Diagnostic Manual-Indica Petrol BSIII Family - Valeo - Ver1.0

TML – Trouble Shooting Guide For Doc. No.
:
475 MPFI Engine’s Fault Codes (DTC) Version : 1.0
TROUBLE SHOOTING GUIDE

FOR 475 MPFI ENGINE’S FAULT CODES (DTC)
PURPOSE:
The purpose of this document is to give details of the Diagnostic trouble code (in short
DTC), its effect on the engine performance and guidelines to resolve them.
This document describes the diagnosis carried out by the Valeo ECU (S2000GEN
software). It also provides the required information for a quick interpretation of the
possible faults recorded by diagnosis tool or a scan-tool.
Besides, the possible causes and repairing steps are given.
NOTE:
It is applicable to all engines in the 475 SI family with Valeo Engine management System (VEMS)
at BSIII emission level.
The engines includes 1.2ltr (65Ps), 1.4ltr (70Ps, 85Ps, 100Ps) engines. The applicable vehicles
are Indica, Indigo and Marina vehicles. The details provided are generic and can be followed for
all engine types mentioned above.
Author: Viswanatha HC Page 1 of 75

Dept : ERC Eng
Project: 475 MPFI Engine Diagnostics Copyright © with TATA MOTORS
This document must not be used in any way, such as copying and redistributing to third parties, without our consent
TML – Trouble Shooting Guide For Doc. No. :
Revision History
Page No. for

Prepared By Approved By Date Reason For Changes Changes Ver.
Viswanatha H C
L Srinivasan 07.07.07 - Draft
Muthu Shanmugam -
Viswanatha H C -
L Srinivasan 25.07.07 New release 1.0
Muthu Shanmugam

Dept : ERC Eng
Contents of the document
1 What Is DTC? ........................................................................................................................................ 5

2 Structure of DTC.................................................................................................................................... 5
3 DTC list.................................................................................................................................................. 6
4 How read the DTC fault code ................................................................................................................ 7
4.1 Tata Diagnostic Tool (TDT) ........................................................................................................................................8
4.2 Diagnostic link connector (DLC).................................................................................................................................9
4.3 Check Engine Lamp (CEL)..........................................................................................................................................9
5 Electronic control unit (ECU) ................................................................................................................ 9
5.1 ECU Pin Out details ...................................................................................................................................................10
6 CEL & DTC Management ................................................................................................................... 14
6.1 CEL Activation Strategy ............................................................................................................................................14
6.2 CEL Extinguishing.....................................................................................................................................................14
6.3 Non monitoring (Inactivation) Zone ..........................................................................................................................14
7 Repairing steps..................................................................................................................................... 14
8 Diagnosis Forms .................................................................................................................................. 15
CAMSHAFT DIAGNOSIS .............................................................................................................................................................16
INTAKE AIR TEMPERATURE SENSOR DIAGNOSIS - I ....................................................................................................................18
INTAKE AIR TEMPERATURE SENSOR DIAGNOSIS - II ...................................................................................................................20
PUMP AND ACTUATORS RELAY DIAGNOSIS ................................................................................................................................21
IGNITION COIL (A) CONTROL DIAGNOSIS ...................................................................................................................................23
IGNITION COIL (B) CONTROL DIAGNOSIS ...................................................................................................................................25
UPSTREAM O2 SENSOR HEATING DIAGNOSIS .............................................................................................................................27
LOW BATTERY VOLTAGE DIAGNOSIS ........................................................................................................................................28
HIGH BATTERY VOLTAGE DIAGNOSIS ........................................................................................................................................29
THROTTLE ANGLE DIAGNOSIS (LOW) ........................................................................................................................................30
THROTTLE ANGLE DIAGNOSIS (HIGH) .......................................................................................................................................32
WATER TEMPERATURE SENSOR FUNCTIONAL DIAGNOSIS ..........................................................................................................33
WATER TEMPERATURE SENSOR ELECTRICAL DIAGNOSIS - I.......................................................................................................35
WATER TEMPERATURE SENSOR ELECTRICALDIAGNOSIS - II ......................................................................................................36
VEHICLE SPEED DIAGNOSIS - I ...................................................................................................................................................37
VEHICLE SPEED DIAGNOSIS - II..................................................................................................................................................38
KNOCKING SIGNAL DIAGNOSIS ..................................................................................................................................................39
UPSTREAM O2 SENSOR DIAGNOSIS - I .......................................................................................................................................41
UPSTREAM O2 SENSOR DIAGNOSIS - II ......................................................................................................................................43
OXYGEN SENSOR DIAGNOSIS .....................................................................................................................................................44
UPSTREAM O2 SENSOR DIAGNOSIS - III.....................................................................................................................................45
COOLING FAN RELAY CONTROL DIAGNOSIS ...............................................................................................................................46
INTAKE PRESSURE ELECTRICAL DIAGNOSIS - I...........................................................................................................................47
INTAKE PRESSURE ELECTRICAL DIAGNOSIS - II..........................................................................................................................49
INTAKE PRESSURE FUNCTIONAL DIAGNOSIS ..............................................................................................................................50
ECU DIAGNOSIS - I....................................................................................................................................................................51
ECU DIAGNOSIS - II ..................................................................................................................................................................52
ECU DIAGNOSIS - III .................................................................................................................................................................53
ECU DIAGNOSIS - IV.................................................................................................................................................................54
SENSORS SUPPLY DIAGNOSIS (Supply 1) ..............................................................................................................................55
SENSORS SUPPLY DIAGNOSIS (Supply 2) ..............................................................................................................................56
FUEL INJECTOR CONTROL DIAGNOSIS (CYLINDER N°1)..............................................................................................................57
ADDITIONAL AIR STEPPER (ISC VALVE) CONTROL DIAGNOSIS ..................................................................................................62
CANISTER PURGE VALVE CONTROL DIAGNOSIS .........................................................................................................................64

Dept : ERC Eng
AIR-CONDITIONING COMPRESSOR CONTROL DIAGNOSIS ............................................................................................................66

MALFUNCTION INDICATOR LIGHT CONTROL DIAGNOSIS ............................................................................................................67
MISFIRE DIAGNOSIS - I ..............................................................................................................................................................68
MISFIRE DIAGNOSIS - II .............................................................................................................................................................69
MISFIRE DIAGNOSIS - III............................................................................................................................................................70
AIR/FUEL ADAPTATION DIAGNOSIS - I .......................................................................................................................................71
AIR/FUEL ADAPTATION DIAGNOSIS - II ......................................................................................................................................72
AIR/FUEL ADAPTATION DIAGNOSIS - III.....................................................................................................................................73
AIR/FUEL ADAPTATION DIAGNOSIS - IV ....................................................................................................................................74
ADAPTATIONS OBSERVATIONS DIAGNOSIS ................................................................................................................................75

Dept : ERC Eng
1 What Is DTC?
DTC or Diagnostic Trouble Code (also known as Diagnostic fault code) is a standard code can be defined
as per SAE J1930 as an alphanumeric identifier for a fault condition identified by the ‘On Board
Diagnostic System’.
Diagnostics: The process of identifying the cause or nature of a condition, situation, or problem; to
determine corrective action in repair of automotive systems.
Diagnostic trouble codes are stored in the ECU’s (Electronic Control Unit) memory can be read/accessed
through a diagnostic tool designed to do so. The codes are stored in response to a problem/fault found
in the vehicle.
Each code identifies a particular problem area and is intended to provide the information to the
technician to quickly locate/identify where the fault might be occurring in the vehicle.
2 Structure of DTC
DTC is a five character alphanumeric number. The first character being alphabet represents the area of
the generated the code. For example power-train, body chassis etc. Definitions of next four numeric
characters are represented in the following way:
Example: P0301 – Misfire Cylinder no 1
In general, codes that begin with ‘P0’ are Generic codes, whereas codes that begin with ‘P1’ are
manufacturer-specific.

