Fault System Summary:

Development Fault code F_M_FUEL_TEMP_HI_APV

System Fuel Injection System / Fuel Temperature Sensor

OBD Inducement Non-Inducement

SPN & FMI 2775 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Fuel temp. sensor electrical failures. If found any issue, rectify and
check for DTC Refer circuit diagram:
1 1. Pin back out checks (ECU side and sensor side) Fuel temp. Pin 1 - ECU Pin E97
2. Connector/Sensor physical damage Fuel temp. Pin 2 - ECU Pin E101
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Re-flash ECU dataset and check for DTC again

3 If still issue persists, Replace Fuel temperature sensor and check for DTC Select dataset as per Vehicle configuration(VC)

4 If still issue persists, Replace respective wiring harness

Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0180-11: Fuel temperature sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0180-11 1. Wiring harness issue (Short circuit)

No Vehicle reaction
2. Faulty sensor
CEL ON

Fault System Summary:

Development Fault code F_M_FUEL_TEMP_LO_APV

System Fuel Injection System / Fuel Temperature Sensor

OBD Inducement Non-Inducement

SPN & FMI 2775 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Fuel temp. sensor electrical failures. If found any issue, rectify and
check for DTC Refer circuit diagram:
1 1. Pin back out checks (ECU side and sensor side) Fuel temp. Pin 1 - ECU Pin E97
2. Connector/Sensor physical damage Fuel temp. Pin 2 - ECU Pin E101
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)

3 If still issue persists, Replace Fuel temperature sensor and check for DTC

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0180-29: Fuel temperature sensor - Signal not valid based on reference

sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0180-29 1.Faulty wiring harness

2.Faulty sensor No Vehicle reaction
3.Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FUEL_TEMP_XC_APV

System Fuel Injection System / Fuel Temperature Sensor

OBD Inducement Non-Inducement

SPN & FMI 2775 / 02

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Fuel temperature sensor electrical failures. If found any issue,
rectify it and check for DTC Refer circuit diagram:
1 1. Pin back out checks (ECU side and sensor side) Fuel temp. Pin 1 - ECU Pin E97
2. Connector/Sensor physical damage Fuel temp. Pin 2 - ECU Pin E101
3.Continuity checks (Open / Short circuit failures)
After rectification of step 1, connect Fuel temp. sensor externally and Reference sensors :
2 keep it in ambient with wiring connected. Like that keep reference 1. Ambient temperature sensor
sensors as well. Check temp. difference across all sensors 2. Coolant temperature sensor

3 If difference found within specification, Fit back all 3 sensors into engine. Temperature difference threshold : +/20 deg C

If still issue persists, connect one new Fuel temp. sensor externally and Reference sensors :
4 keep it in ambient with wiring connected. Like that keep reference 1. Ambient temperature sensor
sensors as well. Check temp. difference across all sensors 2. Coolant temperature sensor
If difference found within specification, Fit new Fuel temp. sensor into
5 Temperature difference threshold : +/20 deg C
engine and connect other sensors also
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0090-13: HPV - Circuit Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-13 1. Faulty Wiring harness

2. Faulty HPV
Stop Engine 3. Faulty ECU
BLINK 1. 30% Torque reduction
Lamp

Fault System Summary:

Development Fault code F_M_HPV_OC_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 05

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check HPV actuator electrical failures. If found any issue, rectify it. Start
engine and check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 HPV Pin 1 - ECU Pin E01
2. Connector/Sensor physical damage
HPV Pin 2 - ECU Pin E02
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across HPV pins. If found
2 5V : 1&2, 1&ground
any issues, rectify it. Start engine and check for DTC
0V : 2&ground
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
3 1. HPV Valve test
failed, Replace Common Rail. Start engine and check for DTC
2. Rail pressure test
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5 Perform following services in TDS:
4
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P228D-00: HPV - Controller correction High error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness

Fault Code P228D-00 2. Faulty IMV
3. Faulty HPV
4. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_HP_CTRL_TRIM_HI_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 16

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check for leakages / damage in the fuel line. If found any issues, rectify it. Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
Drive vehicle for 5 Kms and check for DTC return to filters
Check HPV&IMV actuator electrical failures. If found any issue, rectify it. Refer circuit diagram:
Drive vehicle for 5Kms & check for DTC HPV Pin 1 - ECU Pin E01
1. Pin back out checks (ECU side and actuator side) HPV Pin 2 - ECU Pin E02
2
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures) IMV Pin 1 - ECU Pin E105
4. Ensure secondary lock present in the actuator IMV Pin 2 - ECU Pin E104
Check voltages between below HPV connector pins during
If no issues found in step2 , check for voltages across HPV pins. If found Key ON
3
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC 5V : 1&2, 1&ground
0V : 2&ground
If still issue persists, Replace Common rail assembly. Drive vehicle for 5 Perform following services in TDS:
4
Kms and check for DTC 1. RESET HP Pump values test
If still issue persists, Replace IMV. Drive vehicle for 5 Kms and check for Perform following services in TDS:
5
DTC 1. RESET IMV Values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 607 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 608 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P228C-00: HPV - Controller correction Low error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness

Fault Code P228C-00 2. Faulty IMV
3. Faulty HPV
4. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_HP_CTRL_TRIM_LO_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 15

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 609 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check for leakages / damage in the fuel line. If found any issues, rectify it. Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
Drive vehicle for 5 Kms and check for DTC return to filters
Check HPV&IMV actuator electrical failures. If found any issue, rectify it. Refer circuit diagram:
Drive vehicle for 5Kms & check for DTC HPV Pin 1 - ECU Pin E01
1. Pin back out checks (ECU side and actuator side) HPV Pin 2 - ECU Pin E02
2
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures) IMV Pin 1 - ECU Pin E105
4. Ensure secondary lock present in the actuator IMV Pin 2 - ECU Pin E104
Check voltages between below HPV connector pins during
If no issues found in step2 , check for voltages across HPV pins. If found Key ON
3
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC 5V : 1&2, 1&ground
0V : 2&ground
If still issue persists, Replace Common rail assembly. Drive vehicle for 5 Perform following services in TDS:
4
Kms and check for DTC 1. RESET HP Pump values test
If still issue persists, Replace IMV. Drive vehicle for 5 Kms and check for Perform following services in TDS:
5
DTC 1. RESET IMV Values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 610 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 611 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0090-1B: HPV - Current control error (High)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-1B 1. Wiring harness

2. Faulty HPV ( Faulty Rail)
3. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_HP_CRT_CTRL_HIGH_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 18

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 612 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check HPV actuator electrical failures. If found any issue, rectify it. Drive
vehicle for 5Kms & check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 HPV Pin 1 - ECU Pin E01
2. Connector/Sensor physical damage
HPV Pin 2 - ECU Pin E02
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across HPV pins. If found
2 5V : 1&2, 1&ground
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC
0V : 2&ground
If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
3
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
4 1. HPV Valve test
failed, Replace Common Rail. Drive vehicle for 5 Kms and check for DTC
2. Rail pressure test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
5 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
If still issue persists, Replace Common rail assembly. Drive vehicle for 5 Perform following services in TDS:
6
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 613 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 614 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0090-1A: HPV - Current control error (Low)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-1A 1. Wiring harness

2. Faulty HPV ( Faulty Rail)
3. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_HP_CRT_CTRL_LOW_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 17

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 615 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check HPV actuator electrical failures. If found any issue, rectify it. Drive
vehicle for 5Kms & check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 HPV Pin 1 - ECU Pin E01
2. Connector/Sensor physical damage
HPV Pin 2 - ECU Pin E02
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across HPV pins. If found
2 5V : 1&2, 1&ground
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC
0V : 2&ground
If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
3
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
4 1. HPV Valve test
failed, Replace Common Rail. Drive vehicle for 5 Kms and check for DTC
2. Rail pressure test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
5 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
If still issue persists, Replace Common rail assembly. Drive vehicle for 5 Perform following services in TDS:
6
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 616 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 617 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0090-19: HPV - Feedback Current High error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-19 1. Wiring harness

2. Faulty HPV ( Faulty Rail) No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_HP_CRT_FB_HIGH_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 00

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 618 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check HPV actuator electrical failures. If found any issue, rectify it. Drive
vehicle for 5Kms & check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 HPV Pin 1 - ECU Pin E01
2. Connector/Sensor physical damage
HPV Pin 2 - ECU Pin E02
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across HPV pins. If found
2 5V : 1&2, 1&ground
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC
0V : 2&ground
If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
3
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
4 1. HPV Valve test
failed, Replace Common Rail. Drive vehicle for 5 Kms and check for DTC
2. Rail pressure test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
5 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
If still issue persists, Replace Common rail assembly. Drive vehicle for 5 Perform following services in TDS:
6
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 619 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 620 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0090-18: HPV - Feedback Current Low error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-18 1. Wiring harness

2. Faulty HPV ( Faulty Rail) No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_HP_CRT_FB_LOW_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 01

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 621 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check HPV actuator electrical failures. If found any issue, rectify it. Drive
vehicle for 5Kms & check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 HPV Pin 1 - ECU Pin E01
2. Connector/Sensor physical damage
HPV Pin 2 - ECU Pin E02
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across HPV pins. If found
2 5V : 1&2, 1&ground
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC
0V : 2&ground
If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
3
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
4 1. HPV Valve test
failed, Replace Common Rail. Drive vehicle for 5 Kms and check for DTC
2. Rail pressure test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
5 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
If still issue persists, Replace Common rail assembly. Drive vehicle for 5 Perform following services in TDS:
6
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 622 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 623 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0090-F0: HPV High side pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-F0 1. Faulty Wiring harness

2. Faulty HPV
Stop Engine 3. Faulty ECU
BLINK 1. 30% Torque reduction
Lamp

Fault System Summary:

Development Fault code F_M_HPV_HSD_SC2V_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 516202 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 624 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check HPV actuator electrical failures. If found any issue, rectify it. Start
engine and check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 HPV Pin 1 - ECU Pin E01
2. Connector/Sensor physical damage
HPV Pin 2 - ECU Pin E02
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across HPV pins. If found
2 5V : 1&2, 1&ground
any issues, rectify it. Start engine and check for DTC
0V : 2&ground
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
3 1. HPV Valve test
failed, Replace Common Rail. Start engine and check for DTC
2. Rail pressure test
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5 Perform following services in TDS:
4
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 625 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 626 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0090-F1: HPV High side pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-F1 1. Faulty Wiring harness

2. Faulty HPV
Stop Engine 3. Faulty ECU
BLINK 1. 30% Torque reduction
Lamp

Fault System Summary:

