Developed by: Technical Literature Cell. Release Date : Jan 2019/ First Edition. The information provided in this manual is based on the latest product information available at the time of publication. . C Copyright 2019 TATA MOTORS All rights reserved. The information in this manual shall not be reproduced or copied, in whole or in part, in any form without written permission from TATA MOTORS. Vehicles are subject to modification in design, specification and equipment. Also refer the Service Circulars released by Customer Support about product & procedures.
DIAGNOSTIC TROUBLE SHOOTING CODES
DIAGNOSTIC TROUBLE SHOOTING CODES INDEXX 1. ENGINE..........................................................................................................5 - 1084 2. INSTRUMENT CLUSTER ........................................................................ 1085- 11060 3. INFOTAINMENT ...................................................................................... 1107 - 1343 4. BCM ......................................................................................................... 1344 - 2935 5. ESCL........................................................................................................ 29360- 3033 6. ESP .......................................................................................................... 3034 - 3257 7. PEPS......................................................................................................... 3258- 3653 8. ABS..........................................................................................................3654 - 3807 9. FATC........................................................................................................3808- 4262 10 SRS.......................................................................................................... 4263 - 4818 11. IMMOBILIZER..........................................................................................4819 - 4910
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 1 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. Q5 Project – EMS ECU/Component Replacement Procedure Issue Date Author E-mail 0.1 24 Jul 2017 Shashank Addala Prasad M Shashank.Addala@tatatechnologies.com mvskprasad@tatamotors.com
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 2 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. A Document History Issue Date Author Release Status 0.1 24 July 2017 Shashank Addala / Prasad M 1st Draft Release
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 3 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. B Change History Version Page Section Change Details - - - -
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 4 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. TABLE OF CONTENTS A Document History ........................................................................................................................... 2 B Change History................................................................................................................................ 3 C List of Acronyms and Abbreviations................................................................................................. 5 1 Introduction .................................................................................................................................... 6 1.1 General Overview............................................................................................................................ 6 1.2 Scope of the Document ................................................................................................................... 6 1.3 Intended Audience.......................................................................................................................... 6 1.4 IPR Ownership................................................................................................................................. 6 1.5 Reference Documents ..................................................................................................................... 6 2 Project Applicability ........................................................................................................................ 6 3 EMS Replacement Procedure Flowchart .......................................................................................... 7 4 EMS ECU, Component Replacement Procedure ............................................................................... 8 4.1 ECM - Engine Control Module (In case of old ECM communicates) .................................................. 8 4.2 ECM - Engine Control Module (In case of old ECM doesn’t communicates).....................................10 4.3 Single injector ................................................................................................................................13 4.4 All the injectors ..............................................................................................................................14 4.5 Closed coupled DPF + DOC .............................................................................................................15 4.6 DPF pressure sensor .......................................................................................................................16 4.7 Electrical VGT position sensor ........................................................................................................17 4.8 Electrical VGT turbo compressor ....................................................................................................18 4.9 Engine oil replacement...................................................................................................................19 4.10 Rail pressure sensor .......................................................................................................................20 4.11 Regeneration forced............................................................................ Error! Bookmark not defined. 4.12 Air Flow meter ...............................................................................................................................21 4.13 Lambda sensor ...............................................................................................................................22 4.14 EGR high pressure DC Motor ..........................................................................................................23 4.15 Throttle Valve Actuator ..................................................................................................................24 4.16 Reset driven distance max Th2O warning lamp ON.........................................................................25 4.17 Reset driven distance H2O in fuel lamp ON ....................................................................................26 4.18 ECM PROGRAMMING.......................................................................... Error! Bookmark not defined.