Dept : ERC Eng
3 DTC list
List of all the Diagnostic Trouble Codes applicable for the Tata 475 SI engines (BSIII) are given in the
table below. The table contains the exact code description may vary depending upon the make/type of
the diagnostic tool used.
Sl
no P CODE Code Description ERR_CAUSE
Problem in Pressure relevance in stalled
1 P0106 Pressure Sensor Functional Fault engine or Pressure drop at starting or
Pressure High or Pressure Low
2 P0107 Inlet Pressure Sensor Electrical Fault Short Circuit at ground
Open Circuit or pressure Threshold
3 P0108 Inlet Pressure Sensor Electrical Fault
Reached
4 P0112 Admission Air Temperature Sensor Fault Short circuit to ground
5 P0113 Air Temperature Sensor Fault Short circuit at +Ve or Open Circuit
Temperature coherence at starting;
6 P0116 Water Temperature Sensor Fault
Temperature tracker fault
7 P0117 Water Temperature Sensor Fault Short Circuit at ground ( Hot Range)
Short circuit at +Ve ; Open Circuit ( Cold
8 P0118 Water Temperature Sensor Fault
Range); Temperature Threshold reached
9 P0122 Throttle Position Fault Low Throttle Position
10 P0123 Throttle Position Fault High Throttle Position
11 P0130 Up-Stream O2 Sensor Fault Problem in Sensor Signal
12 P0131 Up-Stream O2 Sensor Fault Problem with Sensor Ground connection
Problem with Sensor Signal Voltage not in
13 P0132 Up-Stream O2 Sensor Fault
the Range
Duration of lean to rich transition;
14 P0133 Oxygen Sensor Fault Duration of rich to lean transition;
Variations period; signal cyclic ratio.
15 P0134 Up-Stream O2 Sensor Fault Sensor Open Circuit
Short circuit at +Ve ; Short Circuit at
16 P0135 Up-Stream O2 Sensor Heating Fault
ground
17 P0170 Air Fuel Adaptation Fault
Short Circuit at Ground / Open circuit at
18 P0201 Fuel Injector 1 Fault
INJ1
INJ2
INJ3
INJ4
22 P0262 Fuel Injector Fault 1 Short Circuit at +Ve INJ1
Misfire Fault leading to Catalyst damage; High Emission ; polluting Emission due to
26 P0300
Lambda regulation In thrust Misfire
27 P0301
Lambda regulation In thrust - cyl 1 Misfire cylinder 1
28 P0302
29 P0303
30 P0304
Low knocking signal ; Low instantaneous
31 P0326 Knock Signal Fault
noise detection
32 P0341 Camshaft Position Sensor Fault Sensor Signal open or Short circuit

Dept : ERC Eng
33 P0351 Ignition Coil Fault (Coil A) Short circuit at +Ve

34 P0352 Ignition Coil Fault (Coil B) Short Cicuit at ground; Open Circuit
35 P0444 Canister Purge Control Fault Short Circuit at GND
36 P0445 Canister Purge Control Fault Short Circuit at +Ve
37 P0481 Cooling fan relay control Fault Fan Relay fault
38 P0501 Vehicle Speed Functional Fault Functional diagnosis
39 P0503 Vehicle Speed Electrical Fault Interference signal
Short Circuit at +Ve or GND or Open
40 P1538 Additional Air Stepper Control Fault
circuit
41 P0562 Low Battery Voltage Fault Low Voltage Threshold reached
42 P0563 High Battery Voltage Fault High Voltage Threshold reached
43 P0601 Fault in the ECU Tele - chk fault
44 P0603 Fault in the ECU Kam Fault
45 P0604 Fault in the ECU Ram Fault
46 P0606 Fault in the ECU SPI Fault
Voltage level problem ; High level
47 P0608 Sensor Supply1 Fault Threshold problem or low level Threshold
problem or
Voltage level problem ; High level
48 P0609 Sensor Supply2 Fault Threshold problem or low level Threshold
problem or
49 P0650 MIL indicator light control fault Short Circuit at +Ve or at GND
50 P1123 Air Fuel Adaptation Fault - Fuel Fuel Adaptation fault
51 P1128 Adaptations observations diagnosis Adaptation condition not met
52 P1351 Misfire Fault ;Catalyst damage Misfire fault, can lead to Catalyst damage
53 P1352 Misfire Fault ; Catalyst damage - cyl 1 Misfire detected on Cylinder 1

57 P1371 Misfire Fault; Low Fuel Adaptation Low Fuel Adaptation
Misfire rate is high enough to alter the Misfire fault; Flywheel tolerances/gap
58 P1379
emission performances fault
Short Circuit at Ground or +Ve or Open
59 P1538 Additional air stepper control diagnosis
Circuit
Air-conditioning compressor control
60 P1558 Compressor control Short circuit at +Ve
diagnosis
61 P1559 Air Fuel Adaptation Fault - Stepper Air Fuel Adaptation Fault - Stepper
62 P1626 Supply Relay Fault Open Circuit at +Ve or at ground
63 P1628 Second indicator light control fault Short Circuit at +Ve or at GND
4 How read the DTC fault code

The DTC codes can be read/accessed by using Tata Diagnostic Tool. The tool through the
diagnostic connector will communicate with ECU and read the memory areas and display the
details.
The basic contents of the tool are…
- LAPTOP/ Desk top PC with the software
- Interface Unit (M/s Silicone Engines)
- Communication Cables (OBD & RS232)

Dept : ERC Eng
The following picture shows schematic view of the tool connection details. Please note that the
DLC – Diagnostic link connector is located below co-driver seat (ref section 3.2).
Diagnostic Tool Connections – Schematic View
4.1 Tata Diagnostic Tool (TDT)

The Diagnostic tool is developed for the Tata Vehicle applications, has a capability to communicate with
the ECU on a serial K-line interface. The Tester comprises a vehicle interface unit and custom built user
friendly application software. The user can load it on laptop/Desktop PC.
The vehicle interface unit is light weight and compact in size to facilitate easy portability. This works on
vehicle battery supply. This tester will execute all the commands supported by ECU, which help in
diagnosis of EMS.
The tester provides the information/data sorted in different frame for the effective use. The frames are
menu driven and are
1) Read different Dynamic (actual) data:-
a. Fuelling Data
b. Ignition data
c. O2 Sensor’s Information
d. Engine Sensor Information
e. Drive Information
f. Engine Information
2) Read Failure Codes (DTC)
3) Clear Failure Codes (DTC)
4) Read Failure Context Frame
5) Read Vehicle Identificationn number
6) Read Software Calibration Identification number
7) Read ECU Identification
8) Actuator Test
¾ Fuel injectors (individual)
¾ Power supply relay
¾ Air-conditioning compressor relay
¾ Idle controller
¾ Ignition coil A
¾ Ignition coil B
¾ Cooling fan 1
¾ Cooling fan 2
¾ Canister purge valve
¾ CEL
It is advisable to use the tool for easy diagnosis of ant DTCs. (More information on the Tool like features,
operations etc, please refer the manuals of the TDT).
Dept : ERC Eng
4.2 Diagnostic link connector (DLC)

Tata Diagnostic tool connected to this link communicates to the ECU and reads the memory locations
where the DTC related information is stored. The front end display system presents this data in a user
friendly way.
Diagnostic Link Connector (DLC)
The diagnostic link connector located at the bottom of the co-drive seat, is a standard
ISO 16 pin connector (see fig).
4.3 Check Engine Lamp (CEL)

CEL - Located in the instrument cluster, indicates the presence of any malfunction/fault in the
system/component to the customer.
On ignition ‘ON’ the Check engine lamp comes ON and after engine starting it goes OFF. In case of any
memorized malfunction/fault in the EMS, the lamp remains ON alerting the presence of the abnormality
to the user.
The CEL remains ON as long as the fault is active unless until either the fault is ‘erased’ or it has been
rectified.
5 Electronic control unit (ECU)

Electronic Control Unit (ECU) - ‘Brain’ of the Engine Management System, is central unit, which controls
all the actuators based on the processing of the Sensors inputs in conjunction with various control
algorithms for the optimum working of the Engine/Vehicle.
It is located inside the engine compartment between the battery and the suspension tower. Being the
most important component of the Engine management system, ECU apart from ensuring the optimum
working of the Vehicle, also works as ‘watch dog’ – means keeps an ‘eye’ on the working of the sensors
and actuators. When ever a malfunction/fault occurs in the component or the system the ECU alerts the
user by latching CEL. Apart from latching the lamp the ECU also does the following…
- Stores a DTC in its memory (indicates the faulty component/system)

Dept : ERC Eng
- Stores a context frame (list of parameters indicating the operating condition during the fault
generation) in its memory.
- ‘Limp-home’ or default mode will be activated (if available).
5.1 ECU Pin Out details

The ECU has 84pins allocated in three different connectors viz, M1, CP and M2. Each connector has
matrix of pins with proper identifications (row and column numbers).
ECU CONNECTOR DETAILS
Examples of How identify the Pin is also shown in the picture.

