MAHINDRA SCORPIO CRDe

SCORPIO CRDe
(ALL NEW)
TROUBLE SHOOTING GUIDE

DIAGNOSTIC GUIDE – ENGINE MANAGEMENT SYSTEM
CONFIDENTIAL
RELEASED BY :
• ONLY FOR INTERNAL CIRCULATION WITHIN
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• ALWAYS CHECK FOR THE LATEST VERSION MAHINDRA & MAHINDRA LTD – NASHIK
REV 0 – MAY 2006
Automotive Sector
List of contents
Sr. No. Description Page

No.
1 Guide Lines for Trouble shooting 07
2 Accelerator Pedal – APP 1 14
3 Accelerator Pedal – APP 2 19
4 HFM Sensor 24
5 Air Temperature Sensor 29
6 Cam shaft speed sensor 33
7 Crank shaft speed sensor 37
8 Terminal 15 41
9 ADC Monitoring 43
10 Atmospheric Pressure Sensor 44
11 Battery 46
12 Brake Switch 47
13 Clutch Switch 51
14 Communication Monitoring 56
15 Controller & TPU Monitoring 57
16 Coolant Overheat Lamp – Power Stage 58
17 Coolant Temperature Sensor 61
18 Cruise Control 65
19 ECU Monitoring 70
20 EEPROM Monitoring 71
21 EGR Power Stage 72
22 Error Path for tachometer Signal 75
23 Error Path for Coolant Temperature Output 78
24 Error Path of Offset between Camshaft & Crankshaft 81
25 Fault Path of Air condition Power Stage 83
26 Fuel Temperaure Sensor 87
27 Glow Control Relay Actuator 91
Scorpio CRDe ( All New) Diagnostic Manual - Rev 1 Page 1 of 6

Automotive Sector
Sr. No. Diagnostic Item Page
No.
28 Injector Energising Time 94
29 Injector Power Stage – Chip Specific Errors 95
30 K Line – Diagnostic Connector 96
31 Main Relay 98
32 Metering Unit Pump – Power Stage 102
33 Monitoring Module – Communication Monitoring 106
34 Power Stage Monitoring 107
35 Power Stage Voltage Monitoring 108
36 Rail Pressure Sensor 109
37 Sensor Supply Monitoring – 1 113
38 Sensor Supply Monitoring – 2 117
39 System lamp – Power stage Fault Status 120
40 Vehicle Speed Sensing 123
41 System Lamp Status 126
42 Circuit Diagram 136
43 Wiring Harness , Inter-connectors & Ground Connection 137

Automotive Sector
Index -- DTC codes
DTC Diagnostic Item Page

Code No.
P-0102 Voltage below lower Limit 20
P-0103 Voltage above upper Limit 20
P-0107 Voltage below lower limit 40
P-0108 Voltage above upper limit 40
P-0112 Voltage below lower limit. 25
P-0113 Voltage above upper limit. 25
P-121A Main relay does not open in time 97
P-121B Main relay opens too early 97
P-160A No load 74
P-160B Excess temperature 74
P-160C Short Circuit to Battery 71
P-160D Short Circuit to Ground 71
P-160E No Load 71
P-161F below lower limit of energizing time-Injector 1 92
P-162A Communication error of CJ940 52
P-162B EEPROM: error during last read operation 67
P-162C EEPROM: error during last write operation 67
P-162D EEPROM: default value used 67
P-165E Short Circuit to Battery 54
P-165F Short Circuit to Battery 54

Automotive Sector
Code No.
P-0193 Voltage above upper limit. 109
P-0335 No crankshaft signal 34
P-0336 Wrong crankshaft signal 34
P-0340 No camshaft signal 30
P-0341 Wrong camshaft signal 30
P-0403 No Load 68
P-0404 Excess Temperature 68
P-0405 Short Circuit Ground 68
P-0406 Short Circuit Battery 68
P-0500 HW signal for vehicle speed not valid 122
P-0501 Vehicle speed not plausible with injection mass and engine 122
P-0503 d
Exceeding of the maximum vehicle speed 122
P-0575 Plausibility error for analog signal 61
P-0576 SRC MIN error for analog signal 61
P-0577 SRC MAX error for analog signal 61
P-0704 Clutch signal is not plausible 47
P-1120 Plausibility with APP2 violated 11
P-1210 Chip-specific errors : CY33X internal reset / clock loss / 93
under voltage
P-1211 Chip-specific errors: CY33X is unlocked / CY33X init error 93
P-1212 Chip-specific errors:CY33X is in Test mode 93
P-1213 Chip-specific errors: CY33X SPI communication error 93

/checksum/read back

Automotive Sector
Code No.
P-1214 Chip-specific errors ->CY33X internal parity error 93
P-1215 Chip-specific errors ->CY33X internal program flow error 93
P-1216 Chip-specific errors ->CY33X check of inv. YSEL during ON 93

failed
P-1217 Chip-specific errors ->CY33X ON timeout for at least 1 93
cylinder
P-1220 Plausibility with APP1 violated 16
P-1221 Accelerator Pedal signal not plausible with brake 16
P-1250 No Load 102
P-1252 Short Circuit to Battery 102
P-1253 Short Circuit to Ground 102
P-1340 Offset between camshaft and crankshaft 77
P-1530 Short Circuit to battery 81
P-1531 Short Circuit to ground 81
P-1532 No load 81
P-1600 ADC monitoring : SRC-High error of ADC reference voltage 39
P-1601 ADC monitoring : SRC-Low error of ADC reference voltage 39
P-1602 ADC monitoring : Test impulse error 39
P-1603 ADC monitoring : ADC queue error 39
P-1608 Short circuit to battery 74
P-1609 Short circuit to ground 74
P-1621 below lower limit of energizing time -Injector 2 92
P-1623 below lower limit of energizing time-Injector 3 92
P-1625 below lower limit of energizing time-Injector 4 92
P-1631 (Hardware) CJ940 upper limit: internal supply voltage upper 108
limit

Automotive Sector
Code No.
P-1632 (Hardware) CJ940 lower limit: internal supply voltage lower 108
limit
P-1638 Set, if error-counter of Watchdog or controller are not 66
plausible or the system must shut down
P-1641 Test of redundant shut off paths during initialization: Watch 107
dog switch off path defect
P-1642 Test of redundant shut off paths during initialization: 107
Voltage monitoring upper limit shut off path defect
P-1643 Test of redundant shut off paths during initialization: 107
Voltage monitoring lower limit shut off path defect
P-1656 No Load 116
P-1658 No Terminal T15 signals detected 37
P-1659 Deviation between TPU and system time 53
P-1660 No Load 54
P-1664 The fault path contains the supervision of the SPI-Handler 106
Set, if SPI-communication failed
P-1791 Brake signals not plausible 43
P-1792 Brake signal is defective 43
P-1888 Short Circuit to Ground 88
P-1889 No Load 88
P-1890 Excess temperature 88

Automotive Sector
Guidelines for Troubleshooting
The most basic check that has to be done by the technician is the check
lamp status. (This has also to be done by customer.)
When the Ignition is switched ON. Then the System lamp & overheat lamp
glows for 2-3 sec after turning ON the ignition. If the light does not glow
OFF but remains either blinking or is continuously ON. Then the fault has
to be analyzed using the “Mahindra Insight”. However before going into
the fault diagnosis per se it is worthwhile to do some basic (and the most
common mistakes) checks.
For the Fault diagnosis, besides the diagnostic tool “Mahindra Insight”, a
good multimeter is essential (we recommend use of digital mutimeter)
During the fault diagnosis, under no circumstance, the traditional

method of shorting on to the ground is acceptable. If that practice is
resorted to then it may led to sensor failure.
If any arc welding has to be done then it is essential that besides

removing the battery cable, it is essential that the separate body earth
attached to the ECU has been removed. If not done then the spikes during
welding will cause ECU damage.
At this point of time we would also like to caution that for any trouble
shooting, please avoid the shortcut of jumping the steps and directly
replacing the suspect sensor/actuator.
If the root cause e.g. a terminal loose in the connector is not addressed,
then the problem will get repeated. It will lead to higher cost of repair as
well higher customer dissatisfaction.
The trouble-shooting manual is done in a manner that all the trouble

codes relevant to a sensor/ function are grouped together. After giving
the label of the codes, a brief description of the working, then what are
the conditions under which the DTC can occur. The wiring along with the
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio CRDe ( All New) Diagnostic Manual-
Guidelines for Trouble
Shooting Ver 1 Apr 06
Automotive Sector
socket view is given. The trouble-shooting guide for that group of codes is
in the last.
Preliminary trouble shooting (common for all trouble codes)
• Before checking for any wiring connections for faults, check that all
the FUSES are OK.
• Ensure that the connectors are tightened properly to the sensors.
• Ensure battery voltage is between 8 to 16 Volts. It should not go

below 8 volt, even during cranking.
• Communication to the diagnostic tester will not be established in

following conditions:
1. Main relay not working (In this case engine will not start & no lamp
test)
2. Ignition switch to T15 connection has problems.
3. Diagnostic connector continuity problem (In this case engine will start
& lamp test OK.)
4. Charging for the Simputer very low.
5. Interface box failure (In this case engine will start)
• Following errors can be checked only when Engine is being

cranked/ attempted to crank.
1. Crankshaft
2. Camshaft
3. EGR No load
4. Injector related.

Automotive Sector
If no errors are registered with ignition on, (In diagnostic tester)
attempt to crank & while cranking check for error codes of the
above.
The following errors can only be checked when the vehicle is

being driven:
1. Vehicle speed sensor.
• If the battery voltage falls below 8 Volts, the ECU will stop
functioning. And since it stops functioning, it will not even register the
complaint.
• Check if the Diagnostic is showing any error. Also check the status if it
is healed or if it is present. A healed error will be in green font. A
present font will be in red font. Clear the memory and check if the
error reappears.
At this point of time it will be worthwhile to note that if an error has

become healed by itself. It is indicating that there was an error, which
went off by itself. Normally that indicates loose connection. Or oxidation
of the connectors
If this step is skipped than it is highly probable that since no

corrective action has been taken the problem will occur again.
And the next time the problem may not get healed
automatically. As a general thumb rule, any loose connection
if not attended tends to become worst over a period of time.
Try to see if the problem can be recreated, either by shaking the wires/
slight twisting or in the worst case, slight spraying of the water. Or
blowing a dryer on top of the suspect components.
Please take care to touch only the affected wires

(not any random wire).

Automotive Sector
Refer to the circuit diagrams. It has to be remembered that unnecessary
removal and refitting the connectors can cause bent pins/ loose
connection/ higher probability of oxidation. Causing no or intermittent
connection. Thus the Technician may land up with a new set of problems)
• For errors causing dis-comfort to driver, system lamp will be ON. For
less severe error, (Which will only deteriorate the performance)
system lamp will blink. For some of the faults, which are least severe,
the system lamp will remain off, (but those errors can be seen through
tester).
• Check for the connector’ conditions. Many times continuity is not

obtained if the connectors are contaminated/ oxidation.
• Engine will go to limp home in following condition:

Automotive Sector
1. Accelerator pedal errors ( it will run with constant engine speed of
1200 rpm)
• General sequence of trouble shooting: (To be done after basic checks

of Fuse, Battery voltage)
1. Check for connector’ tightness with respect to the sensor.

2. Check for connector’ conditions. (e.g. pins getting corroded/oxidized)
3. Check for continuity between the sensor/ component & the
corresponding ECU connectors.
4. Check for input / output voltage (Check voltages are within
specification)
5. Check resistance values (Where ever applicable)
6. Still the problem not solved, replace the corresponding sensor/
component with the known OK same type component & check whether
error get solved (After clearing memory status). If yes then only
remove the faulty component.
• For the below mention errors, there is no electrical fault but the cause
is leakage in diesel line (high pressure or low-pressure circuit) or air
lock in diesel line.
1. P1192
2. P1193
3. P1194
4. P1195
5. P1196
These errors are related to hydraulics system. For e.g. due to air lock in
the diesel line, rail pressure does not build up and the error P1192
highlighted.
• For errors like voltage above/below limits or short circuit to

ground/battery, checking the corresponding output voltage from
Mahindra Insight can do confirmation.

Automotive Sector
For e.g. if error related to Rail pressure sensor voltage above upper
limit comes, check the Rail pressure sensor raw voltage through
“Mahindra Insight”
• Before changing any components, ensure that the error is cleared at

least 2-3 times, if after that also the error reappears, the error
reappears.
• Trouble shooting methods related to Turbocharger (Noise, loss of pick

up, smoke) & EGR valve will continue to be same as existing chain
drive engine.
For the following complaints no error codes will appear in the Diagnostic :
Complaint : Vehicle not responding to accelrator. May be permanent or

random behaviour.
Code : none
Proabale reason : The wires between the ECU to accelrator pedal is
having loose connection or the connector has become loose. Normally this
issue has been reported in the interconnector.
Reason it is not detected : When there is loose connection or the
connector has come off, then the Accelrator pedal is detecting the 0
voltage. The ECU interpates it as the Accelrator pedals track 2 is worn
out and is at idle ( 0% pedal pressed) hence does not respond to any
inputs.
Complaint : Vehicle response is poor ,also black smoke at lower RPM’s.