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 5 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. C List of Acronyms and Abbreviations S No. Acronyms/Abbreviations Description 1 EMS Engine Management System 2 ECU Electronic Control Unit 3 CoC Centre of Competence 4 PT Powertrain 5 TML TATA Motors Ltd 6 DTC Diagnostic Trouble Code 7 MT Manual Transmission
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 6 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 1 Introduction This document contains the Procedures sequence to perform in case of component substitution or in case of configuration functions, i.e. the process to be followed whenever an ECU to be replaced or reflashed with new ECU software version or new software calibration version. 1.1 General Overview This document, will guide the service person/technician to correctly follow the steps in case of ECU/component replacement. It will also avoid the situation where vehicle failed to start due to the wrong procedure followed by technician. 1.2 Scope of the Document The scope of this document is limited to define the Component Replacement Procedure requirement. 1.3 Intended Audience The function owners, E&E CoC and ECM supplier are primary audience of this document. 1.4 IPR Ownership All Intellectual Property Rights that are directly or indirectly related to this document shall rest with CoC PT and related TML Internal Departments. 1.5 Reference Documents S No. Document Name Document No. Version No. Release Date - - - - - 2 Project Applicability The requirements specified in this document are applicable for all the MT variants of Q5 project which include Q501 which is a 5-seater application and Q502 which is a 7-seater application.
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 7 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 3 EMS Replacement Procedure Flowchart – In case Old ECM Communicates Figure 1: ECU Substitution Flow chart
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 8 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4 EMS ECU, Component Replacement Procedure 4.1 ECM - Engine Control Module (In case of old ECM communicates) Description: - See Figure 1: ECU Substitution Flow chart for more details. Routine concerning a component to be perform in case of component substitution. Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: IMA classification (for all injectors to be performed). IMA writing includes automatically ZFC1 procedure. IMA codes to be read from old ECM and written on new ECM. Read IMA values from Old ECM after entering into Extended Diagnostic Session: Command: 10 03 Command: $ 22 38 2F Write the Values in New ECM after entering extended Diagnostic Session and Taking Security Access: Command: 10 03 Command: $ 27 03 $ 27 04 XX XX XX XX (XX is the key calculated from the seed received through 27 02 command) Command: $ 2E 38 2F + 36 bytes Step 2: EEPROM DATA reading from old ECU after entering into Extended Diagnostic Session Command: 10 03 Command: $ 22 38 33 (for reading the data from EEPROM) $ 22 38 43 (for reading the data from EEPROM) Step 3: EEPROM DATA writing in the new ECU after entering extended Diagnostic Session and Taking Security Access: Command: $ 10 03 Command: $ 27 03
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 9 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. $ 27 04 XX XX XX XX (XX is the key calculated from the seed received through 27 02 command) Command: $ 2E 38 33 YY (for writing the data back into New ECM) $ 2E 38 43 YY (for writing the data back into New ECM) Where YY is data read from Old ECM Step 4: Proxi realignment / Variant COnfiguration to be done: Perform Variant Configuration Reset: Refer Section 4.21 – Variant Configuration Reset in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document for routine procedure detail. Perform the Variant Configuration after entering extended Diagnostic Session and Taking Security Access: Pick the 6 byte variant configuration value from PLM for specific vehicle variant and save in Tester. Command: $ 10 03 Command: $ 27 03 $ 27 04 XX XX XX XX (XX is the key calculated from the seed received through 27 02 command) Command: $ 2E FE AA YY Where YY is 6 Byte value [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is all procedures are completed and steps are performed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 10 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.2 ECM - Engine Control Module (In case of old ECM doesn’t communicates) Description: - See Figure 1: ECU Substitution Flow chart for more details Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Proxi realignment / Variant Configuration to be done; Perform the Variant Configuration after entering extended Diagnostic Session and Taking Security Access: Pick the 6 byte variant configuration value from PLM for specific vehicle variant and save in Tester. Command: $ 10 03 Command: $ 27 03 $ 27 04 XX XX XX XX (XX is the key calculated from the seed received through 27 02 command) Command: $ 2E FE AA YY Where YY is 6 Byte value Step 2: IMA classification (for all injectors to be performed). IMA writing includes automatically ZFC1 