Pin by Pin wiring assignment details are shown in the table below (for latest pin assignment details,
please refer respective vehicle wiring harness diagrams).

Dept : ERC Eng
Connector M1 Connector M2
PIN Cable PIN Cable
No PIN ASSIGNMENT Colour Code No PIN ASSIGNMENT Colour Code
M1 A1 NOT USED - M2 A1 NOT USED
M1 A2 AIR TEMPERATURE SENSOR BR M2 A2 MAP SENSOR GROUND 1 BrB
M1 A3 SENSOR GROUND 2 LgW M2 A3 UPSTREAM LAMBDA SENSOR + B
M1 A4 Vbatt SWITCH BR M2 A4 NOT USED
M1 B1 NOT USED - M2 B1 ENGINE SPEED SENSOR + W
M1 B2 NOT USED - M2 B2 ENGINE SPEED SENSOR - B
M1 B3 KNOCK SENSOR - B M2 B3 UPSTREAM LAMBDA SIGNAL INPUT - W
M1 B4 THROTTLE POSITION BrG M2 B4 NOT USED -
M1 C1 NOT USED - M2 C1 INLET AIR PRESSURE WO
M1 C2 NOT USED - M2 C2 NOT USED
M1 C3 KNOCK SENSOR + W M2 C3 SENSOR +5V_2 VR
M1 C4 ALTERNATOR CURRENT BrY M2 C4 NOT USED
M1 D1 NOT USED - M2 D1 ICS STEPPER DRIVER OUTPUT D LGO
M1 D2 DOWNSTREAM LAMBDA SENSOR HEATER BrG M2 D2 ICS STEPPER DRIVER OUTPUT B WV
M1 D3 DOWNSTREAM LAMBDA SENSOR - B M2 D3 ICS STEPPER DRIVER OUTPUT C RL
M1 D4 WATER TEMPERATURE INPUT - Rg M2 D4 NOT USED
M1 E1 NOT USED - M2 E1 SENSOR +5V_1 WY
M1 E2 UPSTREAM LAMBDA HEATING DRIVER PB M2 E2 NOT USED
M1 E3 DOWNSTREAM LAMBDA SIGNAL INPUT + W M2 E3 ICS STEPPER DRIVER OUTPUT A GR
M1 E4 WATER TEMPERATURE INPUT + BrW M2 E4 NOT USED
M1 F1 NOT USED - M2 F1 NOT USED
M1 F2 MAIN RELAY DRIVER P M2 F2 PURGE CANISTER YL
M1 F3 CAM SENSOR INPUT W M2 F3 POWER RELAY WG
M1 F4 NOT USED - M2 F4 NOT USED
M1 G1 NOT USED - M2 G1 CHECK ENGINE LAMP LR
M1 G2 NOT USED - M2 G2 INJECTOR CYLINDER 3 YL
M1 G3 COILS 1 AND 4 WL M2 G3 INJECTOR CYLINDER 2 YL
M1 G4 NOT USED - M2 G4 NOT USED
M1 H1 NOT USED - M2 H1 POWER GROUND n4 Br
M1 H2 NOT USED - M2 H2 INJECTOR CYLINDER 1 LG
M1 H3 COILS 2 AND 3 G M2 H3 INJECTOR CYLINDER 4 LgP
M1 H4 POWER GROUND n3 BR M2 H4 NOT USED

Dept : ERC Eng
Connector CP
PIN Cable
No PIN ASSIGNMENT Colour Code
CP A1 NOT USED
CP A2 NOT USED
CP A3 NOT USED
CP A4 NOT USED
CP B1 NOT USED
CP B2 NOT USED
CP B3 L-LINE RG
CP B4 IGNITION SWITCH INPUT GR
CP C1 NOT USED
CP C2 NOT USED
CP C3 AIR CON O/P (Relay Driver) GP
CP C4 CHECK ENGINE LAMP (CEL) WP
CP D1 NOT USED
CP D2 NOT USED
CP D3 AC REQUEST INPUT BY
CP D4 NOT USED
CP E1 NOT USED
CP E2 COOLING FAN - HIGH SPEED GY
CP E3 POWER STEERING STOP INPUT GrW
CP E4 NOT USED
CP F1 NOT USED
CP F2 NOT USED
CP F3 ANTI THEFT LINK WG
CP F4 NOT USED
CP G1 NOT USED
CP G2 VEHICLE SPEED SENSOR INPUT V
CP G3 NOT USED
CP G4 NOT USED
CP H1 NOT USED
CP H2 K LINE YR
CP H3 NOT USED
CP H4 NOT USED
CP J1 NOT USED
CP J2 NOT USED
CP J3 NOT USED
CP J4 COOLING FAN 1 (RELAY DRIVER) Y
CP K1 NOT USED
CP K2 NOT USED
CP K3 NOT USED
CP K4 FAN 2 RELAY DRIVER YB
CP L1 NOT USED
CP L2 NOT USED
CP L3 NOT USED
CP L4 POWER GROUND1 Br
CP M1 NOT USED
CP M2 NOT USED
CP M3 LOW FUEL LEVEL INPUT VR
CP M4 POWER GROUND2 Br

Dept : ERC Eng
Note:
FOR VERSION: NON AC WITH POWER STEERING

All pin outs are same as the reference (above tables) except
CP D3 AC REQUEST INPUT BY NOT CONNECTED

CP C3 AC COMPRESSOR DRIVER GP 12 V SUPPLY
CP E2 COOLING FAN HIGH SPEED GY NOT CONNECTED
FOR VERSION: NON AC WITHOUT POWER STEERING

All pin outs are same as the reference (above tables) except
CP D3 AC REQUEST INPUT BY NOT CONNECTED

CP C3 AC COMPRESSOR DRIVER GP 12 V SUPPLY
CP E2 COOLING FAN HIGH SPEED GY NOT CONNECTED
CP E3 POWER STEERING STOP INPUT GrW NOT CONNECTED
For the cable colour codes please refer the table below:
Cable Code Cable Colour

B BLACK
Br BROWN
G GREEN
Gr GREY
L BLUE
O ORANGE
P PINK
R RED
W WHITE
Y YELLOW
V VIOLET
Lg LIGHT GREEN
Sb SKY BLUE
Cable Colour Codes

Dept : ERC Eng
6 CEL & DTC Management

Software systems are present in the engine control system (ECU) to check correct performance of
Sensors and actuators, and also to check electrical circuit continuity. Open or short circuits can be
detected quickly, whereas correct performance checks by the system's internal monitors are only made
when the engine is in stable conditions for which calibrations are available – for example, cruising at
steady speed.
The software monitors run under defined conditions and can signify that they have run correctly. If the
necessary conditions are not met or are not met for long enough in a trip then the monitors will not run
to completeness.
If a particular monitor ran successfully during a trip after a fault had been detected on an earlier trip but
found no fault then the Diagnostic system could use the information as part of a self-heal process to
recognize a disappeared CEL-active fault en route to CEL deactivation.
6.1 CEL Activation Strategy

The CEL is illuminated to alert the driver after a valid trip when a CEL-active monitor detects and checks
that a fault is present, except for ignition coils and fuel injectors faults the MIL is immediately
active.
A ‘bulb-check’ feature is included to confirm to the driver that the bulb for the CEL is in sound condition
at the start of each trip. The CEL is illuminated at key-on and extinguishes after moving from crank to
run under this strategy. If CEL illumination follows the bulb check, a fault having significant adverse
consequence has been detected.
6.2 CEL Extinguishing

The CEL is extinguished on the fourth drive cycle after a detected CEL-active fault is no longer detected.
But the related information (like P code) will still retained in the memory (as a fugitive) till 40 drive
cycles after which will be erased automatically. It will give information about the history of the faults.
In case of an ‘erasing’ action done via a diagnostic tool, no information will be retained in the ECU
memory.
6.3 Non monitoring (Inactivation) Zone

Monitoring above 2500m altitude and below ambient temperature of –7°C is unreliable because of
driving pattern differences to the target regions, lying above that temperature. The misfire monitoring
strategy is disabled when the fuel level in the tank is below 20% due to the possibility of the air getting
in the system and engine rpm above 4500 rpm. Therefore, the diagnostic system is disabled under this
condition.
7 Repairing steps
Use the DTC codes in conjunction with the vehicle's service manual to ascertain which
systems, circuits or components should be checked or tested for the correct diagnosis of
the fault.