Code : None
Possible cause : HFM sensor is coated with muck or oil.
Method to check- the easiest method is to disconnect the HFM

connector, the ECU takes the default values. If the complaint is
elimnated then HFM sensor is coated with oil film/ muck and thus the air
drift between the actual air flow and the meausred air flow is causing the
complaint.

Automotive Sector
Root cause : Check if the vehicle has gone through flooded waters if not
check for the crank case ventilation system.
Complaint : Black smoke at all RPM’s

Possible cause : Injector tip coking
Why not detected : The ECU monitors the behaviour of the solenoid. Any
deviation gets reported. However on the hydrualic side if the injector
needle is tuck in open or closed conditon , it will not get get noticed by
ECU.

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

P-0123 Voltage above upper limit
P-0122 Voltage below lower limit.
P-1120 Plausibility with APP2 violated.
DTC detection condition Probable cause

Normal Operation
• The Accelerator pedal module (APM) • Open or shorted
outputs a voltage, which is proportional Accelerator pedal
to the Position of accelerator pedal. module circuits,
• The ECU checks whether the voltage loose or wrongs
output by the Accelerator pedal module connections.
is within a specified range. • Accelerator pedal
In addition, it checks that the voltage module failed or
output does not become too large while maladjusted.
the engine is in idling.
Proper Performance
Sensor output voltage has continued to
between 0 to 5V, varying accelerator pedal
position.
Malfunction; out-of-range
• With the changing Accelerator pedal
position, the sensor output voltage has
continued to be 5V or 0V.
Reaction:
APP1 Ver 1 Apr 06
P-0123
P-0122
P-1120
Automotive Sector
• The engine speed not varying with
changing accelerator pedal position.
(Constant 1200 rpm)
• The system lamp is continuously on.
ECU
K45 K09 K30 K46 K31 K08
Gr-B
G-R
R-W Sb
P W-R
5-GND
4-O/P 1 6-O/P
2 3-GND
Vcc Vcc
APP1 APP2

APP1 Ver 1 Apr 06
Automotive Sector
Test Procedure APP1 –
1. Connect the Insight to diagnostic connector.

2. Turn Ignition Switch ON
3. Verify either P0123 or P122 or P1120 are present.
• Turn Ignition switch OFF & disconnect Accelerator pedal connector.

APP1 Ver 1 Apr 06
P-0123
P-0122
P-1120
Automotive Sector
• Turn the Ignition ON & measure voltage between terminal 2 & terminal
3 of the APP1 (from the APP1 connector side.)
• It should be 5 ± 0.3 V
• Is it?
Yes No
Turn Ignition OFF
Measure the continuity between Measure the continuity between

terminal K09 in ECU and Terminal 4 K45 & 2 ( Voltage)
of connector K30 and 3 ( ground)
Continuity is OK? (resistance below Repair the damaged line/
1 Ω) connection
Clear code
Verify that the complaint has been
eliminated.
Yes No
Reconnect. Before reconnection Repair the damaged line/

check that the pins are not bent or connection
oxidation has not taken place.
Clear the codes Clear code
Does the problem persist? Verify that the complaint has been
eliminated.
APP1 Ver 1 Apr 06
Automotive Sector
Yes No
Check the APP 1 resistance in both
the state 0% & 100%
Is it within the specifications
Yes No
Clear code.Replace the Accelerator pedal
Module
Verify that the complaint has been eliminated.

APP1 Ver 1 Apr 06
P-0223
P-0222
P-1220
P-1221
Automotive Sector
Accelerator Pedal (APP2)
Description: The Accelerator pedal module (APM) mounts in place of

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

P-1220 Plausibility with APP1 violated
P-1221 Accelerator Pedal signal not plausible with brake

Proper Performance
Sensor output voltage has continued to • Open or shorted
between 0 to 2.5V, with varying accelerator Accelerator pedal
pedal position. module circuits, loose
or wrongs connections.
• With the fully pressed Accelerator • Accelerator pedal
pedal module, the sensor output module failed or
voltage has continued to be 2.5V or 0 maladjusted.
for 4 sec.
Reaction
• The engine speed not varying with
changing accelerator pedal position.
(Constant 1200 rpm)
• The system lamp is continuously on.

APP2 Ver 1 Apr 06
P-0223
P-0222
P-1220
P-1221
Automotive Sector
ECU
K45 K09 K30 K46 K31 K08
Gr-
G-R B
R-W Sb
P W-
R
4-O/P 1 6-O/P 5-GND

2 3-GND
Vcc Vcc
APP1 APP2

APP2 Ver 1 Apr 06
P-0223
P-0222
P-1220
P-1221
Automotive Sector
Test Procedure APP2 –
1. Connect the Insight to diagnostic connector

3. Verify that either P0223/P0222/P1220 / or P1221 is present.
• Turn Ignition switches OFF & disconnect Accelerator pedal connector.

APP2 Ver 1 Apr 06
P-0223
P-0222
P-1220
P-1221
Automotive Sector
• Turn the Ignition ON & measure voltage between terminal 2 & terminal
3 of the APP2 (from the APP2 connector side.)
• It should be 2.5 ± 0.15 V
• Is it?
Yes No
Turn Ignition OFF

Measure the continuity between Measure the continuity between
terminal K31 in ECU and Terminal 6 K46 & 1 ( Voltage)
of connector K08 and 5 ( ground)
Continuity is OK? (resistance below Repair the damaged line/
1 Ω) connection
Clear code
Verify that the complaint has been
eliminated.
Yes No
Reconnect. Before reconnection Repair the damaged line/

check that the pins are not bent or connection
oxidation has not taken place.
Clear the codes Clear code
Does the problem persist? Verify that the complaint has been
eliminated.
Yes No
Check the APP 2 resistance in both
the state 0% & 100%
Is it within the specifications

APP2 Ver 1 Apr 06
Automotive Sector
Yes No
Replace the Accelerator pedal
Module
Clear code.
Verify that the complaint has been eliminated.

APP2 Ver 1 Apr 06
P-0103
P-0102
Automotive Sector
Air Flow
Description:
Mass air flow rate is measured by detection of heat transfer from a hot
film probe because the change of the mass air flow rate causes change in
the amount of heat being transferred from the hot film probe surface to
the air flow. The airflow sensor generates a pulse so it repeatedly opens
and closes between the 5V voltage supplied from the engine control
module. This results in the change of the temperature of the hot film
probe and in the change of resistance.
DTC Diagnostic item

P-0103 Voltage above upper Limit
P-0102 Voltage below lower Limit

Normal Operation
• The HFM sensor outputs a voltage, • Open or shorted HFM
which corresponds to the intake airflow. sensor circuit, loose or
• The ECU checks whether this voltage is wrong connections.
within a specified range. • Failed HFM sensor.
Normal Operating Requirements
• Ignition switch: ON
• Malfunction lamp: OFF after 2 Sec
• Battery voltage is 8V-16V or more.
Malfunction
• The sensor output voltage has continued
to be 5V or higher.
to be 0.5V or lower.
Reactions:
• System lamp will continuously blink.
Engine will continue to run with default air
flow (depending on Speed & Fuelling)

Air Flow Ver 1 Apr 06
P-0103
P-0102
Automotive Sector
ECU
V cl 4 2
V-B
A29
G
A42 Air flow o/p 5
G-B 3
A44
Ground
R/G 1
A37
Temperature
O/P
Ignition
switch
Bat+ 12V
10 Amp

P-0103
P-0102
Automotive Sector
Test Procedure HFM

3. Verify that either P0103 or P0102 are present.

Automotive Sector
Turn the ignition OFF P-0103
Disconnect HFM sensor. P-0102
Turn the Ignition ON
Measure the voltage between the Terminal A44 ( ground) and A29 (
supply)
It should be 5 ± 0.3 Volts
Is it
Yes No
Check the output voltage ( with Check fuses

engine running)
Signal voltage within the range Check continuity between the A29
& 4 ( voltage)
Check continuity between A44 & 3 (

Ground)
Is it? Repair the open wire.
Clear codes and verify that the HFM
signal ratio is within limit.
Yes No
Switch off the Ignition

Check the connectors if the pins are Check the continuity between the
bent or having oxidation. A42 & 5 ( Signal)
Clear codes & verify if the codes Rectify
are eliminated.
Clear codes and verify that the HFM
signal ratio is within limit.
Automotive Sector
P-0103
P-0102
No
Check the resistance of the HFM sensor ( between 5 & 3) it should be

between 5.119 to 5.892 KOhms
If not OK. Replace the HFM sensor.
Clear codes & verify that the error has been removed.

P-0113
P-0112
Automotive Sector
Air Temperature
DTC Diagnostic item

P-0113 Voltage above upper limit.
Description: The function acquires the raw voltage of the induction air
temperature. The raw value is linearised and monitored for compliance
with the signal range.
The sensor is mounted in HFM.

Normal Operation
• The HFM temperature sensor outputs a • Open or shorted HFM
voltage, which corresponds to the temperature sensor
temperature of intake airflow. circuit, loose or wrong
• The ECU checks whether this voltage is connections.
within a specified range.
• Failed HFM
Normal Operating Requirements temperature sensor.
• Battery voltage is 8V –16 V.
Malfunction
to be 5V or higher.
to be 0.2 V or lower.
Reactions
• Engine will run with default air temp of
20 Degrees Centigrade
• System lamp status for this error is off.

Air Temperature Ver 1 Apr 06
P-0113
P-0112
Automotive Sector
ECU
V-B V cl 4
A29 (5V) 2
A42 G
Air flow o/p 5
G-B 3
A44
Ground
R/G 1
Temperature
A37
O/P
Ignition
switch
Bat+ 12V
10 Amp

P-0113
P-0112
Automotive Sector
Test Procedure AFTSCD –
Codes: P0112, P0113

Turn the ignition OFF

Disconnect HFM sensor.
Turn the Ignition ON
Measure the voltage between the
Terminal A44 ( ground) and A29 (
supply)
P-0113
P-0112
Automotive Sector
It should be 5 ± 0.3 Volts
Is it
Yes No
Check fuses
Check continuity between the A29
& 4 ( voltage)
Check continuity between A44 & 3

( Ground)
Repair the open wire.
Clear codes and verify that error
has been eliminated.
Measure the continuity between A44 & 3 (ground)

• Is it?
Yes No
Check the continuity between the Rectify

A37 & 1 ( output signal)
Clear codes & verify.
Yes No
Replace the HFM sensor Rectify


P-0340
P-0341
Automotive Sector
Camshaft speed sensor

DTC Diagnostic item
P-0340 No camshaft signal
P-0341 Wrong camshaft signal
Description
The Hall effect camshaft position sensor senses the Top dead center
(TDC) point of the # 1 cylinder in the compression stroke. Which allows
the ECU to determine when to start the injection.

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

Camshaft Speed Sensor
Ver 1 Apr 06
P-0340
P-0341
Automotive Sector
Sensor R-L ECU

3 A 11
Vs
Vs
2 R-G
A50
Signal
1 G A20
GND.
Vs= Supply voltage- 5V

Ver 1 Apr 06
P-0340
P-0341
Automotive Sector
Codes: P-0340, P-0341

• Switch off the Ignition

• Disconnect the camshaft sensor connector.
• Turn ON the Ignition.
• Measure the voltage between the A11 (supply)& A 20 (ground).
• It should be 5 ± 0.3 Volts
• Is it?
Yes No
Turn the Ignition OFF Repair the wire.

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

sensor harness.
Is it OK? Clear the error codes & verify

Ver 1 Apr 06
P-0340
P-0341
Automotive Sector
Yes No
Check for physical damage to pins Repair the connection.
or oxidation.
Also check if the connectors are Clear the error codes & verify
moving backwards when inserted.
Is it OK?
Yes No
Replace the camshaft phase sensor Repair the connection.

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

Ver 1 Apr 06
P-0335
P-0336
Automotive Sector
Crankshaft Sensor
DTC Diagnostic item

P-0335 No crankshaft signal
P-0336 Wrong crankshaft signal
Description
In order that the ECU can control the engine at all, the position of the
crankshaft must be known so that the cylinder in compression and the
timing of the next fuel injection can be calculated. The CKP is an
inductive pulse generator, which scans protrusions on the flywheel. Two
teeth are missing, and this gap is situated at 90° before TDC.