Development Fault code F_M_HPV_HSD_SC2G_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 516202 / 04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 627 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check HPV actuator electrical failures. If found any issue, rectify it. Start
engine and check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 HPV Pin 1 - ECU Pin E01
2. Connector/Sensor physical damage
HPV Pin 2 - ECU Pin E02
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across HPV pins. If found
2 5V : 1&2, 1&ground
any issues, rectify it. Start engine and check for DTC
0V : 2&ground
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
3 1. HPV Valve test
failed, Replace Common Rail. Start engine and check for DTC
2. Rail pressure test
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5 Perform following services in TDS:
4
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 628 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 629 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0090-F2: HPV Low side pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-F2 1. Faulty Wiring harness

2. Faulty HPV
Stop Engine 3. Faulty ECU
BLINK 1. 30% Torque reduction
Lamp

Fault System Summary:

Development Fault code F_M_HPV_LSD_SC2V_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 516203 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 630 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check HPV actuator electrical failures. If found any issue, rectify it. Start
engine and check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 HPV Pin 1 - ECU Pin E01
2. Connector/Sensor physical damage
HPV Pin 2 - ECU Pin E02
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across HPV pins. If found
2 5V : 1&2, 1&ground
any issues, rectify it. Start engine and check for DTC
0V : 2&ground
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
3 1. HPV Valve test
failed, Replace Common Rail. Start engine and check for DTC
2. Rail pressure test
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5 Perform following services in TDS:
4
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 631 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 632 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0090-F3: HPV Low side pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-F3 1. Faulty Wiring harness

2. Faulty HPV
Stop Engine 3. Faulty ECU
BLINK 1. 30% Torque reduction
Lamp

Fault System Summary:

Development Fault code F_M_HPV_LSD_SC2G_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 516203 / 04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 633 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check HPV actuator electrical failures. If found any issue, rectify it. Start
engine and check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 HPV Pin 1 - ECU Pin E01
2. Connector/Sensor physical damage
HPV Pin 2 - ECU Pin E02
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across HPV pins. If found
2 5V : 1&2, 1&ground
any issues, rectify it. Start engine and check for DTC
0V : 2&ground
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
3 1. HPV Valve test
failed, Replace Common Rail. Start engine and check for DTC
2. Rail pressure test
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5 Perform following services in TDS:
4
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 635 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0088-92: HPV - Over pressure fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Blockage in Rail return line

Fault Code P0088-92 2. Malfunction of HPV
3. Malfunction of Rail pressure sensor
4. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_OVERPRESSURE_HPV_APV

System Fuel Injection System / HPV Over Pressure Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 02

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 636 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check for Blockage in rail return line. If found any issues, rectify it. Drive Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
vehicle for 5 Kms and check for DTC return to filters
Check HPV actuator electrical failures. If found any issue, rectify it. Start
engine and check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
2 HPV Pin 1 - ECU Pin E01
2. Connector/Sensor physical damage
HPV Pin 2 - ECU Pin E02
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check rail pressure sensor related issues. If found any, rectify it. Drive
3
vehicle for 10Kms in highway and check for DTC
Perform following services in TDS:
If still issue persists, perform actuator tests through TDS. If test is not 1.Rail pressure test
4 passed, replace Common Rail. Drive vehicle for 10Kms in highway and
check for DTC If component replaced, perform
1. RESET HP Pump values test
If still issue persists, Replace Common Rail. Drive vehicle for 10Kms in If component replaced, perform
5
highway and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
If still issue persists, Replace IMV/HP Pump. Drive vehicle for 10Kms in
6 1. RESET IMV values test
highway and check for DTC
2. RESET HP Pump values test
If still issue persists, Replace Rail pressure sensor. Drive vehicle for
7
10Kms in highway and check for DTC
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
8 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
9 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 637 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 638 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0001-9B: IMV - Controller correction High error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Fuel line leakage / Blockage

2. Fuel filter / pre-filter issue
Fault Code P0001-9B 3. Faulty IMV
4. Faulty HP Pump
5. Wiring harness
6. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_IM_CTRL_QHI_HIGH_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 15

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 639 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
return to filters
If still issue persists, check for leakages / damage/kink in the fuel line. If
1
found any issues, rectify it. Drive vehicle for 5 Kms and check for DTC
Perform Service Regeneration at IDLE after issue
rectification
Check IMV actuator electrical failures. If found any issue, rectify it. Drive Refer circuit diagram:
vehicle for 5Kms & check for DTC IMV Pin 1 - ECU Pin E105
1. Pin back out checks (ECU side and actuator side) IMV Pin 2 - ECU Pin E104
2
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures) Perform Service Regeneration at IDLE after issue
4. Ensure secondary lock present in the actuator rectification
Check voltages between below pins during Key ON
3.44 V : 1&2, 1&ground
If no issues found in step2 , check for voltages across IMV pins. If found 0V : 2&ground
3
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC
Perform Service Regeneration at IDLE after issue
rectification
If still issue persists, Check fuel filter condition. Replace filter if found any Perform Service Regeneration at IDLE after issue
4
issues. Drive vehicle for 5 Kms and check for DTC rectification
Perform following services in TDS:
1. RESET IMV values test
If still issue persists, Replace IMV/HP Pump. Drive vehicle for 5 Kms and 2. RESET HP Pump values test
5
check for DTC
Perform Service Regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
6
5 Kms and check for DTC Perform Service Regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
7 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform Service Regeneration at IDLE after issue
rectification

Author: ERC Page 640 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 641 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0001-9C: IMV - Controller correction Low error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Fuel line leakage / Blockage

Fault Code P0001-9C 2. Fuel filter / pre-filter issue
3. Faulty IMV
4. Faulty HP Pump
5. Wiring harness
CEL ON 6. Faulty ECU 1. 50% Torque reduction
2. 1700 rpm Engine speed limitation

Fault System Summary:

Development Fault code F_M_IM_CTRL_QHI_LOW_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 17

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 642 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
return to filters
If still issue persists, check for leakages / damage/kink in the fuel line. If
1
found any issues, rectify it. Drive vehicle for 5 Kms and check for DTC
Perform Service Regeneration at IDLE after issue
rectification
Check IMV actuator electrical failures. If found any issue, rectify it. Drive Refer circuit diagram:
vehicle for 5Kms & check for DTC IMV Pin 1 - ECU Pin E105
1. Pin back out checks (ECU side and actuator side) IMV Pin 2 - ECU Pin E104
2
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures) Perform Service Regeneration at IDLE after issue
4. Ensure secondary lock present in the actuator rectification
Check voltages between below pins during Key ON
3.44 V : 1&2, 1&ground
If no issues found in step2 , check for voltages across IMV pins. If found 0V : 2&ground
3
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC
Perform Service Regeneration at IDLE after issue
rectification
If still issue persists, Check fuel filter condition. Replace filter if found any Perform Service Regeneration at IDLE after issue
4
issues. Drive vehicle for 5 Kms and check for DTC rectification
Perform following services in TDS:
1. RESET IMV values test
If still issue persists, Replace IMV/HP Pump. Drive vehicle for 5 Kms and 2. RESET HP Pump values test
5
check for DTC
Perform Service Regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
6
5 Kms and check for DTC Perform Service Regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
7 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform Service Regeneration at IDLE after issue
rectification

Author: ERC Page 643 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 644 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0001-1B: IMV - Current control error (High)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-1B 1. IMV harness issues

2. Fault IMV
3. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_IM_CRT_CTRL_HIGH_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 00

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 645 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check IMV actuator electrical failures. If found any issue, rectify it. Drive
vehicle for 5Kms & check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 IMV Pin 1 - ECU Pin E105
2. Connector/Sensor physical damage
IMV Pin 2 - ECU Pin E104
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across IMV pins. If found
2 3.44 V : 1&2, 1&ground
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC
0V : 2&ground
If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
3
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
1. IMV test
If still issue persists, Conduct IMV actuator test through TDS. If test failed, 2. IMV Buzz test
4
Replace Common Rail. Drive vehicle for 5 Kms and check for DTC If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
5 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
Perform following services in TDS:
If still issue persists, Replace IMV. Drive vehicle for 5 Kms and check for
6 1. RESET IMV values test
DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 646 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 647 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0001-1A: IMV - Current control error (Low)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-1A 1. IMV harness issues

2. Fault IMV
3. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_IM_CRT_CTRL_LOW_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 01

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 648 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check IMV actuator electrical failures. If found any issue, rectify it. Drive
vehicle for 5Kms & check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 IMV Pin 1 - ECU Pin E105
2. Connector/Sensor physical damage
IMV Pin 2 - ECU Pin E104
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across IMV pins. If found
2 3.44 V : 1&2, 1&ground
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC
0V : 2&ground
If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
3
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
1. IMV test
If still issue persists, Conduct IMV actuator test through TDS. If test failed, 2. IMV Buzz test
4
Replace Common Rail. Drive vehicle for 5 Kms and check for DTC If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
5 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
Perform following services in TDS:
If still issue persists, Replace IMV. Drive vehicle for 5 Kms and check for
6 1. RESET IMV values test
DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 649 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 650 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0001-19: IMV - Feedback Current High error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-19 1. Wiring harness

2. Faulty IMV
3. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_IM_CRT_FB_HIGH_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 16

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 651 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check IMV actuator electrical failures. If found any issue, rectify it. Drive
vehicle for 5Kms & check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 IMV Pin 1 - ECU Pin E105
2. Connector/Sensor physical damage
IMV Pin 2 - ECU Pin E104
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across IMV pins. If found
2 3.44 V : 1&2, 1&ground
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC
0V : 2&ground
If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
3
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
1. IMV test
If still issue persists, Conduct IMV actuator test through TDS. If test failed, 2. IMV Buzz test
4
Replace Common Rail. Drive vehicle for 5 Kms and check for DTC If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
5 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
Perform following services in TDS:
If still issue persists, Replace IMV. Drive vehicle for 5 Kms and check for
6 1. RESET IMV values test
DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 652 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 653 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0001-18: IMV - Feedback Current Low error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-18 1. Wiring harness

2. Faulty IMV
3. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_IM_CRT_FB_LOW_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 18

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 654 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check IMV actuator electrical failures. If found any issue, rectify it. Drive
vehicle for 5Kms & check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 IMV Pin 1 - ECU Pin E105
2. Connector/Sensor physical damage
IMV Pin 2 - ECU Pin E104
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across IMV pins. If found
2 3.44 V : 1&2, 1&ground
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC
0V : 2&ground
If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
3
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
1. IMV test
If still issue persists, Conduct IMV actuator test through TDS. If test failed, 2. IMV Buzz test
4
Replace Common Rail. Drive vehicle for 5 Kms and check for DTC If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
5 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
Perform following services in TDS:
If still issue persists, Replace IMV. Drive vehicle for 5 Kms and check for
6 1. RESET IMV values test
DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 655 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 656 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0001-13: IMV - Open Circuit