Dept : ERC Eng
It also advised that the parts or components should not be replaced with only a
reference to a DTC. The vehicle service manual should be consulted for more information
on possible causes of the fault, along with required testing.
For example, if a DTC reports a sensor fault, note that replacement of the sensor may not
be the solution always. It may not resolve the underlying problem. The root cause for the
fault may be by the systems that the sensor is monitoring or but might even be caused by
the wiring harness connecting the sensor and the ECU.
DTCs may also be triggered by faults earlier down the line. For example, a dirty MAF sensor
might be causing the car to overcompensate in its fuel-trim adjustments. As a result,
oxygen sensors are likely to report fuel mixture problems.
After any repairing steps, erase all failures. Execute a driving cycle where you can bring
together all conditions to allow detection and check the failure with a diagnosis tool. If the
failure remains, check the next repairing step to remove it.
8 Diagnosis Forms
Each DTC (P Code) is explained in following tables (forms) contains the following
information:
- Fault Name and the respective P-Code (Failure code seen on diagnosis tools)
- Diagnosis type (Electrical or Functional)
- CEL lighting: does it light immediately or after a calibrated number of driving cycles?
- CEL: does the fault light the Check Engine Lamp or not?
- ECU Pin-out: corresponding ECU pin numbers
- Minimal conditions for the CEL latching
Apart from the above information the table also provides the information on the corresponding
sensor/actuators like
- operating principle
- location and mounting scheme
- wiring harness and connector
- impact of the respective DTC on the engine performance
- possible causes
- recommended repairing steps

Dept : ERC Eng
INDICA BS III
FORM N°1.
CAMSHAFT DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
Code Error Kind Indicator Light Emission Impact Lighting ECU PINOUT
Connector
CEL Yes After 1 DC Pin n°
P0341 Functional colour
Failure : AAC_capteur Black F3
1. OPERATING PRINCIPLE
The sensor works on the principle of ‘Hall Effect’. A signal voltage is generated by the sensor when the ‘target’ wheel passes through the
sensor supplied with 12V (supply). Based on the ‘signal’ info the ECU reads the position of the cam gear in turn the phase of the engine.
2. DIAGNOSTIC ACTIVATION CONDITIONS (Minimal conditions)
Engine running.
3. LOCATION & WIRING CONNECTIONS
4. DETECTION, DEFAULT MODE , IMPACT, CUSTOMER EFFECT
The misfire diagnosis is inhibited.

Sequential functioning but possibly not phased.
Possible driveability problems (jerking at certain driving conditions etc).
5. POSSIBLE CAUSES

Dept : ERC Eng
i. Air gap between the sensor and the target not respected (Spec 1.5± 0.5mm)
ii. Problem of sensor connection (Connector)
iii. Alignment issue – w r t crankshaft
iv. Wiring Harness – continuity/connection integrity
v. Faulty Sensor
6. REPAIRING STEPS
i. Check the sensor/target air gap (specs: 1.5 ± 0.5 mm)

ii. Check the wiring harness
iii. Replace the sensor
iv. Unitary checking of ECU input/output

Dept : ERC Eng
INDICA BS III
FORM N°2.
INTAKE AIR TEMPERATURE SENSOR DIAGNOSIS - I VARIANTS (PETROL)
CHARACTERISTICS
Connector
Electrical - CEL Yes After 1 DC Pin n°
P0112 colour
Short circuit
Failure : Temp_air_cc0 Black A2
A NTC device, changes the resistance when exposed to variable temperature source. Mounted on the Inlet manifold plenum, in contact
with the inlet air flow.
Ignition key on
This failure is registered if the measured voltage < 0.059V.

On permanent failure, air temperature is estimated according to the water temperature.
Influence on idling regulations, stepper control, injection etc
Degraded starting from cold. Issues on driveability in cold & warm up phase.
5. POSSIBLE CAUSES

Dept : ERC Eng
i. Problem of sensor connection

ii. Faulty sensor
6. REPAIRING STEPS
i. Check values of Air temperature through diagnostic tool.

ii. Check the wiring harness.

Dept : ERC Eng
INDICA BS III
FORM N°3.
INTAKE AIR TEMPERATURE SENSOR DIAGNOSIS - II VARIANTS (PETROL)
CHARACTERISTICS
Electrical - Connector
P0113 Short circuit or colour
open circuit Failures : Temp_air_cc1 and Temp_air_co Black A2
Ignition key on.
Fault is registered if measured voltage > 4.64V

In case of failure, the air temperature is estimated according to the water temperature.
Influence on idling instructions, stepper control, injection.
Degraded starting from cold. Impaired driveability in cold & warm up phase.
4. POSSIBLE CAUSES

ii. Faulty sensor
5. REPAIRING STEPS

Dept : ERC Eng
i. Check the wiring harness

ii. Replace the sensor
iii. Unitary checking of ECU input/output
INDICA BSIII
FORM N°4.
PUMP AND ACTUATORS RELAY DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
Electrical Connector
CEL No Immediate Pin n°
P1626 Open and Short colour
circuit Failures : actionneurs_cc and actionneurs_co Grey F3
1. OPERATING PRINCIPLE.
The ECU activates the power relay which in turn provides 12V supply to the various sensors & actuators.
Ignition key on.

2 different diagnosis : engine stopped, engine running
Battery voltage > 9V
4. DEFAULT MODE , IMPACT, CUSTOMER EFFECT
In some cases, the vehicle will be immobilised.
5. POSSIBLE CAUSES

Dept : ERC Eng
i. Problem of the relay power supply

ii. Faulty relay
6. REPAIRING STEPS
i. Check battery voltage, ground connections.

ii. Check the wiring harness for connections, blown fuses, improper relay seating.
iii. Check for fuel pump operation during ignition ‘ON’ or during cranking.
iv. Check inertia switch or ‘immobiliser’ if present.
v. Replace the relay.
vi. Unitary checking of ECU input/output

Dept : ERC Eng
INDICA BSIII
FORM N°5.
IGNITION COIL (A) CONTROL DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
CEL Yes Immediate Pin n°
P0351 Short circuit, colour
Open circuit Failures : bob_jum_ac_1cc0, bob_jum_ac_2cc0, bob_jum_ac_cc1 Black G3
ECU provides the trigger pulse to switch ON/OFF the power switch built in the coil which provides sparks simultaneously in cylinders
1& 4 or 2&3.
Engine running.
Battery voltage > 9.5 V or
Engine speed < 5000 rpm
The adaptation of the idling stepper position, the air/fuel model adaptive calculation, the air-fuel ratio regulation and the oxygen sensor
monitoring diagnosis are inhibited. Possibility of misfire and impaired driveability.
5. POSSIBLE CAUSES

Dept : ERC Eng
i. Problem of ignition coil connection

ii. Faulty ignition coil
6. REPAIRING STEPS
i. Check the wiring harness for proper fitment of connectors.

ii. Check relay actuation (refer form # 3).
iii. Replace the ignition coil

Dept : ERC Eng
INDICA BSIII
FORM N°6.
IGNITION COIL (B) CONTROL DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
P0352 Short circuit, colour
Open circuit Failures : bob_jum_bd_1cc0, bob_jum_bd_2cc0, bob_jum_bd_cc1 Black H3
Engine running.
The battery voltage > 9.5 V or
the engine speed < 5000 rpm
The adaptation of the idling stepper position, the air/fuel model adaptive calculation, the air-fuel ratio regulation and the oxygen sensor
monitoring diagnosis are inhibited. Possibility of misfire & impaired driveability.
4. POSSIBLE CAUSES
i. Problem of ignition coil connection

ii. Faulty ignition coil

Dept : ERC Eng
5. REPAIRING STEPS
i. Check the wiring harness for proper fitment of connectors.

ii Check relay actuation (refer form # 3).
iii. Replace the ignition coil

Dept : ERC Eng
INDICA BSIII
FORM N°7.
UPSTREAM O2 SENSOR HEATING DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
P0135 Open/Short colour
circuit Failures : chaufso2_am_cc and chaufso2_am_co Black E2
ECU provides grounding for the O2 sensor heater. 12V supply is routed through the power relay.
Engine running.
8V < Battery voltage < 16V
Sensor heating cut-off.

