Version: 1.

3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Table of Contents
Guide For General Electrical Checks: Measurement Using Multi Meter ........................................................................ 12
Guide For General Electrical Checks: Fuse Health ........................................................................................................... 13
Guide For General Electrical Checks: Resistance Measurement ..................................................................................... 14
Guide For General Electrical Checks: Open Circuit / Continuity...................................................................................... 15
Guide For General Electrical Checks: Short Circuit .......................................................................................................... 16
Guide For General Electrical Checks: Short To Battery ................................................................................................... 17
Guide For General Electrical Checks: Short To Ground ................................................................................................... 18
Guide For General Electrical Checks: Short To Other Circuit .......................................................................................... 19
P0299-00: Boost pressure is too low fault....................................................................................................................... 20
P0234-00: Over Boost Pressure Fault .............................................................................................................................. 27
P0403-08: EGR Actuator - Internal Communication failure in ECU ................................................................................. 33
P0403-4B: EGR Actuator - Internal temperature error in ECU ........................................................................................ 37
P0403-79: EGR Actuator - Return spring broken error.................................................................................................... 41
P0403-7C: EGR Actuator - Slow response fault ............................................................................................................... 45
P0403-71: EGR Actuator - Stuck fault .............................................................................................................................. 49
P2457-00: EGR Cooler - Efficiency very low .................................................................................................................... 55
P0403-A1: EGR Actuator - Controller system voltage error ............................................................................................ 58
P0403-F2: EGR Actuator - Negative Pin - Short to Battery .............................................................................................. 63
P0403-F3: EGR Actuator - Negative Pin - Short to Ground.............................................................................................. 68
P0403-13: EGR Actuator - Open load error ..................................................................................................................... 74
P0403-F5: EGR Actuator - Over Current in Negative Pin ................................................................................................. 79
P0403-F4: EGR Actuator - Over Current in Positive Pin ................................................................................................... 84
P0403-F0: EGR Actuator - Positive Pin - Short to Battery................................................................................................ 89
P0403-F1: EGR Actuator - Positive Pin - Short to Ground ............................................................................................... 94
P0400-9B: EGR Flow is too high ....................................................................................................................................... 99
P0400-9C: EGR Flow is too low ...................................................................................................................................... 104
P040A-11: EGR Cooler temperature sensor - Short to Ground ................................................................................... 108

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P040A-12: EGR Cooler temperature sensor - Short to Battery or open........................................................................ 113

P040A-64: EGR Cooler temperature sensor - Signal not valid based on reference sensors ......................................... 118
P0409-14: EGR Actuator position sensor - Short to Ground or Open failure ................................................................ 123
P0409-12: EGR Actuator position sensor - Short to battery.......................................................................................... 128
P0403-54: EGR Actuator - 1st learning failed / Value out of range ............................................................................... 133
P0403-99: EGR Actuator - Learning exceeded wear limit ............................................................................................. 137
P26C5-08: Exhaust Throttle Valve - Internal Communication failure in ECU ................................................................ 141
P26C5-4B: Exhaust Throttle Valve - Internal temperature error in ECU ....................................................................... 145
P26C5-79: Exhaust Throttle Valve - Slow response fault .............................................................................................. 149
P26C5-71: Exhaust Throttle Valve - Stuck fault ............................................................................................................. 154
P26C5-F0: Exhaust Throttle Valve - Negative Pin - Short to Battery ............................................................................. 159
P26C5-F2: Exhaust Throttle Valve - Negative Pin - Short to Ground ............................................................................. 164
P26C5-F5: Exhaust Throttle Valve - Negative Pin Current High .................................................................................... 169
P26C5-13: Exhaust Throttle Valve - Open load error .................................................................................................... 174
P26C5-F3: Exhaust Throttle Valve - Positive Pin - Short to Battery ............................................................................... 179
P26C5-F1: Exhaust Throttle Valve - Positive Pin - Short to Ground .............................................................................. 184
P26C5-F4: Exhaust Throttle Valve - Positive Pin Current High ...................................................................................... 189
P26C5-A1: Exhaust Throttle Valve - Return spring broken............................................................................................ 194
P2BF4-2F: Exhaust Throttle Valve position sensor - Improper signal............................................................................ 199
P2BF4-14: Exhaust Throttle Valve position sensor - Short to Ground .......................................................................... 204
P2BF4-12: Exhaust Throttle Valve position sensor - Short to battery Or Open ............................................................ 209
P26C5-54: Exhaust Throttle Valve - 1st learning failed / Value out of range ................................................................ 214
P26C5-99: Exhaust Throttle Valve - Learning exceeded wear limit............................................................................... 218
P0243-08: Turbo E-Waste gate - Internal Communication failure in ECU..................................................................... 222
P0243-4B: Turbo E-Waste gate - Internal temperature error in ECU............................................................................ 226
P0243-71: Turbo E-Waste gate - Actuator Stuck fault .................................................................................................. 230
P0243-13: Turbo E-Waste gate - Drive Open load error ............................................................................................... 234
P0243-F2: Turbo E-Waste gate - Negative Pin - Short to Battery.................................................................................. 239
P0243-F3: Turbo E-Waste gate - Negative Pin - Short to Ground ................................................................................. 244

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0243-F5: Turbo E-Waste gate - Over Current in Negative Pin..................................................................................... 249

P0243-F4: Turbo E- Waste gate - Over Current in Positive Pin ..................................................................................... 254
P0243-F0: Turbo E-Waste gate - Positive Pin - Short to Battery ................................................................................... 259
P0243-F1: Turbo E- Waste gate - Positive Pin - Short to Ground .................................................................................. 264
P2AB7-14: Turbo E-Waste gate position sensor - Short to Ground or Open ................................................................ 269
P2AB7-12: Turbo E- Waste gate position sensor - Short to battery .............................................................................. 274
P0243-54: Turbo E-Waste gate - 1st learning failed / Value out of range .................................................................... 279
P0243-99: Turbo E- Waste gate – Valve Close hard stop learning out of range High/Low ........................................... 283
P2226-64: Barometric Pressure Sensor - Signal not valid ............................................................................................. 287
P0070-15: Ambient temperature sensor - Short to battery or Open ............................................................................ 290
P0070-11: Ambient temperature sensor - Short to ground .......................................................................................... 295
P0070-64: Ambient temperature sensor - Signal not valid based on reference sensors .............................................. 300
P0235-29: PFM Sensor - Boost pressure sensor signal error ........................................................................................ 305
P0235-64: PFM Sensor - Boost pressure signal not valid (Compared against other sensor) ........................................ 310
P0110-15: Inlet air temperature sensor - Short to Battery or Open ............................................................................. 315
P0110-11: Inlet air temperature sensor - Short to Ground ........................................................................................... 320
P0110-64: Inlet air temperature sensor - Signal not valid based on reference sensors ............................................... 325
P0105-12: Intake Manifold Pressure sensor - Short to Battery..................................................................................... 330
P0105-14: Intake Manifold Pressure sensor - Short to Ground or Open ...................................................................... 335
P0105-64: Intake Manifold Pressure sensor - Signal not valid based on reference sensors......................................... 340
P00E8-15: Intake Manifold temperature sensor - Short to Battery or Open ................................................................ 345
P00E8-11: Intake Manifold temperature sensor - Short to Ground.............................................................................. 350
P00E8-64: Intake Manifold temperature sensor - Signal not valid based on reference sensors .................................. 355
P026A-00: Intercooler Performance - Low efficiency error .......................................................................................... 360
P006A-9B: PFM Sensor - Signal drift error (High) .......................................................................................................... 364
P006A-9C: PFM Sensor - Signal drift error (Low) ........................................................................................................... 368
P0100-29: PFM Sensor - Signal error ............................................................................................................................. 372
P007A-29: Intercooler out temperature - Sensor signal error ...................................................................................... 377
P007A-64: Intercooler out temperature - Signal not valid based on reference sensors............................................... 382

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0100-81: PFM Sensor - SENT 1 data error ................................................................................................................... 387

P0100-86: PFM Sensor - SENT 1 global message error ................................................................................................. 392
P010A-81: PFM Sensor - SENT 2 data error ................................................................................................................... 397
P010A-86: PFM Sensor - SENT 2 global message error ................................................................................................. 402
U0155-00: Lost Communication with Instrument Cluster/VECU .................................................................................. 407
U007B-00: Communication Error - Private CAN Bus Off or Passive Error ..................................................................... 415
U007A-00: Communication Error - Public CAN Bus Off or Passive Error....................................................................... 420
U010E-00: Lost Communication with DCU .................................................................................................................... 424
U0619-00: Lost Communication with DEF Urea Level Sensor ....................................................................................... 428
P0340-99: Cam Sensor - Learning failure ...................................................................................................................... 432
P0340-78: Cam Sensor - Signal drift error ..................................................................................................................... 437
P0340-2F: Cam Sensor - Signal erratic error.................................................................................................................. 442
P0340-31: Cam Sensor - Signal Lost fault ...................................................................................................................... 447
P0340-39: Cam Sensor - Signal Missing error ................................................................................................................ 452
P0016-00: CRANK Sensor - Invalid gap between consecutive signals ........................................................................... 457
P0335-27: CRANK Sensor - Signal Early Detection Error ............................................................................................... 462
P0335-31: CRANK Sensor - Signal Lost fault .................................................................................................................. 467
P0335-1F: CRANK Sensor - Signal Missing ..................................................................................................................... 472
P2226-04: Barometric Pressure Sensor - Sensor internal failure .................................................................................. 477
P2226-08: Barometric Pressure Sensor - Sensor signal failure ..................................................................................... 480
P2226-1C: Barometric Pressure Sensor - Sensor signal out of range ............................................................................ 483
P0641-08: ECU 5V channel communication failure ....................................................................................................... 486
P0641-4B: ECU 5V supply system thermal shutdown ................................................................................................... 489
P0641-00: ECU External supply Channel1 failure ............................................................................................ 492
P0651-00: ECU External supply Channel2 failure .......................................................................................................... 495
P0697-00: ECU External supply Channel3 failure .......................................................................................................... 498
P06D6-00: ECU Internal 3V supply channel failure ....................................................................................................... 501
P06D2-00: ECU Internal 5V Supply channel failure ....................................................................................................... 504
P268A-54: Injector Codes corrupted or not written properly ....................................................................................... 507

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P020A-00: ECU - Internal injection timing fault ............................................................................................................ 510

P020C-00: ECU - Internal injection timing fault ............................................................................................................. 513
P020D-00: ECU - Internal injection timing fault ............................................................................................................ 516
P020B-00: ECU - Internal injection timing fault ............................................................................................................. 519
P060B-00: ECU - Internal memory failure ..................................................................................................................... 522
P060A-48: ECU - Internal memory failure ..................................................................................................................... 525
P060C-43: ECU - Internal memory failure ..................................................................................................................... 528
P0607-44: ECU - Internal memory failure ..................................................................................................................... 531
P0607-05: ECU - Internal memory failure ..................................................................................................................... 534
P060C-44: ECU - Internal memory failure ..................................................................................................................... 537
P060C-05: ECU - Internal memory failure ..................................................................................................................... 540
P060C-49: ECU - Internal memory failure ..................................................................................................................... 543
P060C-42: ECU - Internal memory failure ..................................................................................................................... 546
P060C-45: ECU - Internal memory failure ..................................................................................................................... 549
P0607-04: ECU - Internal memory failure ..................................................................................................................... 552
P060A-49: ECU - Internal memory failure ..................................................................................................................... 555
P060A-42: ECU - Internal memory failure ..................................................................................................................... 558
P060A-45: ECU - Internal memory failure ..................................................................................................................... 561
P060C-47: ECU - Internal memory failure ..................................................................................................................... 564
P060C-00: ECU Internal Memory Failure ....................................................................................................................... 567
P060C-08: ECU Internal Memory Failure ....................................................................................................................... 570
P060C-92: ECU Internal Memory Failure ....................................................................................................................... 573
P062F-00: ECU Non volatile memory error ................................................................................................................... 576
P060C-00: Engine Safety Module - Memory Flash failure ............................................................................................. 579
P0201-56: Cylinder 1 - Injector codes not written / Missing ......................................................................................... 582
P0202-56: Cylinder 2 - Injector codes not written / Missing ......................................................................................... 586
P0203-56: Cylinder 3 - Injector codes not written / Missing ......................................................................................... 590
P0204-56: Cylinder 4 - Injector codes not written / Missing ......................................................................................... 594
P0607-51: EDP (Engine Data Plate) data writing error .................................................................................................. 598

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0607-55: Variant coding not written ........................................................................................................................... 601

P0630-55: Vehicle Identification Number is not written............................................................................................... 604
P0115-15: Engine Coolant temperature sensor - Short to Battery or Open ................................................................. 607
P0115-11: Engine Coolant temperature sensor - Short to Ground ............................................................................... 612
P0115-64: Engine Coolant temperature sensor - Signal not valid based on reference sensors ................................... 617
P0115-2A: Engine Coolant temperature sensor - Signal Stuck at very low ................................................................... 622
P0128-71: Engine Coolant Thermostat stuck fault ........................................................................................................ 627
P0480-9E: E-Viscous FAN - Disengagement failure ....................................................................................................... 630
P0480-13: E-Viscous FAN - Drive open .......................................................................................................................... 635
P0480-12: E-Viscous FAN - Drive Short to Battery ........................................................................................................ 640
P0480-11: E-Viscous FAN - Drive Short to Ground ........................................................................................................ 645
P0480-9F: E-Viscous FAN - Engagement failure ............................................................................................................ 650
P0526-38: E-Viscous FAN - Speed Signal error .............................................................................................................. 655
P0526-29: E-Viscous FAN - Speed Signal invalid error................................................................................................... 660
P0520-15: Engine Oil pressure is too high / Switch not present in the engine ............................................................. 665
P0524-00: Engine Oil pressure is too low ...................................................................................................................... 670
P0217-00: Engine Over heating fault ............................................................................................................................. 675
P0219-00: Engine Over speed fault ............................................................................................................................... 679
P2269-00: Water in fuel fault ........................................................................................................................................ 681
P2264-15: Water In fuel sensor - Short to Battery or Open .......................................................................................... 686
P2264-11: Water in fuel sensor - Short to Ground........................................................................................................ 691
P2031-62: DOC inlet temperature sensor - Signal not valid based on Model............................................................... 696
P1542-00: DPF Regeneration system fault from DCU ................................................................................................... 700
P0263-00: Cylinder 1 - Injector balance low fault ......................................................................................................... 702
P0201-13: Cylinder 1 - Injector Circuit open ................................................................................................................. 707
P0201-2B: Cylinder 1 - Injector Short circuit error ........................................................................................................ 712
P0266-00: Cylinder 2 - Injector balance low fault ......................................................................................................... 717
P0202-13: Cylinder 2 - Injector Circuit Open ................................................................................................................. 722
P0202-2B: Cylinder 2 - Injector Short circuit error ........................................................................................................ 727

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0269-00: Cylinder 3 - Injector balance low fault ......................................................................................................... 732

P0203-13: Cylinder 3 - Injector Circuit Open ................................................................................................................. 737
P0203-2B: Cylinder 3 - Injector Short circuit error ........................................................................................................ 742
P0272-00: Cylinder 4 - Injector balance low fault ......................................................................................................... 747
P0204-13: Cylinder 4 - Injector Circuit Open ................................................................................................................. 752
P0204-2B: Cylinder 4 - Injector Short circuit error ........................................................................................................ 757
P062D-08: Injector Bank 0 - Internal Communication fault .......................................................................................... 762
P062D-04: Injector Bank 0 - Internal Communication fault .......................................................................................... 765
P2146-12: Injector Bank 0 - Short to Battery fault ........................................................................................................ 768
P2146-11: Injector Bank 0 - Short to Ground fault ........................................................................................................ 773
P062E-08: Injector Bank 1 - Internal Communication fault ........................................................................................... 778
P062E-04: Injector Bank 1 - Internal Communication fault ........................................................................................... 781
P2149-12: Injector Bank 1 - Short to Battery fault ........................................................................................................ 784
P2149-11: Injector Bank 1 - Short to Ground fault ........................................................................................................ 789
P00C6-7B: Rail pressure not built at Low tank level during engine cranking ................................................................ 794
P00C6-00: Rail pressure not built at normal tank level during engine cranking ........................................................... 797
P0180-15: Fuel temperature sensor - Short to Battery or Open ................................................................................... 800
P0180-11: Fuel temperature sensor - Short to Ground ................................................................................................ 805
P0180-29: Fuel temperature sensor - Signal not valid based on reference sensors ..................................................... 810
P0090-13: HPV - Circuit Open ........................................................................................................................................ 815
P228D-00: HPV - Controller correction High error ........................................................................................................ 820
P228C-00: HPV - Controller correction Low error ......................................................................................................... 825
P0090-1B: HPV - Current control error (High) ............................................................................................................... 830
P0090-1A: HPV - Current control error (Low)................................................................................................................ 835
P0090-19: HPV - Feedback Current High error .............................................................................................................. 840
P0090-18: HPV - Feedback Current Low error............................................................................................................... 845
P0090-F0: HPV High side pin - Short to Battery ............................................................................................................ 850
P0090-F1: HPV High side pin - Short to Ground ............................................................................................................ 855
P0090-F2: HPV Low side pin - Short to Battery ............................................................................................................. 860

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0090-F3: HPV Low side pin - Short to Ground ............................................................................................................. 865

P0088-92: HPV - Over pressure fault ............................................................................................................................. 870
P0001-9B: IMV - Controller correction High error (Secondary Error) ........................................................................... 875
P0001-9C: IMV - Controller correction Low error (Secondary Error) ............................................................................ 878
P0001-1B: IMV - Current control error (High) (Secondary Error) .................................................................................. 881
P0001-1A: IMV - Current control error (Low) ................................................................................................................ 884
P0001-19: IMV - Feedback Current High error .............................................................................................................. 887
P0001-18: IMV - Feedback Current Low error............................................................................................................... 892
P0001-13: IMV - Open Circuit ........................................................................................................................................ 897
P0001-F0: IMV High side pin - Short to Battery............................................................................................................. 902
P0001-F1: IMV High side pin - Short to Ground ............................................................................................................ 907
P0001-F2: IMV Low side pin - Short to Battery ............................................................................................................. 912
P0001-F3: IMV Low side pin - Short to Ground ............................................................................................................. 917
P0088-94: IMV - Over pressure fault ............................................................................................................................. 922
P0325-00: Accelerometer sensor 1 failure .................................................................................................................... 926
P0330-00: Accelerometer sensor 2 failure .................................................................................................................... 931
P016E-00: Rail Pressure Control - Negative Error (Primary Error) ................................................................................ 936
P016F-00: Rail Pressure Control - Positive Error (Primary Error) .................................................................................. 939
P0190-11: Rail pressure sensor - Short to Ground ........................................................................................................ 942
P0190-12: Rail pressure sensor - Short to Battery or Open .......................................................................................... 947
P0088-22: Rail Pressure Sensor - Signal too high .......................................................................................................... 952
P0087-00: Rail pressure sensor - Signal too Low ........................................................................................................... 957
P2BA7-00: DEF Level Empty Indication ......................................................................................................................... 962
P203F-00: DEF Level Low Indication .............................................................................................................................. 964
P203F-7B: DEF Level near Empty Indication.................................................................................................................. 966
P203F-21: DEF Level very Low Indication ...................................................................................................................... 968
P2BAA-00: Inducement - DEF Consumption fault (Secondary Fault) ............................................................................ 970
P2BA8-00: Inducement - DEF Dosing Stopped Fault (Secondary Fault) ........................................................................ 972
P2BA9-00: Inducement - DEF Quality fault (Secondary Fault) ...................................................................................... 974

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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P2BAE-00: Inducement - DEF SCR System fault (Secondary Fault) ............................................................................... 976
P0645-13: AC relay - Open Circuit ................................................................................................................................. 978
P0645-12: AC relay - Short to Battery ........................................................................................................................... 983
P0645-11: AC relay - Short to Ground ........................................................................................................................... 988
P2138-00: Accelerator foot pedal correlation error...................................................................................................... 993
P2120-29: Accelerator foot Pedal Limp Home fault (Secondary Fault)......................................................................... 998
P2120-71: Accelerator foot Pedal Stuck fault.............................................................................................................. 1001
P2120-15: Accelerator Foot Pedal track1 sensor - Short to Battery or Open ............................................................. 1004
P2120-11: Accelerator Foot Pedal track1 sensor - Short to Ground ........................................................................... 1009
P2125-15: Accelerator Foot Pedal track2 sensor - Short to Battery or Open ............................................................. 1014
P2125-11: Accelerator Foot Pedal track2 sensor - Short to Ground ........................................................................... 1019
P0560-A3: Battery supply Voltage high fault .............................................................................................................. 1024
P0560-A2: Battery supply Voltage Low fault ............................................................................................................... 1028
P2141-A3: Battery Voltage - Channel 2 voltage high failure ....................................................................................... 1032
P2141-A2: Battery Voltage - Channel 2 voltage low failure ........................................................................................ 1036
P0703-12: Brake Safety Switch - Short to Battery ....................................................................................................... 1040
P0504-64: Brake Switch & Safety Brake switch signals are not matching .................................................................. 1045
P083F-00: Clutch top & bottom switch signals are not coherent ............................................................................... 1049
P0830-29: Clutch Top Switch Signal Invalid ................................................................................................................. 1053
P1801-13: DPF Inhibit switch lamp - Open circuit failure............................................................................................ 1058
P1801-12: DPF Inhibit switch lamp - Short to Battery failure ..................................................................................... 1062
P1801-11: DPF Inhibit switch lamp - Short to Ground failure ..................................................................................... 1066
P25BA-9E: DPF Regeneration Request Switch - Stuck fault ........................................................................................ 1070
P260E-13: DPF Regeneration Request switch lamp - Open circuit failure .................................................................. 1075
P260E-12: DPF Regeneration Request switch lamp - Short to Battery failure ............................................................ 1080
P260E-11: DPF Regeneration Request switch lamp - Short to Ground failure............................................................ 1085
P0685-73: ECU Power relay stuck fault ....................................................................................................................... 1090
P0685-13: ECU Power relay electrical fault - Open Circuit .......................................................................................... 1094
P0380-13: Glow Plug - Circuit Open ............................................................................................................................ 1098

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0380-12: Glow plug - Short to Battery....................................................................................................................... 1101

P0380-11: Glow plug - Short to Ground ...................................................................................................................... 1104
P0650-13: MIL Lamp - Open Circuit ............................................................................................................................. 1107
P0650-12: MIL lamp - Short to Battery ........................................................................................................................ 1112
P0650-11: MIL Lamp - Short to Ground....................................................................................................................... 1117
P081D-24: Neutral Gear Switch signal stuck close fault .............................................................................................. 1122
P081D-23: Neutral Gear Switch signal Stuck open fault ............................................................................................. 1127
P0615-13: Start relay - Circuit Open ............................................................................................................................ 1132
P0615-F2: Start relay - Short to Battery ...................................................................................................................... 1136
P0615-F3: Start relay - Short to Ground ...................................................................................................................... 1140
P0500-31: Vehicle speed sensor - Signal loss during vehicle driving .......................................................................... 1144
P0500-01: Vehicle speed sensor - Signal not valid / Sensor not connected ............................................................... 1149
P2226-04: ECU Barometric Sensor Failure .................................................................................................................. 1154
P0641-08: ECU 5V Channel Communication Failure ................................................................................................... 1157
P06D2-00: ECU Internal 5V Supply Channel Failure .................................................................................................... 1160
P0520-12: Engine oil pressure sensor short to battery ............................................................................................... 1163
P0520-14: Engine oil pressure sensor short to ground or open.................................................................................. 1168
P0195-15: Engine Oil temp Sensor short to battery or open ...................................................................................... 1173
P0195-11: Engine Oil temp sensor short to ground .................................................................................................... 1178
P2CEF-13: Oil Thermostat Open Circuit Fault.............................................................................................................. 1183
P2CEF-11: Oil Thermostat short circuit to ground ...................................................................................................... 1188
P2CEF-12: Oil Thermostat short circuit to battery ...................................................................................................... 1193
U0676-56: Fuel Tank Signal Invalid .............................................................................................................................. 1198
U0121- 21: Data Not Received ON TSC 1 CAN............................................................................................................. 1203
P0575-23: Cruise INC(+)-DEC(-) Switch Fault ............................................................................................................... 1207
P0570-23: Cruise INC(+) Switch Stuck Fault ................................................................................................................ 1210
P056C-23: Cruise RES Switch Stuck Fault .................................................................................................................... 1213
P0569-23: Cruise DEC(-) Switch Stuck Fault ................................................................................................................ 1216
P1575- 47: ECU - Internal memory failure................................................................................................................... 1219

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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P1575-48: ECU - Internal memory failure ................................................................................................................... 1222

P061C-00: Internal Control Module Engine RPM Performance .................................................................................. 1225
P0607- 45: Control Module Performance ................................................................................................................... 1228
P060A-00: Internal Control Module Monitoring Processor Performance .................................................................. 1231
P060D-47: Internal Control Module Accelerator Pedal Position Performance ........................................................... 1234
P062B-47: Internal Control Module Fuel Injector Control Performance .................................................................... 1237
P062B-2B: Internal Control Module Fuel Injector Control Performance .................................................................... 1240
P16D2-47: ECU - Internal memory failure ................................................................................................................... 1243
P26C5-9B: Exhaust Flow Control Valve: Closed Position Learning Higher Than Threshold ........................................ 1246
P26C5-9C: Exhaust Flow Control Valve: Closed Position Learning Lower Than Threshold ......................................... 1251
P0697-4B: Sensor Reference Voltage C- Internal Thermal Shutdown ........................................................................ 1256
P06D6-FF: ECU Internal Voltage .................................................................................................................................. 1259

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Guide For General Electrical Checks: Measurement Using Multi Meter

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Guide For General Electrical Checks: Fuse Health

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Guide For General Electrical Checks: Resistance Measurement

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Guide For General Electrical Checks: Open Circuit / Continuity

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Guide For General Electrical Checks: Short Circuit

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Guide For General Electrical Checks: Short To Battery

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Guide For General Electrical Checks: Short To Ground

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Guide For General Electrical Checks: Short To Other Circuit

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P0299-00: Boost pressure is too low fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Boost Pressure Leakage
2. Intake path air leakages
3. Air filter choke
4. Intercooler Blockage /Leakage in intercooler 1. No derate from EMS ECU but Poor pickup
Fault Code P0299-00
may feel due to low boost
5. Incorrect Tappet setting
6. ATS/DPF clogging or Cracking Issues
7. ETV Related issues (ETV Stuck)
8. Turbo hardware failure (Excessive play) Engine emission may go high
MIL ON for 15 secs 9. Faulty EGR or Stuck open EGR Vehicle run with poor pickup
10. Low compression pressure (Valve leakage)
11. Faulty Injector/s
CEL ON 12. Faulty ECU

Fault System Summary:

Development Fault code F_M_VGTH_UNDERBOOST_APV

System Actuators EGR/ETV/Turbo / Boost pressure monitoring

OBD Inducement Non-Inducement

SPN & FMI 1127 / 18

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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Technician Talks:

 Check ECU calibration number. Update calibration in case old revision observed in EMS ECU.
 Boost pressure low error will logged in EMS ECU if Boost Pressure demand and Boost pressure not meeting
during vehicle running.
 Error logged in EMS ECU, if leakage observed in boost pressure hose, hose clamp, leakage in intercooler,
hence rectify the leakage.
 Error logged in EMS ECU, If tappet setting get disturbed due to engine over speeding or not corrected during
service.
 Error logged in EMS ECU, If DPF got chocked/ clogged due to heavy soot accumulated at DPF inlet. So
disconnect the ATS inlet from engine out and check boost pressure and boost pressure demand at flyup (Full
accelerator). If boost pressure matched with boost pressure demand after disconnection of ATS then ECU
with ATS. Please conduct service regeneration to clean the soot from ATS.
 Error logged in EMS ECU, If excessive DEF deposits in SCR mixture or SCR catalyst. Check visually for DEF
deposits & clean the SCR mixture and SCR in case such issue
 Error logged in EMS ECU, If ETV got Stuck or not moving due to mechanical failure. To confirm the failure,
disconnect the ETV wiring harness connector (Coupler) and start the engine, check for Boost Pressure and
Boost pressure demand.
 Error logged in EMS ECU, If EGR valve got stuck open, which results high EGR flow during vehicle running.
Clean EGR valve soot in case of such issue.
 Error logged in EMS ECU, If Turbocharger has excessive play or Turbocharger not working properly. Check the
Turbocharger Visually and in case any doubt, check the Turbocharger with TEL service
 Error logged in EMS ECU, If low compression pressure observed in any cylinder or Engine. Check the
compression pressure through compression gauge. Desired Compression Pressure 30±2 bar. Low
compression pressure due to Valve damage (Inlet & Exhaust), Valve leakage (guide wear), Linear damage.
 Error logged in EMS ECU, If Injector/s not working as desired. Conduct injector Buzzing test. Incase issue not
resolved. Check injector with the help of Delphi Service.
 Error logged in EMS ECU, If EMS ECU not work properly.

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TDS Parameters For Boost Pressure Low Measurement in EMS:

1 Accelerator Pedal Position(%)

2 Air Flow Measured(g/s)
3 Air Flow Modelled(g/s)
4 Air Mass Flow PFM(g/s)
5 EGR Position Demand(%)
6 EGR Position Feedback(%)
7 Engine Speed (Average)(rpm)
8 Engine Stop Reason(-)
9 Engine Stop Request(-)
10 ETV - Position Demand(%)
11 ETV - Position Feedback(%)
12 Total Injected fuel quantity(mg/str)
13 Gear Ratio(-)
14 Ignition Switch status(-)
15 Atmospheric Pressure(kPa)
16 Boost pressure(kPa)
17 Boost pressure demand (kPa)
18 Manifold Absolute Pressure ( From TMAP)(kPa)
19 Rail Pressure Demand(Bar)
20 Rail Pressure Error(bar)
21 Rail pressure_Measured(Bar)
22 Coolant temperature(degC)
23 DOC Inlet Temperature(degC)
24 DPF Inlet Temperature(degc)
25 Fuel Temperature(degC)
26 Inlet air temperature (degC)
27 Intake Manifold temperature(degC)
28 Actual engine brake torque(Nm)
29 Turbocharger_Position Demand(%)
30 Turbocharger_Position feedback(%)
31 Vehicle Speed(kmpH)

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Trouble Shooting Steps:

Sr. No. Steps Specifications

TDS Parameters:
Check for Turbo Waste gate/PFM/ETV electrical errors. If found
[Link] pressure(kPa),2. Boost pressure demand (kPa).
any, rectify and drive vehicle, having engine speed >1350 rpm in
1 Ensure difference in Boost pressure should not be more than 40
constant pedal position and check Boost Pressure and Boost
kPa during vehicle running above Engine rpm of 1350 in a
Pressure demand
constant pedal position.

Air filter choke

Air filter to compressor, compressor to intercooler, Intercooler
Check for intake path air leakages. If found any, rectify and drive to PFM, PFM to Intake manifold, EGR cooler to intake manifold
2
vehicle in above condition. lines

Perform service regeneration at IDLE after issue rectification

Check for air filter choke. If found any, rectify and drive the vehicle
3 Perform service regeneration at IDLE after issue rectification
as per serial no 1 check for DTC

Check for intercooler puncture / Blockages. If found any, rectify

4 Perform service regeneration at IDLE after issue rectification
and drive vehicle as per serial no 1 and check for DTC

If still issue persists, Disconnect the ATS for exhaust line (3 bolts)
and check Boost Pressure and Boost Pressure demand at Fly up in
stand still condition by taking proper fire safety. Difference in Boost
Pressure should be less than 10 kPa at Flyup.
Please ensure DPF/ATS should not clogged (Like Urea deposition or
5 DPF burning). Perform service regeneration at IDLE after issue rectification
If urea deposition found, perform service regeneration once or
twice to remove deposits. If still issue present, replace SCR
system/ATS.
If DPF observed damaged or burned, replace DPF /ATS system.

Perform following Actuator tests :

1. Exhaust throttle Actuation - 0%, 50% & 80%
If still issue persists, Check whether ETV is functioning well or not
After test error between demand & feedback should be less
6 by doing actuator test and drive vehicle as serial no 1 and check
than 4%
for DTC
Perform service regeneration at IDLE after issue rectification

Perform following routine after component Replacement:

1. Turbo Actuator learning Test
If still issue persists, Replace turbo actuator/ turbocharger
7 2. Turbo Actuator Test
assembly and drive vehicle as serial no 1 and check for DTC
Perform service regeneration at IDLE after issue rectification

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If still issue persists, Please conduct Injector Buzz test 4-5 times per
8 Perform service regeneration at IDLE after issue rectification
Injector and drive vehicle as serial no 1 and check for DTC.

If still issue persists, Please check the Injector Performance through

9 the help of Delphi Service and replace or repair it based on Delphi Perform service regeneration at IDLE after issue rectification
feedback.

Steps for Data Copy from Existing ECU, Existing ECU removal,
New ECU Fitment & Software flashing:
Data Copy from Existing ECU:
1. Connect TDS
2. Read Injector Codes
3. Copy Injector codes in a excel file and save it.
Do the ignition OFF, Wait for two minutes. Do the battery cut
off, remove the EMS ECU and fit the new one.
i) Switch ON the Battery Cut off switch
ii) Switch ON the Ignition
iii) Connect TDS
iv) Connect EMS ECU
v) Write VIN & VC number of the existing vehicle in
new ECU
vi) Close the TDS
vii) Connect CVBU reprogramming tool
viii) Select Blank ECU flashing & No access to Older
ECU.
10 If still issue persists, Replace ECU.
ix) Start ECU flashing
x) After successful flashing, Parameter writing &
EUD data writing, ECU will pup of message of
“Ignition Off for 30 sec”. Please follow
instruction as per the guide line.
xi) Close Tata Reprogramming tool.
xii) Connect TDS
xiii) Select EMS ECU
xiv) Select Injector codes, Copy the injector codes
which saved in excel sheet based on cylinder
number.
xv) Select write tab to write the Injector codes in
ECU memory
xvi) Select Replacement tab to write vehicle data in
the new ECU
xvii) Clear all the faults in EMS ECU & DCU
xviii) Start the engine and check for DTC.