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-13 1. Faulty Wiring harness

2. Fault IMV
MIL ON for 15 secs 3. Faulty ECU 1. 30% Torque reduction
CEL BLINK

Fault System Summary:

Development Fault code F_M_IMV_OC_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 05

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 657 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check IMV actuator electrical failures. If found any issue, rectify it. Start
engine and check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 IMV Pin 1 - ECU Pin E105
2. Connector/Sensor physical damage
IMV Pin 2 - ECU Pin E104
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across IMV pins. If found
2 3.44 V : 1&2, 1&ground
any issues, rectify it. Start engine and check for DTC
0V : 2&ground
Perform following services in TDS:
1. IMV test
If still issue persists, Conduct IMV actuator test through TDS. If test failed, 2. IMV Buzz test
3
Replace IMV. Start engine and check for DTC If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
Perform following services in TDS:
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5
4 1. RESET IMV values test
Kms and check for DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 658 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 659 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0001-F0: IMV High side pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-F0 1. Faulty Wiring harness

2. Fault IMV
MIL ON for 15 secs 3. Faulty ECU 1. 30% Torque reduction
CEL BLINK

Fault System Summary:

Development Fault code F_M_IMV_HSD_SC2V_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7027 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check IMV actuator electrical failures. If found any issue, rectify it. Start
engine and check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 IMV Pin 1 - ECU Pin E105
2. Connector/Sensor physical damage
IMV Pin 2 - ECU Pin E104
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across IMV pins. If found
2 3.44 V : 1&2, 1&ground
any issues, rectify it. Start engine and check for DTC
0V : 2&ground
Perform following services in TDS:
1. IMV test
If still issue persists, Conduct IMV actuator test through TDS. If test failed, 2. IMV Buzz test
3
Replace IMV. Start engine and check for DTC If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
Perform following services in TDS:
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5
4 1. RESET IMV values test
Kms and check for DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0001-F1: IMV High side pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-F1 1. Faulty Wiring harness

2. Fault IMV
MIL ON for 15 secs 3. Faulty ECU 1. 30% Torque reduction
CEL BLINK

Fault System Summary:

Development Fault code F_M_IMV_HSD_SC2G_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7027 / 04

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Circuit diagram & Component images

Author: ERC Page 663 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check IMV actuator electrical failures. If found any issue, rectify it. Start
engine and check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 IMV Pin 1 - ECU Pin E105
2. Connector/Sensor physical damage
IMV Pin 2 - ECU Pin E104
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across IMV pins. If found
2 3.44 V : 1&2, 1&ground
any issues, rectify it. Start engine and check for DTC
0V : 2&ground
Perform following services in TDS:
1. IMV test
If still issue persists, Conduct IMV actuator test through TDS. If test failed, 2. IMV Buzz test
3
Replace IMV. Start engine and check for DTC If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
Perform following services in TDS:
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5
4 1. RESET IMV values test
Kms and check for DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0001-F2: IMV Low side pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-F2 1. Faulty Wiring harness

2. Fault IMV
MIL ON for 15 secs 3. Faulty ECU 1. 30% Torque reduction
CEL BLINK

Fault System Summary:

Development Fault code F_M_IMV_LSD_SC2V_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7029 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check IMV actuator electrical failures. If found any issue, rectify it. Start
engine and check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 IMV Pin 1 - ECU Pin E105
2. Connector/Sensor physical damage
IMV Pin 2 - ECU Pin E104
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across IMV pins. If found
2 3.44 V : 1&2, 1&ground
any issues, rectify it. Start engine and check for DTC
0V : 2&ground
Perform following services in TDS:
1. IMV test
If still issue persists, Conduct IMV actuator test through TDS. If test failed, 2. IMV Buzz test
3
Replace IMV. Start engine and check for DTC If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
Perform following services in TDS:
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5
4 1. RESET IMV values test
Kms and check for DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0001-F3: IMV Low side pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-F3 1. Faulty Wiring harness

2. Fault IMV
MIL ON for 15 secs 3. Faulty ECU 1. 30% Torque reduction
CEL BLINK

Fault System Summary:

Development Fault code F_M_IMV_LSD_SC2G_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7029 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check IMV actuator electrical failures. If found any issue, rectify it. Start
engine and check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
1 IMV Pin 1 - ECU Pin E105
2. Connector/Sensor physical damage
IMV Pin 2 - ECU Pin E104
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check voltages between below pins during Key ON
If no issues found in step1 , check for voltages across IMV pins. If found
2 3.44 V : 1&2, 1&ground
any issues, rectify it. Start engine and check for DTC
0V : 2&ground
Perform following services in TDS:
1. IMV test
If still issue persists, Conduct IMV actuator test through TDS. If test failed, 2. IMV Buzz test
3
Replace IMV. Start engine and check for DTC If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
Perform following services in TDS:
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5
4 1. RESET IMV values test
Kms and check for DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0088-94: IMV - Over pressure fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Blockage in Rail return line

Fault Code P0088-94 2. Malfunction of IMV
3. Malfunction of Rail pressure sensor
4. Faulty ECU
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_OVERPRESSURE_IMV_APV

System Fuel Injection System / IMV Over Pressure Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 02

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

If still issue persists, check for Blockage in rail return line. If found any Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Check IMV actuator electrical failures. If found any issue, rectify it. Drive
vehicle for 10Kms in highway and check for DTC
Refer circuit diagram:
1. Pin back out checks (ECU side and actuator side)
2 IMV Pin 1 - ECU Pin E105
2. Connector/Sensor physical damage
IMV Pin 2 - ECU Pin E104
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check rail pressure sensor related issues. If found any, rectify it. Drive
3
vehicle for 10Kms in highway and check for DTC
Perform following services in TDS:
1. IMV test
If still issue persists, perform actuator tests through TDS. If test is not 2. Rail pressure test
4 passed, replace respective component (IMV/HP Pump). Drive vehicle for 3. IMV Buzz test
10Kms in highway and check for DTC If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
Perform following services in TDS:
If still issue persists, Replace IMV/HP Pump. Drive vehicle for 10Kms in
5 1. RESET IMV values test
highway and check for DTC
2. RESET HP Pump values test
If still issue persists, Replace Rail pressure sensor. Drive vehicle for
6
10Kms in highway and check for DTC
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
7 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
8 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0325-00: Accelerometer sensor 1 failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0325-00 1. Faulty wiring harness

2. Fault Knock Sensor No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FCI_ACC_DECODE_APV_0

System Fuel Injection System / Knock Sensor

OBD Inducement Non-Inducement

SPN & FMI 731 / 07

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Knock sensor electrical connections. If found any issue, rectify it.
Drive vehicle for 5Kms & check for DTC
Refer terminal diagram
1. Pin back out checks (ECU side and actuator side)
1 Sensor pin 1 - ECU Pin 33
2. Connector/Sensor physical damage
Sensor pin 2 - ECU Pin 32
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check for other fault codes related to Fuel Injection system. If found any
2 Fault codes related to Injectors/Rail pressure/IMV/HPV
issue, rectify it. Drive vehicle for 5Kms & check for DTC
Check for Injector compression leak test. If found any issues, rectify it. Perform following services in TDS:
3
Drive vehicle for 5Kms & check for DTC 1. Compression leak test
If still issue persists, Replace Knock sensor. Drive vehicle for 5 Kms and
4
check for DTC
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for Select dataset based on Vehicle Identification
5
5 Kms and check for DTC number(VIN)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0330-00: Accelerometer sensor 2 failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0330-00 1. Faulty wiring harness

2. Fault Knock Sensor No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FCI_ACC_DECODE_APV_1

System Fuel Injection System / Knock Sensor

OBD Inducement Non-Inducement

SPN & FMI 6651 / 07

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Knock sensor electrical connections. If found any issue, rectify it.
Drive vehicle for 5Kms & check for DTC
Refer terminal diagram
1. Pin back out checks (ECU side and actuator side)
1 Sensor pin 1 - ECU Pin 31
2. Connector/Sensor physical damage
Sensor pin 2 - ECU Pin 30
3.Continuity checks (Open / Short circuit failures)
4. Ensure secondary lock present in the actuator
Check for other fault codes related to Fuel Injection system. If found any
2 Fault codes related to Injectors/Rail pressure/IMV/HPV
issue, rectify it. Drive vehicle for 5Kms & check for DTC
Check for Injector compression leak test. If found any issues, rectify it. Perform following services in TDS:
3
Drive vehicle for 5Kms & check for DTC 1. Compression leak test
If still issue persists, Replace Knock sensor. Drive vehicle for 5 Kms and
4
check for DTC
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for Select dataset based on Vehicle Identification
5
5 Kms and check for DTC number(VIN)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 680 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P016E-00: Rail Pressure Control - Negative Error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Fuel tank level is low

2. Issues in Low pressure line
Fault Code P016E-00 3. Fuel filter is clogged
4. HPV return line leakage (Common rail is
faulty)
5. High injector back leak (Injector fitment issue)
6. Faulty Injector
MIL ON for 15 secs 1. 30% Torque reduction
7. Faulty IMV/HP Pump
CEL ON 2. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_RPC_CTRL_NEG_APV

System Fuel Injection System / Rail pressure control Monitor

OBD Inducement Non-Inducement

SPN & FMI 18 / 16

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Press the hand primer 150 times to reach fuel near
Check fuel level in the tank. If diesel level is low, refill fuel. Drive vehicle
1 transfer pump inlet. Ensure no leakage or no air trap in
for 10 Kms and check for DTC
low-pressure circuit.
Press the hand primer 150 times to reach fuel near
If still issue persists, check for low pressure fuel lines. If found any issues,
2 transfer pump inlet. Ensure no leakage or no air trap in
rectify it. Drive vehicle for 10 Kms and check for DTC
low-pressure circuit.
Press the hand primer 150 times to reach fuel near
If still issue persists, check for whether fuel filter is clogged. If its clogged,
3 transfer pump inlet. Ensure no leakage or no air trap in
replace it with new one lines. Drive vehicle for 10 Kms and check for DTC
low-pressure circuit.
Perform following test through TDS,
If still issue persists, conduct actuator test. If found any issues, Replace 1. Rail pressure test
4
Common Rail. Drive vehicle for 10 Kms and check for DTC 2. If component replaced, perform RESET HP Pump values
test
If still issue persists, Open rail return line from HPV. Return line flow
Perform following test through TDS,
5 should be very minimal. If found too high, replace HPV/Common Rail.
1. RESET HP Pump values test
Drive vehicle for 10 Kms and check for DTC
If still issue persists, conduct Injector back leak test at idle if engine
Back leak thresholds :
starts. Otherwise perform during cranking. If collected quantity is out of
6 At cranking : <10 ml for cranking duration 8-10 secs
specification, refit injectors along with Quil & Quil nut assemply. Crank
At Idle : <160 ml for 5 mins
the engine and check for rail pressure buildup. Check for DTC
If still issue persists, perform injector buzz test. If found any issues, Perform following services in TDS:
7 Replace respective injector. Crank the engine and check for rail pressure 1. Write proper injector codes (I3C) in ECU after reading it
buildup. Check for DTC from new Injector
Perform following services in TDS:
If still issue persists, Replace HP pump. Crank the engine and check for
8 1. RESET IMV values test
rail pressure buildup. Check for DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
9 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P016F-00: Rail Pressure Control - Positive Error