The diagnosis of catalyst, purge, oxygen sensor monitoring and the air fuel ratio, stepper adaptation strategies are inhibited.
The driveability may be affected. Risks of higher pollution.
5. POSSIBLE CAUSES
i. Problem of upstream sensor heating connection

ii. Faulty sensor heater
6. REPAIRING STEPS

ii. Replace the upstream sensor

Dept : ERC Eng
INDICA BSIII
FORM N°8.
LOW BATTERY VOLTAGE DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
Connector
P0562 Electrical colour
Failure : batterie_basse Black A4
Ignition key on.
Vbatt switch
Fault is registered if battery voltage < 5.3 V

Risk of erratic functioning.
4. POSSIBLE CAUSES
i. Problem of wiring calculator/battery connection

ii. Low battery voltage
iii. Faulty alternator leading to battery drain.
5. REPAIRING STEPS
i. Check battery voltage

ii. Check the alternator load (during engine running, battery voltage should be > 13V under no electrical loads).
iii. Check the wiring harness
iv. Check main relay.
v. Unitary checking of ECU input/output

Dept : ERC Eng
INDICA BSIII
FORM N°9.
HIGH BATTERY VOLTAGE DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
Connector
Failure : batterie_haute Black A4
Ignition key on.
2. DETECTION
Vbatt switch
Fault is registered if battery voltage > 18.5 V.

Risk of erratic functioning and deterioration of components.
4. POSSIBLE CAUSES
i. Wrong battery type

ii. Faulty alternator
5. REPAIRING STEPS
i. Check battery voltage

ii. Check the alternator load

Dept : ERC Eng
INDICA BSIII
FORM N°10.
THROTTLE ANGLE DIAGNOSIS (LOW) VARIANTS (PETROL)
CHARACTERISTICS
Connector
Failure : papillon_basse Black B4
Works base on a “Linear Potentiometer”. Circuit resistance is varied based on throttle opening.
Ignition key on.
Fault is registered if throttle position < 10.16% (absolute)

A default value is assigned to the throttle position.
Bad driveability.
5. POSSIBLE CAUSES
i. Problem of sensor connection.

ii. Faulty sensor / throttle body
6. REPAIRING STEPS

Dept : ERC Eng
i. Check the wiring harness.

ii. Check 5V input to the sensor.
iii. Check resistance of sensor ( specs: ~0.5V @ Idle position, ~ 4.5V @ WOT ). Replace the throttle body if resistance out of specs.

Dept : ERC Eng
INDICA BSIII
FORM N°11.
THROTTLE ANGLE DIAGNOSIS (HIGH) VARIANTS (PETROL)
CHARACTERISTICS
Connector
Failure : papillon_haute Black B4
Ignition key on.
Fault is registered if throttle position >94.14 % (absolute)

A default value is assigned to the throttle position.
Bad driveability.
3. POSSIBLE CAUSES

Faulty sensor / throttle body.
4. REPAIRING STEPS
i. Check the wiring harness (refer form # 10 for circuit diagram)

ii. Check resistance of sensor ( specs: ~0.5V @ Idle position, ~ 4.5V @ WOT ). Replace the throttle body if resistance out of specs.

Dept : ERC Eng
INDICA BSIII
FORM N°12.
WATER TEMPERATURE SENSOR FUNCTIONAL DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
Connector
Failures : Warmup and Tracker temperature check Black E4/D4
Works on principle of “NTC” – change in resistance when exposed to variable temperature source.
Engine running.
After a calibrated number of engine cycles (51456 TDC), the water temperature rise is monitored.
Warmup
If water temperature < 30 °C, then failure is registered.
Tracker (after Warmup)
If the water temperature < Temperature_eau_tracker_value, then failure is registered.
The pressure and temperature diagnosis are inhibited, and default values are assigned. The default remains at least until the next reset.
Bad driveability, deteriorated pollution.
5. POSSIBLE CAUSES

ii. Faulty sensor

Dept : ERC Eng
6. REPAIRING STEPS
i. Check the coolant temperature values using diagnostic tool.

ii. Check the wiring harness
iii. Check resistance of sensor ( specs: 2500Ω @ 20°C, 833.9Ω @ 50°C). Replace the sensor if resistance is not within specs.
iv. Unitary checking of ECU input/output.

Dept : ERC Eng
WATER TEMPERATURE SENSOR ELECTRICAL DIAGNOSIS INDICA BSIII

FORM N°13.
VARIANTS (PETROL)
-I
CHARACTERISTICS
Connector
Electrical CEL Yes After 1 DC Pin n°
P0117 colour
Short circuit
Failure : temp_eau_e_cc0 Black E4/D4
Ignition key on.
For a normal functioning, the value recorded by the converter (in Volts) must be within a calibrated range. If the sensor voltage <= 0.059V,
failure is registered.
The pressure and the water temperature diagnostic are inhibited, and default values are assigned. The default remains at least until the next
reset.
3. POSSIBLE CAUSES

ii. Faulty sensor
4. REPAIRING STEPS

ii. Check resistance of sensor ( specs: 2500Ω @ 20°C, 833.9Ω @ 50°C). Replace the sensor if resistance is not within specs.

Dept : ERC Eng
WATER TEMPERATURE SENSOR ELECTRICALDIAGNOSIS - INDICA BSIII

FORM N°14.
VARIANTS (PETROL)
II
CHARACTERISTICS
P0118 Open/Short colour
circuit Black E4
Failures : Open circuit and VBAT short circuit
Ignition key on
2. DETECTION
Calibrations / Recurrence
Principle : For a normal functioning, the value recorded by the converter (in Volts) must be within
a calibrated range (Cts_sc0_failure_thresh< the sensor voltage < Cts_oc_failure_thresh).
Cts_oc_failure_thresh = 4.639 [V]
Open circuit
Cts_sc1_failure_thresh = 4.858 [V]
If Cts_oc_failure_thresh <= the sensor voltage < Cts_sc1_failure_thresh
Then Failure Panne_temp_eau_e_co_dec = 8
VBAT short circuit Panne_temp_eau_e_co_inc = 10
If the sensor voltage >= Cts_sc1_failure_thresh Panne_temp_eau_e_cc1_dec = 8
Then Failure Panne_temp_eau_e_cc1_inc = 10
Recurrence Æ 256ms
Open circuit
If 4.639 <= the sensor voltage < 4.858, failure is registered.
VBAT short circuit
If the sensor voltage >=4.858, failure is registered.
The pressure and the water temperature diagnostic are inhibited, and default values are assigned. The default remains at least until the next
reset.
4. POSSIBLE CAUSES

ii. Faulty sensor
5. REPAIRING STEPS

ii. Check resistance of sensor ( specs: 2500Ω @ 20°C, 833.9Ω @ 50°C). Replace the sensor if resistance is not within specs.

Dept : ERC Eng
INDICA BSIII
FORM N°15.
VEHICLE SPEED DIAGNOSIS - I VARIANTS (PETROL)
CHARACTERISTICS
Connector
Failure : vitesse_func Brown G2
Provides ‘ON/OFF’ signals when metallic object interrupts magnetic field. The pulses generated by the sensor are processed by the
instrument cluster and fed to the ECU.
Engine running.
Besides, Engine speed >= 1920 rpm and Engine load >= 44 %
Routed through the

instrument cluster
On satisfying the activation conditions, the following is checked:

If the vehicle speed < 1 kmph during 20.48 sec, failure is registered.
The vehicle speed is set to 0 and its acquisition is no more performed. The injection cut off strategy is inhibited.
Driveability and emission are impacted.
5. POSSIBLE CAUSES

ii. Faulty sensor
6. REPAIRING STEPS

ii. Check the input pinion shaft of the sensor. Check for grounding on the firewall.

Dept : ERC Eng
INDICA BSIII
FORM N°16.
VEHICLE SPEED DIAGNOSIS - II VARIANTS (PETROL)
CHARACTERISTICS
Connector
Failure : vitesse_parasite Brown G2
Engine running.
The ECU analyses the coherence of the sensor signal.