procedure. IMA codes to be read either from Server / from the Injector label (Entering to extended Diag. Session and Taking security Access is not required as in above step it has been done) Command: $ 2E 38 2F + 36 bytes Step 3: Below Routine has to be executed Lambda sensor UEGO-1 - ‘Exchange of Defective ECM’(LSU1 $ 02 05 XX) – Sub-function 01 Routine Execution Detail: Refer Section 4.2.1 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 11 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. Step 4: Below Routine to be executed “DPF 1 - Replacement of ECU and Old ECU is not communicating (Set EEPROM values for PFlt_CoRgn Exchange of ECU) ($ 02 06)” Routine Execution Detail: Refer Section 4.3.1 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document Step 5: Below Routine to be executed “TVA DC Motor Test” Routine Execution Detail: Refer Section 4.11 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document Step 6: Below Routine to be executed “EGR high pressure DC Motor Test” Routine Execution Detail: Refer Section 4.7 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document Step 7: Below Routine to be executed “DPF Service Regeneration” Routine Execution Detail: Refer Section 4.3.2.2 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document Step 8: Below Routine to be executed “VGT DC Motor Test” Routine Execution Detail: Refer Section 4.12 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document Step 9: Below Routine to be executed “VGT DC Motor Test” Routine Execution Detail: Refer Section 4.12 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 12 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. Step 9: Engine Oil to be replaced with new Oil Step 10: “Reset of Blinking Engine Oil Pressure Lamp” IOCP Execution Detail: Refer Section 3.9 in ‘TML_PT_Q5_IOCP_EMS Requirement_2921 02 224 A1725_24June2017_V0.2’ document Engine oil parameters reset routine set to following parameters: - RDI 380C - Number of automatic reset procedure (Olil life reset with Examiner): it is increased of 1, - RDI 380D - Number of manual reset procedure (Oil life reset with manual procedure): it does not change, - RDI 380E - Odometer value at last automatic reset procedure (Olil life reset with Examiner): it is set to RDI 2001/RLI 03 value, - RDI 380F - Odometer value at last manual reset procedure (Oil life reset with manual procedure): it does not change , - RDI 3811 - Odometer value at the starting of change oil required indication: it does not change, - RDI 3810 - Remaining distance at exaust oil: it is set to MaxDistT calibrated value, - RDI 3813 - Remaining percentage at exaust oil: it is set to 100% value, - RDI 3818 - Oil life remaining from distance information: it is set to 100% value, - RDI 381A - Oil life remaining from oil exhaust information: it is set to 100% value, - RDI 381B - Oil life remaining from module coolant temperature and crankshaft revolutions: it is set to 100% value. [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 13 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.3 Single injector Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session and Security Access is taken 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: IMA classification ( for single injector), IMA writing includes automatically ZFC1 procedure. IMA codes can be read from old ECM and have to be written on new ECM. Command: $ 2E 38 2X + 9 bytes X: 9 for Injector Cylinder 1 A for Injector Cylinder 2 B for Injector cylinder 3 C for Injector Cylinder 4 Step 2: Below Routine to be executed “Reset Lambda sensor - 4.2.2 ‘Exchange of Injectors, Rail Pressure Sensor and MAF Sensor’ (LSU1 $ 02 05 XX) –Sub-function 02“ Routine Execution Detail: Refer Section 4.2.2 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document Step 3: Below Routine to be executed “DPF injector reset (DPF5) – ‘Set EEPROM values for PFFlt_MassCalc Exchange of an emission relevant engine component’” Routine Execution Detail: Refer Section 4.3.2.3 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 14 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.4 All the injectors Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: IMA classification (for all injectors to be performed). IMA writing includes automatically ZFC1 procedure. IMA codes to be read from Server / Injector Label Command: $ 2E 38 2F + 36 bytes Step 2: Below Routine to be executed “Reset Lambda sensor - 4.2.2 ‘Exchange of Injectors, Rail Pressure Sensor and MAF Sensor’ (LSU1 $ 02 05 XX) –Sub-function 02“ Routine Execution Detail: Refer Section 4.2.2 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document Step 3: Below Routine to be executed “DPF injector reset (DPF5) – ‘Set EEPROM values for PFFlt_MassCalc Exchange of an emission relevant engine component’” Routine Execution Detail: Refer Section 4.3.2.3 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 15 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.5 Closed coupled DPF + DOC Description: - See Figure 1: ECU Substitution Flow chart for more details Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Below Routine to be executed “DPF Service Regeneration” Routine Execution Detail: Refer