Overview:

Fault Code Description Cause Effect on Vehicle

1. IMV/HPV connector issues

Fault Code P016F-00 2. Fuel line issues
3. Faulty IMV
4. Faulty HPV
5. Faulty Injectors
CEL ON 6. Faulty HP pump 1. 50% Torque reduction
2. 1700 rpm Engine speed limitation

Fault System Summary:

Development Fault code F_M_RPC_CTRL_POS_APV

System Fuel Injection System / Rail pressure control Monitor

OBD Inducement Non-Inducement

SPN & FMI 18 / 18

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check rail pressure sensor connector & IMV connector fitted properly. If
1 found loose, refit the connectors. Drive vehicle for 10 Kms and check for
DTC
If still issue persists, check for fuel lines (Low pressure & High pressure
2 lines). If found any issues, rectify it. Drive vehicle for 10 Kms and check
for DTC
Perform following services in TDS:
1. IMV test
2. Rail pressure test
If still issue persists, Conduct IMV actuator test through TDS. If test failed,
3 3. IMV Buzz test
Replace IMV. Drive vehicle for 10 Kms and check for DTC
If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
Perform following test through TDS,
If still issue persists, Conduct Rail pressure actuator test through TDS. If 1. Rail pressure test
4
test failed, Replace IMV. Drive vehicle for 10 Kms and check for DTC 2. If component replaced, perform RESET HP Pump values
test
If still issue persists, conduct Injector back leak test at idle if engine
Back leak thresholds :
starts. Otherwise perform during cranking. If collected quantity is out of
5 At cranking : <10 ml for cranking duration 8-10 secs
specification, refit injectors along with Quil & Quil nut assemply. Drive
At Idle : <160 ml for 5 mins
vehicle for 10 Kms and check for DTC
If still issue persists, perform injector buzz test. If found any issues, Perform following services in TDS:
6
Replace respective injector. Drive vehicle for 10 Kms and check for DTC 1. Cylinder Buzz test (1 to 4)
Perform following services in TDS:
If still issue persists, Replace HP pump. Crank the engine and check for
7 1. RESET IMV values test
rail pressure buildup. Drive vehicle for 10 Kms and check for DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
8 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 686 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0190-11: Rail pressure sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0190-11

MIL ON for 15 secs 1. 30% Torque reduction

1. Wiring harness issue
CEL BLINK 2. Faulty sensor 2. No Pedal Response
3. Engine speed increased to 1200 rpm
4. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_RAIL_PRES_LO_APV

System Fuel Injection System / Rail Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 157 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Rail pressure sensor electrical failures. If found any issue, rectify
and check for DTC
1 1. Pin back out checks (ECU side and sensor side) 16 – 32 V
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
If still issue persists, Replace Rail pressure sensor/Common Rail and
2
check for DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again

Voltages between pins during ignition ON,

1 and 2 -5V
1 and 3- 0V
4 If still issue persists, Replace respective wiring harness 2 and 3 -5V
1 and ground -5V
2 and ground -0V
3 and ground -5V

5 If still issue persists, Replace ECU

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0190-12: Rail pressure sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0190-12

MIL ON for 15 secs 1. 30% Torque reduction

1. Wiring harness issue
CEL BLINK 2. Faulty sensor 2. No Pedal Response
3. Engine speed increased to 1200 rpm
4. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_RAIL_PRES_HI_APV

System Fuel Injection System / Rail Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 157 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Rail pressure sensor electrical failures. If found any issue, rectify Refer circuit diagram and
and check for DTC When Ignition ON & Engine running condition, check
1 1. Pin back out checks (ECU side and sensor side) voltage between points:
2. Connector/Sensor physical damage 5V : 1&2, 2&3, 1&ground, 3&ground
3.Continuity checks (Open / Short circuit failures) 0V : 1&3, 2&ground
If still issue persists, Replace Rail pressure sensor/Common Rail and
2
check for DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0088-22: Rail pressure sensor - Signal too high

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0088-22

MIL ON for 15 secs 1. 30% Torque reduction

1. Wiring harness issue
CEL BLINK 2. Faulty sensor 2. No Pedal Response
3. Engine speed increased to 1200 rpm
4. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_RAILP_CAL_HIGH_APV

System Fuel Injection System / Rail Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 18 / 00

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram and
When Ignition ON & Engine running condition, check
Check Rail pressure sensor electrical failures. If found any issue, rectify
voltage between points:
and check for DTC
5V : 1&2, 2&3, 1&ground, 3&ground
1 1. Pin back out checks (ECU side and sensor side)
0V : 1&3, 2&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform Service Regeneration at IDLE after issue
rectification
If still issue persists, Replace Rail pressure sensor/Common Rail and Perform Service Regeneration at IDLE after issue
2
check for DTC rectification
Select dataset as per Vehicle configuration(VC)
3 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform Service Regeneration at IDLE after issue
rectification
Perform Service Regeneration at IDLE after issue
4 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform Service Regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0087-00: Rail pressure sensor - Signal too Low

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0087-00

MIL ON for 15 secs 1. 30% Torque reduction

1. Wiring harness issue
CEL BLINK 2. Faulty sensor 2. No Pedal Response
3. Engine speed increased to 1200 rpm
4. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_RAILP_CAL_LOW_APV

System Fuel Injection System / Rail Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 18 / 01

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Refer circuit diagram and
When Ignition ON & Engine running condition, check
Check Rail pressure sensor electrical failures. If found any issue, rectify
voltage between points:
and check for DTC
5V : 1&2, 2&3, 1&ground, 3&ground
1 1. Pin back out checks (ECU side and sensor side)
0V : 1&3, 2&ground
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Perform Service Regeneration at IDLE after issue
rectification
If still issue persists, Replace Rail pressure sensor/Common Rail and Perform Service Regeneration at IDLE after issue
2
check for DTC rectification
Select dataset as per Vehicle configuration(VC)
3 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform Service Regeneration at IDLE after issue
rectification
Perform Service Regeneration at IDLE after issue
4 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform Service Regeneration at IDLE after issue
rectification

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2BA7-00: DEF Level Empty Indication

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BA7-00
MIL ON 1. 20 kmpH Vehicle. Speed limitation
1. DEF/Urea tank is empty
SCR Lamp BLINK 2. Engine emissions go high
DEF Lamp BLINK

Fault System Summary:

Development Fault code F_M_J1939_IND_UR_MT_APV

System OBD Inducement / Inducement

OBD Inducement Tank Level Inducement

SPN & FMI 4096 / 31

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

1 Fill DEF / Urea and check for DTC

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Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P203F-00: DEF Level Low Indication

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P203F-00
SCR Lamp ON 1. DEF/Urea tank is low No Vehicle reaction
DEF Lamp ON

Fault System Summary:

Development Fault code F_M_J1939_IND_UR_WRN_APV

System OBD Inducement / Inducement

OBD Inducement Tank Level Inducement

SPN & FMI 5245 / 01

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

1 Fill DEF / Urea and check for DTC

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Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P203F-7B: DEF Level Near Empty Indication

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P203F-7B
SCR Lamp ON 1. DEF/Urea tank is near empty 1. 25% Torque reduction
DEF Lamp BLINK

Fault System Summary:

Development Fault code F_M_J1939_IND_UR_RTN_APV

System OBD Inducement / Inducement

OBD Inducement Tank Level Inducement

SPN & FMI 5245 / 17

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

1 Fill DEF / Urea and check for DTC

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Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P203F-21: DEF Level very Low Indication

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P203F-21 1. DEF/Urea tank level is very low

2. Communication error between DCU & Quality
No Vehicle reaction
sensor
SCR Lamp ON 3. Faulty sensor
DEF Lamp ON

Fault System Summary:

Development Fault code F_M_J1939_IND_UR_ESC_APV

System OBD Inducement / Inducement

OBD Inducement Tank Level Inducement

SPN & FMI 5245 / 18

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

1 Fill DEF / Urea and check for DTC
Check for Urea quality sensor related errors in DCU. If found any, rectify
2
and check for DTC
3 Replace Urea quality sensor. Check for DTC

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2BAA-00: Inducement - DEF Consumption fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BAA-00

1. Vehicle runs with 25% reduced torque

Injected DEF/Urea quantity is wrong due to after 10 hours
SCR Lamp ON
some system failure 2. Vehicle speed restricted to 20 KmpH after
20 hours
2. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_J1939_REAGNT_CNS_APV

System OBD Inducement / Inducement

Dosing Fault Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 4093 / 14

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

This DTC is a status message for warning lamp trigger to indicate driver
1
that level 1 inducement will begin after defined time.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2BA8-00: Inducement - DEF Dosing Stopped Fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BA8-00
1. Vehicle runs with 25% reduced torque
after 10 hours
SCR Lamp ON
DEF Dosing Stopped due to some system fault 2. Vehicle speed restricted to 20 KmpH after
20 hours
2. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_J1939_INTRP_DOSE_APV

System OBD Inducement / Inducement

Dosing Interruption Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 4095 / 14

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

This DTC is a status message for warning lamp trigger to indicate driver
1
that level 1 inducement will begin after defined time.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2BA9-00: Inducement - DEF Quality fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BA9-00

1. Vehicle runs with 25% reduced torque

Poor Urea Quality related errors present in the after 10 hours
SCR Lamp ON
system 2. Vehicle speed restricted to 20 KmpH after
20 hours
2. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_J1939_REAGNT_QUA_APV

System OBD Inducement / Inducement

DEF Quality Group

OBD Inducement
25% Torque Reduction after 10 Hrs; 20 KmpH Speed Limitation after 20 Hrs