The vehicle speed is set to 0 and its acquisition is no more performed. The gear ratio is estimated. The injection cut off strategy is inhibited.
Driveability and emission are impacted.
3. POSSIBLE CAUSES

ii. Faulty sensor
4. REPAIRING STEPS


Dept : ERC Eng
INDICA BSIII
FORM N°17.
KNOCKING SIGNAL DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
Connector
Failures : cliq_capteur and cliq_electrique Black B3/C3
Works on principle of “Piezo Electric”, senses the structure bond vibrations generated by the ‘knocking’. These vibration forces cause a
charge transfer and a voltage is generated in the sensing element. This is passed on to the ECU, where it is processed.
Engine running.
Engine speed >= 2592 rpm and Water themperature >= 80 °C and Throttle position >= 14.06%
In a normal functioning, the electrical signal sent by the sensor must be higher than a threshold. The noise measured by the sensor must be
in a calibrated range.
The knocking detection is reset.
Influence on inhibition of maximum advance calculation and on the anti-knocking air fuel ratio computation. A persistent knocking may
lead to the engine damage. (Possible consequence in fuel consumption).
5. POSSIBLE CAUSES

Dept : ERC Eng

ii. Faulty sensor
6. REPAIRING STEPS


Dept : ERC Eng
INDICA BSIII
FORM N°18.
UPSTREAM O2 SENSOR DIAGNOSIS - I VARIANTS (PETROL)
CHARACTERISTICS
Connector
Electrical & CEL Yes After 1 DC Pin n°
P0130 colour
Functional
Failures : so2_am_signal, lfbk_switch_lean, lfbk_switch_rich Grey A3/B3
Mounted on the exhaust front pipe front, provides ECU with information on the combustion mixture proportion - air/fuel. It assumes two
possible states - rich or lean expressed as 1 volt or 0 (zero) volts respectively.
Engine running
The measured value must be lower than a threshold.

If the sensor voltage >= 4.71, failure is registered.
Two other functional tests are performed and fault registered based on time exceeding a calibrated threshold :
- lean Æ rich transition
- rich Æ lean transition.
The air-fuel ratio regulation is inhibited.
The driveability can be affected and the pollution increases.
5. POSSIBLE CAUSES

ii. Faulty sensor
6. REPAIRING STEPS

Dept : ERC Eng

ii. With diagnostic tool, check the up O2 sensor voltage under normal idle & closed loop conditions (specs: voltage fluctuated between
100 to 900 mV)

Dept : ERC Eng
INDICA BSIII
FORM N°19.
UPSTREAM O2 SENSOR DIAGNOSIS - II VARIANTS (PETROL)
CHARACTERISTICS
Connector
P0131, P0132 colour
Short circuit
Failure : so2_am_masse, so2_am_tension Grey A3/B3
Ignition key on.
The value of voltage must be within specific thresholds, if not, failure is registered.
The last correct value is used.
The air fuel ratio regulation is disturbed.
The driveability can be affected and the pollution higher.
3. POSSIBLE CAUSES

ii. Faulty sensor
4. REPAIRING STEPS


Dept : ERC Eng
INDICA BSIII
FORM N°20.
OXYGEN SENSOR DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
Connector
colour
P0133 Functional
Failures : oxy_sens_lr_resp, oxy_sens_rl_resp, oxy_sens_msr and
oxy_sens_periode
Engine running. (Stabilised engine speed and load.)
The physical characteristics of the oxygen sensors are monitored and must be within calibrated range.
The results can be checked with any EOBD tool (Service 05 compatible).
The Air/fuel adaptation is inhbited when a failure occurs.

Pollution and driveability impact.
3. POSSIBLE CAUSES
i. Faulty oxygen sensor
4. REPAIRING STEPS
i. Replace the upstream oxygen sensor

Dept : ERC Eng
INDICA BSIII
FORM N°21.
UPSTREAM O2 SENSOR DIAGNOSIS - III VARIANTS (PETROL)
CHARACTERISTICS
CEL Yes After 1 DC Connector color Pin n°
P0134 Functional
Failure : so2_am_co Grey A3/B3
Engine running.
Water temperature > -7.5 [°C]
Signal voltage must be within thresholds. If not, failure is registered.

The air fuel ratio regulation is disturbed.
The driveability can be affected and the pollution higher.
3. POSSIBLE CAUSES

ii. Faulty sensor
4. REPAIRING STEPS


Dept : ERC Eng
INDICA BSIII
FORM N°22.
COOLING FAN RELAY CONTROL DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
None No No Pin n°
P0481 Short/Open colour
circuit Failures : commande_gmv_co and commande_gmv_cc Brown K4
Ignition key on.

Water temperature at cooling fan operating range.

Serious impact on the cooling function :
- Air-conditioning compressor stops.
- High speed forcing if the engine temperature goes beyond the same threshold.
3. POSSIBLE CAUSES
i. Problem of cooling fan relay connection

ii. Faulty relay
4. REPAIRING STEPS

ii. Replace the relay

Dept : ERC Eng
INDICA BSIII
FORM N°23.
INTAKE PRESSURE ELECTRICAL DIAGNOSIS - I VARIANTS (PETROL)
CHARACTERISTICS
Connector
P0107 colour
Short circuit
Failure : pres_e_cc Grey/ Black C1/A3
A semiconductor device when excited provides the signal depending upon the pressure acting on the semiconductor diaphragm.
Ignition key on.
Checks whether the intake pressure sensor voltage is within a calibrated range.
If the pressure sensor voltage < 312.32 mV, failure is registered.
In case of failure, the default value used is estimated from the throttle position and the engine speed.
Inaccurate air-fuel ratio control, bad driveability, performance deterioration and deteriorated pollution.
5. POSSIBLE CAUSES

ii. Faulty sensor
6. REPAIRING STEPS

Dept : ERC Eng

ii. Use diagnostic tool and read the values of atm pressure and manifold pressure at ignition key ON (should be equal to ambient).
iii. Start engine and check for values of manifold pressure (should indicate vacuum)
iv. Replace the sensor

Dept : ERC Eng
INDICA BSIII
FORM N°24.
INTAKE PRESSURE ELECTRICAL DIAGNOSIS - II VARIANTS (PETROL)
CHARACTERISTICS
Connector
Electrical colour
P0108
Open circuit A3/C1/
Failure : pres_e_co Black/Grey/Grey
C3
Ignition key on.
If the pressure sensor voltage > 4.71 V, failure is registered.

In case of failure, the default value used is estimated from the throttle position and the engine speed..
Inaccurate air-fuel ratio control. Bad driveability, performance deterioration and deteriorated pollution.
3. POSSIBLE CAUSES

ii. Faulty sensor
4. REPAIRING STEPS
i.. Check the wiring harness

ii. Use diagnostic tool and read the values of atm pressure and manifold pressure at ignition key ON (should be equal to ambient).
iii. Start engine and check for values of manifold pressure (should indicate vacuum)
iv Replace the sensor

Dept : ERC Eng
INDICA BSIII
FORM N°25.
INTAKE PRESSURE FUNCTIONAL DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
Code Error Kind Indicator Light EOBD Type Lighting ECU PINOUT
Connector
colour
P0106 Functional
A3/C1/
Failure : pres_f_in_stall, pres_f_in_cranking. Black/Grey/Grey
C3
Key on, engine moved from cranking to running mode.

In stall mode:
60kPa < Manifold pressure < 110kPa. If not, fault is registered.
In Cranking mode:
During 2.4s after staring, the pressure is memorised. At the end of the delay, one checks that the difference of pressure between that
memorised before starting and the minimum recorded “during” starting is higher to a threshold.
This test is only done if the throttle remains closed and the water temperature is higher to a threshold during the delay.
A default value used is estimated from the throttle position and the engine speed or from atmospheric pressure.
Inaccurate air-fuel ratio control. Bad driveability, performance deterioration and deteriorated pollution.
3. POSSIBLE CAUSES

ii. Faulty sensor
4. REPAIRING STEPS


Dept : ERC Eng
INDICA BSIII
FORM N°26.
ECU DIAGNOSIS - I VARIANTS (PETROL)
CHARACTERISTICS
Connector
Failure : cmm_kam
Ignition key on.
2. LOCATION
Check the coherence of the data saved in eeprom. This test is internal to the ECU.
Default values are used. Possible erratic behaviour.
4. POSSIBLE CAUSES
i. Faulty ECU
5. REPAIRING STEPS
i. Unitary checking of ECU input/output

Dept : ERC Eng
INDICA BSIII
FORM N°27.
ECU DIAGNOSIS - II VARIANTS (PETROL)
CHARACTERISTICS
Connector
Failure : cmm_ram
Ignition key on.
This test is internal to the ECU.

All the modules (including eeprom manager, knocking asic) sharing the SPI resources can fail to operate properly.
3. POSSIBLE CAUSES
i. Faulty ECU
4. REPAIRING STEPS

Dept : ERC Eng
INDICA BSIII
FORM N°28.
ECU DIAGNOSIS - III VARIANTS (PETROL)
CHARACTERISTICS
Connector
Failure : cmm_spi
Engine running.
This test is internal to the ECU.