Section 4.3.2.2 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document Step 2: Below Routine to be executed “Closed coupled DPF exchange ($ 02 07 11)” Routine Execution Detail: Refer Section 4.3.2.4 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 16 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.6 DPF pressure sensor Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Below Routine to be executed “Set EEPROM values for PFFlt_monitor Exchange DPF differential pressure ($020708)” Routine Execution Detail: Refer Section 4.3.2.1 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 17 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.7 Electrical VGT position sensor Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Below Routine to be executed “VGT DC Motor Test” Routine Execution Detail: Refer Section 4.12 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 18 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.8 Electrical VGT turbo compressor Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Below Routine to be executed “VGT DC Motor Test” Routine Execution Detail: Refer Section 4.12 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 19 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.9 Engine oil replacement Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Engine Oil to be replaced with new Oil Step 2: “Reset of Blinking Engine Oil Pressure Lamp” IOCP Execution Detail: Refer Section 3.9 in ‘TML_PT_Q5_IOCP_EMS Requirement_2921 02 224 A1725_24June2017_V0.2’ document Engine oil parameters reset routine set to following parameters: - RDI 380C - Number of automatic reset procedure (Olil life reset with Examiner): it is increased of 1, - RDI 380D - Number of manual reset procedure (Oil life reset with manual procedure): it does not change, - RDI 380E - Odometer value at last automatic reset procedure (Olil life reset with Examiner): it is set to RDI 2001/RLI 03 value, - RDI 380F - Odometer value at last manual reset procedure (Oil life reset with manual procedure): it does not change , - RDI 3811 - Odometer value at the starting of change oil required indication: it does not change, - RDI 3810 - Remaining distance at exaust oil: it is set to MaxDistT calibrated value, - RDI 3813 - Remaining percentage at exaust oil: it is set to 100% value, - RDI 3818 - Oil life remaining from distance information: it is set to 100% value, - RDI 381A - Oil life remaining from oil exhaust information: it is set to 100% value, - RDI 381B - Oil life remaining from module coolant temperature and crankshaft revolutions: it is set to 100% value.
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 20 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.10 Rail pressure sensor Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Below Routine to be executed “Reset of ZFC values and IRS driving cycle counter” Routine Execution Detail: Refer Section 4.1 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document Step 2: Below Routine to be executed “Reset Lambda sensor - 4.2.2 ‘Exchange of Injectors, Rail Pressure Sensor and MAF Sensor’ (LSU1 $ 02 05 XX) –Sub-function 02“ Routine Execution Detail: Refer Section 4.2.2 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 21 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.11 Air Flow meter Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Below Routine to be executed “Reset Lambda sensor - 4.2.2 ‘Exchange of Injectors, Rail Pressure Sensor and MAF Sensor’ (LSU1 $ 02 05 XX) –Sub-function 02“ Routine Execution Detail: Refer Section 4.2.2 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 22 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.12 Lambda sensor Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Below Routine to be executed “Exchange of Lambda Sensor Unit $02 05 03” Routine Execution Detail: Refer Section 4.2.3 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 23 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.13 EGR high pressure DC Motor Description: - See Figure 1: ECU Substitution Flow chart for more details Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Below Routine to be executed “EGR high pressure offset reset and activation of the learning ($ 02 0F)” Routine Execution Detail: Refer Section 4.5 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document Step 2: Below Routine to be executed “EGR high pressure DC Motor Test” Routine Execution Detail: Refer Section 4.7 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 24 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.14 Throttle Valve Actuator Substitution Type: COMPONENT Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Below Routine to be executed “TVA DC Motor Test” Routine Execution Detail: Refer Section 4.11 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 25 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.15 Reset driven distance max Th2O warning lamp ON Substitution Type: FUNCTION Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Below Routine to be executed “Temperature warning lamp ON driven counter reset ($ 02 16)” Routine Execution Detail: Refer Section 4.10 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.]
Q5 Project –EMS ECU/Component Replacement Procedure Q5 Project – EMS ECU/ Component Replacement Procedure Doc No: 2921 02 224 A1730 Date: 24 July 2017 Revision: 0.1 Page 26 of 26 Prepared: Shashank Addala / Prasad M Checked: Prasad M Approved: Satishkumar P This document contains confidential information which is exclusive property of TML. The contents of this document shall not be reproduced, or conveyed, or given to third parties in any manner without the consent of TML. 4.16 Reset driven distance H2O in fuel lamp ON Description: - See Figure 1: ECU Substitution Flow chart for more details Substitution Type: FUNCTION Pre-Conditions: 1. ECU should be in Extended Diagnostic Session 2. Ignition ON (T15_st = 1) 3. Engine not running (NMotV = 0) 4. Gear in neutral position Procedure To Be Followed: Step 1: Below Routine to be executed “Water in fuel lamp ON driven distance counter reset ($ 02 15)” Routine Execution Detail: Refer Section 4.9 in ‘TML_PT_Q5_Routine Procedures_EMS Requirement_2921 02 224 A1724_5June2017_V0.2’ document [Note: Perform Ignition toggle (Ignition OFF and Ignition ON) once procedure is completed in EMS ECU.] END OF DOCUMENT
Q501 4 Cylinder MT Application DTC Troubleshooting Data Version: 0.1 Date: 21-Sep-2018 Prepared By: Mithi Prasad, Sarang Kulkarni, Manish Gupta Checked By: Yogesh Jadhav Approved By: Satish Kumar P Page: 1 of 1052 Copyright © TATA MOTORS Ltd. This document must not be used in any way, such as copying and redistributing to third parties, without the consent of author. EMS Diagnostic Manual for QQ5 (2L Engine) EDC17C69 EMS ECU Document History Ver Date Author Details 0.1 21-Sep-18 Manish Gupta Initial Release
Q501 4 Cylinder MT Application DTC Troubleshooting Data Version: 0.1 Date: 21-Sep-2018 Prepared By: Mithi Prasad, Sarang Kulkarni, Manish Gupta Checked By: Yogesh Jadhav Approved By: Satish Kumar P Page: 2 of 1052 Copyright © TATA MOTORS Ltd. This document must not be used in any way, such as copying and redistributing to third parties, without the consent of author. Change History Issue Section Change details
Q501 4 Cylinder MT Application DTC Troubleshooting Data Version: 0.1 Date: 21-Sep-2018 Prepared By: Mithi Prasad, Sarang Kulkarni, Manish Gupta Checked By: Yogesh Jadhav Approved By: Satish Kumar P Page: 3 of 1052 Copyright © TATA MOTORS Ltd. This document must not be used in any way, such as copying and redistributing to third parties, without the consent of author. Contents Document History ................................................................................................................................................................... 1 Change History ........................................................................................................................................................................ 2 P1D39-04: A/D converter (system internal failures) ..................................................................................................... 16 P060B-01: A/D converter (general signal failure) .......................................................................................................... 18 P0122-11: internal fault path number: short circuit to GND of accelerator pedal signal 1 ...................................... 20 P0123-12: Accelerator pedal potentiometer 1 (circuit short to battery) ..................................................................... 23 P0222-11: Diagnostic fault check of short circuit to ground (signal range check low) of acceleration pedal signal 2 ............................................................................................................................................................................................ 26 P0223-12: Accelerator pedal potentiometer 2 (circuit short to battery) ..................................................................... 29 P2135-62: Accelerator pedal potentiometer congruence (signal compare failure) .................................................. 32 P0531-11: A/C Refrigerant Pressure Sensor "A" Circuit Range/ Performance: Indicates an error when the compressor pressure is not sufficient .............................................................................................................................. 37 P0532-12: A/C Refrigerant Pressure Sensor "A" Circuit Low: Indicates an error when the compressor pressure is above a certain upper limit ............................................................................................................................................ 40 P0097-11: Intake Air Temperature Sensor 2 Circuit Low (Bank 1): Air intake manifold temperature (circuit short to ground) ............................................................................................................................................................................ 43 P0098-15: Intake Air Temperature Sensor 2 Circuit High (Bank 1): Air intake manifold temperature (circuit short to battery or open) .............................................................................................................................................................. 46 P0111-64: Air temperature sensor plausibility check ................................................................................................... 49 P0112-11: Air temperature sensor electrical failure (circuit short to ground)............................................................ 52 P0113-15: Air temperature sensor electrical failure (circuit short to battery or open) ............................................. 55 P2229-17: Atmospheric air pressure sensor (circuit voltage above threshold) ........................................................ 58 P068A-94: Battery disconnection .................................................................................................................................... 60 P0235-61: Positive boost pressure governor deviation (low pressure, signal calculation failure) ......................... 63 P0236-61: Negative boost pressure governor deviation (low pressure, signal calculation failure) ....................... 66 P1C10-41: BRAKE1 CRC check ..................................................................................................................................... 69 P1C11-29: BRAKE1 message counter check ............................................................................................................... 71 U0073-88: Control Module Communication Bus "A" Off : CAN Bus off ..................................................................... 73 U0121-31: Lost Communication With Anti-Lock Brake System (ABS) Control Module: ABS/ESP Node Tout Faulty .................................................................................................................................................................................... 76 U0138-31: Lost Communication With All Terrain Control Module: Drive Control Switch / DCS Node Tout Faulty .............................................................................................................................................................................................. 80
Q501 4 Cylinder MT Application DTC Troubleshooting Data Version: 0.1 Date: 21-Sep-2018 Prepared By: Mithi Prasad, Sarang Kulkarni, Manish Gupta Checked By: Yogesh Jadhav Approved By: Satish Kumar P Page: 4 of 1052 Copyright © TATA MOTORS Ltd. This document must not be used in any way, such as copying and redistributing to third parties, without the consent of author. U0140-31: Lost Communication With Body Control Module: BCM Node Tout Faulty ............................................ 83 U0151-31: Lost Communication With Restraints Control Module: SRS Node Tout Faulty .................................... 89 U0155-31: Lost Communication With Instrument Panel Cluster (IPC) Control Module: IPC Node Tout Faulty . 93 U0164-31: Lost Communication With HVAC Control Module: CCM Climate control Module Node Tout Faulty 97 U0423-81: Invalid Data Received From Instrument Panel Cluster Control Module : IPC Node Invalid data faulty .............................................................................................................................................................................................. 99 U1009-13: CAN Passive Failure .................................................................................................................................... 103 P0565-24: Cruise Control "On" Signal: Cruise ON/Off button stuck key error ....................................................... 106 P0566-24: Brake booster pressure sensor circuit range / performance : Cruise Cncl button stuck key error ... 109 P0567-24: Cruise Control "Resume" Signal: Cruise plus button stuck key error ................................................... 112 P0568-24: Brake Booster Pressure Sensor Circuit High : Cruise Minus button stuck key error ......................... 115 P0576-11: Cruise Control Input Circuit Low: Diagnostic fault check for SRC MIN error when analog key detection is enabled ......................................................................................................................................................... 118 P0577-15: Cruise Control Input Circuit High: Diagnostic fault check for SRC MAX error when analog key detection is enabled ......................................................................................................................................................... 121 P0579-29: Cruise Control Multi-Function Input "A" Circuit Range/Performance: NPL error ................................ 124 P1567-24: When Cruise Active, Cruise + Switch / button is pressed for pro-longed acceleration (Greater than Calibrate-able threshold (Def. 10 Sec)) ........................................................................................................................ 127 P0525-96: Cruise control disabling due to level 2 monitoring of driver assistance system (system internal failures) .............................................................................................................................................................................. 130 P24A4-92: Soot load and mileage with Diesel Particulate Filter lamp ON .............................................................. 132 P242F-97: Diesel Particulate Filter flow resistance monitoring high (level 1, component or system operation obstructed or blocked) ..................................................................................................................................................... 134 P244A-11: Diesel Particulate Filter delta pressure sensor – circuit short to ground ............................................. 137 P244B-15: Diesel Particulate Filter delta pressure sensor (circuit short to battery or open) ................................ 140 P2002-97: Diesel Particulate Filter flow resistance monitoring too high (level 2, component or system operation obstructed or blocked) ..................................................................................................................................................... 143 P2458-92: Diesel Particulate Filter regeneration not ended ...................................................................................... 146 P3012-23: Sport mode switch struck detection ........................................................................................................... 148 P3013-24: Economy mode switch struck detection .................................................................................................... 152 P3014-23: Economy and sport modes switch struck detection ................................................................................ 155 P3019-67: Global DTC for EMS/ABS/ESP/TOD verification failure ......................................................................... 159
Q501 4 Cylinder MT Application DTC Troubleshooting Data Version: 0.1 Date: 21-Sep-2018 Prepared By: Mithi Prasad, Sarang Kulkarni, Manish Gupta Checked By: Yogesh Jadhav Approved By: Satish Kumar P Page: 5 of 1052 Copyright © TATA MOTORS Ltd. This document must not be used in any way, such as copying and redistributing to third parties, without the consent of author. U0415-81: Invalid Data Received From Anti-Lock Brake System (ABS) Control Module: BRK Node Invalid data faulty ................................................................................................................................................................................... 163 U0439-81: Invalid Data Received From All Terrain Control Module : Fault to be logged for Drive Mode Function when: ModeSelectionSwStateStatusNew ==2 (Implausible) .................................................................................... 166 P160C-92: ECM micro reset for second safety level .................................................................................................. 170 P1218 - 92: Recovery hardware of Control Unit (Control Unit reset) - Performance or Incorrect Operation ..... 172 P1D3B-96: ECU internal monitoring 1 (component internal failure) ......................................................................... 174 P1D3C-49: ECU internal monitoring 1 (internal electronic failure) ........................................................................... 176 P1D3E-04: ECU internal monitoring 1 (system internal failures) .............................................................................. 178 P1D41-49: ECU internal monitoring 2 (internal electronic failure) ............................................................................ 180 P060A-96: ECU internal monitoring 2 (component internal failure) ......................................................................... 182 P0600-04: ECU internal monitoring 2 (system internal failures) ............................................................................... 184 P1D40-49: ECU internal monitoring 3 (internal electronic failure) ............................................................................ 186 P060D-96: ECU internal monitoring 4 (component internal failures) ....................................................................... 188 P1D4A-64: ECU internal monitoring 5 (signal plausibility failure) ............................................................................. 190 P1D49-49: ECU internal monitoring 5 (internal electronic failure) ............................................................................ 192 P061C-04: ECU internal monitoring 5 (system internal failures)- System Internal failure .................................... 194 P062B-04: Energizing time monitoring (system internal failures) ............................................................................. 196 P1216-49: Energizing time monitoring (internal electronic failure) ........................................................................... 198 P1219-96: Energizing time monitoring (component internal failure) ........................................................................ 200 P062A-4B: Fuel pump relay command (over temperature) ....................................................................................... 202 P0087-92: Positive fuel pressure governor deviation (step 1) low pressure (signal above upper limit) – Performance or Incorrect Operation .............................................................................................................................. 205 P0088-84: Fuel pressure negative governor deviation, high pressure (signal below lower limit) ........................ 208 P0627-13: Fuel pump relay command (open circuit) .................................................................................................. 211 P0628-11: Fuel pump relay command (circuit short to ground) ................................................................................ 214 P0629-12: Fuel pump relay command (circuit short to battery) ................................................................................ 217 P1087-92: Positive fuel pressure governor deviation (step 2) low pressure (signal above upper limit) - Performance or Incorrect Operation .............................................................................................................................. 220 P268C-55: IMA classification injector 1 missed personalization ............................................................................... 223 P268C-56: check of IMA quantisation type mismatch injector 1 ............................................................................... 225 P268D-55: IMA classification injector 2 missed personalization ............................................................................... 227
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