SPN & FMI 4094 / 14

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

This DTC is a status message for warning lamp trigger to indicate driver
1
that level 1 inducement will begin after defined time.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2BAE-00: Inducement - DEF SCR System fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BAE-00
1. Vehicle runs with 25% reduced torque
after 36 hours
SCR Lamp ON
SCR system faults are present in the system 2. Vehicle speed restricted to 20 KmpH after
100 hours
2. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_J1939_IND_TAMPER_APV

System OBD Inducement / Inducement

Tampering Group
OBD Inducement
25% Torque Reduction after 36 Hrs; 20 KmpH Speed Limitation after 100 Hrs

SPN & FMI 4090 / 14

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

This DTC is a status message for warning lamp trigger to indicate driver
1
that level 1 inducement will begin after defined time.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0645-13: AC relay - Open Circuit

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P0645-13 2. Faulty Relay No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_AC_RELAY_OC_APV

System Vehicle System / AC Relay

OBD Inducement Non-Inducement

SPN & FMI 3583 / 05

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check AC Relay electrical connections. If found any issue, rectify it and
check for DTC
1 1. Pin back out checks (ECU side and relay side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace AC Relay and check for DTC
3 If still issue persists, Replace AC Compressor and check for DTC
4 If still issue persists, Replace wiring harness and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
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Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0645-12: AC relay - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P0645-12 2. Faulty Relay No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_AC_RELAY_SC2V_APV

System Vehicle System / AC Relay

OBD Inducement Non-Inducement

SPN & FMI 3583 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check AC Relay electrical connections. If found any issue, rectify it and
check for DTC
1 1. Pin back out checks (ECU side and relay side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace AC Relay and check for DTC
3 If still issue persists, Replace AC Compressor and check for DTC
4 If still issue persists, Replace wiring harness and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0645-11: AC relay - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P0645-11 2. Faulty Relay No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_AC_RELAY_SC2G_APV

System Vehicle System / AC Relay

OBD Inducement Non-Inducement

SPN & FMI 3583 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check AC Relay electrical connections. If found any issue, rectify it and
check for DTC
1 1. Pin back out checks (ECU side and relay side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace AC Relay and check for DTC
3 If still issue persists, Replace AC Compressor and check for DTC
4 If still issue persists, Replace wiring harness and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 727 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2138-00: Accelerator foot pedal correlation error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2138-00 1. Wiring harness issue

2. Faulty sensor
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_CORREL_APV

System Vehicle System / Acclerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 91 / 02

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 728 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Acc. Pedal sensor electrical failures. If found any issue, rectify and Refer circuit diagram and
check for DTC When Ignition ON & Engine running condition, check
1 1. Pin back out checks (ECU side and sensor side) voltage between points:
2. Connector/Sensor physical damage 5V : 1&3, 4&6, 3&ground, 4&ground
3.Continuity checks (Open / Short circuit failures) 0V : 1&ground, 6&ground
2 If still issue persists, Replace Acc. Pedal Module and check for DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 729 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 730 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2120-29: Accelerator foot Pedal Limph fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2120-29

CEL BLINK 1. Wiring harness issue 1. 30% Torque reduction

2. Faulty sensor
2. No Pedal Response
3. Engine speed increased to 1300 rpm

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_LIMPH_APV

System Vehicle System / Acclerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 91 / 31

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 731 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check for other Acc. Pedal related fault codes. If found any, rectify them
1
and Clear this DTC

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 733 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2120-71: Accelerator foot Pedal Stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2120-71 1. Faulty Bake Relay / Switch

2. Wiring harness issue
3. Faulty Acc. Pedal
CEL BLINK 4. Faulty ECU 1. No Pedal Response
2. Engine speed increased to 1300 rpm

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_STUCK_APV

System Vehicle System / Acclerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 91 / 07

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 734 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check for Brake switch related faults. If found any, rectify it. Drive vehicle
1
for 5 Kms and check for DTC
Check Brake switch signal status with pedal pressed/released condition
in diagnostic tool. If found any issues, check EMS brake relay and brake
When brake pedal pressued - Status in TDS should be
switch settings
"Pressed"
2 If still issue persists, replace EMS brake relay, drive the vehicle and check
When brake pedal is not pressed - Status in TDS should be
for DTC.
"Released"
If still issue persistis, adjust brake switch settings, drive the vehicle &
check for DTC
Check for Acc. Pedal functionality. If found any issues, rectify it OR
3
replace Acc. Pedal. Drive vehicle for 5 Kms and check for DTC
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 735 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 736 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2120-15: Accelerator Foot Pedal track1 sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2120-15 1. Wiring harness issue

2. Faulty sensor
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_T1_HI_APV

System Vehicle System / Acclerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 91 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 737 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Acc. Pedal track1 sensor electrical failures. If found any issue, Refer circuit diagram and
rectify and check for DTC When Ignition ON & Engine running condition, check
1 1. Pin back out checks (ECU side and sensor side) voltage between points:
2. Connector/Sensor physical damage 5V : 1&3, 4&6, 3&ground, 4&ground
3.Continuity checks (Open / Short circuit failures) 0V : 1&ground, 6&ground
2 If still issue persists, Replace Acc. Pedal Module and check for DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 738 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 739 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2120-11: Accelerator Foot Pedal track1 sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2120-11 1. Wiring harness issue

2. Faulty sensor
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_T1_LO_APV

System Vehicle System / Acclerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 91 / 04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 740 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Acc. Pedal track1 sensor electrical failures. If found any issue, Refer circuit diagram and
rectify and check for DTC When Ignition ON & Engine running condition, check
1 1. Pin back out checks (ECU side and sensor side) voltage between points:
2. Connector/Sensor physical damage 5V : 1&3, 4&6, 3&ground, 4&ground
3.Continuity checks (Open / Short circuit failures) 0V : 1&ground, 6&ground
2 If still issue persists, Replace Acc. Pedal Module and check for DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 741 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 742 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2125-15: Accelerator Foot Pedal track2 sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2125-15 1. Wiring harness issue

2. Faulty sensor
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_T2_HI_APV

System Vehicle System / Acclerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 29 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 743 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Acc. Pedal track2 sensor electrical failures. If found any issue, Refer circuit diagram and
rectify and check for DTC When Ignition ON & Engine running condition, check
1 1. Pin back out checks (ECU side and sensor side) voltage between points:
2. Connector/Sensor physical damage 5V : 1&3, 4&6, 3&ground, 4&ground
3.Continuity checks (Open / Short circuit failures) 0V : 1&ground, 6&ground
2 If still issue persists, Replace Acc. Pedal Module and check for DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 744 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 745 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2125-11: Accelerator Foot Pedal track2 sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2125-11 1. Wiring harness issue

2. Faulty sensor
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_T2_LO_APV

System Vehicle System / Acclerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 29 / 04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 746 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Acc. Pedal track2 sensor electrical failures. If found any issue, Refer circuit diagram and
rectify and check for DTC When Ignition ON & Engine running condition, check
1 1. Pin back out checks (ECU side and sensor side) voltage between points:
2. Connector/Sensor physical damage 5V : 1&3, 4&6, 3&ground, 4&ground
3.Continuity checks (Open / Short circuit failures) 0V : 1&ground, 6&ground
2 If still issue persists, Replace Acc. Pedal Module and check for DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 747 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 748 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0560-A3: Battery supply Voltage high fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0560-A3 1. Battery voltage is high

No Vehicle reaction
2. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_BATTERY_PBATT_HI_APV

System Vehicle System / Battery

OBD Inducement Non-Inducement

SPN & FMI 168 / 00

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 749 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the Battery voltage. Please check alternator HW & Wiring. If found Use Multimeter to check battery voltage. Voltage range -
1
any issue, please rectify it and check for DTC 16-32 V.
2 If still error persists, Replace battery
3 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 750 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 751 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0560-A2: Battery supply Voltage Low fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0560-A2 1. Battery voltage is low

No Vehicle reaction
2. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_BATTERY_PBATT_LO_APV

System Vehicle System / Battery

OBD Inducement Non-Inducement

SPN & FMI 168 / 01

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 752 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the Battery voltage. Please check alternator HW & Wiring. If found Use Multimeter to check battery voltage. Voltage range -
1
any issue, please rectify it and check for DTC 16-32 V.
2 If still error persists, Replace battery
3 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 753 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 754 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2141-A3: Battery Voltage - Channel 2 voltage high failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2141-A3 1. Wrong battery voltage output

2. Wrong alternator output
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_BOOST_VINJ_HI_APV

System Vehicle System / Battery

OBD Inducement Non-Inducement

SPN & FMI 2797 / 00

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 755 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the Battery voltage. Please check alternator HW & Wiring. If found Use Multimeter to check battery voltage. Voltage range -
1
any issue, please rectify it and check for DTC 16-32 V.
2 If still error persists, Replace battery
3 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 756 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 757 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2141-A2: Battery Voltage - Channel 2 voltage low failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2141-A2 1. Wrong battery voltage output

2. Wrong alternator output
CEL ON 1. 30% Torque reduction

Fault System Summary:

Development Fault code F_M_BOOST_VINJ_LO_APV

System Vehicle System / Battery

OBD Inducement Non-Inducement

SPN & FMI 2797 / 01

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 758 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the Battery voltage. Please check alternator HW & Wiring. If found Use Multimeter to check battery voltage. Voltage range -
1
any issue, please rectify it and check for DTC 16-32 V.
2 If still error persists, Replace battery
3 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 759 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 760 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0703-12: Brake Safety Switch - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0703-12 1.Brake switch wiring harness connector pin

short to battery No Vehicle reaction
2. Faulty Brake Switch
CEL ON

Fault System Summary:

Development Fault code F_M_BRAKE_SAFETY_S2B_APV

System Vehicle System / Brake Switch

OBD Inducement Non-Inducement

SPN & FMI 597 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 761 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Brake switch electrical connections. If found any issue, rectify it
and check for DTC
1 1. Pin back out checks (ECU side and relay side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Check brake switch setting. If found any, rectify it.. Change connectors or
2 Adjust the Brake switch manually.
sensor if required. Check for DTC
3 If still issue persists, Replace Brake switch and check for DTC

Author: ERC Page 762 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 763 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0504-64: Brake Switch & Safety Brake switch signals are not matching
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0504-64 1. Faulty Brake Switch

2. Brake switch wiring harness connector pin No Vehicle reaction
short to battery
CEL ON

Fault System Summary:

Development Fault code F_M_BRAKE_SWITCH_COH_APV

System Vehicle System / Brake Switch

OBD Inducement Non-Inducement

SPN & FMI 597 / 09

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Brake switch electrical connections. If found any issue, rectify it
and check for DTC
1 1. Pin back out checks (ECU side and relay side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Check brake switch setting. If found any, rectify it.. Change connectors or
2 Adjust the Brake switch manually.
sensor if required. Check for DTC
3 If still issue persists, Replace Brake switch and check for DTC

Author: ERC Page 765 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 766 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P083F-00: Clutch top & bottom switch signals are not coherent
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P083F-00 1. Wrong Clutch Switch Ply Setting

2. Wrong Clutch Switch No Vehicle reaction
3. Wrong wiring harness connection
CEL ON

Fault System Summary:

Development Fault code F_M_CLUTCH_COHERENCE_APV

System Vehicle System / Clutch Switch

OBD Inducement Non-Inducement

SPN & FMI 598 / 07

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Circuit diagram & Component images

Author: ERC Page 767 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check clutch switch setting. If found any, rectify it.. Change connectors or
1 Check both Top & Bottom switches
sensor if required. Check for DTC
Check Clutch switch electrical connections. If found any issue, rectify it
and check for DTC
2 1. Pin back out checks (ECU side and relay side) Ref Terminal diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Check Top & Bottom clutch switch states. If found any issues, rectify it /
3
replace switch. Check for DTC again

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 769 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0830-29: Clutch Top Switch Signal Invalid

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0830-29 1. Wrong Clutch Switch Ply Setting

2. Wrong Clutch Switch No Vehicle reaction
3. Wrong wiring harness connection
CEL ON

Fault System Summary:

Development Fault code F_M_CLUTCH_TOP_APV

System Vehicle System / Clutch Switch

OBD Inducement Non-Inducement

SPN & FMI 598 / 10

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Clutch swith status :
Check clutch switch setting. If found any, rectify it.. Change connectors or
1 Engaged / False - If clutch pedal not pressed
sensor if required. Check for DTC
Disengaged / True - If clutch pedal pressed
Check Clutch switch electrical connections. If found any issue, rectify it
and check for DTC
2 1. Pin back out checks (ECU side and relay side) Ref Terminal diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)

Author: ERC Page 771 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 772 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P1801-13: DPF Inhibit switch lamp - Open circuit failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P1801-13 2. Faulty Switch No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_DPF_INH_LAMP_OC_APV

System Vehicle System / DPF Inhibit switch lamp

OBD Inducement Non-Inducement

SPN & FMI 3695 / 05

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Circuit diagram & Component images

Author: ERC Page 773 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check DPF inhibit switch/lamp electrical connections. If found any issue,
rectify it and check for DTC
1 1. Pin back out checks (ECU side and relay side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace DPF inhibit switch and check for DTC
3 If still issue persists, Replace wiring harness and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 774 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Author: ERC Page 775 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P1801-12: DPF Inhibit switch lamp - Short to Battery failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P1801-12 2. Faulty Switch No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_DPF_INH_LAMP_SC2V_APV

System Vehicle System / DPF Inhibit switch lamp

OBD Inducement Non-Inducement

SPN & FMI 3695 / 03

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Circuit diagram & Component images

Author: ERC Page 776 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check DPF inhibit switch/lamp electrical connections. If found any issue,
rectify it and check for DTC
1 1. Pin back out checks (ECU side and relay side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace DPF inhibit switch and check for DTC
3 If still issue persists, Replace wiring harness and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 777 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Author: ERC Page 778 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P1801-11: DPF Inhibit switch lamp - Short to Ground failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P1801-11 2. Faulty Switch No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_DPF_INH_LAMP_SC2G_APV

System Vehicle System / DPF Inhibit switch lamp

OBD Inducement Non-Inducement

SPN & FMI 3695 / 04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 779 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check DPF inhibit switch/lamp electrical connections. If found any issue,
rectify it and check for DTC
1 1. Pin back out checks (ECU side and relay side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace DPF inhibit switch and check for DTC
3 If still issue persists, Replace wiring harness and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 780 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Author: ERC Page 781 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P25BA-9E: DPF Regeneration Request Switch - Stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P25BA-9E 1. Wiring harness issue

2. Faulty Switch No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_DPF_REGEN_SW_STK_APV

System Vehicle System / DPF Regen request switch

OBD Inducement Non-Inducement

SPN & FMI 3696 / 07

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Circuit diagram & Component images

Author: ERC Page 782 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check DPF inhibit switch/lamp electrical connections. If found any issue,
rectify it and check for DTC
1 1. Pin back out checks (ECU side and relay side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
If still issue persists, Replace DPF Regen Request switch and check for
2
DTC
3 If still issue persists, Replace wiring harness and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 783 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 784 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P260E-13: DPF Regeneration Request switch lamp - Open circuit failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P260E-13 2. Faulty Switch No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_DPF_SW_LMP_OC_APV

System Vehicle System / DPF Regen request switch lamp

OBD Inducement Non-Inducement

SPN & FMI 3696 / 05

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 785 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check DPF inhibit switch/lamp electrical connections. If found any issue,
rectify it and check for DTC
1 1. Pin back out checks (ECU side and relay side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
If still issue persists, Replace DPF Regen Request switch and check for
2
DTC
3 If still issue persists, Replace wiring harness and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 786 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 787 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P260E-12: DPF Regeneration Request switch lamp - Short to Battery failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P260E-12 2. Faulty Switch No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_DPF_SW_LMP_SC2V_APV

System Vehicle System / DPF Regen request switch lamp

OBD Inducement Non-Inducement

SPN & FMI 3696 / 03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 788 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check DPF inhibit switch/lamp electrical connections. If found any issue,
rectify it and check for DTC
1 1. Pin back out checks (ECU side and relay side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
If still issue persists, Replace DPF Regen Request switch and check for
2
DTC
3 If still issue persists, Replace wiring harness and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 789 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 790 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P260E-11: DPF Regeneration Request switch lamp - Short to Ground failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P260E-11 2. Faulty Switch No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_DPF_SW_LMP_SC2G_APV

System Vehicle System / DPF Regen request switch lamp

OBD Inducement Non-Inducement

SPN & FMI 3696 / 04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 791 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check DPF inhibit switch/lamp electrical connections. If found any issue,
rectify it and check for DTC
1 1. Pin back out checks (ECU side and relay side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
If still issue persists, Replace DPF Regen Request switch and check for
2
DTC
3 If still issue persists, Replace wiring harness and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 792 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 793 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0685-13: ECU Power relay electrical fault - Open Circuit

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0685-13 1. Improper Power Latch to ECU

2. ECU Main Relay Stuck open No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_DROPOUT_CU_RELAY_APV

System Vehicle System / ECU Power Relay

OBD Inducement Non-Inducement

SPN & FMI 1485 / 05

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Circuit diagram & Component images

Author: ERC Page 794 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and Use Multimeter to check battery voltage. Voltage range -
1
check for DTC 16-32 V.
Check Main relay & Power hold relay. If found any issue, Replace the
2
relay. Clear DTC & Check for DTC
3 Check for wiring harness. If found any issues, rectify it and check for DTC Relay Pin 85 - ECU Pin E42
4 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 795 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Author: ERC Page 796 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0685-73: ECU Power relay stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0685-73 1. Improper Power Latch to ECU

2. ECU Main Relay Stuck open No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_STUCK_CU_RELAY_APV

System Vehicle System / ECU Power Relay

OBD Inducement Non-Inducement

SPN & FMI 1485 / 07

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Circuit diagram & Component images

Author: ERC Page 797 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and Use Multimeter to check battery voltage. Voltage range -
1
check for DTC 16-32 V.
Check Main relay & Power hold relay. If found any issue, Replace the
2
relay. Clear DTC & Check for DTC
3 Check for wiring harness. If found any issues, rectify it and check for DTC Relay Pin 85 - ECU Pin E42
4 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 798 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Author: ERC Page 799 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0380-13: Glow plug - Circuit Open

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P0380-13 2. Faulty Glow plug No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_GLOW_PLUG_OC_APV

System Vehicle System / Glow Plug Monitor

OBD Inducement Non-Inducement

SPN & FMI 7576 / 05

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Circuit diagram & Component images

Author: ERC Page 800 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Glow plug relay electrical failures. If found any issue, rectify it and
check for DTC
1 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace Glow plug relay and check for DTC
If still issue persists, Replace Glow plug assembly wiring harness and
3
check for DTC
If still issue persists, Replace Glow plug relay wiring harness and check for
4
DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 801 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

Author: ERC Page 802 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0380-12: Glow plug - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P0380-12 2. Faulty Glow plug No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_GLOW_PLUG_SC_APV

System Vehicle System / Glow Plug Monitor

OBD Inducement Non-Inducement

SPN & FMI 7576 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Glow plug electrical failures. If found any issue, rectify it and check
for DTC
1 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace Glow plug relay and check for DTC
If still issue persists, Replace Glow plug assembly wiring harness and
3
check for DTC
If still issue persists, Replace Glow plug relay wiring harness and check for
4
DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0380-11: Glow plug - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P0380-11 2. Faulty Glow plug No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_GLOW_PLUG_SC2G_APV

System Vehicle System / Glow Plug Monitor

OBD Inducement Non-Inducement

SPN & FMI 7576 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Glow plug electrical failures. If found any issue, rectify it and check
for DTC
1 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace Glow plug relay and check for DTC
If still issue persists, Replace Glow plug assembly wiring harness and
3
check for DTC
If still issue persists, Replace Glow plug relay wiring harness and check for
4
DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 807 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0650-13: MIL lamp - Open Circuit

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0650-13 1. Wiring harness issue

2. Faulty cluster No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_ICI_MI_LAMP_OC_APV

System Vehicle System / MIL

OBD Inducement Non-Inducement

SPN & FMI 1213 / 05

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check MIL electrical failures. If found any issue, rectify it and check for
DTC
1 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace MIL relay and check for DTC
3 If still issue persists, Replace Instrument cluster and check for DTC

4 If still issue persists, Replace respective wiring harness and check for DTC

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0650-12: MIL lamp - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0650-12 1. Wiring harness issue

2. Faulty cluster No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_ICI_MI_LAMP_SC_APV

System Vehicle System / MIL

OBD Inducement Non-Inducement

SPN & FMI 1213 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check MIL electrical failures. If found any issue, rectify it and check for
DTC
1 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace MIL relay and check for DTC
3 If still issue persists, Replace Instrument cluster and check for DTC

4 If still issue persists, Replace respective wiring harness and check for DTC

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0650-11: MIL lamp - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0650-11 1. Wiring harness issue