The knocking detection is inhibited.
The driveability may be affected.
3. POSSIBLE CAUSES
i. Faulty ECU
4. REPAIRING STEPS

Dept : ERC Eng
INDICA BSIII
FORM N°29.
ECU DIAGNOSIS - IV VARIANTS (PETROL)
CHARACTERISTICS
Connector
Failure : cmm_tele_chk
Ignition key on.
ECU checks the integrity of the flash data by comparing the calculated checksum of the flash memory to the one memorised during the
code download. This test is internal to the ECU.
The engine can’t be started.
3. POSSIBLE CAUSES
i. Faulty ECU
ii. Problem during downloading
4. REPAIRING STEPS
i. Update ECU software

ii. Unitary checking of ECU input/output

Dept : ERC Eng
SENSORS SUPPLY DIAGNOSIS INDICA BSIII

FORM N°30.
VARIANTS (PETROL)
(Supply 1)
CHARACTERISTICS
CEL Yes After 1 DC Connector color Pin n°
P0608 Electrical
Failure : alim_1 Grey E1
Ignition key on.
For a normal functioning, the supply voltage of the sensors must be within 4.75 and 5.251V.
Outside of this range, a failure occurs.
From the time the failure is detected, the variable keeps its last value. As soon as the failure is confirmed, a default value is assigned when
the failure is memorised.
Erratic “control” of the throttle.
Impaired driveability.
3. POSSIBLE CAUSES
i. Problem of supply connection

ii. Faulty ECU
4. REPAIRING STEPS


Dept : ERC Eng
SENSORS SUPPLY DIAGNOSIS INDICA BSIII

FORM N°31.
VARIANTS (PETROL)
(Supply 2)
CHARACTERISTICS
Connector
Failure : alim_2_eobd Grey C3
Ignition key on.
2. DETECTION
Aim : Ensure that the sensor voltage is within a calibrated range.

Tension_alim_capteur_min < Sensor voltage measured < Tension_alim_capteur_max Tension_alim_capteur_min = 4.748 [V]
If not, a failure occurs. Tension_alim_capteur_max = 5.251 [V]
Panne_alim_2_eobd_dec = 1
Panne_alim_2_eobd_inc = 1
Recuurence Æ 8 ms
For a normal functioning, the supply voltage of the sensors must be within 4.75 and 5.251V.
Outside of this range, a failure occurs.
Impact on the manifold pressure computation.
4. POSSIBLE CAUSES
i. Problem of supply connection

ii. Faulty ECU
5. REPAIRING STEPS


Dept : ERC Eng
INDICA BSIII
FORM N°32.
FUEL INJECTOR CONTROL DIAGNOSIS (CYLINDER N°1) VARIANTS (PETROL)
CHARACTERISTICS
Connector
Electrical CEL Yes Immediate Pin n°
P0201 colour
Open circuit
Failure : injecteur_a_co Grey H2
Injector - a normally closed solenoid valve, opens when the electromagnetic core is energized.
Ignition key on.
Impact on air-fuel control leading to bad driveabilty & high pollutants.
5. POSSIBLE CAUSES

Dept : ERC Eng
i. Problem of injector connection, blown fuse.

ii. Faulty injector
6. REPAIRING STEPS

ii. Check injector coil resistance (specs: 12.25 ± 0.5 Ώ). Replace the injector N°1 if not within specs.
INDICA BSIII
FORM N°33.
CHARACTERISTICS
Connector
Electrical CEL Yes Immediate Pin n°
P0262 colour
Short circuit
Failure : injecteur_a_cc Grey H2
Engine running.
3. POSSIBLE CAUSES
i. Problem of injector connection

ii. Faulty injector
4. REPAIRING STEPS


Dept : ERC Eng
INDICA BSIII
FORM N°34.
CHARACTERISTICS
P0203 Electrical Connector
Open circuit colour
P0268 Electrical
Short circuit Failure : injecteur_b_co, injecteur_b_cc Grey G2
Ignition key on.
3. POSSIBLE CAUSES

ii. Faulty injector
4. REPAIRING STEPS


Dept : ERC Eng
INDICA BSIII
FORM N°35.
CHARACTERISTICS
Open circuit colour
P0271 Electrical
Short circuit Failure : injecteur_c_co, injecteur_c_cc Grey H3
Ignition key on.
3. POSSIBLE CAUSES

ii. Faulty injector
4. REPAIRING STEPS


Dept : ERC Eng
INDICA BSIII
FORM N°36.
CHARACTERISTICS
Open circuit colour
P265 Electrical
Short circuit Failure : injecteur_d_co, injecteur_d_cc Grey G3
Ignition key on.
3. POSSIBLE CAUSES

ii. Faulty injector
4. REPAIRING STEPS

iii. Unitary checking of ECU input/out

Dept : ERC Eng
ADDITIONAL AIR STEPPER (ISC VALVE) CONTROL INDICA BSIII

FORM N°37.
VARIANTS (PETROL)
DIAGNOSIS
CHARACTERISTICS
Connector
colour
P1538 Electrical
D1/D2
Failure : stepper_actu Grey
D3/E3
Air flow into the engine is varied by varying the cross section area ( using a stepper motor). Flow rate is dependent on the engine speed.
Engine running + stepper in active mode & 8V <battery voltage < 16V.
3. LOCATION & WIRING CONNECTIONS.
Impact on idle control and driveability. Possibility of thermal risks in the long run.
5. POSSIBLE CAUSES
i. Problem of ISC valve connection

ii. Faulty ISC valve
6. REPAIRING STEPS

Dept : ERC Eng

ii. Check the single phase coil resistance (specs: 53 ± 5.3Ώ). Replace the ISC valve if not within specs.

Dept : ERC Eng
INDICA BSIII
FORM N°38.
CANISTER PURGE VALVE CONTROL DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
Open circuit colour
P0445 Electrical
Short circuit Failure : purge_co, purge_cc. Grey F2
Canister purge valve is a normally closed solenoid valve fitted in the vapour line which opens/closes depending upon the ECU signal.
Ignition key on.
3. LOCATION & WIRING CONNECTIONS.
Purge inhibited Î Possible fuel smelling, bad driveability under hot conditions.
5. POSSIBLE CAUSES
i. Problem of canister purge valve connection

ii. Faulty purge valve
6. REPAIRING STEPS

Dept : ERC Eng

ii. Check coil resistance (specs: 26 ± 4Ώ). Replace the canister purge valve

Dept : ERC Eng
INDICA BSIII
FORM N°39.
AIR-CONDITIONING COMPRESSOR CONTROL DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
None No No Pin n°
circuit Failures : clim_co and clim_cc Brown C3
Ignition key on.
The air conditioning management is inhibited. (the diagnosis is performed only upto relay stage).
3. POSSIBLE CAUSES
i. Problem of air-conditioning relay connection

ii. Faulty air-conditioning relay
4. REPAIRING STEPS

ii. Replace the air-conditioning relay

Dept : ERC Eng
INDICA BSIII
FORM N°40.
MALFUNCTION INDICATOR LIGHT CONTROL DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
CEL No After 1 DC Pin n°
circuit Failures : alerte_eobd_co and alerte_eobd_cc Brown C4
Ignition key on.
The driver may not be alerted about other possible failures or light always on.
3. POSSIBLE CAUSES
i. Problem of malfunction indicator light connection.

ii. Faulty indicator light.
4. REPAIRING STEPS

ii. Replace the indicator light.
iii. Unitary checking of ECU input/output.

Dept : ERC Eng
INDICA BSIII
FORM N°41.
MISFIRE DIAGNOSIS - I VARIANTS (PETROL)
CHARACTERISTICS
P0300 Connector
P0301 colour
P0303
Functional
P0304 Failures : mf_emiss_i_all, mf_emiss_i_a_1, mf_emiss_i_b_3,
P0302 - -
mf_emiss_i_c_4, mf_emiss_i_d_2, mf_emiss_p_all
P0300
Engine running.
The misfire rate is computed for each cylinder. And a misfire failure is stated if the rate exceeds a threshold according to the engine
conditions.
The oxygen sensor monitoring diagnosis and air fuel adaptation are inhibited.
The driveability may become bad. Risks of deterioration of the engine.
3. POSSIBLE CAUSES
i. Faulty ignition system

ii. Faulty injection & fuel supply system
iii. Engine hardware reasons (eg. Timing, tappet clearances, intake system leakage)
4. REPAIRING STEPS
i. Check the ignition wiring harness and the spark plug condition
ii. Check injection wiring harness and the injector condition
iii. Check the engine compression rate, timing, manifold vacuum @ hot idle & cam phasing.

Dept : ERC Eng
INDICA BSIII
FORM N°42.
MISFIRE DIAGNOSIS - II VARIANTS (PETROL)
CHARACTERISTICS
Connector
CEL Yes Flashing Pin n°
colour
Functional
P1351 Failures : mf_cat_dam_i_all
mf_cat_dam_p_all
Engine running.
The misfire rate is computed for each cylinder. And a misfire failure is stated if the rate is enough high to damage the catalyst (according to
the engine conditions).
The stepper (ISC valve) adaptation, air fuel adaptation and lambda feedback are inhibited.
The driveability may become bad. Risks on deterioration of the engine. Risks on catalyst deterioration leading to higher pollution.
3. POSSIBLE CAUSES
i. Problem of ignition part

ii. Problem of injection part
iii. Engine hardware reasons (eg. Timing, tappet clearances, intake system leakage)
4. REPAIRING STEPS
i. Check the ignition wiring harness and the spark plug contion
ii. Check injection wiring harness and the injector condition
iii. Check the engine compression rate, timing, manifold vacuum @ hot idle & cam phasing.

Dept : ERC Eng
INDICA BSIII
FORM N°43.
MISFIRE DIAGNOSIS - III VARIANTS (PETROL)
CHARACTERISTICS
Connector
None No No Pin n°
Failure : mfw_adapt
Engine running.
The strategy detects the geometrical characteristics of the flywheel.

The ECU determines if the flywheel tooth signal is correctly processed (or valid) in order to avoid errors during the misfire detection.
The driveability may become bad.
3. POSSIBLE CAUSES
i. Geometrical characteristics on the flywheel

ii. Cranchshaft air gap
4. REPAIRING STEPS
i. Check the sensor/flywheel air gap

ii. Check the flywheel
iii. Replace the flywheel

Dept : ERC Eng
INDICA BSIII
FORM N°44.
AIR/FUEL ADAPTATION DIAGNOSIS - I VARIANTS (PETROL)
CHARACTERISTICS
Connector
Failures : adpt_obd_ij_gain and adpt_obd_ij_off and adpt_obd_ij_pres - -
Engine running.
The fuelling and air admission are model based. According to the ageing and functioning conditions, some adaptive parameters are
computed to match the model and the components state. These parameters account for the possible errors between the model and the
measured data. This is used to determine whether the system is faulty or not.
P0170 is related to the injector flow computation adaptations.
The algorithm is reinitialised.
3. POSSIBLE CAUSES
i. Problem on injection part

ii. Problem on the intake manifold
4. REPAIRING STEPS
i. Check injection wiring harness and the injector condition

ii. Check if there is no leakage on the intake manifold

Dept : ERC Eng
INDICA BSIII
FORM N°45.
AIR/FUEL ADAPTATION DIAGNOSIS - II VARIANTS (PETROL)
CHARACTERISTICS
Connector
None - No Pin n°
Failure : adapt_bias_tot - -
Engine running.
2. DETECTION
Principle : The fuelling and air admission are model based. According to the ageing and Calibrations / Recurrence
functioning conditions, some adaptive parameters are computed to match the model and the
components state.
The parameters account for the possible errors between the model and the measured data and are Panne_adapt_bias_tot_dec=255 dec
used to determine whether the system is faulty or not. Panne_adapt_bias_tot_inc=90 dec
Recurrence Æ 256 ms
P1123 is related to injector adaptation.

4. POSSIBLE CAUSES

5. REPAIRING STEPS


Dept : ERC Eng
INDICA BSIII
FORM N°46.
AIR/FUEL ADAPTATION DIAGNOSIS - III VARIANTS (PETROL)
CHARACTERISTICS
P1124 Connector
None - No Pin n°
Functional colour
P1125 Failure : adapt_lin1_thro, adapt_lin2_thro - -
Engine running.
P1124 is related to air intake adaptation (throttle).

3. POSSIBLE CAUSES

4. REPAIRING STEPS


Dept : ERC Eng
INDICA BSIII
FORM N°47.
AIR/FUEL ADAPTATION DIAGNOSIS - IV VARIANTS (PETROL)
CHARACTERISTICS
Connector
None - No Pin n°
Failure : adapt_ lin_byp - -
Engine running.
P1559 is related to ISC system adaptation errors.

3. POSSIBLE CAUSES

4. REPAIRING STEPS


Dept : ERC Eng
INDICA BSIII
FORM N°48.
ADAPTATIONS OBSERVATIONS DIAGNOSIS VARIANTS (PETROL)
CHARACTERISTICS
Connector
None No No Pin n°
Failure : obs_ adaptation
Engine running.
2. DETECTION
Principle: To monitor the conditions of the adaptive calculation.
Panne_obs_adaptation_dec = 255
Panne_obs_adaptation_inc = 255
This strategy monitors the condition of the adaptive calculator. If the required conditions to activate the adaptive algorithm are not satisfied
for a calibrated time, an observation failure is held.
The adaptive strategy is not activated.
4. POSSIBLE CAUSES
i. Adaptation conditions are not bring together
5. REPAIRING STEPS
i. Erase failure
ii. Drive the car on a steady state conditions

Dept : ERC Eng

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TML – Trouble Shooting Guide For Doc. No.

TROUBLE SHOOTING GUIDE

Besides, the possible causes and repairing steps are given.

Author: Viswanatha HC Page 1 of 75

Page No. for

Author: Viswanatha HC Page 2 of 75

Contents of the document

1 What Is DTC? ........................................................................................................................................ 5

Author: Viswanatha HC Page 3 of 75

AIR-CONDITIONING COMPRESSOR CONTROL DIAGNOSIS ............................................................................................................66

Author: Viswanatha HC Page 4 of 75

Example: P0301 – Misfire Cylinder no 1

Author: Viswanatha HC Page 5 of 75

Author: Viswanatha HC Page 6 of 75

33 P0351 Ignition Coil Fault (Coil A) Short circuit at +Ve

53 P1352 Misfire Fault ; Catalyst damage - cyl 1 Misfire detected on Cylinder 1

4 How read the DTC fault code

The basic contents of the tool are…

- LAPTOP/ Desk top PC with the software

- Interface Unit (M/s Silicone Engines)

- Communication Cables (OBD & RS232)

Author: Viswanatha HC Page 7 of 75

Diagnostic Tool Connections – Schematic View

4.1 Tata Diagnostic Tool (TDT)

4.2 Diagnostic link connector (DLC)

Diagnostic Link Connector (DLC)

4.3 Check Engine Lamp (CEL)

5 Electronic control unit (ECU)

Author: Viswanatha HC Page 9 of 75

5.1 ECU Pin Out details

ECU CONNECTOR DETAILS

Examples of How identify the Pin is also shown in the picture.

Author: Viswanatha HC Page 10 of 75

Author: Viswanatha HC Page 11 of 75

Author: Viswanatha HC Page 12 of 75

FOR VERSION: NON AC WITH POWER STEERING

CP D3 AC REQUEST INPUT BY NOT CONNECTED

FOR VERSION: NON AC WITHOUT POWER STEERING

CP D3 AC REQUEST INPUT BY NOT CONNECTED

Cable Code Cable Colour

Cable Colour Codes

Author: Viswanatha HC Page 13 of 75

6 CEL & DTC Management

6.1 CEL Activation Strategy

6.2 CEL Extinguishing

6.3 Non monitoring (Inactivation) Zone

Author: Viswanatha HC Page 14 of 75

Author: Viswanatha HC Page 15 of 75

Failure : AAC_capteur Black F3

2. DIAGNOSTIC ACTIVATION CONDITIONS (Minimal conditions)

3. LOCATION & WIRING CONNECTIONS

4. DETECTION, DEFAULT MODE , IMPACT, CUSTOMER EFFECT

The misfire diagnosis is inhibited.

Author: Viswanatha HC Page 16 of 75

i. Check the sensor/target air gap (specs: 1.5 ± 0.5 mm)

Author: Viswanatha HC Page 17 of 75

2. DIAGNOSTIC ACTIVATION CONDITIONS (Minimal conditions)

3. LOCATION & WIRING CONNECTIONS