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Circuit Schematic Diagram:

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Location and Component Image:

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P0234-00: Over Boost Pressure Fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Restriction nearby positive air charge path to

engine
Fault Code P0234-00
2. Boost pressure sensor (PFM) malfunction
3. Turbo Waste gate actuator faulty / stuck
4. Turbo Internal HW failure
5. Fuel Injectors failure 1. Dynamic Torque reduction.
MIL ON for 15 secs 6. Faulty EGR (Engine Maximum Torque will vary with respect
7. Faulty ECU to Engine speed to Protect the Engine )
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_OVERBOOST_APV

System Actuators EGR/ETV/Turbo / Boost pressure monitoring

OBD Inducement Non-Inducement

SPN & FMI 1127 / 16

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Circuit diagram & Component images

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Technician Talks:

 Check ECU calibration number. Update calibration in case old revision observed in EMS ECU.
 Over Boost pressure error will logged in EMS ECU, if Boost Pressure exceeds from Boost pressure demand
during vehicle running.
 Error logged in EMS ECU, if Boost Pressure sensor (PFM) have some malfunction and reads wrong value.
 Error logged in EMS ECU, If tappet setting get disturbed due to engine over speeding or not corrected during
service.
 Error logged in EMS ECU, If Turbocharger actuator got stuck and excess exhaust gas not released from
bypass valve. Conduct Turbocharger hardware check
 Error logged in EMS ECU, If EGR valve got stuck closed, which results low EGR flow during vehicle running.
Clean EGR valve soot in case of such issue.
 Error logged in EMS ECU, If Injector/s not working as desired. Conduct injector Buzzing test. Incase issue not
resolved. Check injector with the help of Delphi Service.
 Error logged in EMS ECU, If EMS ECU not work properly.

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TDS Measuring Parameters:

1 Accelerator Pedal Position(%)

2 Air Flow Measured(g/s)
3 Air Flow Modelled(g/s)
4 Air Mass Flow PFM(g/s)
5 EGR Position Demand(%)
6 EGR Position Feedback(%)
7 Engine Speed (Average)(rpm)
8 Engine Stop Reason(-)
9 Engine Stop Request(-)
10 ETV - Position Demand(%)
11 ETV - Position Feedback(%)
12 Total Injected fuel quantity(mg/str)
13 Gear Ratio(-)
14 Ignition Switch status(-)
15 Atmospheric Pressure(kPa)
16 Boost pressure(kPa)
17 Boost pressure demand (kPa)
18 Manifold Absolute Pressure ( From TMAP)(kPa)
19 Rail Pressure Demand(Bar)
20 Rail Pressure Error(bar)
21 Rail pressure_Measured(Bar)
22 Coolant temperature(degC)
23 DOC Inlet Temperature(degC)
24 DPF Inlet Temperature(degc)
25 Fuel Temperature(degC)
26 Inlet air temperature (degC)
27 Intake Manifold temperature(degC)
28 Actual engine brake torque(Nm)
29 Turbocharger_Position Demand(%)
30 Turbocharger_Position feedback(%)
31 Vehicle Speed(kmpH)

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Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Perform following services in TDS:

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

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Circuit Schematic Diagram:

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Location and Component Image:

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-08

MIL ON 1. Regeneration Inhibition

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

Fault System Summary:

Development Fault code F_M_EGRH_DIG_COM_APV

System Actuators EGR/ETV/Turbo / EGR Component monitoring

EGR Inducement Group

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

SPN & FMI 5838 / 07

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Circuit diagram & Component images

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Technician Talks:

 Check EMS ECU calibration number. Update calibration in case old revision observed in EMS ECU.
 Check EMS ECU hardware, for any water entry, electrical short circuit, pin damage, pin rusty.
Replace EMS ECU with correct part number.

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
Update EMS ECU software, and recheck DTC. If issue persists, replace
1 2. Read & Write proper injector codes (I3C) from Old
ECU.
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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Circuit Schematic Diagram:

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Location and Component Image:

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-4B

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

Fault System Summary:

Development Fault code F_M_EGRH_DIG_THE_APV

System Actuators EGR/ETV/Turbo / EGR Component monitoring

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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Technician Talks:

 Check EMS ECU hardware, for any water entry, electrical short circuit, pin damage, pin rusty.
Replace EMS ECU with correct part number.
 Check EGR valve assembly for any hardware damage, Pin damage.
TDS Measuring Parameters:
 EGR Position Demand(%)
 EGR Position Feedback(%)

Trouble Shooting Steps:

Sr. No. Steps Specifications

Conduct EGR valve actuator test. If test failed at any positions (0/50/ EGR Actuator test for 0, 50 & 100 should pass.
100) % conduct EGR Learning Reset and EGR learning and repeat the Perform following routine after component Replacement:
1
above process again. If Test actuator failed, replace EGR valve assembly, 1. RESET EGRH values Test
else proceed to next step. 2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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Circuit Schematic Diagram:

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Location and Components Image:

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P0403-79: EGR Actuator - Return spring broken error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-79

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

Fault System Summary:

Development Fault code F_M_EGRH_SPR_BROKEN_APV

System Actuators EGR/ETV/Turbo / EGR Component monitoring

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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Technician Talks:

 Check EGR valve assembly for any hardware damage, Pin damage, Valve Stuck.
 Check excess soot deposits at EGR valve inlet.
 Ensure valve position change during actuator testing.
TDS Measuring Parameters:
 EGR Position Demand(%)
 EGR Position Feedback(%)

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform following services in TDS:
Perform Actuator Demand check through TDS. Check for Demand and
1. Test Actuators - EGR actuator demand check[0%, 50% &
feedback position. If there is too much difference between demand and
1 100%]
measured value, Connect one new EGR actuator assembly externally and
perform necessary services through TDS.
Acceptable deviation : +/- 3%
Perform following services in TDS:
Do Key OFF, wait for 20 secs. Perform Actuator Demand check through 1. Test Actuators - EGR actuator demand check[0%, 50% &
2 TDS. Check Demand and feedback position difference. If difference is 100%]
found OK, start engine and wait for 30 secs. Check for DTC
Acceptable deviation : +/- 3%
Perform following routine after component Replacement:
If there is no DTC, Fix new EGR in the vehicle and perform necessary
3 1. RESET EGRH values Test
services through TDS and check for DTC
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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Circuit Schematic Diagram:

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Location and Component Image:

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P0403-7C: EGR Actuator - Slow response fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-7C

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

Fault System Summary:

Development Fault code F_M_EGRH_SLOW_RESP_INC_APV

System Actuators EGR/ETV/Turbo / EGR Component monitoring

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Technician Talks:

 Check EGR valve assembly for any hardware damage, Pin damage, Valve Stuck.
 Check excess soot deposits at EGR valve inlet.
 Ensure valve position change during actuator testing.
TDS Measuring Parameters:
 EGR Position Demand(%)
 EGR Position Feedback(%)

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Perform following services in TDS:

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

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0403-71: EGR Actuator - Stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-71

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

Fault System Summary:

Development Fault code F_M_EGRH_POS_APV

System Actuators EGR/ETV/Turbo / EGR Component monitoring

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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Technician Talks:

 Ensure valve position change during actuator testing.

 Check EGR valve assembly for any hardware damage, Pin damage, Valve Stuck.
 Check excess soot deposits at EGR valve inlet.
TDS Measuring Parameters:
 EGR Position Demand(%)
 EGR Position Feedback(%)

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks
Checkpoints Acceptance criteria Result Recommended Action Remark
Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 30 Ohm+/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:

1. Test Actuators - EGR actuator demand check[0%, 50% &
Perform EGR Actuator demand check through TDS. Check for EGR
100%]
position demand and feedback. If there is too much difference between
1 demand and Feedback value, Conduct EGR learning Reset & EGR learning
Acceptable deviation : +/- 3%
through TDS during Ignition ON. After successful EGR learning reset and
Learning do the Ignition OFF for 30 Sec
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

Perform EGR Actuator Demand check through TDS. Check Demand and 1. Test Actuators - EGR actuator demand check[0%, 50% &
feedback position difference at 3 positions (0, 50, and 100) %. If 100%]
difference is found OK (within 3 %), start engine and warm up it & Check
2
for DTC. If still EGR stuck error persists, fit one new EGR valve assembly Acceptable deviation : +/- 3%
externally, conduct EGR learning reset and learning. Then repeat step 1
for actuator verification. Perform service regeneration at IDLE after issue
rectification
Perform following routine after component Replacement:
1. RESET EGRH values Test
2. EGR valve learning Test
3 If there is no DTC, Fix new EGR Valve assembly on the vehicle.
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Location and Component Image:

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2457-00: EGR Cooler - Efficiency very low

Overview:

Fault Code Description Cause Effect on Vehicle

[Link] T_EGR Sensor
Fault Code P2457-00
[Link] Soot deposited in EGR cooler
3. Low water supply to EGR cooler
Engine emission may go high & Vehicle may
MIL ON 4. Scaling in EGR cooler due to non use of Engine
run with poor pickup
coolant

Fault System Summary:

Development Fault code F_M_EGRH_COOL_PERF_LO_APV

System Actuators EGR/ETV/Turbo / EGR Cooler monitoring

OBD Inducement Non-Inducement

SPN & FMI 4752 / 07

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Circuit diagram & Component images

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Technician Talks:

 Ensure EGR Cooler excessive soot deposit

 Coolant supply to EGR cooler
 Scaling in coolant path on EGR cooler
 Abnormal temperature reading of EGR cooler Temperature sensor
TDS Measuring Parameters:
 EGR intake Temperature
 Inlet air temperature

Test Conditions:
 Vehicle should be at Ignition ON only (Engine should be off for minimum1 hour)

Trouble Shooting Steps:

Sr. No. Steps Specifications

If found any issues in EGR temperature sensor (Physical damage or
Perform service regeneration at IDLE after issue
1 abnormal data coming to ECU), Then replace the sensor and drive the
rectification
vehicle for 10 Kms in highway and check for DTC
If still problem persists check water supply connection of EGR cooler. If
Perform service regeneration at IDLE after issue
2 found any issues (Hose Pinched, Pipe blocked), rectify it. Drive the
rectification
vehicle for 10 Kms in highway and check for DTC.
If still issue persists, Clean the EGR cooler by compressed air to remove Perform service regeneration at IDLE after issue
3
excessive soot. Drive vehicle for 10 Kms in highway and check for DTC rectification
If still issue persists, Replace EGR Cooler. Drive vehicle for 10 Kms in Perform service regeneration at IDLE after issue
4
highway and check for DTC rectification
Perform service regeneration at IDLE after issue
5 If still issue persists, Replace ECU.
rectification

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Date: 21-01-2025

Circuit Schematic Diagram:

Location and Component Image:

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P0403-A1: EGR Actuator - Controller system voltage error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-A1

1. EGR actuator voltage out of range
MIL ON
2. Mechanical failure of EGR 1. Regeneration Inhibition
3. Faulty ECU
SCR Lamp ON 4. Faulty Wiring Harness 2. Engine emission may go high
3. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_EGRH_VOLTAGE_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Technician Talks:

 EGR Valve check for any hardware failure

 ECU check for any external or internal failure
Trouble shooting Steps:
A. Electrical Interface Integrity Checks
Checkpoints Acceptance criteria Result Recommended Action Remark
Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 30 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
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Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications
Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace EGR Valve assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
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Circuit Schematic Diagram:

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 Version: 1.3
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Location and Component Image:

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-F2

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

Fault System Summary:

Development Fault code F_M_EGRH_S2V_NEG_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Technician Talks:

 Ensure EGR Valve PIN damage & Valve physical damage.

 Wiring check for any short circuit.
 ECU Malfunction.

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 30 ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

TDS Measuring Parameters:

 EGR Position Counts
 EGR Position Demand
 EGR Position Feedback
 Ignition Switch status

Test Conditions:
 Vehicle should be at Ignition ON only during checking.
B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If above electrical checks (Electrical Interface Integrity Checks) passed,
then check EGR valve pin damage or EGR valve failure.
1

If still issue persists, Replace EGR actuator assembly. Conduct EGR valve
Perform following routine after component Replacement:
learning reset & learning. Ignition key off for 30 sec, then do the Ignition
2 1. RESET EGRH values Test
ON and conduct EGR actuator testing (0, 50 & 100) % and it should pass
2. EGR valve learning Test
the test.
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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P0403-F3: EGR Actuator - Negative Pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-F3

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

Fault System Summary:

Development Fault code F_M_EGRH_S2G_NEG_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Technician Talks:

 Ensure EGR Valve PIN damage & Valve physical damage.

 Wiring check for any short circuit.
 ECU Malfunction.
Trouble shooting Steps:
A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 30 ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
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Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 72 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0403-13: EGR Actuator - Open load error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-13

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

Fault System Summary:

Development Fault code F_M_EGRH_OL_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 74 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 30 ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 77 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-F5

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

Fault System Summary:

Development Fault code F_M_EGRH_OC_NEG_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 79 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 30 ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 80 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 82 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-F4

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

Fault System Summary:

Development Fault code F_M_EGRH_OC_POS_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 84 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 30 ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 85 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 86 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 87 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-F0

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

Fault System Summary:

Development Fault code F_M_EGRH_S2V_POS_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 89 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 30 ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 90 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 91 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 92 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 93 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0403-F1

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

Fault System Summary:

Development Fault code F_M_EGRH_S2G_POS_APV

System Actuators EGR/ETV/Turbo / EGR Electrical Monitor

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 94 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 30 ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 95 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace EGR actuator assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 96 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 97 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 98 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0400-9B: EGR Flow is too high

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0400-9B 1. Intake air leakage

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

Fault System Summary:

Development Fault code F_M_EGRH_HFLOW_APV

System Actuators EGR/ETV/Turbo / EGR Flow Monitoring

OBD Inducement Non-Inducement

SPN & FMI 2659 / 16

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Technician Talks:

 Ensure Air flow difference should not exceed 8 grams/ sec between model and actual
 Check Air Path (Air filter, Turbocharger)
Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Check following labels during all steps:

1. EGR Flow correction (Range should be 0.7 to 2.2)
Air flow difference b/w actual and estimated should be less
If still issue persists, Check any errors related to PFM sensor & EGR than 8 g/s.
2 valve actuator. If found any rectify it. Drive vehicle for 10 Kms, TDS Label name :
monitor labels mentioned in specification 2 and check for DTC * Air Flow_Measured
* Air Flow_Modelled

Perform service regeneration at IDLE after issue rectification

If still issue persists, check PFM sensor orientation as per design
3 specification. If found any issues, rectify it . Drive vehicle for 10 Perform service regeneration at IDLE after issue rectification
Kms, monitor labels mentioned in specification 2 and check for DTC

Perform following routines:

If still issue persists, Replace PFM sensor, perform component
1. RESET PFM values Test
4 replacement service. Drive vehicle for 10 Kms, monitor labels
mentioned in specification 2 and check for DTC
Perform service regeneration at IDLE after issue rectification

Perform following services in TDS:

1. Test Actuators - EGR actuator demand check[0%, 50% &
Perform Actuator Demand check through TDS. Check for Demand
100%]
and feedback position. If there is too much difference between
5
demand and measured value, Connect one new EGR actuator
Acceptable deviation : +/- 3%
assembly externally and perform necessary services through TDS.
Perform service regeneration at IDLE after issue rectification

Perform following routine after component Replacement:

Replace that new EGR actuator assembly in vehicle. Drive vehicle 1. RESET EGRH values Test
6 for 10 Kms, monitor labels mentioned in specification 2 and check 2. EGR valve learning Test
for DTC
Perform service regeneration at IDLE after issue rectification

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Perform following services in TDS:

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

After Injector replacement, Write Injector codes (I3C) and

8 If Still Persists, Replace Injector/s conduct service regeneration to burn out the excess deposited
soot from DPF.

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Circuit Schematic Diagram:

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Location and Component Image:

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Date: 21-01-2025

P0400-9C: EGR Flow is too low

Overview:

Fault Code Description Cause Effect on Vehicle

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

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

Fault System Summary:

Development Fault code F_M_EGRH_LOW_FLOW_1_APV

System Actuators EGR/ETV/Turbo / EGR Flow Monitoring

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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Technician Talks:

 Ensure Air flow difference should not exceed 8 grams/ sec between model and actual
 Check exhaust gas leakage in exhaust lines (Before and After EGR Valve) and Exhaust Manifold.
 Check EGR Valve, TMAP Sensor (Fitted on Intake manifold) & TMAP sensor wiring for any issues.

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Check following labels during all steps:

1. EGR Flow correction (Range should be 0.7 to 2.2)
Air flow difference b/w actual and estimated should be
less than 8 g/s.
If still issue persists, Check any errors related to PFM sensor & EGR valve
TDS Label name :
2 actuator. If found any rectify it. Drive vehicle for 10 Kms, monitor labels
* Air Flow_Measured
mentioned in specification 2 and check for DTC
* Air Flow_Modelled

Perform service regeneration at IDLE after issue

rectification

Perform following routines:

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

Difference between model and actual flow should not

exceed 8 g/s and EGR flow correction should not exceed
If Still Problem persists, Replace T- Map Sensor (fitted on inlet manifold)
5 2.8.
and check the Air flow difference between model and actual.
Perform service regeneration at IDLE after issue
rectification

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Perform following services in TDS:

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

Circuit Schematic Diagram:

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Location and Component Image:

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P040A-11 1. Faulty Wiring harness

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

Fault System Summary:

Development Fault code F_M_EGRH_INTAK_T_LO_APV

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

OBD Inducement Non-Inducement

SPN & FMI 412 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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B. Other Interface Integrity Checks

Sr. No. Steps Specifications

1 If still issue persists, Re-flash ECU dataset and check for DTC again
2 If still issue persists, Replace EGR temperature sensor and check for DTC
3 If still issue persists, Replace ECU

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Circuit Schematic Diagram:

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Location and Component Image:

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P040A-12 1. Faulty wiring harness

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

Fault System Summary:

Development Fault code F_M_EGRH_INTAK_T_HI_APV

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

OBD Inducement Non-Inducement

SPN & FMI 412 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Location and Component Image:

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 Version: 1.3
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P040A-64: EGR Cooler temperature sensor - Signal not valid based on

reference sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P040A-64 1. Faulty wiring harness

[Link] T EGR sensor No Vehicle reaction
[Link] ECU
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_EGRH_IN_TEMP_XC_APV

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

OBD Inducement Non-Inducement

SPN & FMI 412 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Temperature difference should be checked at Ignition On
After rectification of step 1, connect EGR temp. sensor externally and only & Before checking vehicle should be parked without
keep it in ambient with wiring connected. Like that keep reference start more than 6 hours.
1
sensors as well. Check temp. difference across all sensors at Ignition On Reference sensors :
only. 1. Coolant temperature sensor
2. Intake manifold temperature sensor (TMAP)
2 If difference found within specification, Fit back all 3 sensors into engine. Temperature difference threshold : +/20 deg C

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

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Circuit Schematic Diagram:

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Location and Component Image:

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Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0409-14

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

Fault System Summary:

Development Fault code F_M_EGRH_FDB_LO_APV

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

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 30 ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
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B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1 If still issue persists, Replace EGR Valve assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Location and Component Image:

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 Version: 1.3
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P0409-12: EGR Actuator position sensor - Short to battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0409-12

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

Fault System Summary:

Development Fault code F_M_EGRH_FDB_HI_APV

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

EGR Inducement Group

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

SPN & FMI 5838 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 30 ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1 If still issue persists, Replace EGR valve assembly and check for DTC 1. RESET EGRH values Test
2. EGR valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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Date: 21-01-2025

Circuit Schematic Diagram:

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Location and Component Image:

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 Version: 1.3
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Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

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

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

Fault System Summary:

Development Fault code F_M_EGRH_LRN_1ST_CL_APV

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

OBD Inducement Non-Inducement

SPN & FMI 3058 / 13

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
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Date: 21-01-2025

P0403-99: EGR Actuator - Learning exceeded wear limit

Overview:

Fault Code Description Cause Effect on Vehicle

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

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

Fault System Summary:

Development Fault code F_M_EGRH_LRN_CL_LGDV_APV

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

OBD Inducement Non-Inducement

SPN & FMI 5829 / 16

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform following routine after component Replacement:

1. RESET EGR Learning
Check EGR actuator for any physical damage. If found any, rectify /
1 2. EGR valve learning Test
Replace component. Clear DTC & Check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform service regeneration at IDLE after issue

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

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-08

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

Fault System Summary:

Development Fault code F_M_EXH_BRK_DIG_COM_APV

System Actuators EGR/ETV/Turbo / ETV Component monitoring

OBD Inducement Non-Inducement

SPN & FMI 8322 / 19

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1 Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 143 of 1261

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-4B

MIL ON 1. Delayed Torque reduction

1. Exhaust throttle actuator internal failures
2. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_DIG_THE_APV

System Actuators EGR/ETV/Turbo / ETV Component monitoring

OBD Inducement Non-Inducement

SPN & FMI 5627 / 17

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1 Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 146 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 147 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P26C5-79: Exhaust Throttle Valve - Slow response fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-79

1. Stuck of Exhaust throttle valve
MIL ON 2. Mechanical failure of ETV 1. 25% Torque reduction
3. Malfunction of ECU 2. Engine emission go high & Vehicle run
CEL ON with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_SPR_BRKN_APV

System Actuators EGR/ETV/Turbo / ETV Component monitoring

OBD Inducement Non-Inducement

SPN & FMI 8322 / 10

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks
Checkpoints Acceptance criteria Result Recommended Action Remark
Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
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Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1. RESET Exhaust brake Values Test
If there is no DTC, Fix new Exhaust throttle in the vehicle and perform 2. Exhaust throttle valve learning Test
1
necessary services through TDS and check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 152 of 1261

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P26C5-71: Exhaust Throttle Valve - Stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-71

1. Faulty wiring harness

MIL ON 2. Faulty ETV actuator 1. 25% Torque reduction
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_POS_APV

System Actuators EGR/ETV/Turbo / ETV Component monitoring

OBD Inducement Non-Inducement

SPN & FMI 8322 / 07

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 155 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1. RESET Exhaust brake Values Test
If there is no DTC, Fix new Exhaust throttle in the vehicle and perform 2. Exhaust throttle valve learning Test
1
necessary services through TDS and check for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

Author: ERC Page 156 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 157 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-F0

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

Fault System Summary:

Development Fault code F_M_EXH_BRK_S2V_NEG_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 11792 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 159 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 160 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 161 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 162 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 163 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-F2

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

Fault System Summary:

Development Fault code F_M_EXH_BRK_S2G_NEG_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 11796 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 164 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 165 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 166 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 167 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 168 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-F5

1. Exhaust Throttle Actuator motor failure (over
MIL ON
current on pin E26) 1. 25% Torque reduction
2. Faulty Wiring harness
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_OC_NEG_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 11796 / 06

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 169 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 170 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 171 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 172 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 173 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P26C5-13: Exhaust Throttle Valve - Open load error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-13

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

Fault System Summary:

Development Fault code F_M_EXH_BRK_OL_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 8322 / 05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 174 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 175 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 176 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 177 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 178 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-F3

1. Exhaust throttle motor positive pin S2V (pin
MIL ON E47) 1. Delayed Torque reduction
[Link] wiring Harness 2. Regeneration Inhibition
3. Faulty ECU
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_S2V_POS_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 11796 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 179 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 180 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 181 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 182 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 183 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-F1

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

Fault System Summary:

Development Fault code F_M_EXH_BRK_S2G_POS_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 11792 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 184 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 185 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 186 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 187 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 188 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-F4

1. Exhaust Throttle Actuator motor failure (over
MIL ON
current on pin E47) 1. 25% Torque reduction
2. Faulty wiring harness
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_OC_POS_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 11792 / 06

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 189 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 190 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 191 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 192 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 193 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P26C5-A1: Exhaust Throttle Valve - Return spring broken

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-A1

MIL ON
1. Exhaust Throttle actuator voltage out of range 1. 25% Torque reduction
2. Mechanical failure of ETV
3. Faulty ECU 2. Regeneration Inhibition
3. Engine emission go high & Vehicle run
with poor pickup
Urea dosing will be stopped

Fault System Summary:

Development Fault code F_M_EXH_BRK_VOLTAGE_APV

System Actuators EGR/ETV/Turbo / ETV Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 8322 / 12

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 194 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
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Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
2 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 197 of 1261

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BF4-2F 1. Faulty wiring Harness

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

Fault System Summary:

Development Fault code F_M_EXH_BRK_FDB_NOI_APV

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

OBD Inducement Non-Inducement

SPN & FMI 5625 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 199 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

ETV Actuator should pass at three different positions (0,
1 Conduct ETV actuator test at Ignition ON 50, 80 %).
Acceptable limit ± 3 %
Perform following routine after component Replacement:
2 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
3 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BF4-14

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

Fault System Summary:

Development Fault code F_M_EXH_BRK_FDB_LO_APV

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

OBD Inducement Non-Inducement

SPN & FMI 5625 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 204 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
2 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 207 of 1261

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BF4-12

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

Fault System Summary:

Development Fault code F_M_EXH_BRK_FDB_HI_APV

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

OBD Inducement Non-Inducement

SPN & FMI 5625 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 209 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
2 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 212 of 1261

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Fault Code Description Cause Effect on Vehicle

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

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

Fault System Summary:

Development Fault code F_M_EXH_BRK_LN1ST_CL_APV

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

OBD Inducement Non-Inducement

SPN & FMI 5625 / 13

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Do Ignition OFF and wait for 20 secs and Do Key ON. Clear DTC & Check
1
for DTC.
If still issue persists, Check for any errors related to Exhaust Throttle. If
2
found any, rectify it and check for DTC
If still issue persists, Clear DTC and perform actuator reset & learning Perform following routine after component Replacement:
3 service through TDS. Do Key off, wait for 20 secs and do key ON. Clear 1. RESET Exhaust brake Values Test
DTC & Check for DTC again 2. Exhaust throttle valve learning Test
Perform following services in TDS:
Perform Actuator Demand check through TDS. Check for Demand and
1. Test Actuators - Exhaust throttle demand check[0%,
feedback position. If there is too much difference between demand and
4 50% & 80%]
measured value, Connect one new Exhaust throttle assembly externally
and perform necessary services through TDS.
Acceptable deviation : +/- 3%
Select dataset based on Vehicle Identification
5 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
6 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 216 of 1261

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

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

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

Fault System Summary:

Development Fault code F_M_EXH_BRK_LNCL_LDV_APV

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

OBD Inducement Non-Inducement

SPN & FMI 8322 / 09

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 218 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Perform following services in TDS:

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

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 220 of 1261

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0243-08: Turbo E-Waste gate - Internal Communication failure in ECU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-08

1. Wastegate actuator internal failures
MIL ON for 15 secs 2. Faulty ECU 1. 25% Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_DIG_COM_APV

System Actuators EGR/ETV/Turbo / Turbocharger Component monitoring

OBD Inducement Non-Inducement

SPN & FMI 646 / 19

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1 Replace turbo actuator/ turbocharger assembly and check for DTC 1. RESET VGTH Values Test
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 224 of 1261

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-4B

1. Wastegate actuator internal failures
MIL ON for 15 secs 2. Faulty ECU 1. 25% Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_DIG_THE_APV

System Actuators EGR/ETV/Turbo / Turbocharger Component monitoring

OBD Inducement Non-Inducement

SPN & FMI 5788 / 15

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 226 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Perform following routine after component Replacement:
1 Replace turbo actuator/ turbocharger assembly and check for DTC 1. RESET VGTH Values Test
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 227 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 228 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0243-71: Turbo E-Waste gate - Actuator Stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

[Link] gate actuator/motor stuck inside
Fault Code P0243-71 [Link] flap damage
[Link] link damage
4. Faulty ECU Engine emission go high
MIL ON for 15 secs
5. Faulty wiring harness Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_VGTH_HB_POS_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 7381 / 07

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 230 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Perform following services in TDS:

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

Ensure wiring harness continuity between ECU to Turbocharger

4 Refer wiring harness continuity schematic.
connector

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 232 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 233 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0243-13: Turbo E-Waste gate - Drive Open load error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0243-13 1. Faulty wiring Harness

2. Waste gate actuator hardware issues
MIL ON for 15 secs 3. Faulty ECU 1. 25% Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_OL_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 5451 / 05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 234 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 235 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
2 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 236 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 237 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 238 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0243-F2: Turbo E-Waste gate - Negative Pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

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

current on pin E21)
2. Faulty wiring Harness
MIL ON for 15 secs 3. Faulty ECU 1. 25% Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_S2V_NEG_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 6294 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 239 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 240 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
2 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 241 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 242 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 243 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0243-F3: Turbo E-Waste gate - Negative Pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

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

current on pin E21)
2. Faulty wiring Harness
MIL ON for 15 secs 3. Faulty ECU 1. 25% Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_S2G_NEG_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 6294 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 244 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 245 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
2 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 246 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 247 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 248 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0243-F5: Turbo E-Waste gate - Over Current in Negative Pin

Overview:

Fault Code Description Cause Effect on Vehicle

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

current on pin E21)
[Link] wiring Harness
MIL ON for 15 secs 3. Faulty ECU 1. 25% Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_OC_NEG_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 6294 / 06

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 249 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 250 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
2 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 251 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 252 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 253 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0243-F4: Turbo E- Waste gate - Over Current in Positive Pin

Overview:

Fault Code Description Cause Effect on Vehicle

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

current on pin E42)
2. Faulty wiring Harness
MIL ON for 15 secs 3. Faulty ECU 1. 25 % Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_OC_POS_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 5421 / 06

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 254 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 255 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
2 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 256 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 257 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 258 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0243-F0: Turbo E-Waste gate - Positive Pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

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

current on pin E42)
2. Faulty wiring Harness
MIL ON for 15 secs 3. Faulty ECU 1. 25% Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_S2V_POS_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 5421 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 259 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
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Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
2 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0243-F1: Turbo E- Waste gate - Positive Pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

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

current on pin E42)
2. Faulty wiring Harness
MIL ON for 15 secs 3. Faulty ECU 1. 25% Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_S2G_POS_APV

System Actuators EGR/ETV/Turbo / Turbocharger Electrical Monitor

OBD Inducement Non-Inducement

SPN & FMI 5421 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset based on Vehicle Identification
1 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
2 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2AB7-14 1. Faulty wiring Harness

2. Waste gate actuator internal failures
MIL ON for 15 secs 3. Faulty ECU 1. 25% Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_FDB_LO_APV

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

OBD Inducement Non-Inducement

SPN & FMI 1188 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
1 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 272 of 1261

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2AB7-12: Turbo E- Waste gate position sensor - Short to battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2AB7-12 1. Faulty wiring Harness

2. Waste gate actuator internal failures
MIL ON for 15 secs 3. Faulty ECU 1. 25% Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_VGTH_FDB_HI_APV

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

OBD Inducement Non-Inducement

SPN & FMI 1188 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following routine after component Replacement:
If still issue persists, Replace turbo actuator/ turbocharger assembly and
1 1. RESET VGTH Values Test
check for DTC
2. Turbo Actuator learning Test
2 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 277 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0243-54: Turbo E-Waste gate - 1st learning failed / Value out of range
Overview:

Fault Code Description Cause Effect on Vehicle

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

2. Faulty Turbocharger No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_VGTH_HB_LN1ST_CL_APV

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

OBD Inducement Non-Inducement

SPN & FMI 1188 / 13

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0243-99: Turbo E- Waste gate – Valve Close hard stop learning out of range
High/Low
Overview:

Fault Code Description Cause Effect on Vehicle

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

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

Fault System Summary:

Development Fault code F_M_VGTH_HB_LRN_ CL_HI_APV & F_M_VGTH_HB_LRN_ CL_LO_APV

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

OBD Inducement Non-Inducement

SPN & FMI 0000 / 00

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 285 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2226-64: Barometric Pressure Sensor - Signal not valid

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2226-64

[Link] sensor
MIL ON for 15 secs [Link] ECU 1. No Torque Derate
CEL ON

Fault System Summary:

Development Fault code F_M_ATMOS_P_XC_APV

System Air Intake System / Ambient Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 108 / 02

Visit next 2 page(s) for Troubleshooting steps,

Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0070-15 1. Faulty Wiring harness

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

Fault System Summary:

Development Fault code F_M_EXT_AIR_TEMP_HI_APV

System Air Intake System / Ambient Temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 171 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0070-11: Ambient temperature sensor - Short to ground

Overview:

Fault Code Description Cause Effect on Vehicle

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

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

Fault System Summary:

Development Fault code F_M_EXT_AIR_TEMP_LO_APV

System Air Intake System / Ambient Temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 171 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0070-64 [Link] wiring harness

[Link] sensor No Vehicle reaction
[Link] ECU
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_EXT_AIR_TEMP_XC_APV

System Air Intake System / Ambient Temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 171 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

After rectification of step 1, connect Ambient temp. sensor externally Reference sensors :
1 and keep it in ambient with wiring connected. Like that keep reference 1. Inlet Air temperature sensor (IAT)
sensors as well. Check temp. difference across all sensors 2. Intercooler out temperature sensor (PFM)

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

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0235-29

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

Fault System Summary:

Development Fault code F_M_BOOSTP_SENT_FDAT_APV

System Air Intake System / Boost pressure monitoring

Dosing Interruption Group

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

SPN & FMI 5541 / 19

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

1 Check the Electrical Connectivity (Open & Short Circuit) as per

methodology mentioned in “Electrical Trouble shooting Guide” below. Connectivity to be ensured as per Circuit diagram

Damage of sensor/ Broken Sensor

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Electrical Trouble shooting Guide: Electrical Short & Open Circuit

Checkpoints Acceptance criteria Result Recommended Action Remark
Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 308 of 1261

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Fault Code Description Cause Effect on Vehicle

Fault Code P0235-64

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

Fault System Summary:

Development Fault code F_M_BOOST_P_XC_APV

System Air Intake System / Boost pressure monitoring

Dosing Interruption Group

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

SPN & FMI 5541 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Reference sensors :
1. Ambient pressure sensor
After rectification of step 1, connect PFM sensor externally and keep it in
2. TMAP/Intake manifold pressure sensor
1 ambient with wiring connected. Like that keep reference sensors as well.
Check pressure difference across all sensors
Perform service regeneration at IDLE after issue
rectification
Pressure difference threshold : +/- 8 kPa
If difference found within specification, Fit PFM sensor into engine and
2
connect other sensors as well. Perform service regeneration at IDLE after issue
rectification
Reference sensors :
1. Ambient pressure sensor
If still issue persists, connect one new PFM sensor externally and keep it
2. TMAP/Intake manifold pressure sensor
3 in ambient with wiring connected. Like that keep reference sensors as
well. Check pressure difference across all sensors
Perform service regeneration at IDLE after issue
rectification
Pressure difference threshold : +/- 8 kPa
Perform following services in TDS:
If difference found within specification, Fit new PFM sensor into engine 1. RESET PFM Sensor Learning
4
and connect other sensors also
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0110-15 1. Faulty Wiring harness

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

Fault System Summary:

Development Fault code F_M_INLET_AIR_HI_APV

System Air Intake System / Inlet Air temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 172 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 318 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0110-11 1. Faulty Wiring harness

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

Fault System Summary:

Development Fault code F_M_INLET_AIR_LO_APV

System Air Intake System / Inlet Air temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 172 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 323 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Fault Code Description Cause Effect on Vehicle

Fault Code P0110-64 [Link] wiring harness

[Link] sensor No Vehicle reaction
[Link] ECU
MIL ON for 15 secs

Fault System Summary:

Development Fault code F_M_INLET_AIR_TEMP_XC_APV

System Air Intake System / Inlet Air temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 172 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 325 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 326 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

After rectification of step 1, connect Inlet Air temp. sensor externally and Reference sensors :
1 keep it in ambient with wiring connected. Like that keep reference 1. Ambient temperature sensor
sensors as well. Check temp. difference across all sensors 2. Intercooler out temperature sensor(PFM)

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

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

Author: ERC Page 327 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 328 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0105-12

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

Fault System Summary:

Development Fault code F_M_MAP_SENSOR_HI_APV

System Air Intake System / Intake Manifold pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 3563 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 330 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of component-side coupler only
Measure Component side resistance 15degC : 3068ohms, Pass Proceed to step 4 Component electrical
Between pin 1 & 2 20degC : 2499ohms, check OK
3 Kept sensor outside (Open to air) with 25degC: 2056ohms, Fail Replace the part Clear DTC and recheck
30degC: 1706ohms,
35degC : 1411ohms
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 331 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 332 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 333 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 334 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

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

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

Fault System Summary:

Development Fault code F_M_MAP_SENSOR_LO_APV

System Air Intake System / Intake Manifold pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 102 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 335 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of component-side coupler only
Measure Component side resistance 15degC : 3068ohms, Pass Proceed to step 4 Component electrical
Between pin 1 & 2 20degC : 2499ohms, check OK
3 Kept sensor outside (Open to air) with 25degC: 2056ohms, Fail Replace the part Clear DTC and recheck
30degC: 1706ohms,
35degC : 1411ohms
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 336 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 337 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 338 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 339 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

reference sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0105-64 [Link] wiring harness

[Link] sensor
[Link] ECU Engine emission go high
MIL ON for 15 secs
Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_MAP_XC_APV

System Air Intake System / Intake Manifold pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 3563 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 340 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of component-side coupler only
Measure Component side resistance 15degC : 3068ohms, Pass Proceed to step 4 Component electrical
Between pin 1 & 2 20degC : 2499ohms, check OK
3 Kept sensor outside (Open to air) with 25degC: 2056ohms, Fail Replace the part Clear DTC and recheck
30degC: 1706ohms,
35degC : 1411ohms
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 341 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Reference sensors :
1. Ambient pressure sensor
After rectification of step 1, connect TMAP sensor externally and keep it
2. PFM/Boost pressure sensor
1 in ambient with wiring connected. Like that keep reference sensors as
well. Check pressure difference across all sensors
Perform service regeneration at IDLE after issue
rectification
Pressure difference threshold : +/- 8 kPa
If difference found within specification, Fit TMAP sensor into engine and
2
connect other sensors as well. Perform service regeneration at IDLE after issue
rectification
Reference sensors :
1. Ambient pressure sensor
If still issue persists, connect one new TMAP sensor externally and keep it
2. PFM/Boost pressure sensor
3 in ambient with wiring connected. Like that keep reference sensors as
well. Check pressure difference across all sensors
Perform service regeneration at IDLE after issue
rectification
Pressure difference threshold : +/- 8 kPa
If difference found within specification, Fit new TMAP sensor into engine
4
and connect other sensors also Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
5 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 342 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 343 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 344 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

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

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

Fault System Summary:

Development Fault code F_M_IP_TEMP_HI_APV

System Air Intake System / Intake Manifold temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 105 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 345 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of component-side coupler only
Measure Component side resistance 15degC : 3068ohms, Pass Proceed to step 4 Component electrical
Between pin 1 & 2 20degC : 2499ohms, check OK
3 Kept sensor outside (Open to air) with 25degC: 2056ohms, Fail Replace the part Clear DTC and recheck
30degC: 1706ohms,
35degC : 1411ohms
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 346 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications
If still issue persists, Replace TMAP/Intake manifold temperature sensor Perform service regeneration at IDLE after issue
1
and check for DTC rectification
Select dataset as per Vehicle configuration(VC)
2 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform service regeneration at IDLE after issue
3 If still issue persists, Replace respective wiring harness
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
4 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

Author: ERC Page 347 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 348 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 349 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P00E8-11

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

Fault System Summary:

Development Fault code F_M_IP_TEMP_LO_APV

System Air Intake System / Intake Manifold temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 105 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 350 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of component-side coupler only
Measure Component side resistance 15degC : 3068ohms, Pass Proceed to step 4 Component electrical
Between pin 1 & 2 20degC : 2499ohms, check OK
3 Kept sensor outside (Open to air) with 25degC: 2056ohms, Fail Replace the part Clear DTC and recheck
30degC: 1706ohms,
35degC : 1411ohms
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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Location and Component Image:

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

reference sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P00E8-64 [Link] wiring harness

[Link] sensor
[Link] ECU Engine emission go high
MIL ON for 15 secs
Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_INTAKE_PLEN_TEMP_XC_APV

System Air Intake System / Intake Manifold temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 105 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of component-side coupler only
Measure Component side resistance 15degC : 3068ohms, Pass Proceed to step 4 Component electrical
Between pin 1 & 2 20degC : 2499ohms, check OK
3 Kept sensor outside (Open to air) with 25degC: 2056ohms, Fail Replace the part Clear DTC and recheck
30degC: 1706ohms,
35degC : 1411ohms
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P026A-00: Intercooler Performance - Low efficiency error

Overview:

Fault Code Description Cause Effect on Vehicle

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

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

Fault System Summary:

Development Fault code F_M_INTERCOOLER_PERF_LO_APV

System Air Intake System / Intercooler performance Monitor

OBD Inducement Non-Inducement

SPN & FMI 5285 / 07

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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Trouble Shooting Steps:

Sr. No. Steps Specifications

Check E-Viscous FAN/PFM sensor electrical failures. If found any Perform service regeneration at IDLE after issue
1
issue, rectify it and check for DTC rectification

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

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Circuit Schematic Diagram:

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Location and Component Image:

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Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P006A-9B

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

Fault System Summary:

Development Fault code F_M_AMF_CORR_HI_FFR_APV

System Air Intake System / PFM Air Mass flow Monitor

Dosing Interruption Group

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

SPN & FMI 132 / 20

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Air filter choke
Air filter to compressor, compressor to intercooler,
Intercooler to PFM, PFM to Intake manifold, EGR cooler to
Check Intake air leakage / Air filter related issues. If found any, rectify the
1 intake manifold lines
same. Drive vehicle for 10 Kms and check for DTC
Perform service regeneration at IDLE after issue
rectification
If anything found in step1, after rectification drive vehicle for 10 Kms and Perform service regeneration at IDLE after issue
2
check for DTC rectification
Damage of sensor/ Broken Sensor
Perform following services in TDS: (If PFM is changed)
Check any physical damage of PFM & TMAP Sensor. If found any, replace
3 1. RESET PFM Sensor Learning
respective sensor. Drive vehicle for 10 Kms and check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
Check the air mass flow during idling through Diagnostic Tester. If its out
1. RESET PFM Sensor Learning
4 of specification, Replace PFM sensor. Drive vehicle for 10 Kms and check
Perform service regeneration at IDLE after issue
for DTC
rectification
If still issue persists, Replace TMAP sensor. Check the air mass flow
Perform service regeneration at IDLE after issue
5 during idling through Diagnostic Tester. Drive vehicle for 10 Kms and
rectification
check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.3
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Circuit Schematic Diagram:

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 Version: 1.3
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Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P006A-9C

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

Fault System Summary:

Development Fault code F_M_AMF_CORR_LO_FFR_APV

System Air Intake System / PFM Air Mass flow Monitor

Dosing Interruption Group

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

SPN & FMI 132 / 21

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Air filter choke
Air filter to compressor, compressor to intercooler,
Intercooler to PFM, PFM to Intake manifold, EGR cooler to
Check Intake air leakage / Air filter related issues. If found any, rectify the
1 intake manifold lines
same. Drive vehicle for 10 Kms and check for DTC
Perform service regeneration at IDLE after issue
rectification
If anything found in step1, after rectification drive vehicle for 10 Kms and Perform service regeneration at IDLE after issue
2
check for DTC rectification
Damage of sensor/ Broken Sensor
Perform following services in TDS: (If PFM is changed)
Check any physical damage of PFM & TMAP [Link] found any, replace
3 1. RESET PFM Sensor Learning
respective sensor. Drive vehicle for 10 Kms and check for DTC
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
Check the air mass flow during idling through Diagnostic Tester. If its out
1. RESET PFM Sensor Learning
4 of specification, Replace PFM sensor. Drive vehicle for 10 Kms and check
Perform service regeneration at IDLE after issue
for DTC
rectification
If still issue persists, Replace TMAP sensor. Check the air mass flow
Perform service regeneration at IDLE after issue
5 during idling through Diagnostic Tester. Drive vehicle for 10 Kms and
rectification
check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
6 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform service regeneration at IDLE after issue
rectification

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 Version: 1.3
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Circuit Schematic Diagram:

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 Version: 1.3
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Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0100-29: PFM Sensor - Signal error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0100-29

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

Fault System Summary:

Development Fault code F_M_AMF_SENT_FDAT_APV

System Air Intake System / PFM Air Mass flow Monitor

Dosing Interruption Group

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

SPN & FMI 132 / 19

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P007A-29: Intercooler out temperature - Sensor signal error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P007A-29

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

Fault System Summary:

Development Fault code F_M_IC_SENT_FDATA_APV

System Air Intake System / PFM Intercooler outlet temperature sensor

Dosing Interruption Group

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

SPN & FMI 2630 / 09

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Air flow threshold : 25-35 g/s

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

Perform service regeneration at IDLE after issue

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 380 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 381 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P007A-64

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

Fault System Summary:

Development Fault code F_M_IC_OUT_TEMP_XC_APV

System Air Intake System / PFM Intercooler outlet temperature sensor

Dosing Interruption Group

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

SPN & FMI 2630 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 382 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 383 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 385 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 386 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0100-81: PFM Sensor - SENT 1 data error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0100-81

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

Fault System Summary:

Development Fault code F_M_SENT1_SENSR_FDAT_APV

System Air Intake System / PFM Sensor

Dosing Interruption Group

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

SPN & FMI 516200 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 387 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 388 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 389 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 390 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 391 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0100-86

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

Fault System Summary:

Development Fault code F_M_SENT1_SENSOR_APV

System Air Intake System / PFM Sensor

Dosing Interruption Group

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

SPN & FMI 516200 / 19

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 392 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 393 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 394 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 395 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 396 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P010A-81: PFM Sensor - SENT 2 data error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P010A-81

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

Fault System Summary:

Development Fault code F_M_SENT2_SENSR_FDAT_APV

System Air Intake System / PFM Sensor

Dosing Interruption Group

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

SPN & FMI 516201 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 397 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 398 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 399 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 400 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 401 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P010A-86

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

Fault System Summary:

Development Fault code F_M_SENT2_SENSOR_APV

System Air Intake System / PFM Sensor

Dosing Interruption Group

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

SPN & FMI 516201 / 19

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 402 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 403 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 404 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 405 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 406 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

U0155-00: Lost Communication with Instrument Cluster/VECU

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness Faulty

Fault Code U0155-00 No Vehicle reaction
2. I CAN & P CAN BUS error

Fault System Summary:

Development Fault code F_M_J1939_DD_TIMEOUT_APV & F_M_J1939_CM2_TMO_APV

System CAN Errors / Instrument Cluster / VECU

OBD Inducement Non-Inducement

SPN & FMI 516206 / 19

Visit next 5 page(s) for Troubleshooting steps

& Circuit Diagram

Author: ERC Page 407 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps: Electrical Interface Integrity Checks For ICAN

Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
At Ignition ON & w/o disconnecting any coupler
Verify fuse health (fuse-link continuity) as Resistance less Pass Proceed to next step
1 per Table-1 & Cabin fuse box for GDCU, than 1.0 ohm Fail Replace the fuse as per fuse Clear DTC and
IC & VECU Fuses box sticker rating recheck
Ignition off (wait for 2 min), Disconnect Battery negative post & remove Instrument Cluster from coupler
Measure the resistance between Pin 27& 60Ohm ± 10% Pass Proceed to Step number 6 No issue in Stub &
2 28 at Instrument Cluster harness end node
connector Fail Proceed to next step 3
Ignition off (wait for 2 min), Connect Instrument Cluster, Disconnect Battery negative post & Term Resistor (Near IC)
Pass Replace Term Resistor Term Resistor
Measure the resistance at harness side faulty
3 120 Ohm ± 10%
coupler of Term Resistor Pin A & B Fail Proceed to next step 4
Ignition off (wait for 2 min), Disconnect Battery negative post , Connect Term Resistor & remove GDCU
Measure the resistance at harness side Pass Replace GDCU GDCU faulty
4 120 Ohm ± 10%
coupler of GDCU at Pin 10 & 20. Fail Proceed to next step 5
Ignition off (wait for 2 min), Disconnect Battery negative post & Disconnect stub 1 by 1 as mentioned in Table-5(except GDCU )
Failure Identify and replace the Stub Component faulty
Case 1 component which removal
Measure & monitor the resistance at leads to 120 Ohm resistance
5 harness side coupler of Term Resistor Pin 120 Ohm ± 10% criteria.
A & B to identify the faulty node/stub Failure Even after removal of all the
Case 2 stub still issue persist proceed
for step 6

Ignition off (wait for 2 min), Disconnect Battery negative post & all the stubs/node coupler present on CAN BUS
Open circuit (Continuity) Checks IN CAN Resistance less Pass Proceed to next step 7 No Open circuit in
HI of Terminating node and all other than 1.0 ohm CAN HI
6
stub/node (refer table 5) CAN HI at Fail Harness Faulty. Replace
wiring harness side Harness
Open circuit (Continuity) Checks IN CAN Resistance less Pass Proceed to step 8 No Open circuit in
LO of Terminating node and all other than 1.0 ohm CAN BUS
7
stub/node (refer table 5) CAN LO at Fail Harness Faulty. Replace
wiring harness side Harness

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Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
Ignition off (wait for 2 min), Disconnect - Battery negative post & all the Stubs/Node coupler present on CAN BUS
Short circuit Checks between Wiring Resistance more Pass Proceed to Step 9 No SC in CAN HI
8 harness side CAN HI and CAN LO of Term than 10.0 kohm & CAN LO
Resistor Pin A & B. Fail Replace Harness
Short circuit to Ground to be Check at Resistance more Pass Proceed to Step 10
wiring Harness side for both CAN HI and than 10.0 kohm Fail Replace Harness
9
CAN LO of Term Resistor Pin A & B
with respect to Battery -Ve Terminal
Short circuit to Battery to be Check at Resistance more Pass Harness is OK Node 2
Wiring Harness for both CAN HI and CAN than 10.0 kohm component to be
10 LO of Term Resistor Pin A & B with checked at bench
respect to Battery +Ve Terminal level
Fail Replace Harness
If Instrument Cluster is Pass Proceed to next step
blank/unpowered, check for Open circuit Resistance less Fail Check Power supply and
13
Checks in supply and ground-ref than 1.0 ohm Ground connections continuity
connections as per table x
Pass Proceed for node integrity
checks
check for VECU Open circuit Checks in Resistance less
14 Fail Check Power supply and
supply and ground-ref connections than 1.0 ohm
Ground connections continuity
as per table x
Note :- After ignition off wait for 2 minutes before taking next step

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Diagram : ICAN

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps: Electrical Interface Integrity Checks For PCAN

Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
At Ignition ON & w/o disconnecting any coupler
Verify fuse health (fuse-link continuity) as Resistance less Pass Proceed to next step
1 per Table-1 & Cabin fuse box for GDCU, IC & than 1.0 ohm Fail Replace the fuse as per fuse Clear DTC and
VECU Fuses box sticker rating recheck
Ignition off (wait for 2 min), Disconnect Battery negative post & remove ABS from coupler
Measure the resistance between Pin 1 & 3 Of 60Ohm ± 10% Pass Proceed to Step number 7 No issue in Stub
2 15 pole Harness connector of ABS/ESC ECU. & end node
Fail Proceed to next step 3
Ignition off (wait for 2 min), Connect ABS ECU, Disconnect Battery negative post & Term Resistor 1 (Near DCU)
Pass Replace Term Resistor 1 Term Resistor 1
Measure the resistance at harness side faulty
3 120 Ohm ± 10%
coupler of Term Resistor 1 Pin A & B Fail Proceed to next step 4
Ign off (wait for 2 min), Disconnect Battery negative post, Connect Term Resistor 1(Near DCU) & remove Term Resistor 2 (Near SAS)
Pass Replace Term Resistor 2 Term Resistor 2
Measure the resistance at harness side faulty
4 120 Ohm ± 10%
coupler of Term Resistor 2 Pin A & B Fail Proceed to next step 5
Ignition off (wait for 2 min), Disconnect Battery negative post & Disconnect stub 1 by 1 as mentioned in Table-5(except Term Resistor 2)
Failure Identify and replace the Stub Component
Case 1 component which removal faulty
Measure & monitor the resistance at harness leads to 120 Ohm resistance
5 side coupler of Term Resistor 1(Near DCU) 120 Ohm ± 10% criteria.
Pin A & B to identify the faulty node/stub Failure Even after removal of all the
Case 2 stub still issue persist
proceed for step 6

Ignition off (wait for 2 min), Disconnect Battery negative post & all the stubs/node coupler present on CAN BUS
Open circuit (Continuity) Checks IN CAN HI of Resistance less Pass Proceed to next step 7 No Open circuit
Terminating node and all other stub/node than 1.0 ohm in CAN HI
6
(refer table 5) CAN HI at wiring harness side Fail Identify the Faulty Harness at
Step 8
Open circuit (Continuity) Checks IN CAN LO Resistance less Pass Proceed to step 9 No Open circuit
of Terminating node and all other stub/node than 1.0 ohm in CAN BUS
7
(refer table 5) CAN LO at wiring harness side Fail Identify the Faulty Harness at
Step 8
Ignition off (wait for 2 min), Disconnect Battery negative post, inline connector & all the Stubs/Node coupler present on CAN BUS
To identify the affected harness for open Resistance less Pass No open circuit. Proceed to
8 circuit, repeat step 6 &7 for all male-female than 1.0 ohm next step
inline connector Fail replace the faulty harness

Author: ERC Page 411 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
Ignition off, Disconnect - Battery negative post & all the Stubs/Node coupler present on CAN BUS
Short circuit Checks between Wiring Resistance more Pass Proceed to Step 10 No SC in CAN HI &
harness side CAN HI and CAN LO of Term than 10.0 kohm CAN LO
9
Resistor Pin A & B. Fail Identify the Faulty Harness at
Step 12
Short circuit to Ground to be Check at Resistance more Pass Proceed to Step 11
wiring Harness side for both CAN HI and than 10.0 kohm Fail Identify the Faulty Harness at
10
CAN LO of Term Resistor Pin A & B Step 12
with respect to Battery -Ve Terminal
Short circuit to Battery to be Check at Resistance more Pass Harness is OK Term Resistor 2 to be
Wiring Harness for both CAN HI and CAN than 10.0 kohm checked at bench
11 LO of Term Resistor Pin A & B with level and replace
respect to Battery +Ve Terminal Fail Identify the Faulty Harness at
Step 12
Ignition off , Disconnect - Battery negative post, all the Stubs/Node coupler present on CAN BUS & inline Connector
Short Circuit test at male/female inline Resistance more Pass Harness is OK Term Resistor 2 to be
connector with all other remaining than 10.0 kohm checked at bench
12 circuits in same wiring harness. level and replace
Fail Replace the faulty harness
Note :- After ignition off wait for 2 minutes before taking next step

Trouble shooting Steps: Node Integrity Checks for ICAN and PCAN Nodes
A. ICAN Nodes Integrity Checks
Acceptance
Step Checkpoints Result Recommended Action Remark
criteria
At Ignition ON & with all nodes couplers ( VMS, VECU, Infotaimnent) disconnected except GDCU and Instrument Cluster
Clear and Check for U0155-00 DTC in EMS No DTC Pass Proceed to next step
ECU OR the nodes in Fail Update Instrument Cluster
ICAN e,g, software and recheck.
Instrument If issue still persists, replace
1
Cluster should Instrument Cluster
be able to
connect with
TDS
Same as step1 but connecting nodes one-by-one (refer table 5)
Clear and Check for U0155-00 DTC in EMS Pass Repeat step with next node
ECU connections ;
If all nodes over, proceed to
PCAN Nodes Integrity Checks
2 No DTC
Fail If applicable, update the node
software;
If issue still persists, replace
the node

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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B. PCAN Nodes Integrity Checks

Acceptance
Step Checkpoints Result Recommended Action Remark
criteria
At Ignition ON & with all nodes couplers ( ABS ECU, DCU) disconnected except GDCU
Clear and Check for U0155-00 DTC in EMS No DTC Pass Proceed to next step
ECU Fail Update GDCU software and
1 recheck.
If issue still persists, replace
GDCU
Same as step1 but connecting nodes one-by-one (refer table 5)
Clear and Check for U0155-00 DTC in EMS Pass Repeat step with next node
ECU connections ;
2 No DTC Fail If applicable, update the node
software;
If issue still persists, replace
the node

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Diagram : PCAN

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code U007B-00

EMS ECU unable to transmit or receive CAN

frames on ECAN bus. Dosing interrupted
MIL ON Active/manual regeneration will not
happen.
Torque and speed limitation after specified
SCR Lamp ON
duration

Fault System Summary:

Development Fault code F_M_BUS_OFF_CAN2_APV & F_M_PASSIV_ERR_CAN2_APV

System CAN Errors / Network

Dosing Interruption Group

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

SPN & FMI 5842 / 31

Visit next 3 page(s) for Troubleshooting steps

& Circuit Diagram

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps: Electrical Interface Integrity Checks For ECAN

Acceptance
Step Checkpoints Result Recommended Action Remark
criteria
At Ignition OFF & w/o disconnecting any coupler
Verify Resistance less Pass Proceed to next step
1. Fuse health (fuse-link continuity) as per than 1.0 ohm Fail Replace the fuse as per fuse Clear DTC and
1
Table-1 & Cabin fuse box for EMS & DCU box sticker rating recheck
IGN and supply Fuses
Ignition off, Disconnect Battery negative post & remove Upstream NOx from coupler
Measure the resistance between Pin 3 & 4 60 Ohm ± 10% Pass Proceed to Step number 6 No issue in Stub &
2 Of Harness connector of Upstream NOx end node
Fail Proceed to next step 3
Ignition off , Connect Upstream NOx, Disconnect Battery negative post & DCU
Measure the resistance at harness side 53 Pass Replace DCU DCU faulty
3 120 Ohm ± 10%
pole coupler of DCU Pin 14 & 15 Fail Proceed to next step 4
Ign off , Disconnect Battery negative post, Connect DCU & remove EMS ECU coupler
Measure the resistance at harness side 91 Pass Replace EMS ECU EMS ECU faulty
4 120 Ohm ± 10%
pole coupler of EMS ECU Pin 77 & 78 Fail Proceed to next step 5
Ignition off, Disconnect Battery negative post & Disconnect stub 1 by 1 as mentioned in Table-5(except DCU)
Failure Identify and replace the Stub Component faulty
Case 1 component which removal
Measure & monitor the resistance at leads to 120 Ohm resistance
5 harness side 91 pole coupler of EMS ECU 120 Ohm ± 10% criteria.
Pin 77 & 78 to identify the faulty node/stub Failure Even after removal of all the
Case 2 stub still issue persist
proceed for step 6

Ignition off , Disconnect Battery negative post & all the stubs/node coupler present on CAN BUS
Open circuit (Continuity) Checks IN CAN HI Resistance less Pass Proceed to next step 7 No Open circuit in
of Terminating node and all other than 1.0 ohm CAN HI
6
stub/node (refer table 5) CAN HI at wiring Fail Identify the Faulty Harness at
harness side Step 8
Open circuit (Continuity) Checks IN CAN LO Resistance less Pass Proceed to step 9 No Open circuit in
of Terminating node and all other than 1.0 ohm CAN BUS
7
stub/node (refer table 5) CAN LO at wiring Fail Identify the Faulty Harness at
harness side Step 8
Ignition off, Disconnect Battery negative post, inline connector & all the Stubs/Node coupler present on CAN BUS
To identify the affected harness for open Resistance less Pass No open circuit. Proceed to
8 circuit, repeat step 6 &7 for all male-female than 1.0 ohm next step
inline connector Fail replace the faulty harness
Ignition off, Disconnect - Battery negative post & all the Stubs/Node coupler present on CAN BUS
Short circuit Checks between CAN HI and Resistance more Pass Proceed to Step 10 No SC in CAN HI
CAN LO of EMS ECU harness side 91pole than 10.0 kohm & CAN LO
9
coupler Pin 77 & 78. Fail Identify the Faulty Harness at
Step 12
10 Pass Proceed to Step 11

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Short circuit to Ground to be Check at both Fail Identify the Faulty Harness at
CAN HI and CAN LO of EMS ECU harness Resistance more Step 12
side 91pole coupler Pin 77 & 78 than 10.0 kohm
with respect to Battery -Ve Terminal
Short circuit to Battery to be Check at both Resistance more Pass Harness is OK Term Resistor 2
CAN HI and CAN LO of EMS ECU harness than 10.0 kohm to be checked at
side 91pole coupler Pin 77 & 78 with bench level and
11
respect to Battery +Ve Terminal replace
Fail Identify the Faulty Harness at
Step 12
Ignition off , Disconnect - Battery negative post, all the Stubs/Node coupler present on CAN BUS & inline Connector
Short Circuit test at male/female inline Resistance more Pass Harness is OK Term Resistor 2
connector with all other remaining circuits than 10.0 kohm to be checked at
12 in same wiring harness. bench level and
replace
Fail Replace the faulty harness
Pass Proceed to Node Integrity
Checks
Open circuit Checks for DCU and Other Resistance less
13 Fail Check Power supply and
nodes supply and ground-ref connections than 1.0 ohm
Ground connections continuity
as per table 6
Note :- After ignition off wait for 2 minutes before taking next step

Trouble shooting Steps: Node Integrity Checks for ECAN

Acceptance
Step Checkpoints Result Recommended Action Remark
criteria
At Ignition ON & with all nodes couplers (NOx1, NOx2, PM, UQLS) disconnected except DCU
Clear and Check for U007B DTC in EMS ECU No DTC Pass Proceed to next step
FailUpdate DCU software and
1 recheck.
If issue still persists, replace
DCU
Same as step1 but connecting nodes one-by-one (refer table 5)
Clear and Check for U007B DTC in EMS ECU Pass Repeat step with next node
connections
2 No DTC
Fail Replace the node

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

EMS ECU unable to transmit or receive CAN

Fault Code U007A-00 No Vehicle reaction
frames on PCAN bus.

Fault System Summary:

Development Fault code F_M_BUS_OFF_CAN1_APV & F_M_PASSIV_ERR_CAN1_APV

System CAN Errors / Network

OBD Inducement Non-Inducement

SPN & FMI 516234 / 19

Visit next 3 page(s) for Troubleshooting steps,

& Circuit diagram

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps: Electrical Interface Integrity Checks For PCAN

Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
At Ignition ON & w/o disconnecting any coupler
Verify fuse health (fuse-link continuity) as Resistance less Pass Proceed to next step
1 per Table-1 & Cabin fuse box for GDCU, IC & than 1.0 ohm Fail Replace the fuse as per fuse Clear DTC and
VECU Fuses box sticker rating recheck
Ignition off (wait for 2 min), Disconnect Battery negative post & remove ABS from coupler
Measure the resistance between Pin 1 & 3 Of 60Ohm ± 10% Pass Proceed to Step number 7 No issue in Stub
2 15 pole Harness connector of ABS/ESC ECU. & end node
Fail Proceed to next step 3
Ignition off (wait for 2 min), Connect ABS ECU, Disconnect Battery negative post & Term Resistor 1 (Near DCU)
Pass Replace Term Resistor 1 Term Resistor 1
Measure the resistance at harness side faulty
3 120 Ohm ± 10%
coupler of Term Resistor 1 Pin A & B Fail Proceed to next step 4
Ign off (wait for 2 min), Disconnect Battery negative post, Connect Term Resistor 1(Near DCU) & remove Term Resistor 2 (Near SAS)
Pass Replace Term Resistor 2 Term Resistor 2
Measure the resistance at harness side faulty
4 120 Ohm ± 10%
coupler of Term Resistor 2 Pin A & B Fail Proceed to next step 5
Ignition off (wait for 2 min), Disconnect Battery negative post & Disconnect stub 1 by 1 as mentioned in Table-5(except Term Resistor 2)
Failure Identify and replace the Stub Component
Case 1 component which removal faulty
Measure & monitor the resistance at harness leads to 120 Ohm resistance
5 side coupler of Term Resistor 1(Near DCU) 120 Ohm ± 10% criteria.
Pin A & B to identify the faulty node/stub Failure Even after removal of all the
Case 2 stub still issue persist
proceed for step 6

Ignition off (wait for 2 min), Disconnect Battery negative post & all the stubs/node coupler present on CAN BUS
Open circuit (Continuity) Checks IN CAN HI of Resistance less Pass Proceed to next step 7 No Open circuit
Terminating node and all other stub/node than 1.0 ohm in CAN HI
6
(refer table 5) CAN HI at wiring harness side Fail Identify the Faulty Harness at
Step 8
Open circuit (Continuity) Checks IN CAN LO Resistance less Pass Proceed to step 9 No Open circuit
of Terminating node and all other stub/node than 1.0 ohm in CAN BUS
7
(refer table 5) CAN LO at wiring harness side Fail Identify the Faulty Harness at
Step 8
Ignition off (wait for 2 min), Disconnect Battery negative post, inline connector & all the Stubs/Node coupler present on CAN BUS
To identify the affected harness for open Resistance less Pass No open circuit. Proceed to
8 circuit, repeat step 6 &7 for all male-female than 1.0 ohm next step
inline connector Fail replace the faulty harness

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
Ignition off, Disconnect - Battery negative post & all the Stubs/Node coupler present on CAN BUS
Short circuit Checks between Wiring Resistance more Pass Proceed to Step 10 No SC in CAN HI &
harness side CAN HI and CAN LO of Term than 10.0 kohm CAN LO
9
Resistor Pin A & B. Fail Identify the Faulty Harness at
Step 12
Short circuit to Ground to be Check at Resistance more Pass Proceed to Step 11
wiring Harness side for both CAN HI and than 10.0 kohm Fail Identify the Faulty Harness at
10
CAN LO of Term Resistor Pin A & B Step 12
with respect to Battery -Ve Terminal
Short circuit to Battery to be Check at Resistance more Pass Harness is OK Term Resistor 2 to be
Wiring Harness for both CAN HI and CAN than 10.0 kohm checked at bench
11 LO of Term Resistor Pin A & B with level and replace
respect to Battery +Ve Terminal Fail Identify the Faulty Harness at
Step 12
Ignition off , Disconnect - Battery negative post, all the Stubs/Node coupler present on CAN BUS & inline Connector
Short Circuit test at male/female inline Resistance more Pass Harness is OK Term Resistor 2 to be
connector with all other remaining than 10.0 kohm checked at bench
12 circuits in same wiring harness. level and replace
Fail Replace the faulty harness
Note :- After ignition off wait for 2 minutes before taking next step

Trouble shooting Steps: Node Integrity Checks for PCAN

Acceptance
Step Checkpoints Result Recommended Action Remark
criteria
At Ignition ON & with all nodes couplers disconnected except GDCU
Clear and Check for U007A DTC in EMS ECU No DTC Pass Proceed to next step
1
Fail NA
Same as step1 but connecting nodes one-by-one (refer table 5)
Clear and Check for U007A DTC in EMS ECU Pass Repeat step with next node
connections
2 No DTC
Fail Replace the node

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 423 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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U010E-00: Lost Communication with DCU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code U010E-00

EMS ECU unable to receive CAN frames from

MIL ON DCU on ECAN bus.
SCR Lamp ON
1. Engine emissions go high
2. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

F_M_J1939_TMLPM8_TMO_APV,
Development Fault code F_M_J1939_INDCCNTR_T_APV,F_M_J1939_HCDI1_TMO_APV,F_M_J1939_EEC3_TMOUT_APV,
F_M_J1939_DPFC1_TMO_APV, F_M_J1939_DM1_TMO_APV_0---4, F_M_J1939_DDSPM5_TMO_APV.
System CAN Errors / Private CAN DCU

Dosing Interruption Group

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

SPN & FMI 5842 / 31

Visit next 3 page(s) for Troubleshooting steps,

& Circuit diagram

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Electrical Trouble shooting Guide: ECAN

Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
At Ignition ON & w/o disconnecting any coupler
Verify fuse health (fuse-link continuity) as Resistance less Pass Proceed to next step
1 per Table-1 & Cabin fuse box for EMS & DCU than 1.0 ohm Fail Replace the fuse as per fuse Clear DTC and
IGN Fuses box sticker rating recheck
Ignition off, Disconnect Battery negative post & remove Upstream NOx from coupler
Measure the resistance between Pin 3 & 4 Of 60 Ohm ± 10% Pass Proceed to Step number 7 No issue in Stub
2 Harness connector of Upstream NOx & end node
Fail Proceed to next step 3
Ignition off , Connect Upstream NOx, Disconnect Battery negative post & DCU
Measure the resistance at harness side 53 Pass Replace DCU DCU faulty
3 120 Ohm ± 10%
pole coupler of DCU Pin 14 & 15 Fail Proceed to next step 4
Ign off , Disconnect Battery negative post, Connect DCU & remove EMS ECU coupler
Measure the resistance at harness side 91 Pass Replace EMS ECU EMS ECU faulty
4 120 Ohm ± 10%
pole coupler of EMS ECU Pin 77 & 78 Fail Proceed to next step 5
Ignition off, Disconnect Battery negative post & Disconnect stub 1 by 1 as mentioned in Table-5(except DCU)
Failure Identify and replace the Stub Component
Case 1 component which removal faulty
Measure & monitor the resistance at harness leads to 120 Ohm resistance
5 side 91 pole coupler of EMS ECU Pin 77 & 78 120 Ohm ± 10% criteria.
to identify the faulty node/stub Failure Even after removal of all the
Case 2 stub still issue persist
proceed for step 6

Ignition off , Disconnect Battery negative post & all the stubs/node coupler present on CAN BUS
Open circuit (Continuity) Checks IN CAN HI of Resistance less Pass Proceed to next step 7 No Open circuit
Terminating node and all other stub/node than 1.0 ohm in CAN HI
6
(refer table 5) CAN HI at wiring harness side Fail Identify the Faulty Harness at
Step 8
Open circuit (Continuity) Checks IN CAN LO Resistance less Pass Proceed to step 9 No Open circuit
of Terminating node and all other stub/node than 1.0 ohm in CAN BUS
7
(refer table 5) CAN LO at wiring harness side Fail Identify the Faulty Harness at
Step 8
Ignition off, Disconnect Battery negative post, inline connector & all the Stubs/Node coupler present on CAN BUS
To identify the affected harness for open Resistance less Pass No open circuit. Proceed to
8 circuit, repeat step 6 &7 for all male-female than 1.0 ohm next step
inline connector Fail replace the faulty harness

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
Ignition off, Disconnect - Battery negative post & all the Stubs/Node coupler present on CAN BUS
Short circuit Checks between CAN HI and Resistance more Pass Proceed to Step 10 No SC in CAN HI &
CAN LO of EMS ECU harness side 91pole than 10.0 kohm CAN LO
9
coupler Pin 77 & 78. Fail Identify the Faulty Harness at
Step 12
Short circuit to Ground to be Check at Resistance more Pass Proceed to Step 11
both CAN HI and CAN LO of EMS ECU than 10.0 kohm Fail Identify the Faulty Harness at
10
harness side 91pole coupler Pin 77 & 78 Step 12
with respect to Battery -Ve Terminal
Short circuit to Battery to be Check at Resistance more Pass Harness is OK Term Resistor 2 to be
both CAN HI and CAN LO of EMS ECU than 10.0 kohm checked at bench
11 harness side 91pole coupler Pin 77 & 78 level and replace
with respect to Battery +Ve Terminal Fail Identify the Faulty Harness at
Step 12
Ignition off , Disconnect - Battery negative post, all the Stubs/Node coupler present on CAN BUS & inline Connector
Short Circuit test at male/female inline Resistance more Pass Harness is OK Term Resistor 2 to be
connector with all other remaining than 10.0 kohm checked at bench
12 circuits in same wiring harness. level and replace
Fail Replace the faulty harness
Pass Update DCU software;
If problem still persists,
replace DCU and reprogram
Open circuit Checks for DCU and Other Resistance less
13 DCU software.
nodes supply and ground-ref connections than 1.0 ohm
Fail Check Power supply and
Ground connections
continuity as per table 6
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 427 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

U0619-00: Lost Communication with DEF Urea Level Sensor

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_J1939_AT1T1I1_TMO_APV

System CAN Errors / Urea Quality Sensor

OBD Inducement Non-Inducement

SPN & FMI 3517 / 19

Visit next 3 page(s) for Troubleshooting steps,

& Circuit diagram.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps: Electrical Interface Integrity Checks For ECAN

Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
At Ignition ON & w/o disconnecting any coupler
Verify fuse health (fuse-link continuity) as Resistance less Pass Proceed to next step
1 per Table-1 & Cabin fuse box for EMS & DCU than 1.0 ohm Fail Replace the fuse as per fuse Clear DTC and
IGN Fuses box sticker rating recheck
Ignition off, Disconnect Battery negative post & remove Upstream NOx from coupler
Measure the resistance between Pin 3 & 4 Of 60 Ohm ± 10% Pass Proceed to Step number 7 No issue in Stub
2 Harness connector of Upstream NOx & end node
Fail Proceed to next step 3
Ignition off , Connect Upstream NOx, Disconnect Battery negative post & DCU
Measure the resistance at harness side 53 Pass Replace DCU DCU faulty
3 120 Ohm ± 10%
pole coupler of DCU Pin 14 & 15 Fail Proceed to next step 4
Ign off , Disconnect Battery negative post, Connect DCU & remove EMS ECU coupler
Measure the resistance at harness side 91 Pass Replace EMS ECU EMS ECU faulty
4 120 Ohm ± 10%
pole coupler of EMS ECU Pin 77 & 78 Fail Proceed to next step 5
Ignition off, Disconnect Battery negative post & Disconnect stub 1 by 1 as mentioned in Table-5(except DCU)
Failure Identify and replace the Stub Component
Case 1 component which removal faulty
Measure & monitor the resistance at harness leads to 120 Ohm resistance
5 side 91 pole coupler of EMS ECU Pin 77 & 78 120 Ohm ± 10% criteria.
to identify the faulty node/stub Failure Even after removal of all the
Case 2 stub still issue persist
proceed for step 6

Ignition off , Disconnect Battery negative post & all the stubs/node coupler present on CAN BUS
Open circuit (Continuity) Checks IN CAN HI of Resistance less Pass Proceed to next step 7 No Open circuit
Terminating node and all other stub/node than 1.0 ohm in CAN HI
6
(refer table 5) CAN HI at wiring harness side Fail Identify the Faulty Harness at
Step 8
Open circuit (Continuity) Checks IN CAN LO Resistance less Pass Proceed to step 9 No Open circuit
of Terminating node and all other stub/node than 1.0 ohm in CAN BUS
7
(refer table 5) CAN LO at wiring harness side Fail Identify the Faulty Harness at
Step 8
Ignition off, Disconnect Battery negative post, inline connector & all the Stubs/Node coupler present on CAN BUS
To identify the affected harness for open Resistance less Pass No open circuit. Proceed to
8 circuit, repeat step 6 &7 for all male-female than 1.0 ohm next step
inline connector Fail replace the faulty harness

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
Ignition off, Disconnect - Battery negative post & all the Stubs/Node coupler present on CAN BUS
Short circuit Checks between CAN HI and Resistance more Pass Proceed to Step 10 No SC in CAN HI &
CAN LO of EMS ECU harness side 91pole than 10.0 kohm CAN LO
9
coupler Pin 77 & 78. Fail Identify the Faulty Harness at
Step 12
Short circuit to Ground to be Check at Resistance more Pass Proceed to Step 11
both CAN HI and CAN LO of EMS ECU than 10.0 kohm Fail Identify the Faulty Harness at
10
harness side 91pole coupler Pin 77 & 78 Step 12
with respect to Battery -Ve Terminal
Short circuit to Battery to be Check at Resistance more Pass Harness is OK Term Resistor 2 to be
both CAN HI and CAN LO of EMS ECU than 10.0 kohm checked at bench
11 harness side 91pole coupler Pin 77 & 78 level and replace
with respect to Battery +Ve Terminal Fail Identify the Faulty Harness at
Step 12
Ignition off , Disconnect - Battery negative post, all the Stubs/Node coupler present on CAN BUS & inline Connector
Short Circuit test at male/female inline Resistance more Pass Harness is OK Term Resistor 2 to be
connector with all other remaining than 10.0 kohm checked at bench
12 circuits in same wiring harness. level and replace
Fail Replace the faulty harness
13 Pass Replace DEF-Level and
Open circuit Checks for DEF Level and Quality Sensor
Resistance less
Quality sensor supply and ground-ref Fail Check Power supply and
than 1.0 ohm
connections Ground connections
continuity as per table x
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0340-99: Cam Sensor - Learning failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness

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

Fault System Summary:

Development Fault code F_M_APS_CAM_LEARNING_APV

System Crank/Cam Sensor / Cam Sensor

OBD Inducement Non-Inducement

SPN & FMI 636 / 13

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 432 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, Perform Reset APS service through TDS. Do Key off
1 Routine name : RESET APS values
and wait for 20 secs and Do Key ON. Start engine and check for DTC
Check air gap between cam sensor and trigger wheel as per specification.
2 0.65 to 1.35 mm
If found any issue, rectify it. Start engine and check for DTC
Perform following routine after component Replacement:
3 Replace CAM sensor. Start engine and check for DTC
1. RESET APS values

Check for trigger wheel mounting bolts torque. If torque is out of 1 Kg-m for 8.8 class
4
specification, rectify it. Start engine and check for DTC 1.5 Kg-m for 10.9 class

Perform following services in TDS:

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

Author: ERC Page 434 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 435 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 436 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0340-78: Cam Sensor - Signal drift error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness

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

Fault System Summary:

Development Fault code F_M_APS_CAM_DRIFT_APV

System Crank/Cam Sensor / Cam Sensor

OBD Inducement Non-Inducement

SPN & FMI 636 / 09

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 437 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 438 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, Perform Reset APS service through TDS. Do Key off
1 Routine name : RESET APS values
and wait for 20 secs and Do Key ON. Start engine and check for DTC
Check air gap between cam sensor and trigger wheel as per specification.
2 0.65 to 1.35 mm
If found any issue, rectify it. Start engine and check for DTC
Perform following routine after component Replacement:
3 Replace CAM sensor. Start engine and check for DTC
1. RESET APS values

Check for trigger wheel mounting bolts torque. If torque is out of 1 Kg-m for 8.8 class
4
specification, rectify it. Start engine and check for DTC 1.5 Kg-m for 10.9 class

Perform following services in TDS:

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

Author: ERC Page 439 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 440 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 441 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0340-2F: Cam Sensor - Signal erratic error

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_APS_CAM_ERRATIC_APV

System Crank/Cam Sensor / Cam Sensor

OBD Inducement Non-Inducement

SPN & FMI 636 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 442 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 443 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, Perform Reset APS service through TDS. Do Key off
1 Routine name : RESET APS values
and wait for 20 secs and Do Key ON. Start engine and check for DTC
Check air gap between cam sensor and trigger wheel as per specification.
2 0.65 to 1.35 mm
If found any issue, rectify it. Start engine and check for DTC
Perform following routine after component Replacement:
3 Replace CAM sensor. Start engine and check for DTC
1. RESET APS values

Check for trigger wheel mounting bolts torque. If torque is out of 1 Kg-m for 8.8 class
4
specification, rectify it. Start engine and check for DTC 1.5 Kg-m for 10.9 class

Perform following services in TDS:

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

Author: ERC Page 444 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 445 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0340-31: Cam Sensor - Signal Lost fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty wiring harness

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

Fault System Summary:

Development Fault code F_M_APS_CAM_LOST_APV

System Crank/Cam Sensor / Cam Sensor

OBD Inducement Non-Inducement

SPN & FMI 636 / 11

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 447 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 448 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, Perform Reset APS service through TDS. Do Key off
1 Routine name : RESET APS values
and wait for 20 secs and Do Key ON. Start engine and check for DTC
Perform following routine after component Replacement:
2 Replace CAM sensor. Start engine and check for DTC
1. RESET APS values

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 450 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 451 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0340-39: Cam Sensor - Signal Missing error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness

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

Fault System Summary:

Development Fault code F_M_APS_CAM_MISSING_APV

System Crank/Cam Sensor / Cam Sensor

OBD Inducement Non-Inducement

SPN & FMI 636 / 08

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 452 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, Perform Reset APS service through TDS. Do Key off
1 Routine name : RESET APS values
and wait for 20 secs and Do Key ON. Start engine and check for DTC
Check air gap between cam sensor and trigger wheel as per specification.
2 0.65 to 1.35 mm
If found any issue, rectify it. Start engine and check for DTC
Perform following routine after component Replacement:
3 Replace CAM sensor. Start engine and check for DTC
1. RESET APS values

Check for trigger wheel mounting bolts torque. If torque is out of 1 Kg-m for 8.8 class
4
specification, rectify it. Start engine and check for DTC 1.5 Kg-m for 10.9 class

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 455 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 456 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness

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

Fault System Summary:

Development Fault code F_M_APS_INVALID_GAP_APV

System Crank/Cam Sensor / Crank Sensor

OBD Inducement Non-Inducement

SPN & FMI 190 / 10

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 457 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 458 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check burr deposition on crank sensor tip, clean the burrs if noticed.
1
Start engine and check for DTC
Check gap between crank sensor and trigger wheel as per specification. If
2 0.75 to 1.3 mm
found any issue, rectify it. Start engine and check for DTC
3 Replace crank sensor. Start engine and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
5 Replace flywheel. Start engine and check for DTC

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 460 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 461 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0335-27: CRANK Sensor - Signal Early Detection Error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness

Fault Code P0335-27 2. Burr deposits in sensor
3. Air gap is out of specification
4. Faulty sensor
5. Faulty ECU
CEL ON 6. Faulty flywheel 1. Delayed Torque reduction

Fault System Summary:

Development Fault code F_M_APS_CRANK_EARLY_APV

System Crank/Cam Sensor / Crank Sensor

OBD Inducement Non-Inducement

SPN & FMI 190 / 08

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 462 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 463 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check burr deposition on crank sensor tip, clean the burrs if noticed.
1
Start engine and check for DTC
Check gap between crank sensor and trigger wheel as per specification. If
2 0.75 to 1.3 mm
found any issue, rectify it. Start engine and check for DTC
3 Replace crank sensor. Start engine and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
5 Replace flywheel. Start engine and check for DTC

Author: ERC Page 464 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 465 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 466 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0335-31: CRANK Sensor - Signal Lost fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness

Fault Code P0335-31 2. Burr deposits in sensor
3. Air gap is out of specification
4. Faulty sensor
5. Faulty ECU
CEL ON 6. Faulty flywheel 1. 25% Torque reduction

Fault System Summary:

Development Fault code F_M_APS_CRANK_LOST_APV

System Crank/Cam Sensor / Crank Sensor

OBD Inducement Non-Inducement

SPN & FMI 190 / 11

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 467 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 468 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check burr deposition on crank sensor tip, clean the burrs if noticed.
1
Start engine and check for DTC
Check gap between crank sensor and trigger wheel as per specification. If
2 0.75 to 1.3 mm
found any issue, rectify it. Start engine and check for DTC
3 Replace crank sensor. Start engine and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
5 Replace flywheel. Start engine and check for DTC

Author: ERC Page 469 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 470 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 471 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0335-1F: CRANK Sensor - Signal Missing

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness

Fault Code P0335-1F 2. Burr deposits in sensor
3. Air gap is out of specification
4. Faulty sensor
5. Faulty ECU
CEL ON 6. Faulty flywheel 1. Delayed Torque reduction

Fault System Summary:

Development Fault code F_M_APS_CRANK_MISS_APV

System Crank/Cam Sensor / Crank Sensor

OBD Inducement Non-Inducement

SPN & FMI 190 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 472 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 473 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check burr deposition on crank sensor tip, clean the burrs if noticed.
1
Start engine and check for DTC
Check gap between crank sensor and trigger wheel as per specification. If
2 0.75 to 1.3 mm
found any issue, rectify it. Start engine and check for DTC
3 Replace crank sensor. Start engine and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU. 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
5 Replace flywheel. Start engine and check for DTC

Author: ERC Page 474 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 475 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 476 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2226-04: Barometric Pressure Sensor - Sensor internal failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2226-04

1. Faulty Barometric Sensor
MIL ON for 15 secs 1. No Torque reduction
2. Faulty ECU
2. Vehicle may run with low pickup, high
CEL ON
smoke, frequent DPF regen & misfire issues

Fault System Summary:

Development Fault code F_M_BARO_CONT_DG_APV & F_M_BARO_STRTUP_DG_APV

System ECU Internal/Memory / Ambient Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 108 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 477 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 478 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 479 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2226-08: Barometric Pressure Sensor - Sensor signal failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2226-08

1. Faulty Barometric Sensor
MIL ON for 15 secs 1. No Torque reduction
2. Faulty ECU
2. Vehicle may run with low pickup, high
CEL ON
smoke, frequent DPF regen & misfire issues

Fault System Summary:

Development Fault code F_M_BARO_SPI_APV

System ECU Internal/Memory / Ambient Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 108 / 19

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 480 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 481 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 482 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2226-1C

1. Faulty Barometric Sensor
MIL ON for 15 secs 1. 25 % Torque reduction
2. Faulty ECU
2. Vehicle may run with low pickup, high
CEL ON
smoke, frequent DPF regen & misfire issues

Fault System Summary:

Development Fault code F_M_BARO_OOR_APV

System ECU Internal/Memory / Ambient Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 108 / 09

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 483 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 484 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 485 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0641-08: ECU 5V channel communication failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0641-08

CEL ON 1. Faulty ECU 1. No Pedal Response

2. Old version software
2. Engine speed increased to 1300 rpm
3. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_VEXT_SPI_C3PS_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 00 / 00

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Remove sensors mentioned in step 2, one by one. If fault gets resolved, Perform service regeneration at IDLE after issue
1
Replace particular sensor. Start engine and check for DTC rectification
1. Accelerator Pedal Sensor
2. Fan Speed sensor
3. Turbocharger position sensor
4. Exhaust throttle sensor
5. Oil Temperature & Pressure Sensor
2 Sensors needs to be checked 6. EGR Position Sensor
7. TMAP Sensor
8. PFM Sensor
9. Rail Pressure Sensor
10. CAM Sensor

Select dataset as per Vehicle configuration(VC)

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0641-4B

CEL ON 1. Faulty ECU 1. No Pedal Response

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

Fault System Summary:

Development Fault code F_M_VEXT_THERMAL_SHT_APV & F_M_T_SHTDWN_GLOBAL_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3509 / 07

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 490 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0641-00: ECU External supply Channel1 failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0641-00

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

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

Fault System Summary:

Development Fault code F_M_VEXT1_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3509 / 12

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

16-32V
Check the battery voltage. If battery voltage is out of range, rectify it and
1
check for DTC Perform service regeneration at IDLE after issue
rectification
Sensors need to be checked :
1. Accelerator Pedal Sensor
Check mentioned sensor and related circuit electrical failures. If found 2. Fan Speed sensor
2 any issue, rectify and check for DTC. 3. Turbocharger position sensor
Perform Continuity checks ( Short circuit failures ) 4. Exhaust throttle sensor
[Link] Temperature & Pressure Sensor

Troubleshooting Hint:
1. Accelerator Pedal Sensor
Remove all the sensors mentioned, clear and recheck for this DTC. If DTC
2. Fan Speed sensor
goes away, repeat steps in this order:
3. Turbocharger position sensor
3 1. Clear DTC, ensure that the DTC is not logged
4. Exhaust throttle sensor
2. Reconnect a sensor in the list
[Link] Temperature & Pressure Sensor
3. Check if the DTC re-appears. If yes, replace the sensor.
4. repeat steps 1-3 for another component in the list
4 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0651-00: ECU External supply Channel2 failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0651-00

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

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

Fault System Summary:

Development Fault code F_M_VEXT2_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3510 / 12

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

16-32V
Check the battery voltage. If battery voltage is out of range, rectify it and
1
check for DTC Perform service regeneration at IDLE after issue
rectification

Sensors need to be checked :

Check mentioned sensor and related circuit electrical failures. If found 1. Accelerator Pedal Sensor
2 any issue, rectify and check for DTC. 2. EGR Position Sensor
Perform Continuity checks ( Short circuit failures ) 3. TMAP Sensor
4. PFM Sensor

Troubleshooting Hint:
Remove all the sensors mentioned, clear and recheck for this DTC. If DTC Sensors need to be checked :
goes away, repeat steps in this order: 1. Accelerator Pedal Sensor
3 1. Clear DTC, ensure that the DTC is not logged 2. EGR Position Sensor
2. Reconnect a sensor in the list 3. TMAP Sensor
3. Check if the DTC re-appears. If yes, replace the sensor. 4. PFM Sensor
4. Repeat steps 1-3 for another component in the list
4 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0697-00: ECU External supply Channel3 failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0697-00

1. ECU Supply Voltage short circuit
CEL ON 1. No Pedal Response
2. Faulty ECU
2. Engine speed increased to 1300 rpm
3. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_VEXT3_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3511 / 12

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

16-32V
Check the battery voltage. If battery voltage is out of range, rectify it and
1
check for DTC Perform service regeneration at IDLE after issue
rectification

Check mentioned sensor and related circuit electrical failures. If found Sensors need to be checked :
2 any issue, rectify and check for DTC. 1. Rail pressure Sensor
Perform Continuity checks ( Short circuit failures ) 2. CAM sensor

Troubleshooting Hint:
Remove all the sensors mentioned, clear and recheck for this DTC. If DTC
goes away, repeat steps in this order: Sensors need to be checked :
3 1. Clear DTC, ensure that the DTC is not logged 1. Rail pressure Sensor
2. Reconnect a sensor in the list 2. CAM sensor
3. Check if the DTC re-appears. If yes, replace the sensor.
4. Repeat steps 1-3 for another component in the list
4 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P06D6-00: ECU Internal 3V supply channel failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P06D6-00

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

Fault System Summary:

Development Fault code F_M_VEXT_VCCLBUCK_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3514 / 12

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 502 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P06D2-00: ECU Internal 5V Supply channel failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P06D2-00

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

Fault System Summary:

Development Fault code F_M_VEXT_VCC_APV & F_M_T_SHTDWN_VCC_APV

System ECU Internal/Memory / ECU Electrical

OBD Inducement Non-Inducement

SPN & FMI 3513 / 12

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Author: ERC Page 504 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 505 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P268A-54: Injector Codes corrupted or not written properly

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P268A-54

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

Fault System Summary:

Development Fault code F_M_C2I_RAM_INTEGRITY_APV

System ECU Internal/Memory / Hardware

OBD Inducement Non-Inducement

SPN & FMI 2797 / 13

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P020A-00: ECU - Internal injection timing fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P020A-00

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

Fault System Summary:

Development Fault code F_M_ETC_TMNG_CHECK_0_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 7384 / 02

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 511 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 512 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P020C-00: ECU - Internal injection timing fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P020C-00

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

Fault System Summary:

Development Fault code F_M_ETC_TMNG_CHECK_1_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 7386 / 02

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 514 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P020D-00: ECU - Internal injection timing fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P020D-00

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

Fault System Summary:

Development Fault code F_M_ETC_TMNG_CHECK_2_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 7387 / 02

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 517 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P020B-00: ECU - Internal injection timing fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P020B-00

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

Fault System Summary:

Development Fault code F_M_ETC_TMNG_CHECK_3_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 7385 / 02

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 520 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060B-00: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_ESM_ADC_MON_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516172 / 12

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 523 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 524 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060A-48: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_ESM_CLOCK_MON_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516209 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 525 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 526 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 527 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060C-43: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_ESM_FUNC_SAFE_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516210 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 528 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 529 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 530 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0607-44: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_ESM_L2_PRIME_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516211 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 531 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 532 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 533 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0607-05: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_ESM_LOCK_MON_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516212 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 534 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 535 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 536 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060C-44: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_ESM_MEM_CFG_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516213 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 537 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 538 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 539 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060C-05: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_ESM_MEM_PROTECT_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516214 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 540 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 541 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 542 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060C-49: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_ESM_MEM_RAM_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516215 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 543 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 544 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 545 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060C-42: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_ESM_MM_QUERY_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516216 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 546 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 547 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 548 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060C-45: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_ESM_PFC_FAIL_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516217 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 549 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 550 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 551 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0607-04: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

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

Fault System Summary:

Development Fault code F_M_ESM_RESET_MON_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516218 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 552 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 553 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 554 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060A-49: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060A-49
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_SOP_OUTEN_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516219 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 555 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 556 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 557 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060A-42: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060A-42
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_SOP_TEST_FC_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516220 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 558 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 559 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 560 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060A-45: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060A-45
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_SOP_TEST_MM_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516221 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 561 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 562 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 563 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060C-47: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-47
1. Faulty ECU No Vehicle reaction
CEL ON

Fault System Summary:

Development Fault code F_M_ESM_WATCHDOG_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516222 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 564 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 565 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 566 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060C-00: ECU Internal Memory Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-00

CEL ON 1. Faulty ECU No Vehicle reaction
STOP Engine Lamp ON

Fault System Summary:

Development Fault code F_M_C3MIO_CONFIG_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516224 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 567 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060C-08: ECU Internal Memory Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-08 1. Faulty ECU No Vehicle reaction

Fault System Summary:

Development Fault code F_M_C3MIO_SPI_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516223 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060C-92: ECU Internal Memory Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-92 1. Faulty ECU No Vehicle reaction

Fault System Summary:

Development Fault code F_M_C3MIO_STATE_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516225 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 574 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P062F-00: ECU Non volatile memory error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P062F-00
CEL ON [Link] ECU 1. No Pedal Response
2. Engine speed increased to 1300 rpm

Fault System Summary:

Development Fault code F_M_P_L_NVM_DEVICE_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516226 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060C-00: Engine Safety Module - Memory Flash failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060C-00
CEL ON 1. Faulty ECU No Vehicle reaction
Stop Engine
ON
Lamp

Fault System Summary:

Development Fault code F_M_ESM_MEM_FLASH_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516224 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 580 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0201-56: Cylinder 1 - Injector codes not written / Missing

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0201-56 1. Injector correction code not written

2. Faulty ECU
CEL ON 1. No Pedal Response

Fault System Summary:

Development Fault code F_M_C2I_DATA_APV_0

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 651 / 13

Visit next 3 page(s) for Troubleshooting steps,

Injector Coding Scheme & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Enter Injector codes Manually
Write I3C code in Cylinder No 1, key off for 30 sec. Clear DTC and Check
1
for DTC Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
2 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

Perform service regeneration at IDLE after issue

rectification

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Injector Coding Scheme:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0202-56: Cylinder 2 - Injector codes not written / Missing

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0202-56 1. Injector correction code not written

2. Faulty ECU
CEL ON 1. No Pedal Response

Fault System Summary:

Development Fault code F_M_C2I_DATA_APV_3

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 652 / 13

Visit next 3 page(s) for Troubleshooting steps,

Injector Coding Scheme & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Enter Injector codes Manually
Write I3C code in Cylinder No 1, key off for 30 sec. Clear DTC and Check
1
for DTC Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
2 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 587 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Injector Coding Scheme:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0203-56: Cylinder 3 - Injector codes not written / Missing

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0203-56 1. Injector correction code not written

2. Faulty ECU
CEL ON 1. No Pedal Response

Fault System Summary:

Development Fault code F_M_C2I_DATA_APV_1

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 653 / 13

Visit next 3 page(s) for Troubleshooting steps,

Injector Coding Scheme & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Enter Injector codes Manually
Write I3C code in Cylinder No 1, key off for 30 sec. Clear DTC and Check
1
for DTC Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
2 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

Perform service regeneration at IDLE after issue

rectification

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Injector Coding Scheme:

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 Version: 1.3
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Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0204-56: Cylinder 4 - Injector codes not written / Missing

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0204-56 1. Injector correction code not written

2. Faulty ECU
CEL ON 1. No Pedal Response

Fault System Summary:

Development Fault code F_M_C2I_DATA_APV_2

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 654 / 13

Visit next 3 page(s) for Troubleshooting steps,

Injector Coding Scheme & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Enter Injector codes Manually
Write I3C code in Cylinder No 1, key off for 30 sec. Clear DTC and Check
1
for DTC Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
2 Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

Perform service regeneration at IDLE after issue

rectification

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Injector Coding Scheme:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0607-51: EDP (Engine Data Plate) data writing error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0607-51
1. Engine variant coding data not written
CEL ON 1. No Pedal Response

Fault System Summary:

Development Fault code F_M_EDP_WRITE_APV

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 516205 / 13

Visit next 2 page(s) for Troubleshooting steps

& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0607-55: Variant coding not written

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0607-55
Variant Coding not written
CEL ON 1. No Pedal Response

Fault System Summary:

Development Fault code F_M_VARIANT_CODING_WRITE_APV

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 516204 / 13

Visit next 3 page(s) for Troubleshooting steps

& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 602 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0630-55: Vehicle Identification Number is not written

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0630-55 VIN not written No Vehicle reaction

Fault System Summary:

Development Fault code F_M_VIN_ID_VIRG_APV

System ECU Internal/Memory / Read/write parameters

OBD Inducement Non-Inducement

SPN & FMI 237 / 13

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 604 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 605 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0115-15: Engine Coolant temperature sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0115-15 1. Faulty Wiring harness

2. Faulty sensor
MIL ON for 15 secs Vehicle runs with poor pickup

Fault System Summary:

Development Fault code F_M_COOLANT_HI_APV

System Engine Protection / Coolant temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 110 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of component-side coupler only
Measure Component side resistance 10degC : 3791ohms, Pass Proceed to step 4 Component electrical
Between pin 1 & 2 20degC : 2500ohms, check OK
3 25degC: 2057ohms, Fail Replace the part Clear DTC and recheck
30degC: 1706ohms,
40degC: 1174ohms
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

For Resistance checks, Kept sensor outside (Open to air)
10degC : 3791ohms, 20degC : 2500ohms, 25degC:
If still issue persists, Replace coolant temperature sensor and check for
1 2057ohms, 30degC: 1706ohms, 40degC: 1174ohms
DTC
Measured resistance has to be compared against local
ambient temperature
2 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
3 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 610 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0115-11: Engine Coolant temperature sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0115-11 1. Faulty wiring Harness

2. Faulty sensor
MIL ON for 15 secs Vehicle runs with poor pickup

Fault System Summary:

Development Fault code F_M_COOLANT_LO_APV

System Engine Protection / Coolant temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 110 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 612 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of component-side coupler only
Measure Component side resistance 10degC : 3791ohms, Pass Proceed to step 4 Component electrical
Between pin 1 & 2 20degC : 2500ohms, check OK
3 25degC: 2057ohms, Fail Replace the part Clear DTC and recheck
30degC: 1706ohms,
40degC: 1174ohms
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 613 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 614 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 615 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 616 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0115-64: Engine Coolant temperature sensor - Signal not valid based on

reference sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0115-64 [Link] wiring harness

[Link] sensor
[Link] ECU
MIL ON for 15 secs Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_COOLANT_TEMP_XC_APV

System Engine Protection / Coolant temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 110 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 617 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of component-side coupler only
Measure Component side resistance 10degC : 3791ohms, Pass Proceed to step 4 Component electrical
Between pin 1 & 2 20degC : 2500ohms, check OK
3 25degC: 2057ohms, Fail Replace the part Clear DTC and recheck
30degC: 1706ohms,
40degC: 1174ohms
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 618 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Reference sensors :
1. Ambient temperature sensor
2. Fuel temperature sensor
After rectification of step 1, connect Coolant temp. sensor externally and
1 keep it in ambient with wiring connected. Like that keep reference For Resistance checks, Kept sensor outside (Open to air)
sensors as well. Check temp. difference across all sensors 10degC : 3791ohms, 20degC : 2500ohms, 25degC:
2057ohms, 30degC: 1706ohms, 40degC: 1174ohms
Measured resistance has to be compared against local
ambient temperature

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

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

Author: ERC Page 619 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 620 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0115-2A: Engine Coolant temperature sensor - Signal Stuck at very low

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0115-2A 1. Faulty Wiring harness

2. Faulty sensor
MIL ON for 15 secs Vehicle runs with poor pickup

Fault System Summary:

Development Fault code F_M_COOLANT_SIR_LO_APV

System Engine Protection / Coolant temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 110 / 01

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 622 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of component-side coupler only
Measure Component side resistance 10degC : 3791ohms, Pass Proceed to step 4 Component electrical
Between pin 1 & 2 20degC : 2500ohms, check OK
3 25degC: 2057ohms, Fail Replace the part Clear DTC and recheck
30degC: 1706ohms,
40degC: 1174ohms
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 623 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

For Resistance checks, Kept sensor outside (Open to air)
10degC : 3791ohms, 20degC : 2500ohms, 25degC:
If still issue persists, Replace coolant temperature sensor and check for
1 2057ohms, 30degC: 1706ohms, 40degC: 1174ohms
DTC
Measured resistance has to be compared against local
ambient temperature
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 624 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 625 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0128-71: Engine Coolant Thermostat stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0128-71 1. Faulty Thermostat

2. Faulty Coolant Temperature Sensor
MIL ON for 15 secs Vehicle may run with poor pickup

Fault System Summary:

Development Fault code F_M_COOLANT_TH_APV

System Engine Protection / Coolant thermostat

OBD Inducement Non-Inducement

SPN & FMI 1659 / 07

Visit next 2 page(s) for Troubleshooting steps

& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check fault codes related to coolant temperature sensor. If found any,
1
rectify it and check for DTC

If still issue persists, start engine and check coolant temperature at Idle.
2
Coolant temperature should reach minimum 65 deg C within 30 mins.

3 If temp. not increased, Replace thermostat and repeat step 2

4 If still issue persists, Replace coolant thermostat and repeat step 2 Hot water temperature range – 80-100 deg C.
5 If still issue persists, Replace ECU

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0480-9E: E-Viscous FAN - Disengagement failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0480-9E 1. Faulty E Viscous fan

2. Faulty ECU No Vehicle reaction
CEL ON 3. Faulty wiring harness

Fault System Summary:

Development Fault code F_M_FAN_CLUTCH_STUCK_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 11

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 630 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 40 Ohm Pass Proceed to step 4 Component electrical
3 Between pin A& F check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 631 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, Start engine and raise engine speed to flyup. Check
FAN speed. After 1 min, FAN speed should lesser than 500 rpm if coolant.
1
temp. lesser than 88 deg C. If not, Replace E-Viscous FAN assembly and
check for DTC
2 If still issue persists, Replace E-Viscous FAN assembly and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 632 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 633 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0480-13: E-Viscous FAN - Drive open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0480-13 1. Faulty Wiring harness

2. Faulty E-Viscous FAN No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FAN1_DRIVE_OC_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 635 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 40 Ohm Pass Proceed to step 4 Component electrical
3 Between pin A& F check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 636 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 637 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 638 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 639 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0480-12: E-Viscous FAN - Drive Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0480-12 1. Faulty Wiring harness

2. Faulty E-Viscous FAN No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FAN1_DRIVE_SC2V_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 640 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 40 Ohm Pass Proceed to step 4 Component electrical
3 Between pin A& F check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 641 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 642 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 643 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 644 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0480-11: E-Viscous FAN - Drive Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0480-11 1. Faulty Wiring harness

2. Faulty E-Viscous FAN No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FAN1_DRIVE_SC2G_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 645 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 40 Ohm Pass Proceed to step 4 Component electrical
3 Between pin A& F check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 646 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 647 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 648 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 649 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0480-9F: E-Viscous FAN - Engagement failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0480-9F 1. Faulty E Viscous fan

2. Faulty ECU No Vehicle reaction
CEL ON 3. Faulty wiring harness

Fault System Summary:

Development Fault code F_M_FAN_CLUTCH_SLIP_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 650 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 40 Ohm Pass Proceed to step 4 Component electrical
3 Between pin A& F check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 651 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 652 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 653 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 654 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0526-38: E-Viscous FAN - Speed Signal error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Engine over speed due to improper gear shift

Fault Code P0526-38 2. Faulty Wiring harness
No Vehicle reaction
3. Faulty E-Viscous FAN
4. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FAN_SENSOR_PERIOD_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 655 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 40 Ohm Pass Proceed to step 4 Component electrical
3 Between pin A& F check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 656 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications
Check errors related to Engine over speed. If found any, check over
1 speed counters and understand the real cause of engine over speed.
Clear DTC, drive vehicle for 5 Kms and Check for DTC
2 If still issue persists, Replace E-Viscous FAN assembly and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 657 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 658 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 659 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0526-29: E-Viscous FAN - Speed Signal invalid error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Engine over speed due to improper gear shift

Fault Code P0526-29 2. Faulty Wiring harness
No Vehicle reaction
3. Faulty E-Viscous FAN
4. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FAN_SENSOR_SPEED_APV

System Engine Protection / E-Viscous FAN

OBD Inducement Non-Inducement

SPN & FMI 1071 / 10

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 660 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 40 Ohm Pass Proceed to step 4 Component electrical
3 Between pin A& F check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 661 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check errors related to Engine over speed. If found any, check over
1 speed counters and understand the real cause of engine over speed.
Clear DTC, drive vehicle for 5 Kms and Check for DTC
2 If still issue persists, Replace E-Viscous FAN assembly and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 662 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 663 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 664 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0520-15: Engine Oil pressure is too high / Switch not present in the engine
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0520-15 1. Switch is not fitted

2. Engine oil pressure is high No Vehicle reaction
Oil Pres.
ON 3. Faulty wiring harness
Lamp

Fault System Summary:

Development Fault code F_M_OIL_PRES_CAL_HI_STP_APV

System Engine Protection / Oil Pressure switch

OBD Inducement Non-Inducement

SPN & FMI 100 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 665 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 666 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, Check oil level. If found high oil level, remove excess
1 oil and maintain proper oil level. Drive vehicle for 5 Kms and stop engine
and check for DTC
2 If still issue persists, Replace oil pressure switch

Author: ERC Page 667 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 668 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 669 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0524-00: Engine Oil pressure is too low

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0524-00
CEL ON
1. Engine oil pressure is low
Oil Pres. ON 1. 25 % Torque reduction
Lamp 2. Faulty wiring harness
2. 1500 rpm Engine speed limitation

Fault System Summary:

Development Fault code F_M_OIL_PRES_CAL_LO_RUN_APV

System Engine Protection / Oil Pressure switch

OBD Inducement Non-Inducement

SPN & FMI 100 / 01

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 670 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 671 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, Check oil level. If found low oil level, fill oil and
Start the Engine and check oil pressure at idle should be
1 maintain proper oil level. Drive vehicle for 5 Kms and stop engine and
greater than 2 bar (Through Diagnostic tool)
check for DTC
If still issue persists, check presence of oil pressure switch in the engine.
2 Or Replace oil pressure switch. Drive vehicle for 5 Kms and stop engine
and check for DTC

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0217-00: Engine Over heating fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Low coolant level

Fault Code P0217-00 2. Mechanical failure of E viscous fan, Coolant
sensor No Vehicle reaction
3. Mechanical issue of Coolant Pump
4. Failure of poly V belt
CEL ON

Fault System Summary:

Development Fault code F_M_ENG_OVER_HEAT_APV

System Engine Protection / Over Heat Monitor

OBD Inducement Non-Inducement

SPN & FMI 5100 / 31

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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Trouble Shooting Steps:

Sr. No. Steps Specifications

1 Check coolant level in expansion tank. If found low, fill up to max level

Check Coolant temp. sensor & E-Viscous FAN electrical failures. If found
2
any issue, rectify it and check for DTC

If still issue persists, Check E-Viscous FAN HW related errors & physical
3
function of FAN. If found any issues, rectify it.
If still issue persists, Check coolant pump V-belt condition. If found any Put thermostat in hot water and check for its function.
4
issues, Replace it Hot water temperature range – 80-100 deg C
Check coolant thermostat functionality and related errors. If found any
5
issues, rectify it
6 Check water pump impeller for any defect. If found defective, Replace it.
Check Coolant color, if found black check EGR Cooler & measure the
7
cylinder compression pressure.
If nothing is found, It might not be the genuine error. Clear DTC and
8
release vehicle.

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Circuit Schematic Diagram:

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Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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P0219-00: Engine Over speed fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Engine Speed above 2800 rpm, due to
Fault Code P0219-00 abnormal gear change No Vehicle reaction
2. Faulty Crank sensor

Fault System Summary:

Development Fault code F_M_ENGINE_OVERSPD_APV

System Engine Protection / Over Speed Monitor

OBD Inducement Non-Inducement

SPN & FMI 2812 / 31

Visit next page(s) for Troubleshooting steps

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check errors related to Crank sensor. If found any, rectify it and run
1
vehicle for 15 mins and check for DTC
Keep the Ignition ON,
Check Engine over speed data in EMS through Tata Diagnostic tool. Connect TDS, Select EMS  Vehicle Parameters  Group
2 (Speed, gear ratio, vehicle speed, etc.,). If any abnormal gear shift found, Parameters  EUD Engine Over Speed Data.
inform driver, not to perform improper gearshifts  Instant 4 is the recent over speed value.

Start the vehicle and Check Engine speed at Full accelerator pedal. If
3 engine speed within specification clear the fault and release the vehicle 2400 ± 50 rpm
and inform driver not to conduct over speed.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2269-00: Water in fuel fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Water collected in Filter

Fault Code P2269-00 2. Found fluid other than diesel
3. Faulty wiring harness
4. Faulty sensor
5. Faulty ECU
WIF Lamp ON 1. Delayed Torque reduction

Fault System Summary:

Development Fault code F_M_WATER_IN_FUEL_APV

System Engine Protection / Water in fuel Sensor

OBD Inducement Non-Inducement

SPN & FMI 97 / 31

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Remove WIF sensor from fuel filter and drain water/other fluid. If found
1
any. Drive vehicle for 5 Kms and check for DTC
If found any other fluid other than diesel, check fuel tank. Drain complete
2 fuel and Replace it with proper diesel, Replace filters as well if required.
Drive vehicle for 5 Kms and check for DTC
If still issue persists, Replace WIF sensor. Drive vehicle for 5 Kms and
3
check for DTC
If still issue persists, Replace prefilter element. Drive vehicle for 5 Kms
4
and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2264-15: Water In fuel sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2264-15 1. Water in Fuel sensor short to ground

2. Faulty sensor
CEL ON
3. Faulty ECU 1. Delayed Torque reduction
4. Faulty wiring harness
WIF LAMP ON

Fault System Summary:

Development Fault code F_M_WIF_SENSOR_SC2V_APV

System Engine Protection / Water in fuel Sensor

OBD Inducement Non-Inducement

SPN & FMI 97 / 03

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommneded Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
3 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass No open circuit. Proceed to
open circuit, repeat step 4 for all applicable next step
4 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Proceed to
connector end with all other than 10.0 kohm next step.
8
remaining EMS specific circuits in Fail Identify the affected harness
wiring harness. and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
9 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Remove WIF sensor from fuel filter and drain water/other fluid. If found
1
any. Drive vehicle for 5 Kms and check for DTC

2 Check Electrical continuity Refer Schematic diagram

If still issue persists, Replace WIF sensor. Drive vehicle for 5 Kms and
3
check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2264-11: Water in fuel sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2264-11 1. Water in Fuel sensor short to ground

2. Faulty sensor
CEL ON
3. Faulty ECU 1. Delayed Torque reduction
4. Faulty wiring harness
WIF LAMP ON

Fault System Summary:

Development Fault code F_M_WIF_SENSOR_SC2G_APV

System Engine Protection / Water in fuel Sensor

OBD Inducement Non-Inducement

SPN & FMI 97 / 04

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommneded Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
3 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass No open circuit. Proceed to
open circuit, repeat step 4 for all applicable next step
4 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Proceed to
connector end with all other than 10.0 kohm next step.
8
remaining EMS specific circuits in Fail Identify the affected harness
wiring harness. and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
9 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Remove WIF sensor from fuel filter and drain water/other fluid. If found
1
any. Drive vehicle for 5 Kms and check for DTC

2 Check electrical continuity from EMS to WIF sensor Refer schematic diagram

If still issue persists, Replace WIF sensor. Drive vehicle for 5 Kms and
3
check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2031-62: DOC inlet temperature sensor - Signal not valid based on Model
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2031-62

1. Deviation in temperature signal between
sensor and Modelled value
MIL ON 1. Regeneration Inhibition
2. Faulty sensor
2. Engine emission may go high & Vehicle
may run with poor pickup

Fault System Summary:

Development Fault code F_M_DOC_IN_TEMP_PLAU_APV

System Exhaust System / DOC Upstream temperature sensor

OBD Inducement Non-Inducement

SPN & FMI 4765 / 09

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Exhaust / Intake air leakage in the system. If anything found, Perform service regeneration at IDLE after issue
1
please rectify and run vehicle around 10 Kms and check for DTCs rectification
Check DTCs related to PFM,ETV, Turbo Wastegate actuator. If found any, Perform service regeneration at IDLE after issue
2
rectify the same and drive vehicle for 10 Kms and check for DTCs rectification
If No leakages / DTCs found, Replace the DOC inlet temperature sensor Perform service regeneration at IDLE after issue
3
with new one. rectification

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 Version: 1.3
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Circuit Schematic Diagram:

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 Version: 1.3
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Location and Component Image:

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 Version: 1.3
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P1542-00: DPF Regeneration system fault from DCU

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P1542-00
DPF system faults are inhibiting Regeneration
1. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_DUC_EMS_REACT12_APV

System Exhaust System / Regeneration System fault

OBD Inducement Non-Inducement

SPN & FMI 3700 / 02

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 Version: 1.3
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Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Rectify other system faults in ECU & DCU. Perform service regeneration
1
and check for DTC

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0263-00: Cylinder 1 - Injector balance low fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Other system errors (Rail
Fault Code P0263-00 pressure/EGR/ETV/Intake air system/cylinder-1
injector)
No Vehicle reaction
2. Incorrect tappet setting
CEL ON 3. Faulty Injector in cylinder 1
4. Low compression in cylinder 1

Fault System Summary:

Development Fault code F_M_FCI_INJ_BAL_LOW_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 651 / 09

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Other system errors :
EGR Electrical / function fault codes
Check indicated torque at engine low idle & high idle. If torque found out
Rail pressure sensor errors
of specification, then injector balance fault triggered because of other
Exhaust throttle electrical / stuck closed
system failures, check specification for more details. If found any issues,
Intake air system related errors like PFM/Intake manifold
1 rectify it and start engine.
pressure/temperatures
Ensure engine has proper tappet setting values.
DPF related failures
After rectification, Raise engine speed to 1500-1700 rpm and keep it for
2 mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

2. Indicated torque range :
Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
If no faults observed, remove after ETV pipe & check whether ETV is
3. Perform ETV Actuator test in TDS-ECU (Test Actuator
stuck closed physically by performing actuator tests (0%,50%&100%). If
Tab- 0%,50% & 100%)
actuator is not moving, replace ETV & perform tests mentioned in
2 3. ETV error allowed during actuator test : +/- 5%
specification.
4. Perform ETV Actuator learning test through TDS-ECU if
After rectification, Raise engine speed to 1500-1700 rpm and keep it for
ETV replaced
2 mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

If still issue persists, detach / disconnect ATS from ETV pipe & check 2. Indicated torque range :
indicated torque in Low Idle & high Idle. If torque found within Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
specification, then DPF might be having issues. Remove/Replace DPF & 3. Perform DPF replacement service through TDS-DCU if
3
check for DTC. DPF is replaced
After rectification, Raise engine speed to 1500-1700 rpm and keep it for
2 mins. Check for DTC. Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Injector shut off test
If no issues found in step 3, Conduct Injector actuator test through 2. Injector Buzz test
diagnostic tool. If found any issues, replace particular injector/wiring 3. If injector changed, Write proper injector codes (I3C) in
4
harness based on finding & start engine. Raise engine speed to 1500- ECU after reading it from new Injector
1700 rpm and keep it for 2 mins. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Raise engine
5
speed to 1500-1700 rpm and keep it for 2 mins. Check for DTC Perform service regeneration at IDLE after issue
rectification
1. Ensure Injector back leak should not exceed 160ml with
If still issue persists, Perform injector back leak test. If back leak found
all injectors
out of specification, Remove & Refit injector along with quill & quill nut.
6
Apply proper tightening torque. Start engine, Raise engine speed to
Perform service regeneration at IDLE after issue
1500-1700 rpm and keep it for 2 mins. Check for DTC
rectification

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Perform following services in TDS:

1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace Injector1 & write I3C code. Start engine,
from new Injector
7 Raise engine speed to 1500-1700 rpm and keep it for 2 mins. Check for
DTC
Perform service regeneration at IDLE after issue
rectification

If Still issue persists, Check compression pressure through compression

8 30±2 bar
gauge

Perform following services in TDS:

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

Author: ERC Page 704 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 705 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 706 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0201-13: Cylinder 1 - Injector Circuit open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0201-13

1. Faulty Wiring harness
2. Injector 1 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_OC_INJ_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 651 / 05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 707 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 4 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 708 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
1 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

2 Ensure electrical continuity between ECU and Injector Refer Schematic diagram

Perform following services in TDS:

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

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 709 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 710 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 711 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0201-2B: Cylinder 1 - Injector Short circuit error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0201-2B

1. Faulty Wiring harness
2. Injector 1 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_SC_INJ_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 651 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 712 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 4 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 713 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
1 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

2 Ensure electrical continuity between ECU and Injector Refer Schematic diagram

Perform following services in TDS:

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

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 714 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 715 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 716 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0266-00: Cylinder 2 - Injector balance low fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Other system errors (Rail
Fault Code P0266-00 pressure/EGR/ETV/Intake air system/cylinder-2
Injector)
No Vehicle reaction
2. Injector 2 is faulty
CEL ON 3. Incorrect tappet setting
4. Low compression in the cylinder 2

Fault System Summary:

Development Fault code F_M_FCI_INJ_BAL_LOW_APV_3

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 652 / 09

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 717 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Other system errors :
EGR Electrical / functional fault codes
Check indicated torque at engine low idle & high idle. If torque found out
Rail pressure sensor errors
of specification, then injector balance fault triggered because of other
Exhaust throttle electrical / stuck closed
system failures, check specification for more details. If found any issues,
Intake air system related errors like PFM/Intake manifold
1 rectify it and start engine.
pressure/temperatures
Ensure correct tappet setting.
DPF related failures
After rectification, Raise engine speed to 1500-1700 rpm and keep it for
2 mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

2. Indicated torque range :
Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
If no faults observed, remove after ETV pipe & check whether ETV is
3. Perform ETV Actuator test in TDS-ECU (Test Actuator
stuck closed physically by performing actuator tests (0%,50%&100%). If
Tab- 0%,50% & 100%)
actuator is not moving, replace ETV & perform tests mentioned in
2 3. ETV error allowed during actuator test : +/- 5%
specification.
4. Perform ETV Actuator learning test through TDS-ECU if
After rectification, Raise engine speed to 1500-1700 rpm and keep it for
ETV replaced
2 mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

If still issue persists, detach / disconnect ATS from ETV pipe & check 2. Indicated torque range :
indicated torque in Low Idle & high Idle. If torque found within Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
specification, then DPF might be having issues. Remove/Replace DPF & 3. Perform DPF replacement service through TDS-DCU if
3
check for DTC. DPF is replaced
After rectification, Raise engine speed to 1500-1700 rpm and keep it for
2 mins. Check for DTC. Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Injector shut off test
If no issues found in step 3, Conduct Injector actuator test through 2. Injector Buzz test
diagnostic tool. If found any issues, replace particular injector/wiring 3. If injector changed, Write proper injector codes (I3C) in
4
harness based on finding & start engine. Raise engine speed to 1500- ECU after reading it from new Injector
1700 rpm and keep it for 2 mins. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Raise engine
5
speed to 1500-1700 rpm and keep it for 2 mins. Check for DTC Perform service regeneration at IDLE after issue
rectification
1. Ensure Injector back leak should not exceed 160ml with
If still issue persists, Perform injector back leak test. If back leak found
all injectors
out of specification, Remove & Refit injector along with quill & quill nut.
6
Apply proper tightening torque. Start engine, Raise engine speed to
Perform service regeneration at IDLE after issue
1500-1700 rpm and keep it for 2 mins. Check for DTC
rectification

Author: ERC Page 718 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Perform following services in TDS:

1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace Injector 2 & write I3C code. Start engine,
from new Injector
7 Raise engine speed to 1500-1700 rpm and keep it for 2 mins. Check for
DTC
Perform service regeneration at IDLE after issue
rectification

8 Conduct compression pressure check through compression gauge 30 ± 2 bar

Perform following services in TDS:

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

Author: ERC Page 719 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 720 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 721 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0202-13: Cylinder 2 - Injector Circuit Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0202-13

1. Faulty Wiring harness
2. Injector 2 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_OC_INJ_APV_3

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 652 / 05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 722 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 3 & 8 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 723 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
1 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

2 Ensure wiring harness continuity between ECU and Injector Refer Schematic diagram

Perform following services in TDS:

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

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 724 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 725 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 726 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0202-2B: Cylinder 2 - Injector Short circuit error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0202-2B

1. Faulty Wiring harness
2. Injector 2 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_SC_INJ_APV_3

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 652 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 727 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 3 & 8 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 728 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
1 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

2 Ensure wiring harness continuity between ECU and Injector Refer schematic diagram

Perform following services in TDS:

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

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 729 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 730 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 731 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0269-00: Cylinder 3 - Injector balance low fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Other system errors (Rail
Fault Code P0269-00 pressure/EGR/ETV/Intake air system/cylinder-3
Injector)
No Vehicle reaction
2. Injector 3 is faulty
CEL ON 3. Incorrect tappet setting
4. Compression pressure low in cylinder 3

Fault System Summary:

Development Fault code F_M_FCI_INJ_BAL_LOW_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 653 / 09

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 732 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications
Other system errors :
EGR Electrical / functional fault codes
Check indicated torque at engine low idle & high idle. If torque found out
Rail pressure sensor errors
of specification, then injector balance fault triggered because of other
Exhaust throttle electrical / stuck closed
system failures, check specification for more details. If found any issues,
Intake air system related errors like PFM/Intake manifold
1 rectify it and start engine.
pressure/temperatures
Ensure correct tappet setting in the cylinder.
DPF related failures
After rectification, Raise engine speed to 1500-1700 rpm and keep it for
2 mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

2. Indicated torque range :
Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
If no faults observed, remove after ETV pipe & check whether ETV is
3. Perform ETV Actuator test in TDS-ECU (Test Actuator
stuck closed physically by performing actuator tests (0%,50%&100%). If
Tab- 0%,50% & 100%)
actuator is not moving, replace ETV & perform tests mentioned in
2 3. ETV error allowed during actuator test : +/- 5%
specification.
4. Perform ETV Actuator learning test through TDS-ECU if
After rectification, Raise engine speed to 1500-1700 rpm and keep it for
ETV replaced
2 mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

If still issue persists, detach / disconnect ATS from ETV pipe & check 2. Indicated torque range :
indicated torque in Low Idle & high Idle. If torque found within Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
specification, then DPF might be having issues. Remove/Replace DPF & 3. Perform DPF replacement service through TDS-DCU if
3
check for DTC. DPF is replaced
After rectification, Raise engine speed to 1500-1700 rpm and keep it for
2 mins. Check for DTC. Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Injector shut off test
If no issues found in step 3, Conduct Injector actuator test through 2. Injector Buzz test
diagnostic tool. If found any issues, replace particular injector/wiring 3. If injector changed, Write proper injector codes (I3C) in
4
harness based on finding & start engine. Raise engine speed to 1500- ECU after reading it from new Injector
1700 rpm and keep it for 2 mins. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Raise engine
5
speed to 1500-1700 rpm and keep it for 2 mins. Check for DTC Perform service regeneration at IDLE after issue
rectification
1. Ensure Injector back leak should not exceed 160ml with
If still issue persists, Perform injector back leak test. If back leak found
all injectors
out of specification, Remove & Refit injector along with quill & quill nut.
6
Apply proper tightening torque. Start engine, Raise engine speed to
Perform service regeneration at IDLE after issue
1500-1700 rpm and keep it for 2 mins. Check for DTC
rectification

Author: ERC Page 733 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Perform following services in TDS:

1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace Injector 3 & write I3C code. Start engine,
from new Injector
7 Raise engine speed to 1500-1700 rpm and keep it for 2 mins. Check for
DTC
Perform service regeneration at IDLE after issue
rectification

8 Conduct compression pressure test through compression gauge 30 ± 2 bar

Perform following services in TDS:

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

Author: ERC Page 734 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 735 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 736 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0203-13: Cylinder 3 - Injector Circuit Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0203-13

1. Wiring harness issue
2. Injector 3 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_OC_INJ_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 653 / 05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 737 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 9 & 10 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 738 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
1 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

2 Ensure electrical continuity between ECU and Injector Refer Schematic diagram

Perform following services in TDS:

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

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 739 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 740 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 741 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0203-2B: Cylinder 3 - Injector Short circuit error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0203-2B

1. Wiring harness issue
2. Injector 3 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_SC_INJ_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 653 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 742 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 9 & 10 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 743 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
1 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

2 Ensure electrical continuity between ECU and Injector Refer schematic diagram

Perform following services in TDS:

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

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 744 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 745 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 746 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0272-00: Cylinder 4 - Injector balance low fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Other system errors (Rail
Fault Code P0272-00 pressure/EGR/ETV/Intake air system)
2. Injector 4 is faulty No Vehicle reaction
3. Incorrect tappet setting
CEL ON
4. Low compression pressure

Fault System Summary:

Development Fault code F_M_FCI_INJ_BAL_LOW_APV_2

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 654 / 09

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 747 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Other system errors :
EGR Electrical / functional fault codes
Check indicated torque at engine low idle & high idle. If torque found out
Rail pressure sensor errors
of specification, then injector balance fault triggered because of other
Exhaust throttle electrical / stuck closed
system failures, check specification for more details. If found any issues,
Intake air system related errors like PFM/Intake manifold
1 rectify it and start engine.
pressure/temperatures
Ensure correct tappet setting.
DPF related failures
After rectification, Raise engine speed to 1500-1700 rpm and keep it for
2 mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

2. Indicated torque range :
Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
If no faults observed, remove after ETV pipe & check whether ETV is
3. Perform ETV Actuator test in TDS-ECU (Test Actuator
stuck closed physically by performing actuator tests (0%,50%&100%). If
Tab- 0%,50% & 100%)
actuator is not moving, replace ETV & perform tests mentioned in
2 3. ETV error allowed during actuator test : +/- 5%
specification.
4. Perform ETV Actuator learning test through TDS-ECU if
After rectification, Raise engine speed to 1500-1700 rpm and keep it for
ETV replaced
2 mins. Check for DTC.
Perform service regeneration at IDLE after issue
rectification

1. Keep gear in Neutral & put Handbrake ON

If still issue persists, detach / disconnect ATS from ETV pipe & check 2. Indicated torque range :
indicated torque in Low Idle & high Idle. If torque found within Low idle : 50-85 Nm; High Idle : 130 - 170 Nm
specification, then DPF might be having issues. Remove/Replace DPF & 3. Perform DPF replacement service through TDS-DCU if
3
check for DTC. DPF is replaced
After rectification, Raise engine speed to 1500-1700 rpm and keep it for
2 mins. Check for DTC. Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

1. Injector shut off test
If no issues found in step 3, Conduct Injector actuator test through 2. Injector Buzz test
diagnostic tool. If found any issues, replace particular injector/wiring 3. If injector changed, Write proper injector codes (I3C) in
4
harness based on finding & start engine. Raise engine speed to 1500- ECU after reading it from new Injector
1700 rpm and keep it for 2 mins. Check for DTC
Perform service regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Raise engine
5
speed to 1500-1700 rpm and keep it for 2 mins. Check for DTC Perform service regeneration at IDLE after issue
rectification
1. Ensure Injector back leak should not exceed 160ml with
If still issue persists, Perform injector back leak test. If back leak found
all injectors
out of specification, Remove & Refit injector along with quill & quill nut.
6
Apply proper tightening torque. Start engine, Raise engine speed to
Perform service regeneration at IDLE after issue
1500-1700 rpm and keep it for 2 mins. Check for DTC
rectification

Author: ERC Page 748 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Perform following services in TDS:

1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace Injector 4 & write I3C code. Start engine,
from new Injector
7 Raise engine speed to 1500-1700 rpm and keep it for 2 mins. Check for
DTC
Perform service regeneration at IDLE after issue
rectification

8 Conduct compression pressure through compression gauge 30 ± 2 bar

Perform following services in TDS:

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

Author: ERC Page 749 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 750 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 751 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0204-13: Cylinder 4 - Injector Circuit Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0204-13

1. Wiring harness issue
2. Injector 4 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_OC_INJ_APV_2

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 654 / 05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 752 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 5 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 753 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
1 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

2 Ensure wiring harness continuity between ECU & Injector Refer Schematic Diagram

Perform following services in TDS:

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

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 754 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 755 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 756 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0204-2B: Cylinder 4 - Injector Short circuit error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0204-2B

1. Wiring harness issue
2. Injector 4 is faulty
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_SC_INJ_APV_2

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 654 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 757 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 5&2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 758 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
from new Injector
1 If still issue persists, Replace Injector & write I3C code. Check for DTC
Perform service regeneration at IDLE after issue
rectification

2 Ensure electrical continuity between ECU and Injector Refer Schematic diagram.

Perform following services in TDS:

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

Perform service regeneration at IDLE after issue

rectification

Author: ERC Page 759 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 760 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 761 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P062D-08: Injector Bank 0 - Internal Communication fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P062D-08
1. Faulty ECU Engine emission may go high
MIL ON
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_DIAG_READ_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2797 / 19

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 762 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 763 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 764 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P062D-04: Injector Bank 0 - Internal Communication fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P062D-04
1. Faulty ECU Engine emission may go high
MIL ON
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_DIAG_RESET_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2797 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 765 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 766 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 767 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

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

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2146-12 1. Injector Bank 0 (Cylinder 1 or Cylinder

4) high side pins short to battery
MIL ON 2. Faulty wiring harness 1. Engine speed increased to 1200 rpm
3. Faulty ECU 2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_BANK_SC2VBAT_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2797 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 768 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
Between below pins check OK
3
A. (1 & 4) and Fail Replace the part Clear DTC and recheck
B. (2 & 5)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 769 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace specific injector(1 or 4 or both) and check from new Injector(s)
2
for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

Author: ERC Page 770 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 771 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 772 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2146-11: Injector Bank 0 - Short to Ground fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2146-11 1. Injector Bank 0 (Cylinder 1 or Cylinder

4) high side pins short to ground
MIL ON 2. Faulty Wiring harness 1. Engine speed increased to 1200 rpm
3. Faulty ECU 2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_BANK_SC2GND_APV_0

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2797 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 773 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
Between below pins check OK
3
A. (1 & 4) and Fail Replace the part Clear DTC and recheck
B. (2 & 5)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 774 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace specific injector(1 or 4 or both) and check from new Injector(s)
2
for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

Author: ERC Page 775 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 776 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 777 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P062E-08: Injector Bank 1 - Internal Communication fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P062E-08
1. Faulty ECU Engine emission may go high
MIL ON
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_DIAG_READ_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2798 / 19

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 778 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 779 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 780 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P062E-04: Injector Bank 1 - Internal Communication fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P062E-04
1. Faulty ECU Engine emission may go high
MIL ON
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_DIAG_RESET_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2798 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 781 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 782 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 783 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2149-12: Injector Bank 1 - Short to Battery fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2149-12

1. Faulty Injector (Cylinder 2 or Cylinder 3)
2. Faulty Wiring Harness
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty ECU
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_BANK_SC2VBAT_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2798 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 784 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
Between below pins check OK
3
A. (3 & 8) and Fail Replace the part Clear DTC and recheck
B. (9 & 10)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 785 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace specific injector(2 or 3 or both) and check from new Injector(s)
2
for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

Author: ERC Page 786 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 787 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 788 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2149-11: Injector Bank 1 - Short to Ground fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2149-11

1. Faulty Injector (Cylinder 2 or Cylinder 3)
2. Faulty ECU
MIL ON 1. Engine speed increased to 1200 rpm
3. Faulty wiring Harness
2. Engine emission may go high
Vehicle run with poor pickup

Fault System Summary:

Development Fault code F_M_FCI_BANK_SC2GND_APV_1

System Fuel Injection System / Fuel Injector Monitor

OBD Inducement Non-Inducement

SPN & FMI 2798 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 789 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
Between below pins check OK
3
A. (3 & 8) and Fail Replace the part Clear DTC and recheck
B. (9 & 10)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 790 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Select dataset as per Vehicle configuration(VC)
1 If still issue persists, Re-flash ECU dataset and check for DTC again
Perform service regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. Write proper injector codes (I3C) in ECU after reading it
If still issue persists, Replace specific injector(2 or 3 or both) and check from new Injector(s)
2
for DTC
Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P00C6-7B: Rail pressure not built at Low tank level during engine cranking
Overview:

Fault Code Description Cause Effect on Vehicle

1. Fuel tank level is low
2. Issues in Low pressure line
3. Fuel filter is clogged
4. HPV return line leakage (Common rail is
Fault Code P00C6-7B Starting delay or Starting Trouble
faulty)
5. High injector back leak (Injector fitment issue)
6. Faulty Injector
7. Faulty IMV/HP Pump

Fault System Summary:

Development Fault code F_M_RPC_BUILD_LOWTK_APV

System Fuel Injection System / Fuel tank level monitor

OBD Inducement Non-Inducement

SPN & FMI 5585 / 17

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Press the hand primer 150 times to reach fuel near
Check fuel level in the tank. If diesel level is low, refill fuel. Crank the
1 transfer pump inlet. Ensure no leakage or no air trap in
engine and check for rail pressure buildup. Check for DTC
low-pressure circuit.
If still issue persists, check for low pressure fuel lines. If found any issues, Press the hand primer 150 times to reach fuel near
2 rectify it. Crank the engine and check for rail pressure buildup. Check for transfer pump inlet. Ensure no leakage or no air trap in
DTC low-pressure circuit.
If still issue persists, check for whether fuel filter is clogged. If its clogged, Press the hand primer 150 times to reach fuel near
3 replace it with new one lines. Crank the engine and check for rail transfer pump inlet. Ensure no leakage or no air trap in
pressure buildup. Check for DTC low-pressure circuit.
If still issue persists, open rail pressure return line from HPV. During
cranking there should not be any fuel flow in the line. If found any, If component replaced, perform
4
replace HPV/Common Rail. Crank the engine and check for rail pressure 1. RESET HP Pump values test
buildup. Check for DTC
If still issue persists, conduct Injector back leak test during cranking. If
collected quantity is out of specification, refit injectors along with Quill &
5 Back leak should be < 10 ml @ cranking duration 8-10 secs
Quill nut assembly. Crank the engine and check for rail pressure buildup.
Check for DTC
If still issue persists, perform injector buzz test. If found any issues, Perform following services in TDS:
6 Replace respective injector. Crank the engine and check for rail pressure 1. Write proper injector codes (I3C) in ECU after reading it
buildup. Check for DTC from new Injector
Perform following services in TDS:
If still issue persists, Replace HP pump. Crank the engine and check for
7 1. RESET IMV values test
rail pressure buildup. Check for DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
8 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 796 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P00C6-00: Rail pressure not built at normal tank level during engine cranking
Overview:

Fault Code Description Cause Effect on Vehicle

1. Issues in Low pressure line

2. Fuel filter is clogged
Fault Code P00C6-00 3. HPV return line leakage (Common rail is
Starting delay or Starting Trouble
faulty)
4. High injector back leak (Injector fitment issue)
5. Faulty Injector
CEL ON 6. Faulty IMV/HP Pump

Fault System Summary:

Development Fault code F_M_RPC_BUILD_NRMTK_APV

System Fuel Injection System / Fuel tank level monitor

OBD Inducement Non-Inducement

SPN & FMI 5585 / 01

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 797 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Press the hand primer 150 times to reach fuel near
Check fuel level in the tank. If diesel level is low, refill fuel. Crank the
1 transfer pump inlet. Ensure no leakage or no air trap in
engine and check for rail pressure buildup. Check for DTC
low-pressure circuit.
If still issue persists, check for low pressure fuel lines. If found any issues, Press the hand primer 150 times to reach fuel near
2 rectify it. Crank the engine and check for rail pressure buildup. Check for transfer pump inlet. Ensure no leakage or no air trap in
DTC low-pressure circuit.
If still issue persists, check for whether fuel filter is clogged. If its clogged, Press the hand primer 150 times to reach fuel near
3 replace it with new one lines. Crank the engine and check for rail transfer pump inlet. Ensure no leakage or no air trap in
pressure buildup. Check for DTC low-pressure circuit.
If still issue persists, open rail pressure return line from HPV. During
cranking there should not be any fuel flow in the line. If found any, If component replaced, perform
4
replace HPV/Common Rail. Crank the engine and check for rail pressure 1. RESET HP Pump values test
buildup. Check for DTC
If still issue persists, conduct Injector back leak test during cranking. If
collected quantity is out of specification, refit injectors along with Quill &
5 Back leak should be < 10 ml @ cranking duration 8-10 secs
Quill nut assembly. Crank the engine and check for rail pressure buildup.
Check for DTC
If still issue persists, perform injector buzz test. If found any issues, Perform following services in TDS:
6 Replace respective injector. Crank the engine and check for rail pressure 1. Write proper injector codes (I3C) in ECU after reading it
buildup. Check for DTC from new Injector
Perform following services in TDS:
If still issue persists, Replace HP pump. Crank the engine and check for
7 1. RESET IMV values test
rail pressure buildup. Check for DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
8 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 799 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0180-15: Fuel temperature sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0180-15 1. Faulty Wiring Harness

No Vehicle reaction
2. Faulty sensor
CEL ON

Fault System Summary:

Development Fault code F_M_FUEL_TEMP_HI_APV

System Fuel Injection System / Fuel Temperature Sensor

OBD Inducement Non-Inducement

SPN & FMI 2775 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 800 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 801 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

1 If still issue persists, Re-flash ECU dataset and check for DTC again

2 If still issue persists, Replace Fuel temperature sensor and check for DTC Select dataset as per Vehicle configuration(VC)

3 If still issue persists, Replace respective wiring harness

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 803 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0180-11: Fuel temperature sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0180-11 1. Faulty Wiring Harness

No Vehicle reaction
2. Faulty sensor
CEL ON

Fault System Summary:

Development Fault code F_M_FUEL_TEMP_LO_APV

System Fuel Injection System / Fuel Temperature Sensor

OBD Inducement Non-Inducement

SPN & FMI 2775 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 805 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

1 If still issue persists, Ensure electrical continuity between ECU and sensor Refer schematic diagram

2 If still issue persists, Replace Fuel temperature sensor and check for DTC

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 808 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0180-29: Fuel temperature sensor - Signal not valid based on reference

sensors
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0180-29 [Link] wiring harness

[Link] sensor No Vehicle reaction
[Link] ECU

Fault System Summary:

Development Fault code F_M_FUEL_TEMP_XC_APV

System Fuel Injection System / Fuel Temperature Sensor

OBD Inducement Non-Inducement

SPN & FMI 2775 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 810 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

After rectification of step 1, connect Fuel temp. sensor externally and Reference sensors :
1 keep it in ambient with wiring connected. Like that keep reference 1. Ambient temperature sensor
sensors as well. Check temp. difference across all sensors 2. Coolant temperature sensor

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

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.3
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Date: 21-01-2025

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0090-13: HPV - Circuit Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-13 1. Faulty Wiring harness

2. Faulty HPV
Stop Engine 3. Faulty ECU
ON 1. 25 % Torque reduction
Lamp

Fault System Summary:

Development Fault code F_M_HPV_OC_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 815 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 816 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Following parameters needs to be check in TDS:
Connect TDS and check HPV current demand and Feedback during
1 1. HPV Current demand
Ignition ON. Difference should not more than 10 mA.
2. HPV Current Feedback

2 Ensure electrical continuity between ECU & HPV connector Refer schematic diagram

3 If still issue persists, Replace Common Rail assembly and check for DTC

Perform following services in TDS:

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

Author: ERC Page 817 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 818 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P228D-00: HPV - Controller correction High error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness

Fault Code P228D-00 2. Faulty IMV
3. Faulty HPV
4. Faulty ECU
CEL ON 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_HP_CTRL_TRIM_HI_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 16

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 820 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 821 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check for leakages / damage in the fuel line. If found any issues, rectify it. Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
Drive vehicle for 5 Kms and check for DTC return to filters
If still issue persists, Replace Common rail assembly. Drive vehicle for 5 Perform following services in TDS:
2
Kms and check for DTC 1. RESET HP Pump values test
If still issue persists, Replace IMV. Drive vehicle for 5 Kms and check for Perform following services in TDS:
3
DTC 1. RESET IMV Values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 822 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 823 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 824 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P228C-00: HPV - Controller correction Low error

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness

Fault Code P228C-00 2. Faulty IMV
3. Faulty HPV
4. Faulty ECU
CEL ON 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_HP_CTRL_TRIM_LO_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 15

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 825 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 826 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check for leakages / damage in the fuel line. If found any issues, rectify it. Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
Drive vehicle for 5 Kms and check for DTC return to filters
If still issue persists, Replace Common rail assembly. Drive vehicle for 5 Perform following services in TDS:
2
Kms and check for DTC 1. RESET HP Pump values test
If still issue persists, Replace IMV. Drive vehicle for 5 Kms and check for Perform following services in TDS:
3
DTC 1. RESET IMV Values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 827 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 828 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 829 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0090-1B: HPV - Current control error (High)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-1B 1. Faulty Wiring harness

2. Faulty HPV (Faulty Rail)
3. Faulty ECU
CEL ON 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_HP_CRT_CTRL_HIGH_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 18

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 830 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 831 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
2 1. HPV Valve test
failed, Replace Common Rail. Drive vehicle for 5 Kms and check for DTC
2. Rail pressure test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
3 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
If still issue persists, Replace Common rail assembly. Drive vehicle for 5 Perform following services in TDS:
4
Kms and check for DTC 1. RESET HP Pump values test

5 If still issue persists, replace IMV and check for error

Perform following services in TDS:

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

Author: ERC Page 832 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 833 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 834 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0090-1A: HPV - Current control error (Low)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-1A 1. Faulty Wiring harness

2. Faulty HPV (Faulty Rail)
3. Faulty ECU
CEL ON 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_HP_CRT_CTRL_LOW_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 17

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 835 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 836 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
2 1. HPV Valve test
failed, Replace Common Rail. Drive vehicle for 5 Kms and check for DTC
2. Rail pressure test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
3 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
If still issue persists, Replace Common rail assembly. Drive vehicle for 5 Perform following services in TDS:
4
Kms and check for DTC 1. RESET HP Pump values test

5 If still issue persists, replace IMV and check

Perform following services in TDS:

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

Author: ERC Page 837 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 838 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 839 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0090-19: HPV - Feedback Current High error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-19 1. Faulty Wiring harness

2. Faulty HPV (Faulty Rail) No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_HP_CRT_FB_HIGH_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 00

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 840 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 841 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
2 1. HPV Valve test
failed, Replace Common Rail. Drive vehicle for 5 Kms and check for DTC
2. Rail pressure test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
3 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
If still issue persists, Replace Common rail assembly. Drive vehicle for 5 Perform following services in TDS:
4
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 842 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 843 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 844 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0090-18: HPV - Feedback Current Low error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-18 1. Faulty Wiring harness

2. Faulty HPV (Faulty Rail) No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_HP_CRT_FB_LOW_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 01

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 845 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 846 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
2 1. HPV Valve test
failed, Replace Common Rail. Drive vehicle for 5 Kms and check for DTC
2. Rail pressure test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
3 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
If still issue persists, Replace Common rail assembly. Drive vehicle for 5 Perform following services in TDS:
4
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 847 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 848 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 849 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0090-F0: HPV High side pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-F0 1. Faulty Wiring harness

2. Faulty HPV
Stop Engine 3. Faulty ECU
ON 1. 25 % Torque reduction
Lamp

Fault System Summary:

Development Fault code F_M_HPV_HSD_SC2V_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 516202 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 850 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 851 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
1 1. HPV Valve test
failed, Replace Common Rail. Start engine and check for DTC
2. Rail pressure test
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5 Perform following services in TDS:
2
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 852 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 853 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 854 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0090-F1: HPV High side pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-F1 1. Faulty Wiring harness

2. Faulty HPV
Stop Engine 3. Faulty ECU
ON 1. 25 % Torque reduction
Lamp

Fault System Summary:

Development Fault code F_M_HPV_HSD_SC2G_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 516202 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 855 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 856 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
1 1. HPV Valve test
failed, Replace Common Rail. Start engine and check for DTC
2. Rail pressure test
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5 Perform following services in TDS:
2
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 857 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 858 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 859 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0090-F2: HPV Low side pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-F2 1. Faulty Wiring harness

2. Faulty HPV
Stop Engine 3. Faulty ECU
ON 1. 25 % Torque reduction
Lamp

Fault System Summary:

Development Fault code F_M_HPV_LSD_SC2V_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 516203 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 860 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 861 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
1 1. HPV Valve test
failed, Replace Common Rail. Start engine and check for DTC
2. Rail pressure test
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5 Perform following services in TDS:
2
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 862 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 863 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 864 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0090-F3: HPV Low side pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0090-F3 1. Faulty Wiring harness

2. Faulty HPV
Stop Engine 3. Faulty ECU
ON 1. 25 % Torque reduction
Lamp

Fault System Summary:

Development Fault code F_M_HPV_LSD_SC2G_APV

System Fuel Injection System / HPV Monitor

OBD Inducement Non-Inducement

SPN & FMI 516203 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 865 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 866 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Perform following services in TDS:
If still issue persists, Conduct HPV actuator test through TDS. If test
1 1. HPV Valve test
failed, Replace Common Rail. Start engine and check for DTC
2. Rail pressure test
If still issue persists, Replace Common Rail assembly. Drive vehicle for 5 Perform following services in TDS:
2
Kms and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
3 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 867 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 868 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 869 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0088-92: HPV - Over pressure fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Blockage in Rail return line
Fault Code P0088-92 2. Malfunction of HPV
3. Malfunction of Rail pressure sensor
4. Malfunction in IMV
CEL ON 5. Faulty ECU 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_OVERPRESSURE_HPV_APV

System Fuel Injection System / HPV Over Pressure Monitor

OBD Inducement Non-Inducement

SPN & FMI 5571 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 870 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 871 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check for Blockage in rail return line. If found any issues, rectify it. Drive Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
vehicle for 5 Kms and check for DTC return to filters
Check rail pressure sensor related issues. If found any, rectify it. Drive
2
vehicle for 10Kms in highway and check for DTC
Perform following services in TDS:
If still issue persists, perform actuator tests through TDS. If test is not [Link] pressure test
3 passed, replace Common Rail. Drive vehicle for 10Kms in highway and
check for DTC If component replaced, perform
1. RESET HP Pump values test
If still issue persists, Replace Common Rail. Drive vehicle for 10Kms in If component replaced, perform
4
highway and check for DTC 1. RESET HP Pump values test
Perform following services in TDS:
If still issue persists, Replace IMV/HP Pump. Drive vehicle for 10Kms in
5 1. RESET IMV values test
highway and check for DTC
2. RESET HP Pump values test
If still issue persists, Replace Rail pressure sensor. Drive vehicle for
6
10Kms in highway and check for DTC
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
7 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
8 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 872 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 873 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 874 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0001-9B: IMV - Controller correction High error (Secondary Error)

Overview:

Fault Code Description Cause Effect on Vehicle

1. Its secondary error. Primary error is Rail
Pressure control positive/ Negative error. It’s
due to Fuel line leakage / Blockage
Fault Code P0001-9B
2. Fuel filter / pre-filter issue
3. Faulty IMV
4. Faulty HP Pump
5. Other system errors (Rail pressure/IMV)
CEL ON 6. Faulty ECU 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_IM_CTRL_QHI_HIGH_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 15

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 875 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

This error is due to the Primary error of Rail Pressure control Positive/ Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
Negative. Refer Rail pressure control positive and negative error return to filters
1 corrective steps for the error resolution.
Check for leakages / damage/kink in the fuel line. If found any issues, Perform Service Regeneration at IDLE after issue
rectify it. Drive vehicle for 5 Kms and check for DTC rectification

Check Injector back leak through TDS

2 Back leak quantity should be less than 160 ml.
(EMS-> Routine Test-> Injector Back Leak Test)

Check voltages between below pins during Key ON

3.44 V : 1&2, 1&ground
If no issues found in step 2, Check IMV current demand and feedback
0V : 2&ground
3 through TDS. If found any issues, rectify it. Please refer reference voltage
values
Perform Service Regeneration at IDLE after issue
rectification
If still issue persists, Check fuel filter condition. Replace filter if found any Perform Service Regeneration at IDLE after issue
4
issues. Drive vehicle for 5 Kms and check for DTC rectification
Perform following services in TDS:
1. RESET IMV values test
If still issue persists, Replace IMV/HP Pump. Drive vehicle for 5 Kms and 2. RESET HP Pump values test
5
check for DTC
Perform Service Regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
6
5 Kms and check for DTC Perform Service Regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
7 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform Service Regeneration at IDLE after issue
rectification

Author: ERC Page 876 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 877 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0001-9C: IMV - Controller correction Low error (Secondary Error)

Overview:

Fault Code Description Cause Effect on Vehicle

1. Its secondary error. Primary error is Rail

Pressure control positive/ Negative error. It’s
Fault Code P0001-9C due to Fuel line leakage / Blockage
2. Fuel filter / pre-filter issue
3. Faulty IMV
4. Faulty HP Pump
CEL ON 5. Other system errors (Rail pressure/IMV) 1. Delayed Torque reduction
6. Faulty ECU

Fault System Summary:

Development Fault code F_M_IM_CTRL_QHI_LOW_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 17

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 878 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

This error is due to the Primary error of Rail Pressure control Positive/ Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
Negative. Refer Rail pressure control positive and negative error return to filters
1 corrective steps for the error resolution.
Check for leakages / damage/kink in the fuel line. If found any issues, Perform Service Regeneration at IDLE after issue
rectify it. Drive vehicle for 5 Kms and check for DTC rectification

Check Injector back leak through TDS

2 Back leak quantity should be less than 160 ml.
(EMS-> Routine Test-> Injector Back Leak Test)

Check voltages between below pins during Key ON

3.44 V : 1&2, 1&ground
If no issues found in step 2, Check IMV current demand and feedback
0V : 2&ground
3 through TDS. If found any issues, rectify it. Please refer reference voltage
values
Perform Service Regeneration at IDLE after issue
rectification
If still issue persists, Check fuel filter condition. Replace filter if found any Perform Service Regeneration at IDLE after issue
4
issues. Drive vehicle for 5 Kms and check for DTC rectification
Perform following services in TDS:
1. RESET IMV values test
If still issue persists, Replace IMV/HP Pump. Drive vehicle for 5 Kms and 2. RESET HP Pump values test
5
check for DTC
Perform Service Regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
6
5 Kms and check for DTC Perform Service Regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
7 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform Service Regeneration at IDLE after issue
rectification

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 880 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0001-1B: IMV - Current control error (High) (Secondary Error)

Overview:

Fault Code Description Cause Effect on Vehicle

1. Its secondary error. Primary error is Rail
Fault Code P0001-1B Pressure control positive/ Negative error. It’s
due to Fuel line leakage / Blockage. IMV harness
issues
CEL ON 2. Fault IMV 1. 25 % Torque reduction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_IM_CRT_CTRL_HIGH_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 00

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 881 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

This error is due to the Primary error of Rail Pressure control Positive/ Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
Negative. Refer Rail pressure control positive and negative error return to filters
1 corrective steps for the error resolution.
Check for leakages / damage/kink in the fuel line. If found any issues, Perform Service Regeneration at IDLE after issue
rectify it. Drive vehicle for 5 Kms and check for DTC rectification

Check Injector back leak through TDS

2 Back leak quantity should be less than 160 ml.
(EMS-> Routine Test-> Injector Back Leak Test)

Check voltages between below pins during Key ON

3.44 V : 1&2, 1&ground
If no issues found in step 2, Check IMV current demand and feedback
0V : 2&ground
3 through TDS. If found any issues, rectify it. Please refer reference voltage
values
Perform Service Regeneration at IDLE after issue
rectification
If still issue persists, Check fuel filter condition. Replace filter if found any Perform Service Regeneration at IDLE after issue
4
issues. Drive vehicle for 5 Kms and check for DTC rectification
Perform following services in TDS:
1. RESET IMV values test
If still issue persists, Replace IMV/HP Pump. Drive vehicle for 5 Kms and 2. RESET HP Pump values test
5
check for DTC
Perform Service Regeneration at IDLE after issue
rectification
Select dataset as per Vehicle configuration(VC)
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
6
5 Kms and check for DTC Perform Service Regeneration at IDLE after issue
rectification
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
2. Read & Write proper injector codes (I3C) from Old
7 If still issue persists, Replace ECU ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]
4. Perform Service Regeneration at IDLE after issue
rectification

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 883 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0001-1A: IMV - Current control error (Low)

Overview:

Fault Code Description Cause Effect on Vehicle

1. Its secondary error. Primary error is Rail
Fault Code P0001-1A Pressure control positive/ Negative error. It’s
due to Fuel line leakage / Blockage. IMV harness
issues
CEL ON 2. Fault IMV 1. 25 % Torque reduction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_IM_CRT_CTRL_LOW_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 01

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 884 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check for leakages / damage in the fuel line. If found any issues, rectify it. Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
Drive vehicle for 5 Kms and check for DTC return to filters
Perform following services in TDS:
1. IMV test
If still issue persists, Conduct IMV actuator test through TDS. If test failed, 2. IMV Buzz test
2
Replace Common Rail. Drive vehicle for 5 Kms and check for DTC If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
3 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
Perform following services in TDS:
If still issue persists, Replace IMV. Drive vehicle for 5 Kms and check for
4 1. RESET IMV values test
DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 885 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 886 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0001-19: IMV - Feedback Current High error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-19 1. Wiring harness

2. Faulty IMV
3. Faulty ECU
CEL ON 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_IM_CRT_FB_HIGH_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 16

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 887 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 4.7 to 6 Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 888 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check the Electrical Connectivity (Open & Short Circuit) as per

1
methodology mentioned in “Electrical Trouble shooting Guide” below

If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
2
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters

Demand and Feedback current should be inline.

Check IMV current demand and feedback through TDS tool during
3 Difference between demand and feedback should not
Ignition ON
exceed 10 mA.

4 Ensure electrical continuity between IMV and ECU Refer Electrical Schematic

Perform following services in TDS:

If still issue persists, Replace IMV. Drive vehicle for 5 Kms and check for
5 1. RESET IMV values test
DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 889 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 890 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 891 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0001-18: IMV - Feedback Current Low error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-18 1. Wiring harness

2. Faulty IMV
3. Faulty ECU
CEL ON 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_IM_CRT_FB_LOW_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 18

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 892 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 4.7 to 6 Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 893 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check the Electrical Connectivity (Open & Short Circuit) as per

1
methodology mentioned in “Electrical Trouble shooting Guide” below

If still issue persists, check for leakages / damage in the fuel line. If found Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
2
any issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters

Demand and Feedback current should be inline.

Check IMV current demand and feedback through TDS tool during
3 Difference between demand and feedback should not
Ignition ON
exceed 10 mA.

4 Ensure electrical continuity between IMV and ECU Refer Electrical Schematic

Perform following services in TDS:

If still issue persists, Replace IMV. Drive vehicle for 5 Kms and check for
5 1. RESET IMV values test
DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
6 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 894 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 895 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 896 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0001-13: IMV - Open Circuit

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-13 1. Faulty Wiring harness

2. Fault IMV
MIL ON for 15 secs 3. Faulty ECU 1. 25 % Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_IMV_OC_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 897 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 4.7 to 6 Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 898 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check the Electrical Connectivity (Open & Short Circuit) as per

1 Connectivity to be ensured as per Circuit diagram
methodology mentioned in “Electrical Trouble shooting Guide” below

IMV Current demand and Feedback should be inline.

Difference should not exceed 10 mA. If exceeds check
2 Check IMV current demand and Feedback during Ignition ON
,mouth open at IMV connector, ECU connector and check
continuity

Check electrical continuity, Repair or replace wiring harness based on

3 Refer Schematic diagram.
wiring harness condition

4 Replace IMV if fault not resolved on above step

Perform following services in TDS:

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

Author: ERC Page 899 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 900 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 901 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0001-F0: IMV High side pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-F0 1. Faulty Wiring harness

2. Fault IMV
MIL ON for 15 secs 3. Faulty ECU 1. 25 % Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_IMV_HSD_SC2V_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7027 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 902 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 4.7 to 6 Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 903 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check the Electrical Connectivity (Open & Short Circuit) as per

1 Connectivity to be ensured as per Circuit diagram
methodology mentioned in “Electrical Trouble shooting Guide” below

Difference in IMV current demand and Feedback should

2 Ensure IMV current demand and Feedback are inline
not exceed 10 mA.

3 If still issue persists, Repair/ Replace wiring harness based on conditions Refer schematic diagram

4 If still issue persists, Replace IMV and check for error

Perform following services in TDS:

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

Author: ERC Page 904 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 905 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 906 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0001-F1: IMV High side pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-F1 1. Faulty Wiring harness

2. Fault IMV
MIL ON for 15 secs 3. Faulty ECU 1. 25 % Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_IMV_HSD_SC2G_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7027 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 907 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 4.7 to 6 Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 908 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check the Electrical Connectivity (Open & Short Circuit) as per

1 Connectivity to be ensured as per Circuit diagram
methodology mentioned in “Electrical Trouble shooting Guide” below

Difference in IMV current demand and Feedback should

2 Ensure IMV current demand and Feedback are inline
not exceed 10 mA.

3 If still issue persists, Repair/ Replace wiring harness based on conditions Refer schematic diagram

4 If still issue persists, Replace IMV and check for error

Perform following services in TDS:

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

Author: ERC Page 909 of 1261

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 910 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 911 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0001-F2: IMV Low side pin - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-F2 1. Faulty Wiring harness

2. Fault IMV
MIL ON for 15 secs 3. Faulty ECU 1. 25 % Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_IMV_LSD_SC2V_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7029 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 912 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 4.7 to 6 Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 913 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check the Electrical Connectivity (Open & Short Circuit) as per

1 Connectivity to be ensured as per Circuit diagram
methodology mentioned in “Electrical Trouble shooting Guide” below

Difference in IMV current demand and Feedback should

2 Ensure IMV current demand and Feedback are inline
not exceed 10 mA.

3 If still issue persists, Repair/ Replace wiring harness based on conditions Refer schematic diagram

4 If still issue persists, Replace IMV and check for error

Perform following services in TDS:

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

Author: ERC Page 914 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 915 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 916 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0001-F3: IMV Low side pin - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0001-F3 1. Faulty Wiring harness

2. Fault IMV
MIL ON for 15 secs 3. Faulty ECU 1. 25 % Torque reduction
CEL ON

Fault System Summary:

Development Fault code F_M_IMV_LSD_SC2G_APV

System Fuel Injection System / IMV Monitor

OBD Inducement Non-Inducement

SPN & FMI 7029 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 917 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 4.7 to 6 Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 918 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check the Electrical Connectivity (Open & Short Circuit) as per

1 Connectivity to be ensured as per Circuit diagram
methodology mentioned in “Electrical Trouble shooting Guide” below

Difference in IMV current demand and Feedback should

2 Ensure IMV current demand and Feedback are inline
not exceed 10 mA.

3 If still issue persists, Repair/ Replace wiring harness based on conditions Refer schematic diagram

4 If still issue persists, Replace IMV and check for error

Perform following services in TDS:

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

Author: ERC Page 919 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 920 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 921 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0088-94: IMV - Over pressure fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Blockage in Rail return line

Fault Code P0088-94 2. Malfunction of IMV
3. Malfunction of Rail pressure sensor
4. Faulty ECU
CEL ON 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_OVERPRESSURE_IMV_APV

System Fuel Injection System / IMV Over Pressure Monitor

OBD Inducement Non-Inducement

SPN & FMI 7026 / 02

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 922 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

If still issue persists, check for Blockage in rail return line. If found any Tank to filter lines, Filter to HP pump, HP pump to rail, Rail
1
issues, rectify it. Drive vehicle for 5 Kms and check for DTC return to filters
Check rail pressure sensor related issues. If found any, rectify it. Drive
2
vehicle for 10Kms in highway and check for DTC
Perform following services in TDS:
1. IMV test
If still issue persists, perform actuator tests through TDS. If test is not 2. Rail pressure test
3 passed, replace respective component (IMV/HP Pump). Drive vehicle for 3. IMV Buzz test
10Kms in highway and check for DTC If component replaced, perform
1. RESET IMV values test
2. RESET HP Pump values test
Perform following services in TDS:
If still issue persists, Replace IMV/HP Pump. Drive vehicle for 10Kms in
4 1. RESET IMV values test
highway and check for DTC
2. RESET HP Pump values test
If still issue persists, Replace Rail pressure sensor. Drive vehicle for
5
10Kms in highway and check for DTC
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for
6 Select dataset as per Vehicle configuration(VC)
5 Kms and check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 923 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 924 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 925 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0325-00: Accelerometer sensor 1 failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0325-00 1. Faulty wiring harness

2. Fault Knock Sensor No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FCI_ACC_DECODE_APV_0

System Fuel Injection System / Knock Sensor

OBD Inducement Non-Inducement

SPN & FMI 731 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 926 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 927 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check for other fault codes related to Fuel Injection system. If found any
1 Fault codes related to Injectors/Rail pressure/IMV/HPV
issue, rectify it. Drive vehicle for 5Kms & check for DTC
Check for Injector compression leak test. If found any issues, rectify it. Perform following services in TDS:
2
Drive vehicle for 5Kms & check for DTC 1. Compression leak test
If still issue persists, Replace Knock sensor. Drive vehicle for 5 Kms and
3
check for DTC
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for Select dataset based on Vehicle Identification
4
5 Kms and check for DTC number(VIN)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 928 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 929 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 930 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0330-00: Accelerometer sensor 2 failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0330-00 1. Faulty wiring harness

2. Fault Knock Sensor No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_FCI_ACC_DECODE_APV_1

System Fuel Injection System / Knock Sensor

OBD Inducement Non-Inducement

SPN & FMI 6651 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 931 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 932 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check for other fault codes related to Fuel Injection system. If found any
1 Fault codes related to Injectors/Rail pressure/IMV/HPV
issue, rectify it. Drive vehicle for 5Kms & check for DTC
Check for Injector compression leak test. If found any issues, rectify it. Perform following services in TDS:
2
Drive vehicle for 5Kms & check for DTC 1. Compression leak test
If still issue persists, Replace Knock sensor. Drive vehicle for 5 Kms and
3
check for DTC
If still issue persists, Re-flash ECU dataset & start engine. Drive vehicle for Select dataset based on Vehicle Identification
4
5 Kms and check for DTC number(VIN)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 933 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 934 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 935 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P016E-00: Rail Pressure Control - Negative Error (Primary Error)

Overview:

Fault Code Description Cause Effect on Vehicle

1. Issues in Low pressure line

Fault Code P016E-00 2. Fuel filter is clogged
3. HPV return line leakage (Common rail is
faulty)
4. High injector back leak (Injector fitment issue)
5. Faulty Injector
MIL ON for 15 secs
6. Faulty IMV/HP Pump
CEL ON 1. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_RPC_CTRL_NEG_APV

System Fuel Injection System / Rail pressure control Monitor

OBD Inducement Non-Inducement

SPN & FMI 18 / 16

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 936 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Press the hand primer 150 times to reach fuel near
Check fuel level in the tank. If diesel level is low, refill fuel. Drive the
1 transfer pump inlet. Ensure no leakage or no air trap in
vehicle for 10 Kms and check for DTC
low-pressure circuit.
Press the hand primer 150 times to reach fuel near
If still issue persists, check for low pressure fuel lines. If found any issues,
2 transfer pump inlet. Ensure no leakage or no air trap in
rectify it. Drive vehicle for 10 Kms and check for DTC
low-pressure circuit.

Perform following test through TDS,

3 If still issue persists, conduct Injector Back Leak test 1. Injector Back Leak Test. Back leak quantity should be >
160 ml.

If still issue persists, Open rail return line from HPV. Return line flow
Perform following test through TDS,
4 should be very minimal. If found too high, replace HPV/Common Rail.
1. RESET HP Pump values test
Drive vehicle for 10 Kms and check for DTC
If still issue persists, perform injector buzz test. If found any issues, Perform following services in TDS:
5 Replace respective injector. Crank the engine and check for rail pressure 1. Write proper injector codes (I3C) in ECU after reading it
buildup. Check for DTC from new Injector
Perform following services in TDS:
If still issue persists, Replace HP pump. Crank the engine and check for
6 1. RESET IMV values test
rail pressure buildup. Check for DTC
2. RESET HP Pump values test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P016F-00: Rail Pressure Control - Positive Error (Primary Error)

Overview:

Fault Code Description Cause Effect on Vehicle

1. High Injector back leak

2. Low Pressure Fuel supply to Rail
Fault Code P016F-00 3. Low Pressure fuel lines pinching
4. Fuel leakage from High Pressure Fuel lines
5. Clogged Fuel filters
6. Faulty Injectors
CEL ON 7. Faulty HP pump 1. Delayed Torque reduction
8. Faulty Ignition Switch

Fault System Summary:

Development Fault code F_M_RPC_CTRL_POS_APV

System Fuel Injection System / Rail pressure control Monitor

OBD Inducement Non-Inducement

SPN & FMI 18 / 18

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Ensure sufficient fuel available in fuel tank.
Check rail pressure sensor connector & IMV connector fitted properly. If
1
found loose, refit the connectors, and check for DTC.
Ensure no fuel leakage from Low pressure and High Pressure lines.

2 Conduct Injector Back leak through TDS Injector back leak Should be less than 160 ml

If Back leak is less than 160 ml and errors persists, Refer corrective
3 actions step no 4, 5 and 6. If Back leak is greater than 160 ml and errors Ensure no pinching or blockage in fuel lines.
persists, Refer corrective actions step no 7 & 8.

4 Check low pressure fuel lines, Fuel filter for pinching and clogging Ensure correct part number

5 If still the error persists, Replace common rail and check Ensure correct part number

6 If still the error persists, Replace High Pressure Pump Ensure correct part number

If Back leak is greater than 160 ml and errors persists, Then do Injector Refer Injector torque chart in 5L Workshop Manual for
7
quill alignment and check for Injector back leak fitment. Back leak quantity should be less than 160 ml.

Refer Injector torque chart in 5L Workshop Manual for

8 If still issue persists, Replace Injector assembly
fitment.

9 If still issue persist, check Ignition Key working properly Applicable for less than and greater than 160 ml back leak

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0190-11: Rail pressure sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0190-11

MIL ON for 15 secs 1. 25 % Torque reduction

1. Faulty Wiring harness
CEL ON 2. Faulty sensor 2. No Pedal Response
3. Engine speed increased to 1200 rpm
4. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_RAIL_PRES_LO_APV

System Fuel Injection System / Rail Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 157 / 04

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Ensure electrical continuity between Rail Pressure sensor and ECU. If any
1 Refer Schematic diagram
issue observed repair and replace wiring harness.
If still issue persists, Replace Rail pressure sensor/Common Rail and
2
check for DTC
3 If still issue persists, Re-flash ECU dataset and check for DTC again
4 If still issue persists, Replace ECU

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 945 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0190-12: Rail pressure sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0190-12

MIL ON for 15 secs 1. 25 % Torque reduction

1. Faulty Wiring harness
CEL ON 2. Faulty sensor 2. No Pedal Response
3. Engine speed increased to 1200 rpm
4. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_RAIL_PRES_HI_APV

System Fuel Injection System / Rail Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 157 / 03

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Circuit diagram & Component images

Author: ERC Page 947 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 950 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0088-22: Rail Pressure Sensor - Signal too high

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0088-22

MIL ON for 15 secs 1. 25 % Torque reduction

1. Faulty Wiring harness
CEL ON 2. Faulty sensor 2. No Pedal Response
3. Engine speed increased to 1200 rpm
4. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_RAILP_CAL_HIGH_APV

System Fuel Injection System / Rail Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 18 / 00

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Circuit diagram & Component images

Author: ERC Page 952 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 955 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0087-00: Rail pressure sensor - Signal too Low

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0087-00

MIL ON for 15 secs 1. 25 % Torque reduction

1. Faulty Wiring harness
CEL ON 2. Faulty sensor 2. No Pedal Response
3. Engine speed increased to 1200 rpm
4. Regeneration Inhibition

Fault System Summary:

Development Fault code F_M_RAILP_CAL_LOW_APV

System Fuel Injection System / Rail Pressure sensor

OBD Inducement Non-Inducement

SPN & FMI 18 / 01

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
3
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
4
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
5
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 958 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2BA7-00: DEF Level Empty Indication

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BA7-00
MIL ON 1. 20 kmpH Vehicle. Speed limitation
1. DEF/Urea tank is empty
SCR Lamp ON 2. Engine emissions go high
DEF Lamp BLINK

Fault System Summary:

Development Fault code F_M_J1939_IND_UR_MT_APV

System OBD Inducement / Inducement

OBD Inducement Tank Level Inducement

SPN & FMI 4096 / 31

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& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

This error will trigger if DEF level falls below 2.5 %.
1
Fill Tata Genuine DEF and check for DTC

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P203F-00: DEF Level Low Indication

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P203F-00
SCR Lamp ON 1. DEF/Urea tank is low No Vehicle reaction
DEF Lamp ON

Fault System Summary:

Development Fault code F_M_J1939_IND_UR_WRN_APV

System OBD Inducement / Inducement

OBD Inducement Tank Level Inducement

SPN & FMI 7606 / 17

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& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Please ensure DEF level is less than 10 %. Fill Tata Genuine DEF / Urea
1
and check for DTC

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P203F-7B: DEF Level near Empty Indication

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P203F-7B
SCR Lamp ON 1. DEF/Urea tank is near empty 1. 25% Torque reduction
DEF Lamp ON

Fault System Summary:

Development Fault code F_M_J1939_IND_UR_RTN_APV

System OBD Inducement / Inducement

OBD Inducement Tank Level Inducement

SPN & FMI 7606 / 01

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& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

1 Fill Tata Genuine DEF and check for DTC

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P203F-21: DEF Level very Low Indication

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P203F-21 1. DEF/Urea tank level is very low

2. Communication error between DCU & Quality
No Vehicle reaction
sensor
SCR Lamp ON 3. Faulty sensor
DEF Lamp ON

Fault System Summary:

Development Fault code F_M_J1939_IND_UR_ESC_APV

System OBD Inducement / Inducement

OBD Inducement Tank Level Inducement

SPN & FMI 7606 / 01

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& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

1 Fill Tata Genuine DEF and check for DTC
Check for Urea quality sensor related errors in DCU. If found any, rectify
2
and check for DTC
3 Replace Urea quality sensor. Check for DTC

Location and Component Image:

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P2BAA-00: Inducement - DEF Consumption fault (Secondary Fault)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BAA-00

1. Its Group Fault. For actual fault, Please check
the error in DCU (Dosing Control Unit) 1. Vehicle runs with 25% reduced torque
after 10 hours
SCR Lamp ON
2. Vehicle speed restricted to 20 KmpH after
[Link] DEF/Urea quantity is wrong due to 20 hours
some system failure
2. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_J1939_REAGNT_CNS_APV

System OBD Inducement / Inducement

Dosing Fault Group

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

SPN & FMI 5839 / 31

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Trouble Shooting Steps:

Sr. No. Steps Specifications

It’s a Group Fault (Secondary Fault), For Actual fault, please check faults
1 in Dosing Control Unit (DCU). After rectification of the DCU fault, ECU Connect TDS and Check Faults in DCU.
fault will be resolved.

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P2BA8-00: Inducement - DEF Dosing Stopped Fault (Secondary Fault)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BA8-00
1. Vehicle runs with 25% reduced torque
1. Its Group Fault. For actual fault, Please check after 10 hours
SCR Lamp ON
the error in DCU (Dosing Control Unit) 2. Vehicle speed restricted to 20 KmpH after
[Link] Dosing Stopped due to some system fault 20 hours
2. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_J1939_INTRP_DOSE_APV

System OBD Inducement / Inducement

Dosing Interruption Group

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

SPN & FMI 5840 / 07

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Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

It’s a Group Fault (Secondary Fault), For Actual fault, please check faults
1 in Dosing Control Unit (DCU). After rectification of the DCU fault, ECU Connect TDS and Check Faults in DCU.
fault will be resolved.

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2BA9-00: Inducement - DEF Quality fault (Secondary Fault)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BA9-00

1. Its Group Fault. For actual fault, Please check
the error in DCU (Dosing Control Unit) 1. Vehicle runs with 25% reduced torque
after 10 hours
SCR Lamp ON
2. Vehicle speed restricted to 20 KmpH after
[Link] Urea Quality related errors present in the 20 hours
system
2. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_J1939_REAGNT_QUA_APV

System OBD Inducement / Inducement

DEF Quality Group

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

SPN & FMI 5841 / 31

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

It’s a Group Fault (Secondary Fault), For Actual fault, please check faults
1 in Dosing Control Unit (DCU). After rectification of the DCU fault, ECU Connect TDS and Check Faults in DCU.
fault will be resolved.

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2BAE-00: Inducement - DEF SCR System fault (Secondary Fault)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2BAE-00
1. Vehicle runs with 25% reduced torque
1. Its Group Fault. For actual fault, Please check after 36 hours
SCR Lamp ON
the error in DCU (Dosing Control Unit). 2. Vehicle speed restricted to 20 KmpH after
[Link] system faults are present in the system 100 hours
2. OBD Inducement reaction. Refer table
"Fault System Summary" for more details

Fault System Summary:

Development Fault code F_M_J1939_IND_TAMPER_APV

System OBD Inducement / Inducement

Tampering Group
OBD Inducement
25% Torque Reduction after 36 Hrs; 20 KmpH Speed Limitation after 100 Hrs

SPN & FMI 5842 / 31

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

It’s a Group Fault (Secondary Fault), For Actual fault, please check faults
1 in Dosing Control Unit (DCU). After rectification of the DCU fault, ECU Connect TDS and Check Faults in DCU.
fault will be resolved.

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0645-13: AC relay - Open Circuit

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness
Fault Code P0645-13 2. Faulty Relay No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_AC_RELAY_OC_APV

System Vehicle System / AC Relay

OBD Inducement Non-Inducement

SPN & FMI 3583 / 05

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Acceptance
Step Checkpoints Result Recommended Action Remark
criteria
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance 200 to500 Ohm Pass Proceed to next step Component electrical
3 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass No open circuit. Proceed to
open circuit, repeat step 4 for all applicable next step
5 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
6 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
7 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to next step
8 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
9
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
10 remaining circuits in same wiring Fail Replace the faulty harness
harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
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Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
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Circuit Schematic Diagram:

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Location and Component Image:

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0645-12: AC relay - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness
Fault Code P0645-12 2. Faulty Relay No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_AC_RELAY_SC2V_APV

System Vehicle System / AC Relay

OBD Inducement Non-Inducement

SPN & FMI 3583 / 03

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Acceptance
Step Checkpoints Result Recommended Action Remark
criteria
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance 200 to500 Ohm Pass Proceed to next step Component electrical
3 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass No open circuit. Proceed to
open circuit, repeat step 4 for all applicable next step
5 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
6 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
7 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to next step
8 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
9
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
10 remaining circuits in same wiring
harness. Fail Replace the faulty harness

Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
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Circuit Schematic Diagram:

Author: ERC Page 986 of 1261

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 Version: 1.3
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Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0645-11: AC relay - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness
Fault Code P0645-11 2. Faulty Relay No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_AC_RELAY_SC2G_APV

System Vehicle System / AC Relay

OBD Inducement Non-Inducement

SPN & FMI 3583 / 04

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Acceptance
Step Checkpoints Result Recommended Action Remark
criteria
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance 200 to500 Ohm Pass Proceed to next step Component electrical
3 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass No open circuit. Proceed to
open circuit, repeat step 4 for all applicable next step
5 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
6 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
7 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to next step
8 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
9
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
10 remaining circuits in same wiring
harness. Fail Replace the faulty harness

Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2138-00: Accelerator foot pedal correlation error

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2138-00 1. Wiring harness issue

2. Faulty sensor
CEL ON 3. Faulty ECU 1.25 % Torque reduction

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_CORREL_APV

System Vehicle System / Acclerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 91 / 02

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Acceptance
Step Checkpoints Result Recommended Action Remark
criteria
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
3 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass No open circuit. Proceed to
open circuit, repeat step 4 for all applicable next step
4 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
5 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
6 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to next step
7 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
9 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Connect TDS and Check for Accelerator Pedal Track 1 & 2
1 If still issue persists, Replace Acc. Pedal Module and check for DTC
counts. One will be half of other.
2 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
3 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2120-29: Accelerator foot Pedal Limp Home fault (Secondary Fault)

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2120-29

1. Please check faults related to Accelerator. It’s
CEL ON a group fault for accelerator pedal related error
2. Wiring harness issue
1. No Pedal Response
3. Faulty sensor
2. Engine speed increased to 1300 rpm

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_LIMPH_APV

System Vehicle System / Accelerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 91 / 31

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check Accelerator Pedal Track 1, 2 and Accelerator pedal
It’s a secondary Fault (Group Fault). Please check Faults related to
position in TDS. One of the pedal count will be half of
1 accelerator pedal, after rectification of other Accelerator pedal fault, this
another and it will be vary with respect to pedal position
fault will be resolved.
but the ratio will be remain same.

2 Check wiring harness continuity between ECU and Accelerator Pedal.

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1000 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2120-71: Accelerator foot Pedal Stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2120-71 1. Faulty Bake Relay / Switch

2. Wiring harness issue
3. Faulty Acc. Pedal
CEL ON 4. Faulty ECU 1. No Pedal Response
2. Engine speed increased to 1300 rpm

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_STUCK_APV

System Vehicle System / Accelerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 91 / 07

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1001 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check for Brake switch related faults. If found any, rectify it. Drive vehicle
1
for 5 Kms and check for DTC
Check Brake switch signal status with pedal pressed/released condition
in diagnostic tool. If found any issues, check EMS brake relay and brake
When brake pedal pressed - Status in TDS should be
switch settings.
"Pressed"
2 If still issue persists, replace EMS brake relay, drive the vehicle and check
When brake pedal is not pressed - Status in TDS should be
for DTC.
"Released"
If still issue persists, adjust brake switch settings, drive the vehicle &
check for DTC
Check Accelerator Pedal Track 1, 2 and Accelerator pedal
Check for Acc. Pedal functionality. If found any issues, rectify it OR position in TDS. One of the pedal count will be half of
3
replace Acc. Pedal. Drive vehicle for 5 Kms and check for DTC another and it will be vary with respect to pedal position
but the ratio will be remain same.
4 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
5 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1002 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 1003 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2120-15: Accelerator Foot Pedal track1 sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2120-15 1. Faulty Wiring harness

2. Faulty sensor
CEL ON 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_T1_HI_APV

System Vehicle System / Accelerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 91 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1004 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Acceptance
Step Checkpoints Result Recommended Action Remark
criteria
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
3 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass No open circuit. Proceed to
open circuit, repeat step 4 for all applicable next step
4 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
5 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
6 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to next step
7 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
9 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1005 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check Accelerator Pedal Track 1, 2 and Accelerator pedal
position in TDS. One of the pedal count will be half of
1 If still issue persists, Replace Acc. Pedal Module and check for DTC
another and it will be vary with respect to pedal position
but the ratio will be remain same.
2 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
3 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1006 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1007 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1008 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2120-11: Accelerator Foot Pedal track1 sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2120-11 1. Faulty Wiring Harness

2. Faulty sensor
CEL ON 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_T1_LO_APV

System Vehicle System / Accelerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 91 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1009 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Acceptance
Step Checkpoints Result Recommneded Action Remark
criteria
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
3 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass No open circuit. Proceed to
open circuit, repeat step 4 for all applicable next step
4 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
5 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
6 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to next step
7 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
9 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1010 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check Accelerator Pedal Track 1, 2 and Accelerator pedal
position in TDS. One of the pedal count will be half of
1 If still issue persists, Replace Acc. Pedal Module and check for DTC
another and it will be vary with respect to pedal position
but the ratio will be remain same.
2 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
3 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1011 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1012 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1013 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2125-15: Accelerator Foot Pedal track2 sensor - Short to Battery or Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2125-15 1. Faulty Wiring harness

2. Faulty sensor
CEL ON 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_T2_HI_APV

System Vehicle System / Accelerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 29 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1014 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Acceptance
Step Checkpoints Result Recommneded Action Remark
criteria
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
3 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass No open circuit. Proceed to
open circuit, repeat step 4 for all applicable next step
4 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
5 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
6 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to next step
7 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
9 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1015 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check Accelerator Pedal Track 1, 2 and Accelerator pedal
position in TDS. One of the pedal count will be half of
1 If still issue persists, Replace Acc. Pedal Module and check for DTC
another and it will be vary with respect to pedal position
but the ratio will be remain same.
2 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
3 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1016 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1017 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1018 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2125-11: Accelerator Foot Pedal track2 sensor - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2125-11 1. Wiring harness issue

2. Faulty sensor
CEL ON 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_PEDAL_FOOT_T2_LO_APV

System Vehicle System / Accelerator Pedal

OBD Inducement Non-Inducement

SPN & FMI 29 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1019 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Acceptance
Step Checkpoints Result Recommneded Action Remark
criteria
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
3 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass No open circuit. Proceed to
open circuit, repeat step 4 for all applicable next step
4 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
5 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
6 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to next step
7 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
9 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1020 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check Accelerator Pedal Track 1, 2 and Accelerator pedal
position in TDS. One of the pedal count will be half of
1 If still issue persists, Replace Acc. Pedal Module and check for DTC
another and it will be vary with respect to pedal position
but the ratio will be remain same.
2 If still issue persists, Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
3 If still issue persists, Replace respective wiring harness
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1021 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1022 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1023 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0560-A3: Battery supply Voltage high fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0560-A3 1. Battery voltage is high

No Vehicle reaction
2. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_BATTERY_PBATT_HI_APV

System Vehicle System / Battery

OBD Inducement Non-Inducement

SPN & FMI 168 / 00

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1024 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the Battery voltage. Please check alternator HW & Wiring. If found Use Multi meter to check battery voltage. Voltage range -
1
any issue, please rectify it and check for DTC 16-32 V.
2 If still error persists, Replace battery
3 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1025 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1026 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1027 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0560-A2: Battery supply Voltage Low fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0560-A2 1. Battery voltage is low

No Vehicle reaction
2. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_BATTERY_PBATT_LO_APV

System Vehicle System / Battery

OBD Inducement Non-Inducement

SPN & FMI 168 / 01

Visit next 3 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1028 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the Battery voltage. Please check alternator HW & Wiring. If found Use Multi meter to check battery voltage. Voltage range -
1
any issue, please rectify it and check for DTC 16-32 V.
2 If still error persists, Replace battery
3 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1029 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1030 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1031 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2141-A3: Battery Voltage - Channel 2 voltage high failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wrong battery voltage output
Fault Code P2141-A3
2. Wrong alternator output
3. Faulty ECU
CEL ON 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_BOOST_VINJ_HI_APV

System Vehicle System / Battery

OBD Inducement Non-Inducement

SPN & FMI 2797 / 00

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the Battery voltage. Please check alternator HW & Wiring. If found Use Multi meter to check battery voltage. Voltage range -
1
any issue, please rectify it and check for DTC 16-32 V.
2 If still error persists, Replace battery
3 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2141-A2: Battery Voltage - Channel 2 voltage low failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2141-A2 1. Wrong battery voltage output

2. Wrong alternator output
CEL ON 3. Faulty ECU 1. 25 % Torque reduction

Fault System Summary:

Development Fault code F_M_BOOST_VINJ_LO_APV

System Vehicle System / Battery

OBD Inducement Non-Inducement

SPN & FMI 2797 / 01

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the Battery voltage. Please check alternator HW & Wiring. If found Use Multi meter to check battery voltage. Voltage range -
1
any issue, please rectify it and check for DTC 16-32 V.
2 If still error persists, Replace battery
3 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0703-12: Brake Safety Switch - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

1. Brake switch wiring harness connector pin
Fault Code P0703-12 short to battery
No Vehicle reaction
2. Faulty Brake Switch
CEL ON 3. Faulty EMS Brake Relay

Fault System Summary:

Development Fault code F_M_BRAKE_SAFETY_S2B_APV

System Vehicle System / Brake Switch

OBD Inducement Non-Inducement

SPN & FMI 597 / 03

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Pass None No electrical error
Actuator/ Routine test through TDS (if Successful perceived. Clear DTC
1 prompted) prompt from and Recheck
TDS Fail Proceed to next step
Verify fuse health (fuse-link continuity) Resistance less Pass Proceed to next step
2 as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as per Resistance less Pass Proceed to next step
4 Table-2 than 1.0 ohm Fail Identify the affected harness and
replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass No Open circuit, proceed to next
open circuit, repeat step 4 for all male- applicable step
5 female inline connector (Refer table Fail replace the faulty harness
Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
6 than 10.0 kohm Fail Identify the affected harness and
replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
7 Table-4 than 10.0 kohm Fail Identify the affected harness and
replace.
Shot-circuit-to-Ground as per Table-4 Resistance more Pass Proceed to next step
8 than 10.0 kohm Fail Identify the affected harness and
replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
9 connector end with all other remaining than 10.0 kohm Fail Identify the affected harness and
EMS specific circuits in wiring harness. replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female inline Resistance more Pass Harness is OK
connector with all other remaining than 10.0 kohm
circuits in same wiring harness.
10
(Ensure removal of component-side, Fail Replace the faulty harness
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check brake switch setting. If found any, rectify it.. Change connectors or
1 Adjust the Brake switch manually.
sensor if required. Check for DTC
Check EMS Brake Relay. Replace the EMS Brake relay if any issue
2 Use EMS Brake Relay with correct part number
observed.
3 If still issue persists, Replace Brake switch and check for DTC

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0504-64: Brake Switch & Safety Brake switch signals are not matching
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0504-64 1. Faulty Brake Switch

No Vehicle reaction
2. Faulty Wiring Harness
CEL ON

Fault System Summary:

Development Fault code F_M_BRAKE_SWITCH_COH_APV

System Vehicle System / Brake Switch

OBD Inducement Non-Inducement

SPN & FMI 597 / 09

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check the Electrical Connectivity (Open & Short Circuit) as per

1 Connectivity to be ensured as per Circuit diagram
methodology mentioned in “Electrical Trouble shooting Guide” below

Check Brake Switch, Brake Safety Switch, Brake Light switch parameters All Mentioned parameters will be pressed if Brake Pedal
2
through Tata Diagnostic Tool Pressed and will be Released if Brake pedal released.
Check EMS Brake relay for working, If found any issue use as per part
3
number
Check brake switch connector and Brake pedal free play If found any,
4 Adjust the Brake Pedal manually.
rectify it.. Change connectors or sensor if required. Check for DTC
5 If still issue persists, Replace Brake switch and check for DTC

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P083F-00: Clutch top & bottom switch signals are not coherent
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P083F-00 1. Wrong Clutch Switch Paly Setting

2. Wrong Clutch Switch No Vehicle reaction
3. Wrong wiring harness connection
CEL ON

Fault System Summary:

Development Fault code F_M_CLUTCH_COHERENCE_APV

System Vehicle System / Clutch Switch

OBD Inducement Non-Inducement

SPN & FMI 598 / 07

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check clutch switch setting. If found any, rectify it.. Change connectors or
1 Check both Top & Bottom switches
sensor if required. Check for DTC

Check the Electrical Connectivity (Open & Short Circuit) as per

2
methodology mentioned in “Electrical Trouble shooting Guide” below

Connect TDS and Check Clutch Switch Status. Clutch

Check Top & Bottom clutch switch states. If found any issues, rectify it / Switch state should be Engaged if Clutch Pedal not
3
replace switch. Check for DTC again Pressed and Clutch Switch state will be disengaged if
Clutch Pedal will be Pressed.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0830-29: Clutch Top Switch Signal Invalid

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0830-29 1. Wrong Clutch Switch Play Setting

2. Wrong Clutch Switch No Vehicle reaction
3. Faulty Wiring Harness
CEL ON

Fault System Summary:

Development Fault code F_M_CLUTCH_TOP_APV

System Vehicle System / Clutch Switch

OBD Inducement Non-Inducement

SPN & FMI 598 / 10

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommneded Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side Switch pressed Pass Proceed to next step Component electrical
CONTINUITY in Clutch Switch state: CLOSE check OK
3
contacts Switch un-pressed Fail Replace the part Clear DTC and recheck
state: OPEN ?
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Harness is OK
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
5
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
6 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
7 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to next step
8 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
9
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring Fail Replace the faulty harness
10 harness.
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Clutch switch status :
Check clutch switch setting. If found any, rectify it. Change connectors or
1 Engaged / False - If clutch pedal not pressed
sensor if required. Check for DTC
Disengaged / True - If clutch pedal pressed

Check the Electrical Connectivity (Open & Short Circuit) as per

2 Connectivity to be ensured as per Circuit diagram
methodology mentioned in “Electrical Trouble shooting Guide” below

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P1801-13: DPF Inhibit switch lamp - Open circuit failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P1801-13 2. Faulty Switch LED No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_DPF_INH_LAMP_OC_APV

System Vehicle System / DPF Inhibit switch lamp

OBD Inducement Non-Inducement

SPN & FMI 3695 / 05

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance Not applicable Pass Proceed to next step Component electrical
3 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Proceed to next step
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
5
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Check if short circuit in DPF Regen Resistance more Pass Proceed to next step
6 coupler pins other than intended than 10.0 kohm Fail Identify the affected harness
ones and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
8 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P1801-12: DPF Inhibit switch lamp - Short to Battery failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P1801-12 2. Faulty Switch LED No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_DPF_INH_LAMP_SC2V_APV

System Vehicle System / DPF Inhibit switch lamp

OBD Inducement Non-Inducement

SPN & FMI 3695 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommneded Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance Not applicable Pass Proceed to next step Component electrical
3 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Proceed to next step
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
5
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Check if short circuit in DPF Regen Resistance more Pass Proceed to next step
6 coupler pins other than intended than 10.0 kohm Fail Identify the affected harness
ones and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
8 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P1801-11: DPF Inhibit switch lamp - Short to Ground failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P1801-11 2. Faulty Switch No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_DPF_INH_LAMP_SC2G_APV

System Vehicle System / DPF Inhibit switch lamp

OBD Inducement Non-Inducement

SPN & FMI 3695 / 04

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Circuit diagram & Component images

Author: ERC Page 1066 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance Not applicable Pass Proceed to next step Component electrical
3 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Proceed to next step
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
5
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Check if short circuit in DPF Regen Resistance more Pass Proceed to next step
6 coupler pins other than intended than 10.0 kohm Fail Identify the affected harness
ones and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
8 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1067 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 1068 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1069 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P25BA-9E: DPF Regeneration Request Switch - Stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P25BA-9E 1. Wiring harness issue

2. Faulty Switch No Vehicle reaction
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_DPF_REGEN_SW_STK_APV

System Vehicle System / DPF Regen request switch

OBD Inducement Non-Inducement

SPN & FMI 3696 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1070 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance Not applicable Pass Proceed to next step Component electrical
3 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Proceed to next step
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
5
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Check if short circuit in DPF Regen Resistance more Pass Proceed to next step
6 coupler pins other than intended than 10.0 kohm Fail Identify the affected harness
ones and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
8 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1071 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 1072 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1073 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1074 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P260E-13: DPF Regeneration Request switch lamp - Open circuit failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P260E-13 2. Faulty Switch No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_DPF_SW_LMP_OC_APV

System Vehicle System / DPF Regen request switch lamp

OBD Inducement Non-Inducement

SPN & FMI 3696 / 05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1075 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance Not applicable Pass Proceed to next step Component electrical
3 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Proceed to next step
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
5
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Check if short circuit in DPF Regen Resistance more Pass Proceed to next step
6 coupler pins other than intended than 10.0 kohm Fail Identify the affected harness
ones and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
8 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1076 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 1077 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1078 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1079 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P260E-12: DPF Regeneration Request switch lamp - Short to Battery failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P260E-12 2. Faulty Switch No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_DPF_SW_LMP_SC2V_APV

System Vehicle System / DPF Regen request switch lamp

OBD Inducement Non-Inducement

SPN & FMI 3696 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1080 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance Not applicable Pass Proceed to next step Component electrical
3 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Proceed to next step
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
5
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Check if short circuit in DPF Regen Resistance more Pass Proceed to next step
6 coupler pins other than intended than 10.0 kohm Fail Identify the affected harness
ones and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
8 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1081 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 1082 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1083 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1084 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P260E-11: DPF Regeneration Request switch lamp - Short to Ground failure

Overview:

Fault Code Description Cause Effect on Vehicle

1. Wiring harness issue
Fault Code P260E-11 2. Faulty Switch No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_DPF_SW_LMP_SC2G_APV

System Vehicle System / DPF Regen request switch lamp

OBD Inducement Non-Inducement

SPN & FMI 3696 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1085 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance Not applicable Pass Proceed to next step Component electrical
3 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to next step
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Proceed to next step
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
5
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Check if short circuit in DPF Regen Resistance more Pass Proceed to next step
6 coupler pins other than intended than 10.0 kohm Fail Identify the affected harness
ones and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
8 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1086 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 1087 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1088 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1089 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0685-73: ECU Power relay stuck fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty ECU main relay
Fault Code P0685-73 2. Faulty Wiring Harness
3. Improper Power latch (Battery cut off done
before power latch) No Vehicle reaction
4. Calibration flashed but Error not cleared
CEL ON
5. Low Battery/discharged battery
6. Faulty ECU

Fault System Summary:

Development Fault code F_M_STUCK_CU_RELAY_APV

System Vehicle System / ECU Power Relay

OBD Inducement Non-Inducement

SPN & FMI 1485 / 07

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1090 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 200 to 500 Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1091 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and Use Multi meter to check battery voltage. Voltage range -
1
check for DTC 16-32 V.
Check Main relay & Power hold relay. If found any issue, Replace the
2
relay. Clear DTC & Check for DTC
Minimum 30 sec required to do the Battery cut off after
3 Ensure Battery cutoff not done, immediately after ignition OFF
ignition off.
Ensure if EMS ECU calibration then errors needs to be cleared through
4 Connect TDS and clear EMS errors.
Tata Diagnostic Tool
Check the Electrical Connectivity (Open & Short Circuit) as per
5
methodology mentioned in “Electrical Trouble shooting Guide” below
6 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1092 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1093 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0685-13: ECU Power relay electrical fault - Open Circuit

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring Harness
Fault Code P0685-13 2. Faulty ECU main relay
No Vehicle reaction
3. Faulty ECU
CEL ON 4. Low Battery/worn out battery

Fault System Summary:

Development Fault code F_M_DROPOUT_CU_RELAY_APV

System Vehicle System / ECU Power Relay

OBD Inducement Non-Inducement

SPN & FMI 1485 / 05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1094 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 200 to 500 Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Check the battery voltage. If battery voltage is out of range, rectify it and Use Multi meter to check battery voltage. Voltage range -
1
check for DTC 16-32 V.
Check Main relay & Power hold relay. If found any issue, Replace the
2
relay. Clear DTC & Check for DTC
Minimum 30 sec required to do the Battery cut off after
3 Ensure Battery cutoff not done, immediately after ignition OFF
ignition off.
Ensure if EMS ECU calibration then errors needs to be cleared through
4 Connect TDS and clear EMS errors.
Tata Diagnostic Tool
Check the Electrical Connectivity (Open & Short Circuit) as per
5
methodology mentioned in “Electrical Trouble shooting Guide” below
6 Re-flash ECU dataset and check for DTC again Select dataset as per Vehicle configuration(VC)
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0380-13: Glow Plug - Circuit Open

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness
Fault Code P0380-13 2. Faulty Glow plug No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_GLOW_PLUG_OC_APV

System Vehicle System / Glow Plug Monitor

OBD Inducement Non-Inducement

SPN & FMI 7576 / 05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1098 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0380-12: Glow plug - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness
Fault Code P0380-12 2. Faulty Glow plug No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_GLOW_PLUG_SC_APV

System Vehicle System / Glow Plug Monitor

OBD Inducement Non-Inducement

SPN & FMI 7576 / 03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0380-11: Glow plug - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

1. Faulty Wiring harness
Fault Code P0380-11 2. Faulty Glow plug No Vehicle reaction
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_GLOW_PLUG_SC2G_APV

System Vehicle System / Glow Plug Monitor

OBD Inducement Non-Inducement

SPN & FMI 7576 / 04

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0650-13: MIL Lamp - Open Circuit

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0650-13 1. Faulty Wiring harness

MIL self check at Ignition ON will not be
2. Faulty cluster
seen
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_ICI_MI_LAMP_OC_APV

System Vehicle System / MIL

OBD Inducement Non-Inducement

SPN & FMI 1213 / 05

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommneded Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to step 5
3 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace, proceed to step 4
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Harness is OK. Proceed to step
open circuit, repeat step 4 for all applicable 5
4 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
5 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
6 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK.
inline connector with all other than 10.0 kohm
remaining circuits in same wiring Fail Replace the faulty harness
8 harness.
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

1 If still issue persists, Replace MIL relay and check for DTC
2 If still issue persists, Replace Instrument cluster and check for DTC

3 If still issue persists, Replace respective wiring harness and check for DTC

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1110 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0650-12: MIL lamp - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0650-12 1. Faulty Wiring harness

MIL will be OFF, MI Lamp Self check will not
2. Faulty cluster
be seen at Ignition ON
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_ICI_MI_LAMP_SC_APV

System Vehicle System / MIL

OBD Inducement Non-Inducement

SPN & FMI 1213 / 03

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Circuit diagram & Component images

Author: ERC Page 1112 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to step 5
3 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace, proceed to step 4
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Harness is OK. Proceed to step
open circuit, repeat step 4 for all applicable 5
4 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
5 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
6 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK.
inline connector with all other than 10.0 kohm
remaining circuits in same wiring Fail Replace the faulty harness
8 harness.
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

1 If still issue persists, Replace MIL relay and check for DTC
2 If still issue persists, Replace Instrument cluster and check for DTC

3 If still issue persists, Replace respective wiring harness and check for DTC

Perform following services in TDS:

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

Author: ERC Page 1114 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1115 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1116 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0650-11: MIL Lamp - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0650-11 1. Faulty Wiring harness

MI Lamp will be continuously ON, MI lamp
2. Faulty cluster
self-check pattern will not be seen.
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_ICI_MI_LAMP_SC2G_APV

System Vehicle System / MIL

OBD Inducement Non-Inducement

SPN & FMI 1213 / 04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1117 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to step 5
3 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace, proceed to step 4
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Harness is OK. Proceed to step
open circuit, repeat step 4 for all applicable 5
4 male-female inline connector (Refer Fail replace the faulty harness
table Table-3)

At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to next step
5 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to next step
6 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
7
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK.
inline connector with all other than 10.0 kohm
remaining circuits in same wiring Fail Replace the faulty harness
8 harness.
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

1 If still issue persists, Replace MIL relay and check for DTC
2 If still issue persists, Replace Instrument cluster and check for DTC

3 If still issue persists, Replace respective wiring harness and check for DTC

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1120 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P081D-24: Neutral Gear Switch signal stuck close fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Switch not present
2. Faulty Wiring Harness
Fault Code P081D-24 No Vehicle reaction
3. Switch malfunction
4. Faulty Gearbox

Fault System Summary:

Development Fault code F_M_NEUTRAL_STK_CL_APV

System Vehicle System / Neutral gear switch

OBD Inducement Non-Inducement

SPN & FMI 604 / 20

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1122 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to Next step
Verify fuse health (fuse-link Resistance less Pass Pr Proceed to Next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to Next step
3 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Harness is OK
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
4
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to Next step
5 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to Next step
6 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to Next step
7 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to Next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
9 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, Replace Neutral switch. Start engine and check for
1
DTC
If still issue persists, Replace respective wiring harness. Start engine and
2
check for DTC
If still issue persists, check any mechanical damage of gearbox. If found
3
any, rectify it and start engine. Check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1124 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Location and Component Image:

Author: ERC Page 1125 of 1261

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 Version: 1.3
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Date: 21-01-2025

Author: ERC Page 1126 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P081D-23: Neutral Gear Switch signal Stuck open fault

Overview:

Fault Code Description Cause Effect on Vehicle

1. Switch not present
Will not Indicate Neutral Indication
2. Faulty Wiring Harness
Fault Code P081D-23 correctly on Vehicle
3. Switch malfunction Will affect starting of vehicle
4. Faulty Gearbox

Fault System Summary:

Development Fault code F_M_NEUTRAL_STK_OP_APV

System Vehicle System / Neutral gear switch

OBD Inducement Non-Inducement

SPN & FMI 604 / 21

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1127 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to Next step
Verify fuse health (fuse-link Resistance less Pass Pr Proceed to Next step
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to Next step
3 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Harness is OK
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
4
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to Next step
5 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to Next step
6 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to Next step
7 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to Next step
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
9 harness. Fail Replace the faulty harness
(Ensure removal of component-side,
EMS ECU side couplers & inline
connector shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

A. Other Interface Integrity Checks

Sr. No. Steps Specifications

If still issue persists, Replace Neutral switch. Start engine and check for
1
DTC
If still issue persists, Replace respective wiring harness. Start engine and
2
check for DTC
If still issue persists, check any mechanical damage of gearbox. If found
3
any, rectify it and start engine. Check for DTC
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
4 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1129 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1130 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1131 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0615-13: Start relay - Circuit Open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0615-13 1. Wiring harness issue

2. Faulty Relay Vehicle will not start
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_SR_LSD_OC_APV

System Vehicle System / Start Relay

OBD Inducement Non-Inducement

SPN & FMI 677 / 05

Visit next 3 page(s) for Troubleshooting steps,

& Circuit diagram

Author: ERC Page 1132 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance 100 to 500 Ohm Pass Proceed to step 4 Component electrical
3 (Starter Relay) check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to step 5
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Harness is OK
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
5
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to step 7
6 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to step 8
7 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to step 9
8 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to step 10
connector end with all other than 10.0 kohm Fail Identify the affected harness
9
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
10 harness. Fail Replace the faulty harness
(Ensure removal of component-side, EMS
ECU side couplers & inline connector
shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1133 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 1134 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1135 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0615-F2: Start relay - Short to Battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0615-F2 1. Wiring harness faulty

2. Faulty Relay Vehicle will not start
3. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_SR_LSD_SC2V_APV

System Vehicle System / Start Relay

OBD Inducement Non-Inducement

SPN & FMI 6385 / 03

Visit next 3 page(s) for Troubleshooting steps,

& Circuit diagram

Author: ERC Page 1136 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance 100 to 500 Ohm Pass Proceed to step 4 Component electrical
3 (Starter Relay) check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to step 5
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Harness is OK
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
5
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to step 7
6 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to step 8
7 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to step 9
8 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to step 10
connector end with all other than 10.0 kohm Fail Identify the affected harness
9
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
10 harness. Fail Replace the faulty harness
(Ensure removal of component-side, EMS
ECU side couplers & inline connector
shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1137 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 1138 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1139 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0615-F3: Start relay - Short to Ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0615-F3 4. Wiring harness faulty

5. Faulty Relay Vehicle will not start
6. Faulty ECU
CEL ON

Fault System Summary:

Development Fault code F_M_SR_LSD_SC2G_APV

System Vehicle System / Start Relay

OBD Inducement Non-Inducement

SPN & FMI 6385 / 04

Visit next 3 page(s) for Troubleshooting steps,

& Circuit diagram

Author: ERC Page 1140 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1 than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
At Ignition Off & remove component side coupler only
Measure Component side resistance 100 to 500 Ohm Pass Proceed to step 4 Component electrical
3 (Starter Relay) check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass Proceed to step 5
4 per Table-2 than 1.0 ohm Fail Identify the affected harness
and replace.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
To identify the affected harness for Refer steps 4 as Pass Harness is OK
open circuit, repeat step 4 for all applicable Fail replace the faulty harness
5
male-female inline connector (Refer
table Table-3)
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass Proceed to step 7
6 than 10.0 kohm Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass Proceed to step 8
7 Table-4 than 10.0 kohm Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass Proceed to step 9
8 4 than 10.0 kohm Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass Proceed to step 10
connector end with all other than 10.0 kohm Fail Identify the affected harness
9
remaining EMS specific circuits in and replace.
wiring harness.
At Ignition Off & removal of component-side, EMS ECU side couplers & inline connectors
Short Circuit test at male/female Resistance more Pass Harness is OK
inline connector with all other than 10.0 kohm
remaining circuits in same wiring
10 harness. Fail Replace the faulty harness
(Ensure removal of component-side, EMS
ECU side couplers & inline connector
shown in circuit diagram)
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1141 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

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

Author: ERC Page 1142 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1143 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0500-31: Vehicle speed sensor - Signal loss during vehicle driving

Overview:

Fault Code Description Cause Effect on Vehicle

1. Sensor not connected
Fault Code P0500-31 2. Wiring harness faulty
3. Instrument cluster Issues No Vehicle reaction
4. Sensor is faulty
CEL ON 5. Faulty ECU

Fault System Summary:

Development Fault code F_M_VSS_SIGNAL_LOSS_APV

System Vehicle System / Vehicle speed sensor

OBD Inducement Non-Inducement

SPN & FMI 1624 / 07

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1144 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per below referring to schematic: than 1.0 ohm next step
1. VSS signal (3) to Fail Identify the affected harness
Instrument Cluster VSS and replace.
input
2. Instrument Cluster Speed
3
Output (17) to EMS ECU
Speed Input (31)
3. Speed Sensor supply (1) to
Instrument Cluster Supply
4. Speed Sensor Ground (2)
to Battery negative
At Ignition Off & removal of both component-side, EMS ECU side couplers
Check for undesired Short Circuit to Resistance more Pass No short circuit. Proceed to
other pins in Speed Sensor than 10.0 kohm next step.
4
connector Fail Identify the affected harness
and replace.
Check for undesired Short Circuit to Resistance more Pass No short circuit(SCB). Proceed
other pins in Instrument Cluster than 10.0 kohm to next step.
5
connector Fail Identify the affected harness
and replace.
Check for undesired Short Circuit to Resistance more Pass Harness is OK
6 other pins in EMS ECU V-connector than 10.0 kohm Fail Identify the affected harness
(91-pin coupler) and replace.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1145 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Ensure Vehicle Speed showing in Instrument Cluster during vehicle
1 running, If vehicle speed showing on cluster then Vehicle speed sensor
and wiring harness up to Instrument cluster is as desired
Connect Tata Diagnostic Tool, Select Vehicle speed from Single
Vehicle speed in EMS data should change with respect to
2 parameters and ensure vehicle speed is received to EMS ECU during
vehicle movement.
vehicle running.
If Vehicle speed not observed in EMS data, then check electrical
3 Refer schematic diagram
connection between Instrument cluster and EMS ECU.
If electrical connection observed as per schematic, then write EMS
4 Connect CVBU reprogramming tool and Flash EMS ECU.
variant data.

5 If still issue persists, Replace Instrument cluster Use new Instrument cluster based on VC number.
If Vehicle speed not showing in Instrument cluster during driving, then
6 check Vehicle speed sensor electrical connection and vehicle speed Refer schematic diagram
sensor.
If any issue observed in wiring harness continuity, repair the wiring
7 Refer schematic diagram
harness or replace it based on the wiring harness condition.
If wiring harness continuity observed as desired, check vehicle speed
8 sensor physical damage, if any issue observed replace it & Check for DTC
during vehicle running.
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
9 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1146 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1147 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1148 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0500-01: Vehicle speed sensor - Signal not valid / Sensor not connected
Overview:

Fault Code Description Cause Effect on Vehicle

1. Vehicle Speed Sensor not connected

Fault Code P0500-01 2. Wiring harness faulty
3. Faulty Vehicle Speed Sensor
4. Other HW issues like ETV failure,
Injector failure, DPF failures
CEL ON 1. Poor Pickup
5. Faulty ECU

Fault System Summary:

Development Fault code F_M_VSS_CONSISTENCY_APV

System Vehicle System / Vehicle speed sensor

OBD Inducement Non-Inducement

SPN & FMI 1624 / 02

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1149 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per below referring to schematic: than 1.0 ohm next step
5. VSS signal (3) to Fail Identify the affected harness
Instrument Cluster VSS and replace.
input
6. Instrument Cluster Speed
3
Output (17) to EMS ECU
Speed Input (31)
7. Speed Sensor supply (1) to
Instrument Cluster Supply
8. Speed Sensor Ground (2)
to Battery negative
At Ignition Off & removal of both component-side, EMS ECU side couplers
Check for undesired Short Circuit to Resistance more Pass No short circuit. Proceed to
other pins in Speed Sensor than 10.0 kohm next step.
4
connector Fail Identify the affected harness
and replace.
Check for undesired Short Circuit to Resistance more Pass No short circuit(SCB). Proceed
other pins in Instrument Cluster than 10.0 kohm to next step.
5
connector Fail Identify the affected harness
and replace.
Check for undesired Short Circuit to Resistance more Pass Harness is OK
6 other pins in EMS ECU V-connector than 10.0 kohm Fail Identify the affected harness
(91-pin coupler) and replace.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1150 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Ensure Vehicle Speed showing in Instrument Cluster during vehicle
1 running, If vehicle speed showing on cluster then Vehicle speed sensor
and wiring harness up to Instrument cluster is as desired
Connect Tata Diagnostic Tool, Select Vehicle speed from Single
Vehicle speed in EMS data should change with respect to
2 parameters and ensure vehicle speed is received to EMS ECU during
vehicle movement.
vehicle running.
If Vehicle speed not observed in EMS data, then check electrical
3 Refer schematic diagram
connection between Instrument cluster and EMS ECU.
If electrical connection observed as per schematic, then write EMS
4 Connect CVBU reprogramming tool and Flash EMS ECU.
variant data.

5 If still issue persists, Replace Instrument cluster Use new Instrument cluster based on VC number.
If Vehicle speed not showing in Instrument cluster during driving, then
6 check Vehicle speed sensor electrical connection and vehicle speed Refer schematic diagram
sensor.
If any issue observed in wiring harness continuity, repair the wiring
7 Refer schematic diagram
harness or replace it based on the wiring harness condition.
If wiring harness continuity observed as desired, check vehicle speed
8 sensor physical damage, if any issue observed replace it & Check for DTC
during vehicle running.
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
9 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1151 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1152 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1153 of 1261

Copyright by TATA MOTORS Ltd.

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2226-04: ECU Barometric Sensor Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2226-04

1. Barometric pressure sensor fitted on the ECU

is not working.
CEL ON
MIL MIL ON 1. No Vehicle reaction
for 15 S

Fault System Summary:

Development Fault code F_M_BARO_CONT_DG_APV & F_M_BARO_STRTUP_DG_APV

System ECU/ Barometric Sensor

OBD Inducement Non-Inducement

SPN & FMI 108 / 12

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0641-08: ECU 5V Channel Communication Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0641-08

1. Failure of Microcontroller inside ECU for
Injector.
1. No Pedal Response
CEL ON
2. Engine Speed increased 1300 rpm

Fault System Summary:

Development Fault code F_M_VEXT_SPI_C3PS_APV

System ECU/ Microcontroller

OBD Inducement Non-Inducement

SPN & FMI 00 / 00

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P06D2-00: ECU Internal 5V Supply Channel Failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P06D2-00

1. Failure of Microcontroller inside ECU
2. Faulty ECU
1. No Pedal Response.
CEL ON
2. Idle RPM increased to 1200

Fault System Summary:

Development Fault code F_M_VEXT_VCC_APV & F_M_T_SHTDWN_VCC_APV

System ECU/ Microcontroller

OBD Inducement Non-Inducement

SPN & FMI 3513 / 12

Visit next 2 page(s) for Troubleshooting steps,

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Use Tata Flashing tool & correct VC number for ECU

1 Re-flash the ECU through Tata flashing tool
flashing.

1. Take New ECU & Select Blank ECU flashing

having no access to older Ecu.
2. Use correct VC number for flashing.
3. After successful flashing, Write VIN (Chassis
2 If still faults persists, replace ECU.
Number) & VC number in the ECU through TDS
Tool in Write Data
4. Write the Injector I3C codes fitted on engine

3 Please check error after engine starting

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0520-12: Engine oil pressure sensor short to battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0520-12

1. Faulty wiring harness
2. Oil Pressure Sensor switch faulty
3. Faulty ECU
CEL ON 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OIL_PRESS_CNTS_HI_APV

System Wiring Harness/ Oil Pressure Sensor/ ECU

OBD Inducement Non-Inducement

SPN & FMI 100/03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If problem persists, replace with a new oil pressure sensor & check the
1
error after engine starting

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1166 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

OIL Pressure & Temperature sensor

TML Part No: 5709 1522 01 02

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0520-14: Engine oil pressure sensor short to ground or open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0520-14

1. Faulty wiring harness
2. Oil Pressure Sensor switch faulty
3. Faulty ECU
CEL ON 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OIL_PRESS_CNTS_LO_APV

System Wiring Harness/ Oil Pressure Sensor/ ECU

OBD Inducement Non-Inducement

SPN & FMI 100/04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1168 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If problem persists, replace with a new oil pressure sensor & check the
1
error after engine starting

Perform following services in TDS:

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

Author: ERC Page 1170 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1171 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

OIL Pressure & Temperature sensor

TML Part No: 5709 1522 01 02

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0195-15: Engine Oil temp Sensor short to battery or open

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0195-15

1. Faulty wiring harness
2. Oil Temperature Sensor faulty
3. Faulty ECU
CEL ON 1. Delayed Torque Reduction

Fault System Summary:

Development Fault code F_M_OIL_TEMP_SENS_HI_APV

System Wiring Harness/ Oil Temperature Sensor/ ECU

OBD Inducement Non-Inducement

SPN & FMI 175/03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1173 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1174 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If problem persists, replace with a new oil temperature sensor & check
1
the error after engine starting

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

OPEN CKT CHECK MATRIX SHORT CKT CHECK MATRIX

EGR PIN Continuty EMS ECU Pin EGR PIN 1 2 3 4 5 6 BATT GND
1 <--------> 89 1 NA SC NC SC SC SC SCB SCG
2 <--------> 94 2 SC NA NC SC SC SC SCB SCG
3 <--------> NC 3 NC NC NA NC NC NC NC NC
4 <--------> 10 4 SC SC NC NA SC SC SCB SCG
5 <--------> 68 5 SC SC NC SC NA SC SCB SCG
6 <--------> 51 6 SC SC NC SC SC NA SCB SCG
TABLE-2 TABLE-3

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

OIL Pressure & Temperature sensor

TML Part No: 5709 1522 01 02

Author: ERC Page 1177 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0195-11: Engine Oil temp sensor short to ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0195-11

1. Faulty wiring harness
2. Oil Temperature Sensor faulty
3. Faulty ECU
CEL ON 1. Delayed Torque Reduced

Fault System Summary:

Development Fault code F_M_OIL_TEMP_SENS_LO_APV

System Wiring Harness/ Oil Temperature Sensor/ ECU

OBD Inducement Non-Inducement

SPN & FMI 175/04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1178 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1179 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If problem persists, replace with a new oil temperature sensor & check
1
the error after engine starting

Perform following services in TDS:

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

Author: ERC Page 1180 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1181 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

OIL Pressure & Temperature sensor

TML Part No: 5709 1522 01 02

Author: ERC Page 1182 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2CEF-13: Oil Thermostat Open Circuit Fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2CEF-13

1. Faulty wiring harness
2. Faulty Oil Thermostat
3. Faulty ECU
CEL ON 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OIL_THRMST_OC_APV

System Wiring Harness/ Oil Thermostat/ ECU

OBD Inducement Non-Inducement

SPN & FMI 4813/05

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1183 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1184 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If problem persists, replace with a new oil thermostat & check the error
1
after engine starting

Perform following services in TDS:

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

Author: ERC Page 1185 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1186 of 1261

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Location and Component Image:

OIL Thermostat

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P2CEF-11: Oil Thermostat short circuit to ground

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2CEF-11 1. Faulty wiring harness

2. Faulty Oil Thermostat
3. Faulty ECU
CEL ON 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OIL_THRMST_SC2G_APV

System Wiring Harness/ Oil Thermostat/ ECU

OBD Inducement Non-Inducement

SPN & FMI 4813/04

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 5 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If problem persists, replace with a new oil thermostat & check the error
1
after engine starting

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

OIL Thermostat

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P2CEF-12: Oil Thermostat short circuit to battery

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P2CEF-12

1. Faulty wiring harness
2. Faulty Oil Thermostat
3. Faulty ECU
CEL ON 1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_OIL_THRMST_SC2V_APV

System Wiring Harness/ Oil Thermostat/ ECU

OBD Inducement Non-Inducement

SPN & FMI 4813/03

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance xxx Ohm Pass Proceed to step 4 Component electrical
3 Between pin 1 & 2 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

If problem persists, replace with a new oil thermostat & check the error
1
after engine starting

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

OIL Thermostat

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

U0676-56: Fuel Tank Signal Invalid

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code U0676-56

1. AFT Fuse blown
2. No Fuel available in Fuel Tank
3. Faulty Fuel Level Sensor
1. No Vehicle reaction

Fault System Summary:

Development Fault code F_M_FUEL_SIGNAL_INVALID_APV.

System CAN errors /Fuel Tank Level / ECU

OBD Inducement Non-Inducement

SPN & FMI 516238/19

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to next step
Verify fuse health (fuse-link Resistance less Pass Proceed to next step
continuity) than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
2
REV Lamp/REV Horn fuse in cabin
fuse box
At Ignition Off & removal of both FuelLevelSensor/AFTSensor-side and Instrument Cluster side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per as per below: than 1.0 ohm next step
Ignition-Switch  Fuel Level Fail Identify the affected harness
Sensor 1 and replace.
3 Fuel Level Sensor 2  Ground/
Battery negative
Fuel Level Sensor 3  Instrument
Cluster 1

At Ignition Off & removal of both AFT/FuelLevelSensor-side, Instrument Cluster side couplers
Short Circuit checks Resistance more Pass No short circuit. Proceed to
Check for undesired shorts at Fuel than 10.0 kohm next step.
4
Level Sensor 2 pin and at Instrument Fail Identify the affected harness
Cluster 1 pin and replace.
short-circuit-to-batt checks : Resistance more Pass No short circuit(SCB). Proceed
At Level Sensor 2 pin and at than 10.0 kohm to next step.
5
Instrument Cluster 1 pin Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground : Resistance more Pass No short circuit(SCG). Harness
At Level Sensor 2 pin and at than 10.0 kohm is OK
6
Instrument Cluster 1 pin Fail Identify the affected harness
and replace.
Note :- After ignition off wait for 2 minutes before taking next step

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B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Ensure sufficient fuel available in the tank. If fuel level observed low Minimum 20 % fuel should be available for smooth
1
refill fuel running.

Check if Engine RPM reflects in Instrument Cluster Engine RPM Gauge.

2 If not reflecting, please check for CAN related DTCs in GDCU and rectify
those.

If still problem persists. Remove the fuel level sensor from the tank,
3 move the float position by hand & check the fuel level in cluster. If still
problem persists replace the Fuel level sensor with correct part number.

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Circuit Schematic Diagram:

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 Version: 1.3
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Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

U0121- 21: Data Not Received ON TSC 1 CAN

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code U021-21

1. PTO or Any External CAN data not
received on the specified time
2. ABS ECU not connected
1. No Vehicle reaction for normal
3. Faulty External PTO or TSC 1 controller
operation
2. P.T.O will not work

Fault System Summary:

Development Fault code F_M_TSC1_TIMEOUT_APV_5.

System CAN errors /External Controller Error / ABS ECU connection issue

OBD Inducement Non-Inducement

SPN & FMI 3349/19

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Circuit diagram & Component images

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TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps: Electrical Interface Integrity Checks For PCAN

Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
At Ignition ON & w/o disconnecting any coupler
Verify fuse health (fuse-link continuity) as Resistance less Pass Proceed to next step
1 per Table-1 & Cabin fuse box for GDCU, IC & than 1.0 ohm Fail Replace the fuse as per fuse Clear DTC and
VECU Fuses box sticker rating recheck
Ignition off (wait for 2 min), Disconnect Battery negative post & remove ABS from coupler
Measure the resistance between Pin 1 & 3 Of 60Ohm ± 10% Pass Proceed to Step number 7 No issue in Stub
2 15 pole Harness connector of ABS/ESC ECU. & end node
Fail Proceed to next step 3
Ignition off (wait for 2 min), Connect ABS ECU, Disconnect Battery negative post & Term Resistor 1 (Near DCU)
Pass Replace Term Resistor 1 Term Resistor 1
Measure the resistance at harness side faulty
3 120 Ohm ± 10%
coupler of Term Resistor 1 Pin A & B Fail Proceed to next step 4
Ign off (wait for 2 min), Disconnect Battery negative post, Connect Term Resistor 1(Near DCU) & remove Term Resistor 2 (Near SAS)
Pass Replace Term Resistor 2 Term Resistor 2
Measure the resistance at harness side faulty
4 120 Ohm ± 10%
coupler of Term Resistor 2 Pin A & B Fail Proceed to next step 5
Ignition off (wait for 2 min), Disconnect Battery negative post & Disconnect stub 1 by 1 as mentioned in Table-5(except Term Resistor 2)
Failure Identify and replace the Stub Component
Case 1 component which removal faulty
Measure & monitor the resistance at harness leads to 120 Ohm resistance
5 side coupler of Term Resistor 1(Near DCU) 120 Ohm ± 10% criteria.
Pin A & B to identify the faulty node/stub Failure Even after removal of all the
Case 2 stub still issue persist
proceed for step 6

Ignition off (wait for 2 min), Disconnect Battery negative post & all the stubs/node coupler present on CAN BUS
Open circuit (Continuity) Checks IN CAN HI of Resistance less Pass Proceed to next step 7 No Open circuit
Terminating node and all other stub/node than 1.0 ohm in CAN HI
6
(refer table 5) CAN HI at wiring harness side Fail Identify the Faulty Harness at
Step 8
Open circuit (Continuity) Checks IN CAN LO Resistance less Pass Proceed to step 9 No Open circuit
of Terminating node and all other stub/node than 1.0 ohm in CAN BUS
7
(refer table 5) CAN LO at wiring harness side Fail Identify the Faulty Harness at
Step 8
Ignition off (wait for 2 min), Disconnect Battery negative post, inline connector & all the Stubs/Node coupler present on CAN BUS
To identify the affected harness for open Resistance less Pass No open circuit. Proceed to
8 circuit, repeat step 6 &7 for all male-female than 1.0 ohm next step
inline connector Fail replace the faulty harness

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Acceptance
Checkpoints Result Recommended Action Remark
Step criteria
Ignition off, Disconnect - Battery negative post & all the Stubs/Node coupler present on CAN BUS
Short circuit Checks between Wiring Resistance more Pass Proceed to Step 10 No SC in CAN HI &
harness side CAN HI and CAN LO of Term than 10.0 kohm CAN LO
9
Resistor Pin A & B. Fail Identify the Faulty Harness at
Step 12
Short circuit to Ground to be Check at Resistance more Pass Proceed to Step 11
wiring Harness side for both CAN HI and than 10.0 kohm Fail Identify the Faulty Harness at
10
CAN LO of Term Resistor Pin A & B Step 12
with respect to Battery -Ve Terminal
Short circuit to Battery to be Check at Resistance more Pass Harness is OK Term Resistor 2 to be
Wiring Harness for both CAN HI and CAN than 10.0 kohm checked at bench
11 LO of Term Resistor Pin A & B with level and replace
respect to Battery +Ve Terminal Fail Identify the Faulty Harness at
Step 12
Ignition off , Disconnect - Battery negative post, all the Stubs/Node coupler present on CAN BUS & inline Connector
Short Circuit test at male/female inline Resistance more Pass Harness is OK Term Resistor 2 to be
connector with all other remaining than 10.0 kohm checked at bench
12 circuits in same wiring harness. level and replace
Fail Replace the faulty harness
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
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Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0575-23: Cruise INC(+)-DEC(-) Switch Fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0575-23 1. Cruise INC(+) and DEC (-) switch Cruise will not work
operating at the same time
2. Faulty Cruise Switch
3. Faulty Wiring Harness

Fault System Summary:

Development Fault code F_M_CRUISE_ACL_DCL_SW_APV

System Cruise Switch

OBD Inducement Non-Inducement

SPN & FMI 602/31

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps: Electrical Interface Integrity Checks For Cruise Circuit

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side contact Resistance more Pass Proceed to step 4 Component electrical
3 shorts between ACL and DCL pin than 10 kohm check OK
terminals in Combi Switch Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0570-23: Cruise INC(+) Switch Stuck Fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0575-23 1. Cruise INC(+) switch reporting ON state Cruise will not work
for more than 10s
2. Faulty Cruise Switch
3. Faulty Wiring Harness

Fault System Summary:

Development Fault code F_M_CRUISE_ACL_SW_STK_APV

System Cruise Switch

OBD Inducement Non-Inducement

SPN & FMI 602/07

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Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps: Electrical Interface Integrity Checks For Cruise Circuit

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side contact Resistance more Pass Proceed to step 4 Component electrical
shorts between these terminals in than 10 kohm check OK
3 combi switch Fail Replace the part Clear DTC and recheck
a) INC and COMM pin
b) INC and CRUISE ON pin
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
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Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P056C-23: Cruise RES Switch Stuck Fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P056C-23 1. Cruise RES switch reporting ON state for Cruise will not work
more than 10s
2. Faulty Cruise Switch
3. Faulty Wiring Harness

Fault System Summary:

Development Fault code F_M_CRUISE_CANCEL_STK_APV

System Cruise Switch

OBD Inducement Non-Inducement

SPN & FMI 5603/07

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps: Electrical Interface Integrity Checks For CRUISE Circuit

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side contact Resistance more Pass Proceed to step 4 Component electrical
shorts between these terminals in than 10 kohm check OK
3 combi switch Fail Replace the part Clear DTC and recheck
a) RES and COMM pin
b) RES and CRUISE ON pin
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1214 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1215 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0569-23: Cruise DEC(-) Switch Stuck Fault

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0569-23 1. Cruise DEC(-) switch reporting ON state Cruise will not work
for more than 10s
2. Faulty Cruise Switch
3. Faulty Wiring Harness

Fault System Summary:

Development Fault code F_M_CRUISE_DCL_SW_STK_APV

System Cruise Switch

OBD Inducement Non-Inducement

SPN & FMI 602/07

Visit next 2 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1216 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps: Electrical Interface Integrity Checks For Cruise Circuit

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side contact Resistance more Pass Proceed to step 4 Component electrical
shorts between these terminals in than 10 kohm check OK
3 combi switch Fail Replace the part Clear DTC and recheck
a) DEC and COMM pin
b) DEC and CRUISE ON pin
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1217 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1218 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P1575- 47: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P1575-47 1. Old EMS Software version
Cruise Control Deactivation
CEL ON 2. Faulty ECU hardware

Fault System Summary:

Development Fault code F_M_ESM_CRUISE_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516283/19

Visit next 2 page(s) for Troubleshooting steps

& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 1220 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P1575-48: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P1575-48 1. Old Software version Reduced torque activation & Cruise control
CEL ON 2. Faulty ECU hardware deactivation

Fault System Summary:

Development Fault code F_M_ESM_CRUISE_OFF_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 516222 / 12

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 1222 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 1223 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1224 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P061C-00: Internal Control Module Engine RPM Performance

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P061C-00 1. Old Software
Reduced torque activation
CEL ON 2. Faulty ECU

Fault System Summary:

Development Fault code F_M_ESM_ENG_SPD_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 00/00

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 1225 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 1226 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1227 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0607- 45: Control Module Performance

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0607-45 1. Old Software Engine Off demand / Starter Off demand
CEL ON 2. Faulty ECU /CAN & Fuel Pump Off demand affected

Fault System Summary:

Development Fault code F_M_ESM_L2_QM_SCHED_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 00/00

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 1228 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 1229 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060A-00: Internal Control Module Monitoring Processor Performance

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060A-00 1. Old Software
No effect
CEL ON 2. Faulty ECU

Fault System Summary:

Development Fault code F_M_ESM_MM_TRIP_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 00/00

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 1231 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 1232 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P060D-47: Internal Control Module Accelerator Pedal Position Performance

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P060D-47 1. Old Software Reduced torque and Cruise Control
CEL ON 2. Faulty ECU Deactivation

Fault System Summary:

Development Fault code F_M_ESM_PEDAL_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 00/00

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 1234 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 1235 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1236 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P062B-47: Internal Control Module Fuel Injector Control Performance

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P062B-47 1. Old Software Reduced torque and Cruise Control
CEL ON 2. Faulty ECU Deactivation

Fault System Summary:

Development Fault code F_M_ESM_PLS_CHECK_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 00/00

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 1237 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 1238 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P062B-2B: Internal Control Module Fuel Injector Control Performance

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P062B-2B 1. Old Software Reduced torque and Cruise Control
CEL ON 2. Faulty ECU Deactivation

Fault System Summary:

Development Fault code F_M_ESM_PLS_CMP_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 00/00

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 1240 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 1241 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1242 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P16D2-47: ECU - Internal memory failure

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P16D2-47 1. Old Software
Reduced Torque
CEL ON 2. Faulty ECU

Fault System Summary:

Development Fault code F_M_ESM_RED_TRQ_MON_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 00/00

Visit next 2 page(s) for Troubleshooting steps

& Component images

Author: ERC Page 1243 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

Author: ERC Page 1244 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1245 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P26C5-9B: Exhaust Flow Control Valve: Closed Position Learning Higher Than
Threshold
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-9B 1. Old Software
2. Faulty ETV No reaction
CEL ON
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_EXH_BRK_LRN_CL_HI_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 8322/20

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

Author: ERC Page 1246 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

Author: ERC Page 1247 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Do Ignition OFF and wait for 20 secs and Do Key ON. Clear DTC & Check
1
for DTC.
If still issue persists, Check for any errors related to Exhaust Throttle. If
2
found any, rectify it and check for DTC
If still issue persists, Clear DTC and perform actuator reset & learning Perform following routine after component Replacement:
3 service through TDS. Do Key off, wait for 20 secs and do key ON. Clear 1. RESET Exhaust brake Values Test
DTC & Check for DTC again 2. Exhaust throttle valve learning Test
Perform following services in TDS:
Perform Actuator Demand check through TDS. Check for Demand and
1. Test Actuators - Exhaust throttle demand check[0%,
feedback position. If there is too much difference between demand and
4 50% & 80%]
measured value, Connect one new Exhaust throttle assembly externally
and perform necessary services through TDS.
Acceptable deviation : +/- 3%
Select dataset based on Vehicle Identification
5 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
6 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

Author: ERC Page 1248 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

Author: ERC Page 1249 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1250 of 1261

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P26C5-9C: Exhaust Flow Control Valve: Closed Position Learning Lower Than
Threshold
Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-9C 1. Old Software
2. Faulty ETV No reaction
CEL ON
3. Faulty ECU

Fault System Summary:

Development Fault code F_M_EXH_BRK_LRN_CL_LO_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 8322/21

Visit next 4 page(s) for Troubleshooting steps,

Circuit diagram & Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble shooting Steps:

A. Electrical Interface Integrity Checks

Checkpoints Acceptance criteria Result Recommended Action Remark

Step
At Ignition ON & w/o disconnecting any coupler
Clear DTC and perform Routine Successful Pass None No electrical error
Actuator/ Routine test through TDS prompt from TDS perceived. Clear DTC and
1 (if prompted) Recheck
Fail Proceed to step 2
Verify fuse health (fuse-link Resistance less Pass Proceed to step 3
2 continuity) as per Table-1(Fuse than 1.0 ohm Fail Replace the fuse Clear DTC and recheck
health check procedure)
At Ignition Off & remove component side coupler only
Measure Component side resistance 38 Ohm +/- 10% Pass Proceed to step 4 Component electrical
3 Between pin 4 & 6 check OK
Fail Replace the part Clear DTC and recheck
At Ignition Off & removal of both component-side and EMS ECU side couplers
Open circuit (Continuity) Checks as Resistance less Pass No open circuit. Proceed to
per Table-2 than 1.0 ohm next step
4
Fail Identify the affected harness
and replace.
At Ignition Off & removal of both component-side, EMS ECU side couplers
Short Circuit checks as per Table-4 Resistance more Pass No short circuit. Proceed to
than 10.0 kohm next step.
5
Fail Identify the affected harness
and replace.
short-circuit-to-batt checks as per Resistance more Pass No short circuit(SCB). Proceed
Table-4 than 10.0 kohm to next step.
6
Fail Identify the affected harness
and replace.
Shot-circuit-to-Ground as per Table- Resistance more Pass No short circuit(SCG). Proceed
4 than 10.0 kohm to next step.
7
Fail Identify the affected harness
and replace.
Short Circuit test at EMS ECU Resistance more Pass No short circuit. Harness is OK
connector end with all other than 10.0 kohm Fail Identify the affected harness
8
remaining EMS specific circuits in and replace.
wiring harness.
Note :- After ignition off wait for 2 minutes before taking next step

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

B. Other Interface Integrity Checks

Sr. No. Steps Specifications

Do Ignition OFF and wait for 20 secs and Do Key ON. Clear DTC & Check
1
for DTC.
If still issue persists, Check for any errors related to Exhaust Throttle. If
2
found any, rectify it and check for DTC
If still issue persists, Clear DTC and perform actuator reset & learning Perform following routine after component Replacement:
3 service through TDS. Do Key off, wait for 20 secs and do key ON. Clear 1. RESET Exhaust brake Values Test
DTC & Check for DTC again 2. Exhaust throttle valve learning Test
Perform following services in TDS:
Perform Actuator Demand check through TDS. Check for Demand and
1. Test Actuators - Exhaust throttle demand check[0%,
feedback position. If there is too much difference between demand and
4 50% & 80%]
measured value, Connect one new Exhaust throttle assembly externally
and perform necessary services through TDS.
Acceptable deviation : +/- 3%
Select dataset based on Vehicle Identification
5 If still issue persists, Re-flash ECU dataset and check for DTC again
number(VIN)
Perform following routine after component Replacement:
6 If still issue persists, Replace Exhaust throttle assembly and check for DTC 1. RESET Exhaust brake Values Test
2. Exhaust throttle valve learning Test
Perform following services in TDS:
1. ECU Replacement & Select dataset as per Vehicle
configuration(VC)
7 If still issue persists, Replace ECU 2. Read & Write proper injector codes (I3C) from Old
ECU/Engine
3. All actuator learning services [EGR / Exhaust Throttle /
Turbocharger]

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Circuit Schematic Diagram:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P0697-4B: Sensor Reference Voltage C- Internal Thermal Shutdown

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P0697-4B 1. Faults related to internal 5V supply
2. Faults related to Rail Pressure sensor
3. Faulty CAM Sensor Various performance issues
CEL ON
4. Old Software version
5. Faulty ECU

Fault System Summary:

Development Fault code F_M_T_SHTDWN_VREF3_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 3511/12

Visit next 2 page(s) for Troubleshooting steps

& Component images

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

Check for DTCs related to Rail Pressure Sensor, Cam Sensor, If any error
No DTCs related to Rail Pressure, Cam Sesnor and internal
persists repair those errors.
1 5V supply should be present after respective corrective
Check Internal 5V supply; trouble shoot them and then check for this DTC
actions
again

Software version as per Vehicle configuration(VC)

Re-flash the EMS ECU with latest software version and check for DTC
2
again Perform service regeneration at IDLE after issue
rectification

Perform following services in TDS:

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

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

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 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

P06D6-FF: ECU Internal Voltage

Overview:

Fault Code Description Cause Effect on Vehicle

Fault Code P26C5-9C 1. Old Software
Various performance issues
CEL ON 2. Faulty ECU

Fault System Summary:

Development Fault code F_M_VEXT_VCCL_APV

System ECU Internal/Memory / Memory Monitor

OBD Inducement Non-Inducement

SPN & FMI 00/00

Visit next 2 page(s) for Troubleshooting steps

& Component images

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Trouble Shooting Steps:

Sr. No. Steps Specifications

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

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This document must not be used in any way, such as copying and redistributing to third parties, without our consent
 Version: 1.3
TML 5L BS VI Phase 2 - ECU Diagnostic Manual
Date: 21-01-2025

Location and Component Image:

Author: ERC Page 1261 of 1261

Copyright by TATA MOTORS Ltd.

This document must not be used in any way, such as copying and redistributing to third parties, without our consent