2. Faulty cluster No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_ICI_MI_LAMP_SC2G_APV

System Vehicle System / MIL

OBD Inducement Non-Inducement

SPN & FMI 1213 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check MIL electrical failures. If found any issue, rectify it and check for
DTC
1 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace MIL relay and check for DTC
3 If still issue persists, Replace Instrument cluster and check for DTC

4 If still issue persists, Replace respective wiring harness and check for DTC

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P081D-24: Neutral Gear Switch signal stuck close fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Switch not present
Fault Code P081D-24 2. Switch malfunction No Vehicle reaction
3. Faulty Gearbox

Fault System Summary:

Development Fault code F_M_NEUTRAL_STK_CL_APV

System Vehicle System / Neutral gear switch

OBD Inducement Non-Inducement

SPN & FMI 604 / 20

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Neutral switch electrical failures. If found any issue, rectify it and
check for DTC
1 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
If still issue persists, Replace Neutral switch. Start engine and check for
2
DTC
If still issue persists, Replace respective wiring harness. Start engine and
3
check for DTC
If still issue persists, check any mechanical damage of gearbox. If found
4
any, rectify it and start engine. Check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P081D-23: Neutral Gear Switch signal Stuck open fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Switch not present
Fault Code P081D-23 2. Switch malfunction No Vehicle reaction
3. Faulty Gearbox

Fault System Summary:

Development Fault code F_M_NEUTRAL_STK_OP_APV

System Vehicle System / Neutral gear switch

OBD Inducement Non-Inducement

SPN & FMI 604 / 21

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Neutral switch electrical failures. If found any issue, rectify it and
check for DTC
1 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
If still issue persists, Replace Neutral switch. Drive vehicle for 5 Kms and
2
check for DTC
If still issue persists, Replace respective wiring harness. Drive vehicle for 5
3
Kms and check for DTC
If still issue persists, check any mechanical damage of gearbox. If found
4
any, rectify it and start engine. Drive vehicle for 5 Kms and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 822 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0615-13: Start relay - Circuit Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0615-13 1. Wiring harness issue

2. Faulty Relay No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_SR_LSD_OC_APV

System Vehicle System / Start Relay

OBD Inducement Non-Inducement

SPN & FMI 677 / 05

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Starter relay electrical failures. If found any issue, rectify it and
check for DTC
1 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace Starter relay and check for DTC
If still issue persists, Replace Starter relay wiring harness and check for
3
DTC
4 If still issue persists, Replace Starter Motor and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0615-F2: Start relay - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0615-F2 1. Wiring harness issue

2. Faulty Relay No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_SR_LSD_SC2V_APV

System Vehicle System / Start Relay

OBD Inducement Non-Inducement

SPN & FMI 6385 / 03

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Starter electrical failures. If found any issue, rectify it and check for
DTC
1 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace Starter relay and check for DTC
If still issue persists, Replace Starter relay wiring harness and check for
3
DTC
4 If still issue persists, Replace Starter Motor and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 828 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0615-F3: Start relay - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0615-F3 1. Wiring harness issue

2. Faulty Relay No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_SR_LSD_SC2G_APV

System Vehicle System / Start Relay

OBD Inducement Non-Inducement

SPN & FMI 6385 / 04

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Starter electrical failures. If found any issue, rectify it and check for
DTC
1 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
2 If still issue persists, Replace Starter relay and check for DTC
If still issue persists, Replace Starter relay wiring harness and check for
3
DTC
4 If still issue persists, Replace Starter Motor and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 831 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0500-31: Vehicle speed sensor - Signal loss during vehicle driving

Overview:

Fault Code Description Cause Effect on Vehicle

1. Sensor not connected / Wiring harness

Fault Code P0500-31 2. Instrument cluster Issues
No Vehicle reaction
3. Sensor is faulty
4. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_VSS_SIGNAL_LOSS_APV

System Vehicle System / Vehicle speed sensor

OBD Inducement Non-Inducement

SPN & FMI 1624 / 07

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Vehicle speed sensor electrical failures. If found any issue, rectify
it, drive vehicle for 5 Kms & check for DTC
1 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
Check Instrument cluster. If found any issues rectify it / replace
2
Instrument cluster, drive vehicle for 5 Kms & Check for DTC
If still issue persists, Replace Vehicle speed sensor. Drive vehicle for 5
3
Kms and Check for DTC
If still issue persists, Replace Vehicle speed wiring harness. Drive vehicle
4
for 5 Kms and Check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0500-01: Vehicle speed sensor - Signal not valid / Sensor not connected
Overview:

Fault Code Description Cause Effect on Vehicle

1. Other HW issues like ETV failure, Injector

Fault Code P0500-01
failure, DPF failures
2. Sensor not connected / Wiring harness
2. Sensor is faulty
CEL ON 3. Faulty ECU 1. 30% Torque reduction
2. 1500 rpm Engine speed limitation

Fault System Summary:

Development Fault code F_M_VSS_CONSISTENCY_APV

System Vehicle System / Vehicle speed sensor

OBD Inducement Non-Inducement

SPN & FMI 1624 / 02

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Circuit diagram & Component images

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check for other fault codes related to ETV & Injector codes in ECU. DPF
1 related faults(Clogging/higher soot) in DCU. If found any, rectify the same Read fault codes in ECU & DCU
and run vehicle for 5 km and confirm DTC
1. Keep gear in Neutral & put Handbrake ON
2. Indicated torque range :
If no faults observed, remove after ETV pipe & check whether ETV is Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
stuck closed physically by performing actuator tests (0%,50%&100%). If 3. Perform ETV Actuator test in TDS-ECU (Test Actuator
2
actuator is not moving, relpace ETV & perform tests mentioned in Tab- 0%,50% & 100%)
specification. 3. ETV error allowed during actuator test : +/- 5%
4. Perform ETV Actuator learning test through TDS-ECU if
ETV replaced
1. Keep gear in Neutral & put Handbrake ON
If still issue persists, detach / disconnect ATS from ETV pipe & check
2. Indicated torque range :
indicated torque in Low Idle & high Idle. If torque found within
3 Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
specification, then DPF might be having issues. Remove/Replace DPF &
3. Perform DPF replacement service through TDS-DCU if
check for DTC.
DPF is replaced
If still issue persists, Check Vehicle speed sensor electrical failures. If
found any issue, rectify it and check for DTC
4 1. Pin back out checks (ECU side and Actuator side) Refer circuit diagram
2. Connector/Sensor physical damage
3.Continuity checks (Open / Short circuit failures)
If found any issues in step 1, after rectification drive vehicle for 5 Kms
5
and Check for DTC
If still issue persists, Replace Vehicle speed sensor. Drive vehicle for 5
6
Kms and Check for DTC
If still issue persists, Replace Vehicle speed wiring harness. Drive vehicle
7
for 5 Kms and Check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
8 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 837 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 838 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2226-04: ECU Barometric Sensor Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2226-04

1. Barometric pressure sensor fitted on the ECU
is not working.
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_BARO_CONT_DG_APV

System ECU/ Barometric Sensor

OBD Inducement Non-Inducement

SPN & FMI 108 / 12

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Circuit diagram & Component images

Author: ERC Page 839 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

Location and Component Image:

Author: ERC Page 840 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2226-34: ECU Barometric Sensor Failure (Value out of Range- High)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2226-34

1. Barometric pressure sensor value reads very
high (Out of normal operating range)
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_BARO_OOR_HI_APV

System ECU/ Barometric Sensor

OBD Inducement Non-Inducement

SPN & FMI 108 / 09

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Circuit diagram & Component images

Author: ERC Page 841 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

Location and Component Image:

Author: ERC Page 842 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2226-33: ECU Barometric Sensor Failure (Value out of Range- Low)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2226-33

1. Barometric pressure sensor value reads very
low (Out of normal operating range)
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_BARO_OOR_LO_APV

System ECU/ Barometric Sensor

OBD Inducement Non-Inducement

SPN & FMI 108 / 09

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 843 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

Location and Component Image:

Author: ERC Page 844 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0641-08: Failure of Microcontroller inside ECU for Injector

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0641-08

1. Failure of Microcontroller inside ECU for
Injector.
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_C2PS_COM_SDG_APV

System ECU/ Microcontroller

OBD Inducement Non-Inducement

SPN & FMI 3509 / 19

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 845 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

Location and Component Image:

Author: ERC Page 846 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P16D2-01: Failure of Microcontroller inside ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P16D2-01

1. Failure of Microcontroller inside ECU

CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OUT_REG_BOOST_APV

System ECU/ Microcontroller

OBD Inducement Non-Inducement

SPN & FMI 3514 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 847 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

Location and Component Image:

Author: ERC Page 848 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P1697-01: Failure of Microcontroller inside ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P1697-01

1. Failure of Microcontroller inside ECU

CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OUT_REG_BUCKH_APV

System ECU/ Microcontroller

OBD Inducement Non-Inducement

SPN & FMI 3514 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 849 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

Location and Component Image:

Author: ERC Page 850 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P16A3-01: Failure of Microcontroller inside ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P16A3-01

1. Failure of Microcontroller inside ECU

CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OUT_REG_BUCKL_APV

System ECU/ Microcontroller

OBD Inducement Non-Inducement

SPN & FMI 3514 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 851 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

Location and Component Image:

Author: ERC Page 852 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0641-01: Failure of Microcontroller inside ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0641-01

1. Failure of Microcontroller inside ECU

CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OUT_REG_GLOBAL_APV

System ECU/ Microcontroller

OBD Inducement Non-Inducement

SPN & FMI 3509 / 07

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Circuit diagram & Component images

Author: ERC Page 853 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

Location and Component Image:

Author: ERC Page 854 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P06D2-00: Failure of Microcontroller inside ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P06D2-00

1. Failure of Microcontroller inside ECU

CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OUT_REG_VCC_APV

System ECU/ Microcontroller

OBD Inducement Non-Inducement

SPN & FMI 3513 / 12

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Circuit diagram & Component images

Author: ERC Page 855 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

Location and Component Image:

Author: ERC Page 856 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P1641-01: Failure of Microcontroller inside ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P1641-01

1. Failure of Microcontroller inside ECU

CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OUT_REG_VCCL_APV

System ECU/ Microcontroller

OBD Inducement Non-Inducement

SPN & FMI 3514 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 857 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

Location and Component Image:

Author: ERC Page 858 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P1651-01: Failure of Microcontroller inside ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P1651-01

1. Failure of Microcontroller inside ECU

CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OUT_REG_VCCL2_APV

System ECU/ Microcontroller

OBD Inducement Non-Inducement

SPN & FMI 3514 / 12

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Circuit diagram & Component images