Background
• When the engine is running, the • Open, shorted or
Crankshaft Position sensor outputs a wrong connection
pulse signal. crankshaft position
• The ECU checks whether the pulse sensor circuit.
signal is input while the engine is • Failed or damaged
cranking. crankshaft position
sensor.
Normal Operating condition
• Engine is being cranked.
Malfunction
• Normal signal pattern has not been
input for cylinder identification from
the crankshaft position sensor signal
for 4 sec.
• No synchronization between crankshaft
& camshaft signal.
Reaction
• System lamp continuously on.
Crankshaft Sensor
Ver 1 Apr 06
P-0335
P-0336
Automotive Sector
• Engine will not start.
• If engine is running & this fault occurs,
engine will stop immediately.
ISS (Incremental speed sensor/ Crankshaft speed sensor)
Sensor ECU
N S Y
1 A 27
Positive
2 A 12
Negative
Shield
3
B-R A 21

Crankshaft Sensor
Ver 1 Apr 06
P-0335
P-0336
Automotive Sector
Test Procedure ISS

3. Verify that either P0335 or P0336 are present. Please verify after
cranking the engine.
• Turn the Ignition switch OFF.

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

Crankshaft Sensor
Ver 1 Apr 06
P-0335
P-0336
Automotive Sector
Yes No
Measure all terminals for short to Repair the wire.

GND
Is it OK ? Clear code & verify the CKP sensor

is within normal parameters.
Yes No
Check if the sensor is damaged. If Repair the connection.

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

Crankshaft Sensor
Ver 1 Apr 06
P-1658
Automotive Sector
Terminal 15 (Ignition)- contains plausibility error [Sig] of T15
DTC Diagnostic item

P-1658 No Terminal T15 signals detected

Normal operation
• When ignition is ON relay coil will get • Open, shorted or
energized. wrong connection of
• Engine being started. T15 circuit.
Malfunction
• When ignition is ON supply is not coming to
ECU.
• Main relay coil will not get energized.

Terminal 15 Ver 1 Apr 06
P-1658
Automotive Sector
Connect the Insight to diagnostic connector

2. Verify that P-1658 is present.
• Check that the main relay is getting energized

• To check that the relay is getting energized, hear for the clicking
sound from the main relay when the Ignition is switched ON.
• Is it OK
Yes No
Turn the Ignition OFF Follow the Main relay fault finding
procedure.
Measure the continuity of the wire Clear the error codes & verify
between the K28 terminal of the
ECU and the Ignition switch
Is it OK?
Yes No
Check for loose or intermittent Repair the connection.

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

Terminal 15 Ver 1 Apr 06
P-1600
P-1601
P-1602
P-1603
Automotive Sector
ADC Monitoring
Description: Analog to Digital converter inside the ECU is not working

properly
DTC Diagnostic item

P-1600 ADC monitoring : SRC-High error of ADC reference voltage
P-1601
P-1602 ADC monitoring : SRC-Low error of ADC reference voltage
P-1603 ADC monitoring : Test impulse error
ADC monitoring : ADC queue error
Reaction: The System Check lamp will be continuously ON.
Test Procedure:
1. Switch ON Ignition
2. Using diagnostic tester, clear the ECU faults
3. Switch OFF Ignition key and wait for 2 minutes
5. Using diagnostic tester check whether any of the above mentioned
fault is present
6. If fault is still present, switch OFF ignition
7. Replace the ECU with a new one and repeat steps 4 & 5
8. If fault is not present in the new ECU, then the old ECU is defective
and has to be sent back to M&M

ADC Monitoring Ver 1 Apr 06
P-0108
P-0107
Automotive Sector
Atmospheric pressure sensor
DTC Diagnostic item

P-0107 Voltage below lower limit

Normal Operation
• The atmospheric pressure sensor • Failed atmospheric
outputs a voltage, which corresponds to pressure sensor.
atmospheric pressure.
Normal Operation
• Battery voltage is 8V to 12V.
• No error reported in error memory.
Malfunction
to be 5V or higher.
to be 0V or lower.
Reaction
• System lamp will blink.
• Engine will run with default
atmospheric Pressure of 800hPa

Atm Pressure Sensor
Ver 1 Apr 06
P-0108
P-0107
Automotive Sector

3. Verify that either P0108 or P0107 is present.
• Check the battery voltage.

• Clear the error codes.
• Verify if the error has been cleared.
Yes No
Repeat the clear error, for 3 times.

Replace the ECU

Atm Pressure Sensor
Ver 1 Apr 06
P-0563
P-0562
Automotive Sector
Battery
Description:
The system voltage has to guarantee to perform diagnosis functions. The
Electronic Control Unit (ECU) monitors battery voltage. If this code is set,
the System Lamp is off.
DTC Diagnostic item


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

• Check charging system
• Check charging system (including battery) for proper operation.
• Refer the charging system section in the Electrical.
• Charging system OK. ( Voltage during cranking should be 8 to 16 Volts)
Yes No
Check the ECU, problem procedure. Repair or replace.

Battery Ver 1 Apr 06
P-1792
P-1791
Automotive Sector
Brake Switch
Description:
The function acquires and processes the information via the brake
contact and the redundant brake contact. The status message of the
brake position is the output.
DTC Diagnostic item

P-1792 Brake signal is defective
P-1791 Brake signals not plausible
Principle
• The brake switch outputs a voltage, • Open, shorted, loose
which corresponds to the brake or wrong connections
position. of brake switch Wiring.
• The ECU checks whether this voltage is • Brake switch damage
within a specified range (0 or 12V). or faulty
• Brake switch failed or
Normal Operation maladjusted.
• Ignition switch: ON .
• System lamp: OFF after 2 Sec
• Battery voltage is 8V –16V.
Malfunction
• The sensor output voltage has
continued to be 0V in spite of brake
pedal being pressed/not pressed
continued to 12V in spite of brake
pedal being pressed/not pressed
• Main or redundant switch is not
working.
Reaction
• System lamp will be off.
• Cruise control will not work.

Brake Switch
Ver 1 Apr 06
Automotive Sector

Brake Switch
Ver 1 Apr 06
P-1792
P-1791
Automotive Sector
Test Procedure Brake switch --
Codes: P-01792, P-1791

Disconnect the brake switch connector.
• Turn Ignition ON and check the supply voltage to brake switch tow
point connector.
• It should be 12 V when Ignition ON
• Is it?
Yes No
Turn the Ignition OFF Check the 15 Amp fuse after the
main relay
Connect the brake connector Check the supply to K01 & K05
(Fuses of K01 & K05)
Check the voltage at K80 of ECU Repair connections as necessary
input pin when the brake is in
released position
When the brake pedal is pressed

then it should be checked at K17
It should be 12 V Clear codes & verify.
Is it?
Yes No
Replace the brake switch with Turn Ignition OFF

Brake Switch
Ver 1 Apr 06
P-1792
P-1791
Automotive Sector
known good component
Check for error Remove brake switch connection &
check continuity between terminal
K17 & K80 with brake switch
connector
Clear the error memory Is it OK?
No Yes
Repair the connection as necessary. Replace the brake switch with

Clear the error and verify.

Brake Switch
Ver 1 Apr 06
P-0704
Automotive Sector
Clutch Switch –
DTC Diagnostic item

P-0704 Clutch signal is not plausible
Description
The clutch signal is acquired as a hardware signal. The signal is checked
for plausibility using gear information. Error is detected, if there is a
valid gear change without the clutch being pressed during the time that
elapsed since the last gear change.

Normal Operation
• The clutch switch outputs a voltage, • Open, shorted, loose
which corresponds to the clutch or wrong connections
position. of brake switch Wiring.
• The ECU checks whether this voltage is • Clutch switch failed or
within a specified range (0 or 12V). maladjusted.
• Clutch switch damage
Normal Operating Requirements: or faulty.
Malfunction
continued to be 0V in spite of clutch
pedal being pressed/not pressed.
continued to 12V in spite of clutch
pedal being pressed/not pressed.
Reaction:
• System lamp will be off.
• Cruise control will not work.

Clutch Switch Ver 1 Apr 06
P-0704
Automotive Sector
IC Main 14PFT
15 Amp
4 Br-B
K58
4
R G Br-B
Clutch switch
ECU
(normally closed)

P-0704
Automotive Sector
Test Procedure Clutch switch –

3. Verify that error P0704 is present.

P-0704
Automotive Sector
Verify that no error related to vehicle speed (vehicle speed sensor
related) is present. If present, first attend to those complaints then
verify if the error P0704 is present and then proceed.
Disconnect clutch switch connector
Turn the ignition ON
Check supply voltage to clutch switch on connector.
It should be 12 V, when Ignition is ON. Is it?
Yes No
Turn Ignition OFF Check the 15 Amp fuse after the

main relay ( this fuse also controls
EGR & Brake switch)
Connect the clutch switch Check the supply to K01 & K05
connector
Check the voltage at K 58 of the Repair the connections as necessary
ECU pin, when the clutch is in
released condition.
It should be 12 V Clear codes & verify
Is it ?
Yes No
Clear the codes & verify. Turn Ignition OFF

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

P-0704
Automotive Sector
No Yes
Repair the connection as necessary. Replace the clutch switch with

Clear the error memory & verify

P-162A
Automotive Sector
Communication Monitoring
Description: Communication between controller and power stage inside

the ECU is not OK
DTC Diagnostic item

P-162A Communication error of CJ940
Test Procedure:
fault is present

Communication
Monitoring Ver 1 Apr 06
P-1659
Automotive Sector
Controller and TPU Monitoring
Description: Controller and Time processing unit out of sync
DTC Diagnostic item

P-1659 Deviation between TPU and system time
Test Procedure:
fault is present

Controller & TPU
P-165E
P-165F
P-1660
P-1661
Automotive Sector
Coolant overheat Lamp - power stage
DTC Diagnostic item

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

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

Coolant Overheat
Lamp Ver 1 Apr 06
P-165E
P-165F
P-1660
P-1661
Automotive Sector

Coolant Overheat
Lamp Ver 1 Apr 06
P-165E
P-165F
P-1660
P-1661
Automotive Sector

3. Verify that either P1660 or P1661 or P165E or P165F is present.

• Check the connection to the coolant overheat lamp.
• Check the continuity between ECU terminal K94 with overheat lamp.
• Is it OK?
Yes No
Switch ON the Ignition Repair the connection

Check if the supply is coming to the Clear codes and verify that the
overheat lamp overheat lamp is working correctly.
Is it OK
Yes No
Lamp failure. Repair the connection.

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

Coolant Overheat
Lamp Ver 1 Apr 06
P-0118
P-0117
Automotive Sector
Coolant Temperature Sensor
Description: The Water temperature sensor (WTF) is located in a

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


Background
• The engine coolant temperature sensor • Open or shorted
converts the engine coolant temperature Engine Coolant
to a voltage and outputs it. Temperature
• The ECU checks whether the voltage is sensor circuit, or
within a specified range. In addition, it loose or wrong
checks that the engine coolant connection
temperature (signal) does not drop while • Engine Coolant
the engine is warming up. Temperature
sensor failed.
• Sensor output voltage has continued to
be 5V or higher for 4 sec.
be 0.1V or lower for 4 sec.
Reaction:
• System lamp will be on.
Engine will continue to run with water
temperature of 120 deg C.

Coolant Temperatuer
Sensor Ver 1 Apr 06
P-0118
P-0117
Automotive Sector
ECU
A 58 A41
W-R R-G
2
1
Coolant Temperature Sensor

Coolant Temperatuer
Sensor Ver 1 Apr 06
P-0118
P-0117
Automotive Sector
Test Procedure Coolant Temperature Sensor --
Codes: P-0118, P-0117,

• Verify DTC P0118 or P0117 are present.

• Turn the Ignition OFF
• Disconnect the CTS connector.
• Turn Ignition ON and check the voltage between CTS’ signal terminal
1 and ground.
• Is it?
Coolant Temperatuer
Sensor Ver 1 Apr 06
P-0118
P-0117
Automotive Sector
Yes No
Turn the Ignition OFF Open or short between CTS signal

terminal 1 and ECU
Measure continuity between A 58 of Repair as necessary.
ECU & connector terminal 1
Measure continuity between A 41 of
Is it OK
Yes No
Connect CTS connector Open or short between CTS signal

terminal 1 and ECU
Turn Ignition ON Repair as necessary.
Check the voltage of CTS
Is it as per specification
Yes No
Poor terminal contact due to Temporarily install a known good

oxidation, bent or misplaced CTS and check for proper operation.
terminal
Repair as necessary If problem is corrected, replace
CTS.
• Return vehicle to original condition. Clear all DTC.

• Verify by driving vehicle with “Insight” connected and monitor for
error codes.
Coolant Temperatuer
Sensor Ver 1 Apr 06
P-0577
P-0576
P-0575
Automotive Sector
Cruise Control
DTC Diagnostic item

P-0577 SRC MAX error for analog signal
P-0576 SRC MIN error for analog signal
P-0575 Plausibility error for analog signal

Normal operation
• When vehicle is running, no clutch & brake • Open, shorted or
is pressed, by pressing cruise control wrong connection
switch vehicle will go into cruise mode. of cruise control
• Pressing resume key vehicle will circuit.
maintained the previous set speed. • Brake or clutch
• Pressing set + or Set - vehicle speed can be error is set into
adjusted. ECU.
• Pressing OFF switch, vehicle will come out • Switches are not
of cruise mode. responding or
faulty.
Malfunction
• By pressing any of the cruise control
switch vehicle will not go into cruise
mode.
• Vehicle will not respond to set +, Set -,
OFF or resume switch when vehicle is in
cruise mode.

Cruise Control Ver 1 Apr 06
Automotive Sector
ECU
K35 K32 K80 K17 K58
W-B
V P-B Br Br-B
Redundant
brake
switch
On/off
On/Off
Set
Set--
Set +
Set +
Main Clutch
Coast/Resume
brake
switch
15A
Coast / Reset
15A
Cruise Battery + Battery +
control
activator

P-0577
P-0576
P-0575
Automotive Sector

P-0577
P-0576
P-0575
Automotive Sector
1. Turn the Ignition Switch ON
2. Verify that either P0577 or P0576 or P0575 is present.
• Turn the Ignition OFF/ON to measure the Voltages.

• Check the resistances across all the switches when they are activated
Parameter Resistance Voltage

No key pressed 4.323 K Ώ 4.35 V
ON/OFF 150 Ώ 0.9823 V
Coast/Reset 1.63 K Ώ 3.61 V
Set + 810 Ώ 2.845 V
Set - 420 K Ώ 2.035 V
Do the switch show the above value?
Yes No
Switch ON the Ignition Switches are faulty.

Check if there is any error of the Replace the switch with a new good
brake & clutch switch set. Clear part
them
Is there any other error present. Clear codes & verify
Yes No
Diagnose the error & clear it Check the connection of ECU

terminals K 35 & K32 and the cruise
control switch connections
Clear codes & verify that the cruise control is functioning properly.

P-0577
P-0576
P-0575
Automotive Sector
Is it OK?
Yes No
Check for any short or intermittent Repair the connections

connections
Repair it Clear codes & verify that the cruise
control is working properly.
Clear codes & verify that the cruise
control is working properly.

P-1638
Automotive Sector
ECU Monitoring
Description: Monitoring module inside ECU reports a defect
DTC Diagnostic item

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

Engine will shut down
Test Procedure:
fault is present

Mahindra & Mahindra Ltd Scorpio CRDe ( All New) Diagnostic Manual
ECU Monitoring-March 06
P-162B
P-162C
P-162D
Automotive Sector
EEPROM Monitoring
Description: EEPROM storage device inside ECU is not OK
DTC Diagnostic item

P-162B EEPROM: error during last read operation
P-162C EEPROM: error during last write operation
P-162D EEPROM: default value used
Test Procedure:
fault is present

EEPROM Monitoring Ver 1 Apr 06
P-0406
P-0405
P-0403
P-0404
Automotive Sector
EGR power stage
DTC Diagnostic item

P-0406 Short Circuit Battery
P-0405 Short Circuit Ground
P-0403 No Load
Description
A pulse-width-modulated signal is output for the Exhaust Gas
Recirculation actuator control. Converting the air control output into
duty cycle carries this out. The possible defects are short circuit to
battery, ground & no load.
Background
• The ECU checks current flows in the EGR • Open or shorted
solenoid drive circuit when the solenoid EGR solenoid
is ON and OFF. circuit, loose or
Range of check, set conditions. wrong connection.
• When the EGR solenoid is turned OFF, no • EGR solenoid
surge voltage is detected. failed
Normal operation • EGR control
• When engine is running per the EGR vacuum is too low
mapping.
• System lamp off after 2 sec.
Malfunction
• EGR valve will remain open in case of short
circuit to ground fault & remain closed for
other fault conditions.
Reaction
• System lamp will blink in case of short
circuit to ground condition i.e.P0405.For all
other fault condition (related to EGR) lamp
will be OFF.
• Emission will affect.

EGR Power Stage
Ver 1 Apr 06
P-0406
P-0405
P-0403
P-0404
Automotive Sector
*- Twisted pair
Codes: P-0406, P-405, P-403, P404
3. Verify that either P0406 or P0405 or P0403 or P0404 are present.
• Disconnect the EGR control solenoid valve connector.

EGR Power Stage
Ver 1 Apr 06
P-0406
P-0405
P-0403
P-0404
Automotive Sector
• Turn Ignition ON
• Check the voltage between Ground & EGR control solenoid, valve
harness connector terminal. Battery voltage should be present.
• Is it?
Yes No
Turn Ignition OFF Verify that the 15 Amp fuse is OK (

same fuse is also used for brake &
clutch switch)
Disconnect the EGR control solenoid Repair open or short to Ground on
wire between ECU control relay &
EGR control solenoid valve
Disconnect the ECU connector Clear codes & verify
Check the continuity of the EGR
connector with ECU terminal A 60
Is it OK
Yes No
Are the connectors OK ( check for Rectify the wiring/

bent pins or oxidation)
Clear codes & verify
Yes No
Replace EGR solenoid with known Rectify the wiring harness

good components
Clear codes & verify EGR solenoid is within limits
If problem persist, replace EGR

EGR Power Stage
Ver 1 Apr 06
P-160C
P-160D
P-160E
Automotive Sector
Error path for the Tachometer signal
DTC Diagnostic item

P-160C Short Circuit to Battery
P-160D Short Circuit to Ground
P-160E No Load

Normal operation
• When ignition is ON system lamp will be • Open, shorted or
switch OFF after 2sec. wrong connection of
• When engine is running it will show tachometer circuit.
corresponding engine speed on dash
panel.
Malfunction
• When engine is running it wouldn't show
corresponding engine speed on dash
panel.
Reaction
• No impact on vehicle performance.
Only engine speed indication on dash
panel can not be seen.

Error Path for
Tachometer Signal
Ver 1 Apr 06
P-160C
P-160D
P-160E
Automotive Sector
Test Procedure Tachometer signal

3. Verify that either P160C or P160D or P160E is present.

Error Path for
Tachometer Signal
Ver 1 Apr 06
P-160C
P-160D
P-160E
Automotive Sector
• Turn the Ignition OFF.
• Disconnect the tachometer connector from the cluster connections.
• Check the continuity between the ECU connector terminal K48 and
cluster tachometer connections.
• Is it OK?
Yes No
Check if any other error is set for Repair the connections

speed sensor and check for short
circuit.
Check for short with battery or Clear codes & verify that signal is as
Ground per the limit.
Is it?
Yes No
Correct the error and check for Repair cluster connection’s, or they
tachometer error is not available. are not connected properly
Clear codes & verify signal is as per the limit.

Error Path for
Tachometer Signal
Ver 1 Apr 06
P1608
P1609
P160A
P160B
Automotive Sector
Error path of coolant temperature output
Description
The component driver for the coolant temperature outputs the variable
as a PWM signal to the power stage. (Output on the cluster) In normal
operation, the PWM power stage is tested for short circuit to battery, to
ground, open circuit and excess temperature.
DTC Diagnostic item

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

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

• System lamp: OFF after 2 Sec
Malfunction
• No indication of water temperature on
the instrument cluster.

Error Path of Coolant
Temperature Output
Ver 1 Apr 06
P1608
P1609
P160A
P160B
Automotive Sector
Test Procedure Coolant temperature output --

3. Verify that the either of the error codes P1608 or P1609 or P160A or
P160B is present.
Turn the Ignition OFF
• Remove the cluster connections of the coolant temperature indicator.

• Check the continuity between coolant temperature output connector
with K29 of the ECU.
Temperature Output
Ver 1 Apr 06
P1608
P1609
P160A
P160B
Automotive Sector
• Is it OK?
Yes No
Check the cluster lamp fuse Open or short between coolant

temperature output & ECU K29
Check the temperature value in Repair as necessary
Insight.Compare it with physical
measurements
Check the output at K29 when

Ignition is ON
Is it OK Clear the error & verify.
Yes No
Replace the instrument cluster Clear codes & verify.

Verify DTC with coolant
temperature output

Temperature Output
Ver 1 Apr 06
P-1340
Automotive Sector
Error path of offset between camshaft and crankshaft
DTC Diagnostic item

P-1340 Offset between camshaft and crankshaft

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

Error Path of Offset
Betweem Camshaft &
Crankshaft Ver 1 Apr 06
P-1340
Automotive Sector
Segment Speed Sensor (camshaft sensor)
Sensor R-L ECU

3 A 11
Vs
Vs
2 R-G
A50
Signal
1 G A20
GND.
Vs= Supply voltage- 5V

Betweem Camshaft &
P-1340
Automotive Sector
3. Verify that P1340 is present.
Turn the Ignition OFF.

Disconnect the camshaft & also the crankshaft sensors.
Is it OK?
Yes No
Check the flywheel mounting Correct the mounting

Check the wiring harness continuity Clear codes & verify that the signal
between the cam sensor to ECU & is within limit
also the cranks sensor to ECU
Flywheel mounting is OK
Yes No
Check for any manufacturing Correct the mounting.

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

Betweem Camshaft &
P-1530
P-1531
P-1532
P-1533
Automotive Sector
Fault path of air condition power stage

DTC Diagnostic item
P-1530 Short circuit to battery
P-1531 Short circuit to ground
P-1532 No load
P-1533 Excess temperature
Description: The A/C compressor routes the A/C compressor control

signal to the digital power stage output. The power stage is monitored.
An error such as short circuit, open circuit or excess temperature,
occurring at the power stage is reported.
The function routes the control signal for the A/C compressor to the
power stage.
DTC detection condition Probable cause for
malfunction
Normal Operation
• AC relay is OFF when the AC switch &
blower switch is OFF. • No AC gas available.
• The ECU checks whether AC switch is ON • AC relay is not
then it will try to switch ON the AC relay working.
provided blower is ON. • Open or shorted AC
• When AC relay is energized then it will circuits, loose or
switch ON the AC compressor. wrong connections.
Normal Operation • Compressor is not
• Ignition switch: ON working
• Engine is ON • ECU AC circuit
• System lamp: OFF after 2Sec faulty.
• AC switch & blower switches are ON.
Malfunction
• ECU not recognizing 12V when AC switch
is ON.
• ECU output to AC relay has continued to
0.5V or more.
Reaction
• System lamp will blink continuously.
• AC will not work.

Fault Path of Air Condition
Power Stage Ver 1 Apr 06
P-1530
P-1531
P-1532
P-1533
Automotive Sector

3. Verify that either P1530 or P1531 or P1532 or P1533 are present.
• Check that all the AC connections are fitted.

• Check the AC charging.
• Check that the AC & compressor relay are both functioning properly
• Is it OK?
Yes No
Turn the Ignition OFF If needed change the relay & repair
the connections
Measure continuity between K54 Clear codes & verify
and AC switch & AC relay.
Measure continuity between K 70 of
ECU relay.
Is it OK
Yes No
Switch ON the Ignition. Check the fuses ( 15 Amp AC fuse)

Switch ON the AC switch. If required , replace it
Check the voltage between the ECU Repair the connections
terminal K54 & Ground
Also check the voltage between K70

& ground.

P-1530
P-1531
P-1532
P-1533
Automotive Sector
At K70- Gnd. It should be 0 Volts Clear codes & verify that AC is
when in OFF condition and 12 Volts working properly.
when in ON condition.
Switch on the blower
Check the voltage between K 70 &
ground.
It should show 0 Voltage
Is it OK
Yes No
Check AC compressor connections & Repair the connections as per the

supply circuit diagram.
Clear codes & verify AC is working Clear codes & verify AC is working
properly.

P-0182
P-0183
Automotive Sector
Fuel Temperature Sensor

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

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

Fuel Temperature
Sensor Ver 1 Apr 06
P-0182
P-0183
Automotive Sector
ECU
A 52
W G
1 2
Fuel Temperature Sensor

Fuel Temperature
Sensor Ver 1 Apr 06
P-0182
P-0183
Automotive Sector
Test Procedure Fuel Temperature Sensor –
Codes: P-0182, P-0183

• Turn the Ignition OFF

• Disconnect the FTS connector.
• Turn the Ignition ON and check the voltage between FTS’ signal
terminal 1 and ground.
• It should be 5 V ± 0.3 when Ignition ON
• Is it?
Yes No
Turn the Ignition OFF Open or short between FTS signal

terminal 1 and ECU
Measure continuity between A 52 of Repair as necessary.
Measure continuity between A 51 of
Is it OK
Yes No
Connect FTS connector Open or short between FTS signal

terminal 1 and ECU
Turn Ignition ON Repair as necessary.
Check the voltage of FTS ( at A51 &
Fuel Temperature
Sensor Ver 1 Apr 06
P-0182
P-0183
Automotive Sector
A52)
Is it as per specification
Yes No
Poor terminal contact due to Temporarily install a known good

oxidation, bent or misplaced FTS and check for proper operation.
terminal
Repair as necessary If problem is corrected, replace
FTS.
• Return vehicle to original condition. Clear all DTC.

• Verify by driving vehicle with “Insight” connected and monitor for
error codes.

Fuel Temperature
Sensor Ver 1 Apr 06
P-1887
P-1888
P-1889
P-1890
Automotive Sector
Glow control relay actuator
DTC Diagnostic item

P-1887 Short Circuit to Battery
P-1888 Short Circuit to Ground
P-1889 No Load
P-1890 Excess temperature

Normal operation • Open, shorted or
• When ignition is ON after 2 seconds the wrong connection
system lamp will switch OFF. of glow circuit.
• When Ignition is ON glow relay will switch • Fuse is blown.
ON & switch OFF after 10 sec. (If temp. is • Relay is not
lesser than 0 Degree Centigrade) working.
• Glow relay will get energized as per the
logic in the ECU.
Malfunction
• When ignition is ON system lamp will be
ON.
• Relay will not get energized as per ECU
logic.

Glow Control Relay
Actuator Ver 1 Apr 06
Automotive Sector
Test Procedure –

3. Verify that either P-1888 or P-1889 or P-1890 or P1887 is present.
• Check the 15 Amp fuses. If defective, replace.
• Check when the Ignition ON the Glow lamp is ON (Check lamp check:
the system lamp & the overheat lamp should come On for 2 seconds
and then go off)
Glow Control Relay
P-1887
P-1888
P-1889
P-1890
Automotive Sector
• If not On then check lamp & replace
• Check the insertion of glow plug & glow relays.
• Is it OK?
Yes No
Check the ECU between the ECU Repair the terminal of the glow
terminal K 93 and terminal 85 of plug & relay
the relay
When the supply is ON the supply is Clear codes & verify that the glow
coming to terminal 86 & 30 of the plugs are working properly.
relay.
Check the 60 Amp fuse, if faulty,
replace fuse.
Yes No
Check as per the glow plug logic Repair the connection

that the glow plug’s are working. (
the glow plug light will glow ON for
15 seconds)
Check the relay is energizing. Clear codes & verify.
Is it OK
Yes No
Loose or intermittent connections Relay is defective.

Repair connection Change the relay
Clear codes and verify that it is working properly

Glow Control Relay
P-1623
P-1625
P-161F
P-1621
Automotive Sector
Injector Energizing time

Description: Controller not able to control power stage
DTC Diagnostic item
P1623 Below lower limit of enegizing time- Injector # 1
P161F Below lower limit of enegizing time- Injector # 3
Reaction: The System Check lamp will be Off.

Vehicle speed may drop.
Test Procedure –
1. Pl. confirm IMA codes are flashed.

2. Confirm no fuel leakage in low & high pressure circuit.
3. Check the continuity for the high & low sides.
4. Confirm battery voltage is above 10V.
5. Ensure fuel filter is not clogged. (Service interval followed as per
schedule)
6. Check with swapping Injector.
7. If still error persists change the injector.

Injector Energising
Time Ver 1 Apr 06
P-1210
P-1211
P-1212
P-1213
Automotive Sector P-1214
P-1215
Injector power stage- chip specific errors P-1216
P-1217
Description: Injector power stage inside ECU defective
DTC Diagnostic item

P-1210 Chip-specific errors : CY33X internal reset / clock loss /
under voltage
P-1211 Chip-specific errors: CY33X is unlocked / CY33X init error
P-1212 Chip-specific errors:CY33X is in Test mode
P-1213 Chip-specific errors: CY33X SPI communication error
/checksum/read back
P-1214 Chip-specific errors ->CY33X internal parity error
P-1215 Chip-specific errors ->CY33X internal program flow error
P-1216 Chip-specific errors ->CY33X check of inv. YSEL during ON
failed
P-1217 Chip-specific errors ->CY33X ON timeout for at least 1
cylinder

Engine stops.
Test Procedure –
fault is present

Injector Power Stage
Ver 1 Apr 06
Automotive Sector
K line: Diagnostic connector
Connect the diagnostic “Insight “ to the DLC.

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

K line Diagnostic
Connector Ver 1 Apr 06
Automotive Sector
No Yes
Remove the diagnostic tester from Diagnostic connector is OK.

the connector
Switch on the Ignition
Check the voltage of the pin no 4/5
& 7 of the connector ( It should
show 12 Volts when Ignition is ON
and show 0 Volts when Ignition is
switched OFF.
Is it OK?
No Yes
Check connectivity between K25 Check the voltage between the

and diagnostic connector pin no 7 connector pins10 & pin 4/5. It
should show 12 V continuously
If is not OK, then repair If it is not showing , repair the
connection
Check the voltage Otherwise it indicates
less/poor/intermittent contact
Is it OK Repair
Yes No
Connect diagnostic tester & confirm Diagnostic hardware is faulty.

Change the hardware

K line Diagnostic
Connector Ver 1 Apr 06
P121A
P121B
Automotive Sector
Main relay
DTC Diagnostic item

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

Normal operation
• While cranking engine will start properly. • Open, shorted or
wrong connection of
Malfunction main relay.
• Supply will not come to ECU input. • Main relay fuse is
blown.
Reaction • Relay is not working
• No communication with diagnostic tester.

Main Relay Ver 1 Apr 06
P121A
P121B
Automotive Sector

P121A
P121B
Automotive Sector
Engine not cranking- diagnostic tester not responding.
Turn the Ignition OFF.

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

3. Verify that either P121A or P121B is present.
• Ensure that the main relay is inserted properly in the connector

• Remove relay.
• Check the relay externally
• Give 12 Volts to terminal 86 and Ground the terminal 85.
• A clicking sound should be heard.
• If the sound is not heard, replace the relay.
• Check if 12 Volts is available at terminal 30,86 & 85.
• With respect to ground, terminal 87 should show 0 Volts
• Is it OK?
Yes No
Switch ON the Ignition Check the wiring harness

Measure at terminal K72 of ECU or Repair the main relay connections (
terminal 85 of the relay. check the 30 Amp fuse)
Is it showing 0 Volts Clear codes & verify that the main
relay is working properly
Yes No
Measure the voltage at ECU Check that the terminal K 28 of ECU

terminal K05/K01. Or at terminal 87 is showing 12 Volts. If not repair the
of the relay connection.
It should show 12 Volts

P121A
P121B
Automotive Sector
Yes No
Clear codes and verify that the Replace the relay with a known
main relay is working properly good component.
Clear codes and verify that the
main relay is working properly

P-1252
P-1253
P-1250
P-1251
Automotive Sector
Metering unit pump -Power stage
DTC Diagnostic item

P-1253 Short Circuit to Ground
P-1250 No Load

Normal operation
• When ignition is ON pump is getting supply • Open, shorted or
from ECU wrong connection of
• Engine is starting properly. pump circuit.
Malfunction
• When ignition is ON pump is not getting
PWM signal from ECU.
Reaction
• Engine is not starting & error is recorded in
ECU error memory.
• Fuel output is not available from pump.
• System lamp will remain ON.

Metering Unit Pump
Ver 1 Apr 06
P-1252
P-1253
P-1250
P-1251
Automotive Sector
High Pressure Pump (with fuel metering unit)
ECU
A19 A 49
W
Y
2 1 Twisted pair wires

Metering Unit Pump
Ver 1 Apr 06
P-1252
P-1253
P-1250
P-1251
Automotive Sector

3. Verify that either P-1252 or P-1253 or P-1250 or P-1251 is present.
• Check the connections to the pump.

• Check that the connections are connected correctly; and that it is not
connected in reverse way.
• Disconnect the pump and ECU connectors.
• Check the continuity between the ECU terminal A19 and pump
terminal 2
• Check the continuity between the ACY terminal A49 with pump
terminal 1
• Is it OK?
Metering Unit Pump
Ver 1 Apr 06
P-1252
P-1253
P-1250
P-1251
Automotive Sector
Yes No
Check the continuity of ECU Check for terminal contamination.

connector terminal A49 and A19 Repair the connection.
with Battery +ve and Ground.
Is it OK? Clear codes and verify that the
error has been eliminated.
No Yes
Error observed due to loose/ There is a possibility of short circuit

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

Metering Unit Pump
Ver 1 Apr 06
P-1664
Automotive Sector
Monitoring module communication Monitoring
Description: Communication failure with monitoring module.
DTC Diagnostic item

P-1664 The fault path contains the supervision of the SPI-Handler
Set, if SPI-communication failed
Test Procedure –
fault is present.

Monitoring Module –
Communication
P-1641
P-1642
P-1643
Automotive Sector
Power Stage Monitoring

Description: Controller not able to control power stage
DTC Diagnostic item
P-1641 Test of redundant shut off paths during initialization: Watch
dog switch off path defect
P-1642 Test of redundant shut off paths during initialization:
Voltage monitoring upper limit shut off path defect
P-1643 Test of redundant shut off paths during initialization:
Voltage monitoring lower limit shut off path defect

Test Procedure –
fault is present

Power Stage
P-1631
P-1632
Automotive Sector
Power stage voltage Monitoring
Description: Over / Under voltage to power stage detected
DTC Diagnostic item

P-1631 (Hardware) CJ940 upper limit: internal supply voltage upper
P-1632 limit (Hardware) CJ940 lower limit: internal supply voltage
lower limit
Test Procedure –
fault is present
and has to be sent back to M&M.

Power Stage Voltage
P-0193
P-0192
Automotive Sector
Rail Pressure Sensor
DTC Diagnostic item

P-0193 Voltage above upper limit.

Normal operation • Open, shorted or
• When ignition is ON rail pressure sensor wrong connection of
getting supply from ECU. rail pressure sensor
• ECU reads the rail pressure in terms of circuit.
voltage. • Rail pressure sensor
• Engine is starting properly. failed.
• Building pressure in rail.
Malfunction
• Rail pressure output voltage is below
Reaction
• When ignition is ON system lamp is glowing.
Engine is not starting & error is set in
ECU
Error memory.

Ver 1 Apr 06
P-0193
P-0192
Automotive Sector
ECU
A28 A43 A08
O-B R O
3 2 1
V cc V out GND

Ver 1 Apr 06
P-0193
P-0192
Automotive Sector

3. Verify that either P-0193 or P-0192 is present.

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

ECU terminal A28 & pin no 3 of the
RPS.
Continuity between the ECU

terminal A43 & pin no 2 of the RPS
Is it OK? Clear the error codes & verify
Yes No
Connect the rail pressure sensor Repair the wire.

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

Ver 1 Apr 06
P-0193
P-0192
Automotive Sector
Yes No
Change the engine speed and check Rail pressure sensor has failed.
the corresponding increase in RPS
value
( This can be done using the live Change the Rail assembly ( RPS is
data in the “Insight”) not serviced separately)
Is there a change in the RPS Clear codes & verify
Yes No
Clear codes & verify Replace rail.


Ver 1 Apr 06
P-1644
P-1645
Automotive Sector
Sensor supply monitoring 1
DTC Diagnostic item


Normal Operation
The ECU monitors the supply voltage to
camshaft phase sensor, and accelerator pedal
( APP1)
Malfunction
The voltages are beyond the range.
Reactions
System lamp status for this error is ON.

Sensor Supply Monitoring 1
Ver 1 Apr 06
Automotive Sector

Ver 1 Apr 06
P-1644
P-1645
Automotive Sector

• This is related to the cam shaft sensor supply & also APP1 supply
voltage
• Check the connection of the cam shaft sensor supply & accelerator
pedal connector
• Is it OK?
Yes No
Remove the sensor connections of Repair the connection

the camshaft sensor & the
Accelerator pedal
Clear the error Clear codes and verify.
If the error heals then the problem
may be due to poor connection
Does it heal?
No Yes
Clear the codes & verify. Check the continuity between the
ECU connector A11 and the
camshaft terminal 3
Between ECU connector K 45 and

Accelerator pedal Terminal 2
Repair the connection

If the error is still present, then the Reconnect everything
ECU is suspect.
Ver 1 Apr 06
Automotive Sector
Replace ECU with a known good Clear codes and check camphase
one. sensor and Accelerator pedal are
Clear codes & verify. working properly.

Ver 1 Apr 06
P-1646
P-1647
Automotive Sector
Sensor supply monitoring 2
DTC Diagnostic item


Normal Operation
The ECU monitors the supply voltage to Rail
pressure sensor, HFM and accelerator pedal
(APP 2)
Malfunction
The voltages are beyond the range.
Reactions
System lamp status for this error is ON. The

ECU

Ver 1 Apr 06
Automotive Sector

• This is related to the rail pressure sensor, HFM and APP2 supply
voltage
• Check the connection of the rail pressure sensor, HFM & accelerator
pedal connector
• Is it OK?
Yes No

Ver 1 Apr 06
P-1646
P-1647
Automotive Sector
Remove the sensor connections of Repair the connection

the Rail pressure sensor , HFM & the
Accelerator pedal
Clear the error Clear codes and verify.
If the error heals then the problem
may be due to poor connection.
Does it heal?
No Yes
Clear the codes & verify. Check the continuity between the
ECU connector A29 and the HFM
terminal 4
Check the continuity between the
Rail pressure connector terminal 3
and terminal A14 of the ECU
Check the continuity of between
terminal 1 of the Accelerator pedal
(APP2) and K 46 of the ECU
Repair the connection

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

Ver 1 Apr 06
P-1654
P-1655
P-1656
P-1657
Automotive Sector
System lamp -Power Stage fault status
DTC Diagnostic item

P-1656 No Load

Normal Operation
• When Ignition is switched ON the system • Open, shorted or
lamp will glow ON for 2 sec. wrong connection of
• It will switch OFF if no error is set. system lamp circuit.
Malfunction
• When ignition is switched ON the system
lamp does not glow ON.

System Lamp Ver 1 Apr 06
P-1654
P-1655
P-1656
P-1657
Automotive Sector

3. Verify that either P1654 or P1655 or P1666 or P1667 is present.
P-1654
P-1655
P-1656
P-1657
Automotive Sector

• The connections to the system lamp.
• Check the continuity between the ECU terminal K71 with system lamp
• Is it OK?
Yes No
Turn the Ignition OFF Check the fuse.

Disconnect ECU connector A Repair the wire.
Measure the continuity of Ground Clear the error codes & verify
sensor harness.
Is it OK?
Yes No
Lamp failure Repair the connection.

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

P-0503
P-0500
P-0501
Automotive Sector
Vehicle speed sensing
DTC Diagnostic item

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

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

Vehicle Speed Sensing
Ver 1 Apr 06
P-0503
P-0500
P-0501
Automotive Sector

3. Verify that either P0503 or P0500 or P0501 is present.
• Drive the vehicle

• Does the speedometer show the correct value? (Compare the values of
speedometer with the value visible in the “Insight”- use the live data tab in
Insight.)
• Is it OK?
Yes No
Turn the Ignition OFF Repair the cable ( from the pin no 1 to
pin no 5 of the instrument cluster socket-
Ver 1 Apr 06
P-0503
P-0500
P-0501
Automotive Sector
C24)
Inspect the interface between the VSS Clear the error codes & verify
and the speedometer gear in the Gearbox
Is it OK?
Yes No
Disconnect VSS Repair the interface between he

speedometer & the VSS
Disconnect ECU connector Clear codes & verify that VSS signal is
within limit.
Measure the continuity between the
ECU terminal K75 and sensor terminal
3
Is it OK?
Yes No
Check the open circuit between the Repair the wire between VSS connector
sensor Ground & positive supply & ECU terminal
Is it OK Clear codes & verify that VSS signal is
within limit.
Yes No
Verify that the ECU connections are OK Repair short circuit to Ground or
another circuit in wire between VSS
harness connector
If OK replace VSS with a known good Clear codes and verify that the VSS
VSS signal is within range.
Clear codes and verify that the VSS
signal is within range.
If problem persist- replace ECU

Ver 1 Apr 06
Description Error
Type
code System Lamp Status
Sys lamp
Blink On Off
Fault path of air condition power stage blink ☼
AC power stage Short Circuit Battery P-1530 ☼
AC power stage Short Circuit Ground P-1531 ☼
AC power stage No Load P-1532 ☼
AC power stage Excess Temperature P-1533 ☼ TSG
Fault path 1 for air condition pressure off
Air condition pressure: Period Maximum error signal range check P-1800
higher Ø
Air condition pressure: Period Minimum error signal range check P-1801
lower Ø
air condition pressure Duty Cycle Minimum error P-1802 Ø
air condition pressure Duty Cycle Max error P-1803 NA
Fault path 2 for air condition pressure off
air condition pressure entering the Special Operation sector P-1804 Ø
air condition pressure PresDSMDeb1Type P-1805 Ø NA
Fault path for analog air condition pressure off
analog air condition pressure : Voltage above upper limit P-1806 Ø
analog air condition pressure: Voltage below lower limit P-1807 Ø NA
Fault path of air condition power stage off
air condition power stage: CAN Msg. TimeOut error P-1808 Ø
air condition power stage :Non-Plausible CAN Msg. Value P-1809 Ø NA
Error status of ADC monitoring on
ADC monitoring : SRC-High error of ADC reference voltage P-1600
●
ADC monitoring : SRC-Low error of ADC reference voltage P-1601
● Connectors for
ECU
ADC monitoring : Test impulse error P-1602
●
ADC monitoring : ADC queue error P-1603
●
Intake Air Temperature sensor off
Intake Air Temperature sensor: Voltage above upper limit P-0113 Ø
Intake Air Temperature sensor: Voltage below lower limit P-0112 Ø TSG
error path for plausibility check of offset drift of airmass off
plausibility check of offset drift of airmass: airmass ADC raw value P-1101
> threshold high Ø
plausibility check of offset drift of airmass: airmass ADC raw value P-1102
< threshold low Ø
NA
fault path for plausibility check of sensitivity drift of airmass off
plausibility check of sensitivity drift of airmass: airmass ratio is P-1103
higher then threshold high Ø
plausibility check of sensitivity drift of airmass: airmass ratio is P-1104
lower then threshold low Ø
error path for signal range check of airmass blink
signal range check of airmass: Voltage above upper Limit P-0103 ☼ TSG
signal range check of airmass: Voltage below lower Limit P-0102 ☼
fault path of Acclerator Pedal 1 on
Acclerator Pedal 1: Voltage above upper limit P-0123
●
TSG
Acclerator Pedal 1: Voltage below lower limit P-0122
●
plausibility with APP2 violated P-1120
●
fault path of Accelerator Pedal 2 on
Accelerator Pedal 2: Voltage above upper limit P-0223
●
Accelerator Pedal 2: Voltage below lower limit P-0222
● TSG
Scoprio CRDe (All New) System lamp status 1of 10

Description Error
Type
Sys lamp
Blink On Off
plausibility with APP1 violated P-1220
● TSG
error path of atmospheric pressure sensor blink
TSG. (Aft.
atmospheric pressure sensor:Voltage above upper limit P-0108 ☼ Confirming 2-3
atmospheric pressure sensor: Voltage below lower limit P-0107 ☼ times change
atmospheric pressure sensor: Not plausible with boost pressure P-1106 ECU)
sensor ☼
Error path for AccPed and Brake Plausibility on
AccPed and Brake Plausibility: AccPed signal not plausible P-1221
● TSG
AirCtl permanent positive governor deviation off
AirCtl permanent positive governor deviation: Positive governor P-1400
deviation above limit Ø
AirCtl permanent negative governor deviation off
AirCtl permanent negative governor deviation: negative governor P-1401
deviation below limit Ø
fault path for short circuit to battery for BPA power stage off
BPA power stage:Short Circuit Battery P-1604 Ø
fault path for short circuit to ground for BPA power stage off
BPA power stage: Short Circuit Ground P-1605
fault path for no load and excess temparature for BPA power stage
off NA
BPA power stage: No Load P-1606 Ø
BPA power stage: Excess Temperature P-1607 Ø
Error path for Boost pressure sensor off
Boost pressure sensor: Voltage above upper limit P-0235 Ø
Boost pressure sensor:Voltage below lower limit P-0236 Ø
Boost pressure sensor: CAN signal defect P-1235 Ø
Boost pressure sensor: Not plausible with atmospheric pressure P-1236
sensor Ø
battery voltage fault off
battery Voltage above upper limit P-0563 Ø TSG
battery Voltage below lower limit P-0562 Ø
Error path for brake signal off
brake signal is defective P-1791 Ø
brake signals not plausible P-1792 Ø TSG
error path of coolant temperature sensor on
coolant temperature sensor Voltage above upper limit P-0118
●
coolant temperature sensor Voltage below lower limit P-0117
● TSG
coolant temperature sensor Can Msg. value defect P-1119
●
plausibility defect between OTS and CTS P-1121
● NA
error path of coolant temperature output off
coolant temperature output (on dash panel): Short circuit to battery P-1608
Ø
coolant temperature output (on dash panel): Short circuit to ground P-1609
Ø TSG
coolant temperature output (on dash panel): No load P-160A Ø
coolant temperature output (on dash panel): Excess temp. P-160B Ø
Coolant temperature sensor dynamic test off
Coolant temperature sensor dynamic test: Minimum temperature or P-1126
temperature raise no reached whithin time limit Ø NA
error path for Misfire cylinder 1 off
Misfire cylinder 1: number of recognized misfire events above limit P-0301
Ø

Description Error
Type
Sys lamp
Blink On Off
Ø
Ø
NA
Ø
Ø
Ø
error path for misfire in multiple cylinders off
misfire in multiple cylinders: number of recognized misfire events P-0300
above limit Ø
physical plausibility DCS off
physical unplausibility of DCS-demand P-180A NA
Ø
diagnostic fault path signals errors of main clutch signal off
CAN clutch signal is not defined P-1705 Ø NA
clutch signal is not plausible P-0704 Ø TSG
Error path for SRC,Plausibility -> Analog signal off
Cruise control key signal : SRC MAX error for analog signal P-0577 Ø
Cruise control key signal : SRC MIN error for analog signal P-0576 Ø TSG
Cruise control key signal : Plausibility error for analog signal P-0575 Ø
Error path for Key stuck -> Analog signal off
Cruise control Stuck key error for analog signal P-0574 Ø TSG
Error path for the Tachometer signal off
Tachometer signal: Short Circuit Battery P-160C Ø
Tachometer signal: Short Circuit Ground P-160D Ø TSG
Tachometer signal: No Load P-160E Ø
error path of environment air temperature sensor off
environment air temperature sensor: Voltage above upper limit P-160F Ø
environment air temperature sensor: Voltage below lower limit P-1610 Ø NA
environment air temperature sensor : Signal error, only in case of P-1611
CAN Ø
fault path for short circuit to battery for EGR power stage off
EGR power stage(EGR PWM) Short Circuit Battery P-0406 Ø
fault path for short circuit to ground for EGR power stage blink
EGR power stage(EGR PWM) Short Circuit Ground P-0405 ☼
fault path for no load and excess temparature for EGR power stage TSG
off
No Load for EGR power stage (EGR PWM) P-0403 Ø
excess temperature for EGR power stage (EGR PWM) P-0404 Ø
Errorpath for filtered energizing time of Cylinder 1 off
filtered energizing time of Cylinder 1: above upper limit of filtered P-1612
energizing time Ø
filtered energizing time of Cylinder 1: below lower limit of filtered P-1613
energizing time Ø
energizing time Ø

Description Error
Type
Sys lamp
Blink On Off
energizing time Ø
filtered energizing time of Cylinder 3:above upper limit of filtered P-1616
energizing time Ø
energizing time Ø
energizing time Ø
energizing time Ø
filtered energizing time of Cylinder 5: above upper limit of filtered P-161A
energizing time Ø
filtered energizing time of Cylinder 5: below lower limit of filtered P-161B
energizing time Ø
filtered energizing time of Cylinder 6: above upper limit of filtered P-161C
energizing time Ø
filtered energizing time of Cylinder 6: below lower limit of filtered P-161D
energizing time Ø
Errorpath for energizing time calibration injection of Cylinder 1 off NA
energizing time calibration injection of Cylinder 1: above upper limit P-161E
of energizing time Ø
energizing time calibration injection of Cylinder 1: below lower limit P-161F
Errorpath for energizing time calibration injection of Cylinder 2 off
energizing time calibration injection of Cylinder 2: above upper limit P-1620
energizing time calibration injection of Cylinder 2: below lower limit P-1621
energizing time calibration injection of Cylinder 6:above upper limit P-1628
Error path for the fuel consumption signal component driver output
stage off
fuel consumption signal component driver output stage: Short P-180B
Circuit Battery Ø
fuel consumption signal component driver output stage: Short P-180C
Circuit Ground Ø NA
fuel consumption signal component driver output stage: No Load P-180D Ø
fuel consumption signal component driver output stage: Excess P-180E
voltage Ø

Description Error
Type
Sys lamp
Blink On Off
Error path for the fuel consumption signal toggle output off
fuel consumption signal toggle output error P-180F Ø
error path of camshaft failure on
no camshaft signal P-0340
● TSG
wrong camshaft signal P-0341
●
error path of crankshaft failure on
no crankshaft signal P-0335
●
wrong crankshaft signal P-0336
● TSG
error path of offset between camshaft and crankshaft on
wrong offset between camshaft and crankshaft P-1340
●
fault FMTC_trq2qBas_MAP containes non strictly monotonus q
curves off
NA
FMTC_trq2qBas_MAP containes non strictly monotonus q curves: P-1810
Not plausible fault Ø
Fuel Temperature sensor blink
Fuel Temperature sensor: Voltage above upper limit P-0183 ☼ TSG
Fuel Temperature sensor: Voltage below lower limit P-0182 ☼
physical plausibility TSC off
physical unplausibility of (Gearbox)TSC-demand P-1811 NA
Ø
Error path for the glow control relay actuator blink
glow control relay actuator: Short Circuit Battery P-1387 ☼
glow control relay actuator: Short Circuit Ground P-1388 ☼
glow control relay actuator: No Load P-1389 ☼
glow control relay actuator: Excess Temperature P-1390 ☼
Error path for the glow display lamp off
glow display lamp: Short Circuit Battery P-1384 Ø TSG
glow display lamp: Short Circuit Ground P-1385 Ø
glow display lamp: No Load P-1386 Ø
glow display lamp: Excess Temperature P-138A Ø
Errors of Glow control unit off
failure of a glow plug, Relay failure, Short circuit in glow plug, over- P-0380
current Ø
Short circuit in glow plug,over-current,Relay got stuck P-1383 Ø
error state communication - SPI on
communication error of CJ940 P-162A TSG_Check
● connectors.
error state of EEPROM on
EEPROM: error during last read operation P-162B
●
TSG_Check
EEPROM: error during last write operation P-162C
● connectors.
EEPROM: default value used P-162D
●
error path for Recovery which is locked off
Hardware Recovery which is locked: a recovery has occurred P-162E Ø
error path for Recovery which is suppressed off
Hardware Recovery which is suppressed: a recovery has occurred P-162F Ø
error path for Recovery which is visible off
TSG_Check
Hardware Recovery which is visible: a recovery has occurred P-1630 Ø connectors.
error state supply voltage CJ940 upper limit on
(Hardware) CJ940 upper limit: internal supply voltage upper limit P-1631
●
error state supply voltage CJ940 lower limit on

Description Error
Type
Sys lamp
Blink On Off
(Hardware) CJ940 lower limit: internal supply voltage lower limit P-1632
●
error path of air temperature sensor off
air temperature sensor: Voltage above upper limit P-1633 Ø NA
air temperature sensor: Voltage below lower limit P-1634 Ø
Used to indicate when security function is not through on
Immobolizer control: indicates that the recieved pattern and the P-1812
transmitted pattern is not correct ● TSG
Fault path of injection limitation off
Number of injections limited by charge balance P-1635 Ø
Number of injections limited by quantity balance P-1636 Ø NA
Number of injections limited by software P-1637 Ø
fault path bank1-specific errors -> stop engine on
Injector bank 1: short circuit P-0201
●
Injector bank 1: short circuit on Low Side to ground P-1201
●
Injector bank 1 specific error depending on application P-1203
●
Injector bank 1 not-classifyable error P-1204
●
faultpath bank1-specific warnings -> stop engine on
Injector bank 1specific warning : depending on application P-1205
●
Injector bank 1specific warning : depending on application P-1206
●
Injector bank 1specific warning open load P-1207
●
Injector bank 1specific warning depending on application P-1208
●
faultpath bank2-specific errors -> stop engine on
Injector bank 2 short circuit P-0202
●
Injector bank 2: short circuit on Low Side to ground P-1202
●
Injector bank 2: specific error depending on application P-120A
●
Injector bank 2::not-classifyable error P-120B
●
faultpath bank2-specific warnings -> stop engine on
Injector bank 2:specific warnings depending on application P-120C
●
Injector bank 2:specific warnings depending on application P-120D
●
Injector bank 2:specific warnings: open load P-120E
●
Injector bank 2:specific warnings: depending on application P-120F
●
faultpath Chip-specific errors -> stop engine on
faultpath Chip-specific errors : CY33X internal reset / clockloss / P-1210
undervoltage ●
faultpath Chip-specific errors: CY33X is unlocked / CY33X init error P-1211
●
faultpath Chip-specific errors:CY33X is in Testmode P-1212
●
faultpath Chip-specific errors: CY33X SPI communication error P-1213
/checksum/readback ●
faultpath Chip-specific errors -> stop engine on
faultpath Chip-specific errors ->CY33X internal parity error P-1214
●
faultpath Chip-specific errors ->CY33X internal program flow error P-1215
●
faultpath Chip-specific errors ->CY33X check of inv. YSEL during P-1216
ON failed ●
faultpath Chip-specific errors ->CY33X ON timeout for at least 1 P-1217
cylinder ●
faultpath cylinder1-specific errors -> stop engine on

Description Error
Type
Sys lamp
Blink On Off
faultpath cylinder1-specific errors:short circuit on Low Side to P-0261
battery ●
faultpath cylinder1-specific errors: depending on application P-1261
●
faultpath cylinder1-specific errors: short circuit Low Side to High P-0262
Side ●
faultpath cylinder1-specific errors: not-classifyable error P-1262
●
faultpath cylinder1-specific warnings on
faultpath cylinder1-specific warnings-depending on application P-126A
●
faultpath cylinder1-specific warnings-depending on application P-126B
●
faultpath cylinder1-specific warnings-open load P-126C
●
faultpath cylinder1-specific warnings-depending on application P-126D
●
faultpath cylinder2-specific errors ->short circuit on Low Side to P-0264
battery ●
faultpath cylinder2-specific errors ->depending on application P-1264
●
faultpath cylinder2-specific errors ->short circuit Low Side to High P-0265
Side ●
faultpath cylinder2-specific errors ->not-classifyable error P-1265
● TSG
faultpath cylinder2-specific warnings:depending on application P-127A
●
faultpath cylinder2-specific warnings:depending on application P-127B
●
faultpath cylinder2-specific warnings:open load P-127C
●
faultpath cylinder2-specific warnings:depending on application P-127D
●
battery ●
●
Side ●
●
●
●
●
●
battery ●
●
Side ●
●
●
●
●
●

Description Error
Type
Sys lamp
Blink On Off
faultpath cylinder5-specific errors -> stop engine off
battery Ø
faultpath cylinder5-specific errors ->depending on application P-1814 Ø
Side Ø
faultpath cylinder5-specific errors ->not-classifyable error P-1816 Ø
faultpath cylinder5-specific warnings off
faultpath cylinder5-specific warnings:depending on application P-1817 Ø
faultpath cylinder5-specific warnings:open load P-1819 Ø
faultpath cylinder5-specific warnings:depending on application P-181A Ø
faultpath cylinder6-specific errors -> stop engine off
faultpath cylinder6-specific errors ->short circuit on Low Side to P-181B
battery Ø
faultpath cylinder6-specific errors ->depending on application P-181C Ø
faultpath cylinder6-specific errors ->short circuit Low Side to High P-181D
Side Ø
faultpath cylinder6-specific errors ->not-classifyable error P-181E Ø
faultpath cylinder6-specific warnings off
faultpath cylinder6-specific warnings:depending on application P-181F Ø
faultpath cylinder6-specific warnings:open load P-1821 Ø
Power Stage fault status for MIL off
Power Stage fault status for MIL:Short Circuit Battery P-1650 Ø
Power Stage fault status for MIL:Short Circuit Ground P-1651 Ø NA
Power Stage fault status for MIL:No Load P-1652 Ø
Power Stage fault status for MIL:Excess Temperature P-1653 Ø
error path for main relay blink
main relay does not open in time P-121A ☼ TSG
main relay opens too early P-121B ☼
error path of metering unit PWM-powerstage on
open load of metering unit output P-1250
●
excess temperature of metering unit powerstage P-1251
●
short circuit to battery of metering unit output P-1252
● TSG
short circuit to ground of metering unit output P-1253
●
error path of metering unit AD-channel off
signal range check high error of metering unit AD-channel P-1254
signal range check low error of metering unit AD-channel P-1255
the fault path contains the supervision of the communication
between Watchdog of CY310 and the controller.The path is used to
ECU Connectors
handle the reversible Shut-down of the system using the engine
coordinator on
Set, if error-counter of Watchdog or controller are not plausible or P-1638
the system must shut down ●
error path of oil temperature sensor off
oil temperature sensor:Voltage above upper limit P-0198 Ø
oil temperature sensor:Voltage below lower limit P-0197 Ø NA

Description Error
Type
Sys lamp
Blink On Off
NA
oil temperature sensor:signal error for CAN P-1198 Ø
oil temperature sensor:Plausibility error between OTS and CTS P-1199 Ø
Fault path for overrun monitoring on
Energising time exceeds limit of overrun monitoring P-1639
●
Fault path for redundant engine speed calculation in overrun
monitoring on TSG
redundant engine speed calculation in overrun P-163A
monitoring:Plausibility error in engine speed check ●
Permanent governor deviation in PCR off
Permanent governor deviation in PCR:positive governor deviation P-163B
above limit Ø
Permanent governor deviation in PCR off
Permanent governor deviation in PCR:negative governor deviation P-163C
below limit Ø
error path of power stage pre-supply pump off NA
power stage pre-supply pump:Short Circuit Battery P-163D Ø
power stage pre-supply pump:Short Circuit Ground P-163E Ø
power stage pre-supply pump:No Load P-163F Ø
power stage pre-supply pump:Excess Temperature P-1640 Ø
error path of rail pressure on
rail pressure:Voltage above upper limit P-0193
●
rail pressure:Voltage below lower limit P-0192
●
error path RPS offset monitoring on
RPS raw value is above maximum offset P-1190
●
RPS raw value is below minimum offset P-1191
●
faults for checks in MeUn controlled mode off
maximum positive deviation of rail pressure exceeded P-1192 Ø
maximum positive deviation of rail pressure exceeded concerning P-1193
Ø TSG
set flow of fuel
maximum negative rail pressure deviation with metering unit on P-1194
lower limit is exceeded Ø
minimum rail pressure exceeded P-1195 Ø
maximum rail pressure exceeded P-1196 Ø
faults for checks in MeUn controlled mode
on
setpoint of metering unit in overrun mode not plausible P-1197
●
Fault path for test of redundant shut off paths during initialization on
test of redundant shut off paths during initialization:Watch dog P-1641
switch off path defect ●
test of redundant shut off paths during initialization:Voltage P-1642
monitoring upper limit shut off path defect ● TSG
test of redundant shut off paths during initialization:Voltage P-1643
monitoring lower limit shut off path defect ●
sensor supply voltage 1 on
sensor supply voltage 1:Voltage above upper limit P-1644
● TSG
sensor supply voltage 1:Voltage below lower limit P-1645
●
sensor supply voltage 2 on
sensor supply voltage 2:Voltage above upper limit P-1646
● TSG

Description Error
Type
Sys lamp
Blink On Off
TSG
sensor supply voltage 2:Voltage below lower limit P-1647
●
sensor supply voltage 3 off
sensor supply voltage 3:Voltage above upper limit P-1648 Ø NA
sensor supply voltage 3:Voltage below lower limit P-1649 Ø
Power Stage fault status for System lamp off
Power Stage fault status for System lamp:Short Circuit Battery P-1654 Ø
Power Stage fault status for System lamp:Short Circuit Ground P-1655 Ø TSG
Power Stage fault status for System lamp:No Load P-1656 Ø
Power Stage fault status for System lamp:Excess Temperature P-1657 Ø
error path for terminal 15 - contains plausibility error [Sig] of T15 off
No Terminal 15 signals detected P-1658 Ø TSG
TPU monitoring on
Deviation between TPU and system time P-1659 Harware_ECU
● Connection
fault path for short circuit to battery for TVA power stage off
TVA power stage:Short Circuit Battery P-165A Ø
fault path for short circuit to ground for TVA power stage off
TVA power stage:Short Circuit Ground P-165B Ø
fault path for no load and excess temparature for TVA power stage NA
off
TVA power stage:No Load P-165C Ø
TVA power stage:Excess Temperature P-165D Ø
Error Path for Coolant overheat Lamp powerstage off
Coolant overheat Lamp powerstage:Short Circuit Battery P-165E Ø
Coolant overheat Lamp powerstage:Short Circuit Ground P-165F Ø TSG
Coolant overheat Lamp powerstage:No Load P-1660 Ø
Coolant overheat Lamp powerstage:Excess Temperature P-1661 Ø
fault path for short circuit to battery for VSA power stage off
fault path for short circuit to ground for VSA power stage off
NA
fault path for no load and excess temparature for VSA power stage
off
fault path 1 for vehicle speed sensing off
exceeding of the maximum vehicle speed P-0503 Ø
HW signal for vehicle speed not valid P-0500 Ø TSG
vehicle speed not plausible with injection mass and engine speed P-0501 Ø
fault path 2 for vehicle speed sensing off
CAN signal for vehicle speed not valid P-1827 Ø
Errorpath for dataset variant coding, Npl=Requested variant could NA
not be set, Sig=variant dataset defect off
Signal fault P-1662 Ø
Not plausible fault P-1663 Ø
the fault path contains the supervision of the SPI-Handler on
Set, if SPI-communication failed P-1664
● Hardware
Injector energizing time
below lower limit of energizing time P-161F
below lower limit of energizing time P-1621

WIRING HARNESS LAYOUT
HARNESS
DESCRIPTION
No
1 INSTRUMENT PANEL (IP)
2 ENGINE ROOM
3 ENGINE
4 FLOOR
5 DOOR - FRONT RIGHT
6 DOOR - FRONT LEFT
7 DOOR - REAR RIGHT
8 DOOR - REAR LEFT
9 DOOR - BACK DOOR
10 ROOF
11 CENTRAL CONSOLE
12 FOOTSTEP LAMP (Only TC4)
2
10
1
11
5 7
12
6 8
INTER-CONNECTORS - LOCATIONS/PINS/VIEWS
DESCRIPTION LOCATION IC No PINS M/F CONNECTOR VIEW
FLOOR to CHASIS Near FUEL TANK 21 2 F
FLOOR to REAR DOOR B-PILLAR LEFT 22 6 M
ROOF to HM STOP LAMP REAR ROOF PANEL 23 2 F
IP to ENGINE ROOM (Only

in export models)
A-PILLAR RIGHT 24 3 M
M - MALE CONNECTOR WITH PINS

F - FEMALE CONNECTOR
IC- 1, 2, 3, 4, 5, 7,
8, 9, 13, 14, 24 IC- 19, 20
IC- 12 IC- 15
IC- 23
IC- 16 IC- 21
IC- 6
IC- 17
IC- 22
IC - 10 , 11 ,18
Scopio Upgrade_Inter Connectors

GROUND LOCATION CHART
GROUND No DESCRIPTION LOCATION
E1 BATTERY NEGATIVE TERMINAL TO BODY FRONT WHEEL HOUSE PANEL - LEFT
E2 FRONT AND REAR WASHER, EGR FRONT WHEEL HOUSE PANEL - LEFT
E3 PARK, TURN , HEADLAMP - LEFT FRONT WHEEL HOUSE PANEL - LEFT
PARK, TURN , HEADLAMP - RIGHT, CONDENSOR FAN, FRONT FOG, FLWI,
E4 WIPER FRONT
FRONT WHEEL HOUSE PANEL - RIGHT
REALY COILS, SIDE MARKER RIGHT, INTERIROR LAMPS, DIAGNOSTIC,

E5 4WD, ACT. MASTER
A-PILLAR RIGHT
E6 AUDIO A-PILLAR RIGHT

E7 HVAC A-PILLAR LEFT
SIDE MARKER LEFT , TANK UNIT, ILLUMINATION, POWER WINDOW SWITCH -
E8 REAR LEFT
A-PILLAR LEFT
E9
E10 UNUSED
ILLUMINATION POWER WINDOW SWITCH REAR RIGHT, REGISTRATION
E11 PLATE, TAIL LAMP RIGHT, CHSML, WIPER REAR
D-PILLAR RIGHT
E12 TAIL LAMP LEFT D-PILLAR LEFT

E13 UNUSED
E14 BATTERY NEGATIVE TERMINAL TO ENGINE ENGINE BLOCK - LEFT
FLWI - BRAKE FLUID LEVEL WARNING INDICATOR
CHMSL - CENTRAL HIGH MOUNTED STOP LAMP
E5, E6
E11
E4
E9
E13 E14
E10
E2
E3 E1
E12
E7, E8
MAIN FUSE/RELAY BOX - FUSES/CIRCUITS/RATINGS
FUSE No FUSE RATING COLOUR CIRCUIT FUSE No FUSE RATING COLOUR CIRCUIT
1 10A RED INTERIOR LAMPS 12 15A BLUE CIGAR LIGHTER & ACC.
2 10A RED FUEL LID OPERATION 13 15A BLUE FRONT WIPER MOTOR
3 20A YELLOW 4WD - ELECTRIC SHIFT 14 10A RED REAR WIPER MOTOR
4 30A GREEN CONDENSER FAN 15 20A YELLOW CRDe ECU K28
5 15A BLUE FRONT FOG LIGHT 16 10A RED TURN SIGNAL
6 15A BLUE REAR FOG LIGHT 17 10A RED PARKING LIGHTS
7 5A BROWN CRDe DIAGNOSTIC 18 10A RED AUDIO SYSTEM
8 15A BLUE DEMISTER 19 ----- ----- -----
9 5A BROWN SECURITY SYSTEM ECU 20 ----- ----- -----
10 20A YELLOW CENTRAL DOOR LOCKING 21 40A GREEN POWER WINDOW
11 15A BLUE AIR CONDITIONER 22 40A GREEN A/C BLOWER
AUX. FUSE/RELAY BOX - FUSES/CIRCUITS/RATINGS

FUSE No FUSE RATING COLOUR CIRCUIT
1 10A RED A/C REQUEST
2 10A RED HFM SENSOR SUPPLY
3 15A BLUE EGR/BRAKE/CLUTCH SWITCH
4 15A BLUE CRDe ECU SUPPLY - K05
5 15A BLUE CHECK ENGINE LAMP
6 10A RED CRDe ECU SUPPLY - K01
ENGINE COMPARTMENT FUSE/RELAY BOX - FUSES/CIRCUITS/RATINGS

FUSE No FUSE RATING COLOUR CIRCUIT
1 60A YELLOW
2 60A YELLOW
3 60A YELLOW GLOW PLUG
4 30A PINK CRDe ECU SUPPLY
5
6
7
8 15A BLUE HEADLAMP - HIGH
9 15A BLUE HEADLAMP - LOW
10 15A BLUE HORN/HAZARD
11
12 100A BLUE CHARGING SYSTEM
WIRE COLOUR CODES
WIRE CODE WIRE COLOUR
B BLACK
BL BLUE
G GREEN
GR GRAY
O ORANGE
P PINK
R RED
S SKY BLUE
V VIOLET
W WHITE
Y YELLOW
IP to FLOOR A-PILLAR RIGHT 1 21 F
IP to ENGINE FLOOR A-PILLAR RIGHT 4 20 M
IP to ENGINE FLOOR A-PILLAR RIGHT 5 5+2 M
BEHIND CENTER
IP to HVAC
BEZEL 6 5+2 F
IP to TRANSFER CASE A-PILLAR RIGHT 7 3 F
IP to TRANSFER CASE A-PILLAR RIGHT 8 2 M
IP to TRANSFER CASE A-PILLAR RIGHT 9 2 F
IP to ENGINE A-PILLAR LEFT 10 21 M

IP to ENGINE A-PILLAR LEFT 11 20 M
ENGINE ROOM to FOG WHEEL HOUSE

LAMP PANEL -RIGHT 12 2 M
FLOOR to ROOF WIRING A-PILLAR RIGHT 13 6 F
FLOOR to DRIVER DOOR A-PILLAR RIGHT 14 8 M
FLOOR to REAR DOOR B-PILLAR RIGHT 15 6 M
BELOW DRIVER
FLOOR to TRANSFER CASE
SEAT 16 2 F
FLOOR to CONSOLE BELOW CONSOLE 17 12+2 F
FLOOR to CO-DRIVER A-PILLAR LEFT 18 6 F
FLOOR to BACK DOOR D-PILLAR RIGHT 19 13 M
FLOOR to BACK DOOR D-PILLAR RIGHT 20 2 F

ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM
SYMBOL EXPLANATION
Y-R WIRE WITH COLOUR OF WIRE
Y- BASE COLOUR ; R - TRACER COLOUR

Y-R (Refer colour chart for colour codes)
WIRES - NOT JOINED
WIRES - JOINED
SHILEDED WIRE
TWISTED WIRE
CONNECTOR
>> IC12/17 IC12 - CONNECTOR NO
17 - PIN NO IN CONNECTOR 12
EARTH / GROUND
GROUND ON COMPONENT
POWER SOURCE - BATTERY
POWER SOURCE - DC
POWER SOURCE - AC
SYMBOL EXPLANATION
10 A FUSE WITH RATING & DIRECTION OF FLOW
COIL / INDUCTOR
RESISTANCE/RESISTOR
VARIABLE RESISTOR/RHEOSTAT
POTENTIOMETER
SWITCH - PUSH TO MAKE
SWITCH - TOGGLE
SWITCH - PUSH TO BREAK
SWITCH - ON/OFF
CAPACITOR
VARIABLE CAPACITOR
LAMP
SYMBOL EXPLANATION
INDICATOR LAMP
MOTOR
DIODE
ZENNER DIODE
LIGHT EMITTING DIODE (LED)
TRANSISTOR (NPN)
TRANSISTOR (PNP)
30
87 4-POINT, NO (NORMALLY OPEN) RELAY
85 86
30 87 4-POINT, NC (NORMALLY CLOSED) RELAY
85 86
SYMBOL EXPLANATION
30 87 4-POINT, NO (NORMALLY OPEN) RELAY WITH DE-SPIKING

DIODE
85 86
30 4-POINT, NC (NORMALLY CLOSED) RELAY WITH DE-SPIKING

87
DIODE
85 86
87
30
5 POINT RELAY (CHANGE OVER RELAY)
87a
85 86
87
30 5 POINT RELAY (CHANGE OVER RELAY) WITH DE-SPIKING
87a DIODE
85 86
SOLENOID

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SCORPIO CRDe

TROUBLE SHOOTING GUIDE

Sr. No. Description Page

Scorpio CRDe ( All New) Diagnostic Manual - Rev 1 Page 1 of 6

Scorpio CRDe ( All New) Diagnostic Manual - Rev 1 Page 2 of 6

Index -- DTC codes

DTC Diagnostic Item Page

Scorpio CRDe ( All New) Diagnostic Manual - Rev 1 Page 3 of 6

P-1212 Chip-specific errors:CY33X is in Test mode 93

P-1213 Chip-specific errors: CY33X SPI communication error 93

Scorpio CRDe ( All New) Diagnostic Manual - Rev 1 Page 4 of 6

P-1216 Chip-specific errors ->CY33X check of inv. YSEL during ON 93

Scorpio CRDe ( All New) Diagnostic Manual - Rev 1 Page 5 of 6

Scorpio CRDe ( All New) Diagnostic Manual - Rev 1 Page 6 of 6

Guidelines for Troubleshooting

During the fault diagnosis, under no circumstance, the traditional

If any arc welding has to be done then it is essential that besides

The trouble-shooting manual is done in a manner that all the trouble

Preliminary trouble shooting (common for all trouble codes)

• Ensure that the connectors are tightened properly to the sensors.

• Ensure battery voltage is between 8 to 16 Volts. It should not go

• Communication to the diagnostic tester will not be established in

• Following errors can be checked only when Engine is being

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The following errors can only be checked when the vehicle is

1. Vehicle speed sensor.

At this point of time it will be worthwhile to note that if an error has

If this step is skipped than it is highly probable that since no

Please take care to touch only the affected wires

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• Check for the connector’ conditions. Many times continuity is not

• Engine will go to limp home in following condition:

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• General sequence of trouble shooting: (To be done after basic checks

1. Check for connector’ tightness with respect to the sensor.

• For errors like voltage above/below limits or short circuit to

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• Before changing any components, ensure that the error is cleared at

• Trouble shooting methods related to Turbocharger (Noise, loss of pick

Complaint : Vehicle not responding to accelrator. May be permanent or

Complaint : Vehicle response is poor ,also black smoke at lower RPM’s.

Method to check- the easiest method is to disconnect the HFM

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Complaint : Black smoke at all RPM’s

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DTC Diagnostic item

DTC detection condition Probable cause

K45 K09 K30 K46 K31 K08

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Test Procedure APP1 –

1. Connect the Insight to diagnostic connector.

• Turn Ignition switch OFF & disconnect Accelerator pedal connector.

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Turn Ignition OFF

Measure the continuity between Measure the continuity between

Reconnect. Before reconnection Repair the damaged line/