Author: ERC Page 859 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

Location and Component Image:

Author: ERC Page 860 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0641-01: ECU 5 Voltage Supply Issue For Channel 1 Sensors

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0641-01

1. ECU internal 5V supply issue due to associated
sensors or Microcontroller failure inside the ECU
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OUT_REG_VREF1_APV

System Wiring Harness/ Channel 1 Sensors/ECU

OBD Inducement Non-Inducement

SPN & FMI 3509 / 12

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Circuit diagram & Component images

Author: ERC Page 861 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and
1 16-32V
check for DTC

Check mentioned sensor electrical failures. If found any issue, rectify and Sensors needs to be checked:
check for DTC 1. Accelerator Pedal Sensor
2 1. Pin back out checks (ECU side and sensor side) 2. Fan Speed sensor
2. Connector/Sensor physical damage 3. Turbocharger position sensor
3.Continuity checks (Open / Short circuit failures) 4. Exhaust throttle sensor
Remove sensors mentioned in step 2, one by one. If fault gets resolved
3 (Fault will go to memorized state), Replace that specific sensor. Start
engine and check for DTC
4 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 862 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0651-01: ECU 5 Voltage Supply Issue For Channel 2 Sensors

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0651-01

1. ECU internal 5V supply issue due to associated
sensors or Microcontroller failure inside the ECU
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OUT_REG_VREF2_APV

System Wiring Harness/ Channel 2 Sensors/ECU

OBD Inducement Non-Inducement

SPN & FMI 3510 / 12

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Circuit diagram & Component images

Author: ERC Page 863 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

Sensors need to be checked :

Check mentioned sensor electrical failures. If found any issue, rectify and
1. Accelerator Pedal Sensor
check for DTC
2. Vehicle Speed Sensor
2 1. Pin back out checks (ECU side and sensor side)
3. EGR Position Sensor
2. Connector/Sensor physical damage
4. TMAP Sensor
3.Continuity checks (Open / Short circuit failures)
5. PFM Sensor
Remove sensors mentioned in step 2, one by one. If fault gets resolved,
3
Replace particular sensor. Start engine and check for DTC
4 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 864 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0697-01: ECU 5 Voltage Supply Issue For Channel 3 Sensors

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0697-01

1. ECU internal 5V supply issue due to associated
sensors or Microcontroller failure inside the ECU
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OUT_REG_VREF3_APV

System Wiring Harness/ Channel 3 Sensors/ECU

OBD Inducement Non-Inducement

SPN & FMI 3511 / 12

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Circuit diagram & Component images

Author: ERC Page 865 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

Check mentioned sensor electrical failures. If found any issue, rectify and
check for DTC Sensors need to be checked :
2 1. Pin back out checks (ECU side and sensor side) 1. Rail pressure Sensor
2. Connector/Sensor physical damage 2. CAM sensor
3.Continuity checks (Open / Short circuit failures)
Remove sensors mentioned in step 2, one by one. If fault gets resolved,
3
Replace particular sensor. Start engine and check for DTC
4 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 866 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P16D2-75: Thermal shutdown due to ECU Microcontroller Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P16D2-75

1. Thermal shutdown due to ECU
Microcontroller failure.
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_T_SDWN_BOOST_APV

System ECU

OBD Inducement Non-Inducement

SPN & FMI 3514 / 12

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Circuit diagram & Component images

Author: ERC Page 867 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

2 Flash the ECU Select dataset as per Vehicle configuration(VC)

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 868 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P1697-75: Thermal shutdown due to ECU Microcontroller Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P1697-75

1. Thermal shutdown due to ECU
Microcontroller failure.
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_T_SDWN_BUCKH_APV

System ECU

OBD Inducement Non-Inducement

SPN & FMI 3514 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 869 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

2 Flash the ECU Select dataset as per Vehicle configuration(VC)

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 870 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P16A3-75: Thermal shutdown due to ECU Microcontroller Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P16A3-75

1. Thermal shutdown due to ECU
Microcontroller failure.
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_T_SDWN_BUCKL_APV

System ECU

OBD Inducement Non-Inducement

SPN & FMI 3514 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 871 of 896

Copyright by TATA MOTORS Ltd.

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

2 Flash the ECU Select dataset as per Vehicle configuration(VC)

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 872 of 896

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 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P1641-75: Thermal shutdown due to ECU Microcontroller Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P1641-75

1. Thermal shutdown due to ECU
Microcontroller failure.
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_T_SDWN_VCCL_APV

System ECU

OBD Inducement Non-Inducement

SPN & FMI 3514 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 873 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

2 Flash the ECU Select dataset as per Vehicle configuration(VC)

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 874 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P1651-75: Thermal shutdown due to ECU Microcontroller Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P1651-75

1. Thermal shutdown due to ECU
Microcontroller failure.
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_T_SDWN_VCCL2_APV

System ECU

OBD Inducement Non-Inducement

SPN & FMI 3514 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 875 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

2 Flash the ECU Select dataset as per Vehicle configuration(VC)

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 876 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0641-75: Thermal shutdown due to ECU Microcontroller Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0641-75

1. Thermal shutdown due to ECU
Microcontroller failure.
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_T_SHTDWN_GLOBAL_APV

System ECU

OBD Inducement Non-Inducement

SPN & FMI 3509 / 07

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 877 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

2 Flash the ECU Select dataset as per Vehicle configuration(VC)

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 878 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0651-75: Thermal shutdown due to ECU Microcontroller Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0651-75

1. Thermal shutdown due to ECU
Microcontroller failure.
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_T_SHTDWN_VREF2_APV

System ECU

OBD Inducement Non-Inducement

SPN & FMI 3510 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 879 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

2 Flash the ECU Select dataset as per Vehicle configuration(VC)

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 880 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0697-75: Thermal shutdown due to ECU Microcontroller Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0697-75

1. Thermal shutdown due to ECU
Microcontroller failure.
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_T_SHTDWN_VREF3_APV

System ECU

OBD Inducement Non-Inducement

SPN & FMI 3511 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 881 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

2 Flash the ECU Select dataset as per Vehicle configuration(VC)

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 882 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0520-12: Engine oil pressure sensor short to battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0520-12 1. Oil Pressure Sensor connector wiring

harness issue.
2. Oil Pressure Sensor switch faulty
3. Faulty ECU
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OIL_PRESS_CNTS_HI_APV

System Wiring Harness/ Oil Pressure Sensor/ ECU

OBD Inducement Non-Inducement

SPN & FMI 100/03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 883 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

Check oil pressure sensor wiring harness connector for pin back out,
2 terminal damage, If observed any issue repair or replace the wiring
harness

If problem persists, replace with a new oil pressure sensor & check the
3
error after engine starting

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If problem persists, replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 884 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0520-14: Engine oil pressure sensor short to ground or open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0520-14 1. Oil Pressure Sensor connector wiring

harness issue.
2. Oil Pressure Sensor switch faulty
3. Faulty ECU
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OIL_PRESS_CNTS_LO_APV

System Wiring Harness/ Oil Pressure Sensor/ ECU

OBD Inducement Non-Inducement

SPN & FMI 100/04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 885 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

Check oil pressure sensor wiring harness connector for pin back out,
2 terminal damage, If observed any issue repair or replace the wiring
harness

If problem persists, replace with a new oil pressure sensor & check the
3
error after engine starting

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If problem persists, replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 886 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0195-15: Engine Oil temp Sensor short to battery or open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0195-15 1. Oil Temperature Sensor connector

wiring harness issue.
2. Oil Temperature Sensor faulty
3. Faulty ECU
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OIL_TEMP_SENS_HI_APV

System Wiring Harness/ Oil Temperature Sensor/ ECU

OBD Inducement Non-Inducement

SPN & FMI 175/03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 887 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

Check oil temperature sensor wiring harness connector for pin back out,
2 terminal damage, If observed any issue repair or replace the wiring
harness

If problem persists, replace with a new oil temperature sensor & check
3
the error after engine starting

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If problem persists, replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 888 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P0195-11: Engine Oil temp sensor short to ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0195-11 1. Oil Temperature Sensor connector

wiring harness issue.
2. Oil Temperature Sensor faulty
3. Faulty ECU
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OIL_TEMP_SENS_LO_APV

System Wiring Harness/ Oil Temperature Sensor/ ECU

OBD Inducement Non-Inducement

SPN & FMI 175/04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 889 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

Check oil temperature sensor wiring harness connector for pin back out,
2 terminal damage, If observed any issue repair or replace the wiring
harness

If problem persists, replace with a new oil temperature sensor & check
3
the error after engine starting

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If problem persists, replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 890 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2CEF-13: Oil Thermostat Open circuit Fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2CEF-13 1. Oil Thermostat not connected to wiring

harness or wiring harness issue
2. Faulty Oil Thermostat
3. Faulty ECU
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OIL_THRMST_OC_APV

System Wiring Harness/ Oil Thermostat/ ECU

OBD Inducement Non-Inducement

SPN & FMI 4813/05

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 891 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

Check oil thermostat connected to wiring harness or connector pin back

2 out, terminal damage, If observed any issue repair or replace the wiring
harness

If problem persists, replace with a new oil thermostat & check the error
3
after engine starting

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If problem persists, replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 892 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2CEF-11: Oil Thermostat short circuit to ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2CEF-11 1. Oil Thermostat not connected to wiring

harness or wiring harness issue
2. Faulty Oil Thermostat
3. Faulty ECU
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OIL_THRMST_SC2G_APV

System Wiring Harness/ Oil Thermostat/ ECU

OBD Inducement Non-Inducement

SPN & FMI 4813/04

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 893 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

Check oil thermostat connected to wiring harness or connector pin back

2 out, terminal damage, If observed any issue repair or replace the wiring
harness

If problem persists, replace with a new oil thermostat & check the error
3
after engine starting

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If problem persists, replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 894 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

P2CEF-12: Oil Thermostat short circuit to battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2CEF-12 1. Oil Thermostat not connected to wiring

harness or wiring harness issue
2. Faulty Oil Thermostat
3. Faulty ECU
CEL 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OIL_THRMST_SC2V_APV

System Wiring Harness/ Oil Thermostat/ ECU

OBD Inducement Non-Inducement

SPN & FMI 4813/03

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 895 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.0
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 31-01-2023

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and 16-32V
1
check for DTC

Check oil thermostat connected to wiring harness or connector pin back

2 out, terminal damage, If observed any issue repair or replace the wiring
harness

If problem persists, replace with a new oil thermostat & check the error
3
after engine starting

Perform following services in TDS:

1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If problem persists, replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 896 of 896

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent