EMS (3.

3LNG BSVI)

ENGINE MANAGEMENT SYSTEM

EMS (3.3LNG BSVI)

TABLE OF CONTENTS
1. ENGINE MANAGEMENT SYSTEM DESCRIPTION ............................................................................ 01

2. EMS INPUT AND OUTPUT BLOCK DIAGRAM AND OVERVIEW ..................................................... 02

3. ELECTRONIC CONTROL UNIT (ECU) CONNECTOR DETAILS ....................................................... 06

4. EMS SYSTEM SENSORS ..................................................................................................................... 13

A. CRANKK SPEED SENSOR ............................................................................................................. 13

B. CAM SHAFT POSITION SENSOR .................................................................................................. 14

C. BOOST PRESSURE SENSOR ........................................................................................................ 15

D. PFM SENSOR .................................................................................................................................. 17

E. EGR TEMPERATURE SENSOR ..................................................................................................... 18

F. AMBIENT TEMPERATURE SENSOR ............................................................................................. 19

G. COOLANT TEMPERATURE SENSOR ............................................................................................ 20

H. EXHAUST TEMPERATURE SENSORS WITH ROUTING T4, T5 and T6 ...................................... 22

I. DIFFERENTIAL PRESSURE SENSOR (DPS) ............................................................................... 23

J. RAIL PRESSURE SENSOR............................................................................................................. 24

K. WATER IN FUEL SENSOR .............................................................................................................. 25

L. ACCELERATOR PEDAL SENSOR.................................................................................................. 26

M. NOX SENSOR (UPSTREAM/DOWNSTREAM) WITH ROUTING ................................................... 28

N. BRAKE SWITCH .............................................................................................................................. 29

O. CLUTCH SWITCH ............................................................................................................................ 31

P. FUEL TEMPERATURE SENSOR .................................................................................................... 32

5. EMS SYSTEM ACTUATORS ................................................................................................................ 32

A. ELECTRIC ACTUATOR FOR eVGT ................................................................................................. 32

B. GRID HEATER 24VOLT: (If Applicable) .......................................................................................... 33

C. INJECTORS ...................................................................................................................................... 33

D. HIGH PRESSURE FUEL PUMP ....................................................................................................... 34

E. METERING UNIT .............................................................................................................................. 35

F. DeNOx SYSTEM ............................................................................................................................... 35

G. EXHAUST GAS RECIRCULATION VALVE (EGR) ......................................................................... 37

H. COMMON RAIL ................................................................................................................................. 37

I. EXHAUST THROTTLE VALVE ......................................................................................................... 37

EMS (3.3LNG BSVI)
1. ENGINE MANAGEMENT SYSTEM (EMS) NOTE
DESCRIPTION
 For certain faults and for failure of some
sensors the EMS switches to reduced torque
or Limp Home mode. During this mode the
vehicle performance will be restricted and
MIL lamp will be ON.

MAKE: BOSCH Diesel Common Rail System

MODEL / TYPE:
MD1CS018 : 12V
MD1CC898 : 24V

Engine Management System (EMS) comprises of

Electronic Control Unit (ECU), sensors, actuators
and control algorithms that determine the
performance of the Engine as a whole and as part
of the vehicle.
The Electronic Control Unit consist of a 32-bit
microprocessor with peripheral devices like ignition
driver, ADCs device and I/O drivers.
Microprocessor controls the injection parameters
as well as some of the vehicle related outputs such
as Fan, AC drivability in gears, variable turbine
turbocharger, EGR etc. The ECU receives input
from various sensors located on the engine and the
vehicle, and decides the injection quantity, injection
timing, number of injections best suited for the
engine to work with maximum efficiency and
safety. It is the ‘Brain’ of the Engine Management
System. Being the most important component of
the Engine management system, ECU apart from
ensuring the optimum working of the Vehicle, also
keeps an eye on the working of the sensors and
actuators. Whenever a malfunction/fault occurs in
the component or the system the ECU alerts the
user by glowing MIL indicator on instrument
cluster. ECU also does the following:
 Stores a DTC in its memory (indicates the faulty
component/system).
 Stores a context frame (list of parameters
indicating the operating condition during the fault
generation) in its memory.
When the malfunction poses a threat to the
vehicle, the ECU with its control algorithms
operates the vehicle in Limp Home Mode (safe
mode). This protects the component from damage
with some degradation in performance of the
vehicle.

1
EMS (3.3LNG BSVI)

3.3L NG Engine Management System (EMS)

(Input and Output Overview)

INPUT (Sensors)

OUTPUT (Actuators)

Electronic Control Unit (ECU)

(12V / 24V)

2
ELECTRONIC CONTROL UNIT (ECU) CONNECTOR DETAILS

TIGHTENING TORQUE TABLE

DESCRIPTION TORQUE
Hex FL Nut AM6 1.0 Kgfm
Hex FL Screw M6X30 1.0 Kgfm

REMOVAL
1. Open the side flap of battery and disconnect the
battery negative terminal.
2. Disconnect the both connectors of EMS.
(Remove EMS wiring harness connector first then
main wiring harness connector).

FITMENT
1. Locate the ECU on mounting brackets and fit the
six mounting bolts.
Tightening torque for Bolts - 1 Kgfm.
2. Connect the electrical connections (Main W/H
and EMS W/H).
3. Connect the battery negative terminal and close
the side flap.

3. Remove the six mounting screws and take out the

ECU.

3
EMS (3.3LNG BSVI)
VEHICLE CONNECTOR PINOUT DETAILS 24V Pin
Name
No.
Pin
Name K15 A/C medium pressure switch
No.
I_S_ACCHL
K01 Battery plus 1
K70 G_R_DIG
K02 Battery minus 1
K72 Grid heater relay O_S_IMPH
K03 Battery plus 2
K30 Fuel heater relay O_S_FLHT
K04 Battery minus 2
K69 OBD/ MIL lamp O_S_OBD
K05 Battery plus 3
K17 Water in fuel switch I_S_WFS
K06 Battery minus 3
K36 Battery UB 61 (High side driver)
K78 Controller Area Network 0
O_V_RH61
(Inter ECU Communication, Diagnostics)
K90 Starter relay O_S_STRT
K77 No termination resistance
K89 Battery UB 62 (High side driver)
K88 Ignition switch
O_V_RH62
K74 T50 Switch
K59 Electric engine coolant pump
K75 Controller Area Network 1
O_S_EECP
(Flash programming, CCP)
K47 DPF stop indication LED O_S_DPSILP
K76 Termination resistance = 120 Ohm
K91 Reduction agent tank heating valve
K68 Switched battery UB 25 (High side
O_V_RH32
driver)
K28 Reduction agent tank heating valve
K41 Main brake switch I_S_BRKMN
O_S_RATH
K08 Redundant brake switch I_S_BRKRED
K34 Vehicle speed sensor signal from cluster
K45 Accelerator pedal position 1 I_F_VSS
O_V_5VAPP1
K57 Ambient temperature sensor Continental:
K61 Accelerator pedal position 1 I_A_APP1 I_A_ATS
K63 Accelerator pedal position 1 G_R_APP1 K60 Ambient temperature sensor Continental:
K44 Accelerator pedal position 2 G_R_ATS
O_V_5VAPP2 K81 Catalyst temperature sensor 2
K83 Accelerator pedal position 2 I_A_APP2 (Upstream) I_A_EXT1
K84 Accelerator pedal position 2 G_R_APP2 K31 Catalyst temperature sensor 2
K18 I_S_CRCPOS (Upstream) G_R_EXT1
Cruise control (+)/ PTO RPM (+) K39 Temperature sensor SCR T6 (Upstream)
K37 I_S_CRCNEG I_A_CATTSPRE
Cruise control (-)/ PTO RPM (-) K56 Post - Catalyst temperature sensor 1
K12 I_S_CRCOFF Cruise control (off) (Downstream) I_A_CATTSPOST
K32 I_S_CRCRES Cruise control (resume) K79 Post - Catalyst temperature sensor 1
K62 Remote acceleration pedal position 1 (Downstream) G_R_CATTSPOST
K85 Remote acceleration pedal position 2
K40 Main exhaust brake switch K73 Reduction agent electro-mechanical
K86 Torque limitation switch 1 relay O_V_RH31
K42 PTO switch K29 Reduction agent electro-mechanical
K22 AC pressure switch relay O_S_MRHH
K65 Torque limitation switch 2 K21 Reduction agent pressure hose heater
K48 Clutch switch 1 O_S_PHH
K58 Clutch switch 2 K50 Reduction agent throttle hose heater
K19 PTO vehicle switch _S_PTOMOD O_S_THH
K67 PTO RPM selector 1 I_S_PTRPM1 K26 Reduction agent suction hose heater
K14 PTO RPM selector 2 I_S_PTRPM2 O_S_SHH
K16 PTO RPM selector 3 I_S_PTRPM3 K65 I_A_PHH
K64 Remote Acc. pedal selector switch K25 Reduction agent supply module heater
I_S_RMTEN O_S_SMH
K80 Parking brake switch I_S_BRKPS K24 Reduction agent pump pressure sensor
K66 Cabinet tilt switch I_S_CBT V_V_5VPRAS
K82 DPF regeneration stop switch K54 Reduction agent pump pressure sensor
I_S_DPFRST I_A_PRAS

4
EMS (3.3LNG BSVI)
Pin ENGINE CONNECTOR PINOUT DETAILS 24V
Name
No.
Pin
K53 Reduction agent pump pressure sensor Name
No.
G_R_PRAS
A13 Controller Area Network 2 (Inter ECU
K51 Reduction agent reverting valve
Communication) B_D_CANH2
O_V_RH52
A12 Controller Area Network 2 (Inter ECU
K27 Reduction agent reverting valve
Communication) B_D_CANL2
O_S_RARV
A54 Communication interface 1 (LIN) (12V
K71 Reduction agent pump control
LIN support) B_D_COM1
O_V_RH51
A48 EGR valve position feedback sensor
K09 Reduction agent pump control
O_T_EGRPOS
O_T_RAPMP
A49 EGR valve position feedback sensor
K07 Reduction agent pump control
O_T_EGRNEG
G_G_RAPMP
A52 EGR valve position feedback sensor
K10 Reduction agent dosing valve BOSCH (B
V_V_5VEGR
444 043 224) O_T_RAMVH
A51 EGR valve position feedback sensor
K11 Reduction agent dosing valve BOSCH (B
I_A_EGR
444 043 224) O_T_RAMVL
A50 EGR valve position feedback sensor
K49 Engine speed output O_F_ENGN
G_R_EGR
K87 Vehicle speed output signal O_F_VSS
A10 Rail pressure sensor BOSCH (0 281
K33 I_A_EKPDF
006 914) O_V_5VRAILPS
A31 Rail pressure sensor BOSCH (0 281
006 914) I_A_RAILPS
A32 Rail pressure sensor BOSCH (0 281
006 914) G_R_RAILPS
A97 Coolant temperature sensor BOSCH: (0
280 130 093) I_A_CTS
A102 Battery plus output 41 (High side driver)
O_V_RH41
A69 Blower control relay O_S_BLWR
A86 EGR cooling bypass valve
O_S_EGRBV
A40 Oil pump control relay O_S_OILP
A75 EKP relay diagnostic feedback signal
O_S_PSPRLY2
A11 Fuel temperature sensor BOSCH: (0
280 130 093) I_A_FTS1
A88 EGR temperature sensor T3 Sensata:
(DARTS 200D) I_A_TEGR
A78 Oil pressure switch I_S_OPSW
A73 Battery plus output 81 (High side driver)
O_V_RH81
A42 Glow plug relay O_S_GLWRLY
A74 EKP pump relay O_S_PSPRLY1
A71 High exhaust temperature indication
lamp O_S_EXTLP
A85 DOC Temperature sensor upstream T4
Sensata: (DARTS 200D)
I_A_DOCTSUP
A80 Oil temperature sensor I_A_OTS
A57 Oil temperature sensor G_R_OTS
A38 DPF Temperature sensor upstream T5
Sensata: (DARTS 200D)
I_A_TPFLTUS

5
EMS (3.3LNG BSVI)
Pin Pin
Name Name
No. No.
A46 Battery plus output 23 (High side driver) A82 Camshaft speed sensor -Hall effect
O_V_RH23 type sensor -CPS4 (Tonewheel with
A47 AC condenser relay O_S_ACCRLY slots) BOSCH: (0 232 B00 698)
A39 Glow time indication lamp I_F_CAS
O_S_GLWLP A104 Camshaft speed sensor -Hall effect
A09 Boost pressure and temperature sensor type sensor -CPS4 (Tonewheel with
BOSCH: (0 281 006 076) O_V_5VBPS slots) BOSCH: (0 232 B00 698)
A33 Boost pressure and temperature sensor G_R_CAS
BOSCH: (0 281 006 076) I_A_BPS A19 Exhaust throttle valve actuator
A68 Boost pressure and temperature sensor O_T_TVAPOS
BOSCH: (0 281 006 076) I_A_BTS A18 Exhaust throttle valve actuator
A34 Boost pressure and temperature sensor O_T_TVANEG
BOSCH: (0 281 006 076) G_R_BPS A21 ETVA position feedback sensor
A28 Battery plus output 22 (High side driver) V_V_5VTVA
O_V_RH22 A20 ETVA position feedback sensor
A70 AC compressor relay O_S_ACRLY I_A_TVA
A26 Differential pressure sensor signal A17 ETVA position feedback sensor
Continental: (A2C7371850) I_A_PFDP G_R_TVA
A25 Differential pressure sensor signal A61 EVGT O_T_VGTPOS
Continental: (A2C7371850) G_R_PFDP A60 EVGT O_T_VGTNEG
A96 PFM sensor BOSCH: (0 280 B07 022) A63 EVGT position feedback sensor
O_V_5VPFM V_V_5VVGT
A92 PFM sensor BOSCH: (0 280 B07 022) A62 EVGT position feedback sensor
I_D_SENTU3 I_A_VGT
A93 PFM sensor BOSCH: (0 280 B07 022) A59 EVGT position feedback sensor
I_D_SENTU4 G_R_VGT
A81 PFM sensor BOSCH: (0 280 B07 022) A06 Metering unit BOSCH: (0 928 400 757)
G_R_PFM O_V_MEU
A99 E - Viscous fan actuator O_T_FAN A05 Metering unit BOSCH: (0 928 400 757)
A100 MAHLE BEHR (EF35) Fan speed O_T_MEU
sensor I_F_FSS A45 Bank 1 Inj. 1 Cyl.1 O_P_SVH11
A04 MAHLE BEHR (EF35) Fan speed A22 Bank 1 Inj. 1 Cyl.1 O_P_SVL11
sensor G_S_FSS A65 Bank 1 Inj. 2 Cyl.4 O_P_SVH12
A53 Gear neutral switch I_S_GNSW A23 Bank 1 Inj. 2 Cyl.4 O_P_SVL12
A37 Coolant level switch I_S_CLSW A43 Bank 2 Inj. 1 Cyl.3 O_P_SVH21
A87 DPF regeneration start switch A01 Bank 2 Inj. 1 Cyl.3 O_P_SVL21
I_S_DPFRSW A44 Bank 2 Inj. 2 Cyl.2 O_P_SVH22
A90 Oil level switch I_S_OLS A02 Bank 2 Inj. 2 Cyl.2 O_P_SVL22
A84 Crankshaft speed sensor -Inductive
sensor (DG6) (Tonewheel with slots)
BOSCH: (0 281 002 315) I_F_CRSPOS
A105 Crankshaft speed sensor -Inductive
sensor (DG6) (Tonewheel with slots)
BOSCH: (0 281 002 315)
I_F_CRSNEG
A83 Crankshaft speed sensor -Inductive
sensor (DG6) (Tonewheel with slots)
BOSCH: (0 281 002 315) G_R_CRS
A08 Camshaft speed sensor -Hall effect
type sensor -CPS4 (Tonewheel with
slots) BOSCH: (0 232 B00 698)
O_V_5VCAS

6
EMS (3.3LNG BSVI)
VEHICLE CONNECTOR PINOUT DETAILS 12V Pin
Name
Pin No.
Name K09 Accelerator Pedal Module
No.
K02 Battery minus 1 O_V_5VAPP2
K04 Battery minus 2 K31 Accelerator Pedal Module I_A_APP2
K06 Battery minus 3 K25 Accelerator Pedal Module G_R_APP2
K60 CAN Interface 1 K07 Remote Accelerator Pedal Module
O_V_5VRMTAPP2
K77 With termination resistor
K34 Remote Accelerator Pedal Module
K58 CAN Interface 2
G_R_RMTAPP2
K75 Without termination resistor
K56 High exhaust system temperature lamp
K59 CAN-Interface 3
K43 Differential lock
K76 CAN-Interface 3
K69 O_T_FAN
K14 LIN-Interface
K68 Reverse gear switch
K15 KLINE-Interface
K45 A/C On/Off Switch
K28 Vehicle speed sensor input signal
K44 Cruise Control Switches CRCON (ON)
K71 Engine speed output signal
K32 Cruise Control Switches CRCPOS
K35 Vehicle speed output
(Increment/PTO increment)
K72 Coolant temperature indication output
K79 Cruise Control Switches CRCNEG
signal
(Decrement/ PTO decrement)
K26 Vehicle speed sensor ground
K64 Cruise Control Switches CRCNL
K49 Catalytic temp sensor 1 (downstream)
(Cancel/Resume)
K81 Catalytic temp sensor 1 (downstream)
K86 A/C compressor relay
K66 After DPF/ upstream SCR (T6)
K57 Oil bypass relay
K01 Battery plus 1
K21 A/C condenser relay
K03 Battery plus 2
K73 Grid heater relay
K05 Battery plus 3
K18 V_V_PERMBAT
K19 O_S_MRLY
K90 O_T_RAMVH Dosing valve RAMV
K16 I_S_T15
K37 O_T_RAMVL Dosing valve RAMV
K52 Brake switch
K27 I_F_RAULS Reduction Agent; UL&
K85 Redundant brake switch Temp sensor
K36 OBD lamp K48 G_R_RAULS Reduction Agent; UL&
K23 Glow indication lamp Temp sensor
K22 DPF Regeneration Lamp K74 O_S_MPHS Magnetic Coil Pump
K38 Water in fuel lamp K20 O_T_RAMCP Magnetic Coil Pump
K39 Check Engine Lamp K40 O_T_RAPP Reduction agent purge
K80 Start switch T50 input pump
K12 Ambient Temperature Sensor K55 O_S_SCRMRLY SCR main relay
K83 Ambient Temperature Sensor
K41 PTO Switch on/off
K84 Parking brake switch
K46 Clutch Switch 1 (270254509950)
K47 Clutch Switch 2 (270254509950)
K53 4L indication
K51 Regeneration (start) Momentary Switch
K63 Cabin Tilt switch
K30 A/C Pressure sensor switch
K62 Coolant Level switch
K67 Exhaust brake main switch
K50 Oil pressure switch (265454500139)
K08 Accelerator Pedal Module
O_V_5VAPP1
K29 Accelerator Pedal Module I_A_APP1
K24 Accelerator Pedal Module G_R_APP1

7
EMS (3.3LNG BSVI)
ENGINE CONNECTOR PINOUT DETAILS 12V Pin
Name
No.
Pin
Name A28 Coolant Temp. Sensor (Engine)
No.
G_R_CTS
A13 Remote Accelerator Pedal Module
A96 Oil temperature sensor I_A_OTS
O_V_5VRMTAPP1
A12 Particle filter, differential pressure
A72 Remote Accelerator Pedal Module
sensor O_V_5VPFDP
I_A_RMTAPP1
A78 Particle filter, differential pressure
A73 Remote Accelerator Pedal Module
sensor I_A_PFDP
I_A_RMTAPP2
A55 Particle filter, differential pressure
A61 Pre-supply pump Relay O_S_PSP
sensor G_R_PFDP
A57 PTO RPM selector 1 switch
A16 Crankshaft Speed Sensor (Inductive)
I_S_PTRPM1
I_F_CRSPOS
A02 PTO RPM selector 2 switch
A15 Crankshaft Speed Sensor (Inductive)
I_S_PTRPM2
I_F_CRSNEG
A01 PTO RPM selector 3 switch
A35 Crankshaft Speed Sensor (Inductive)
I_S_PTRPM3
G_R_CRS
A75 PTO Vehicle/ Remote Acc. pedal sel.
A09 Camshaft Speed Sensor (Hall)
switch I_S_ACPSLSW
O_V_5VCAS
A70 Regeneration stop switch latchable
A49 Camshaft Speed Sensor (Hall)
I_S_MRGSSW
I_F_CAS
A47 Intake throttle valve actuator and
A81 Camshaft Speed Sensor (Hall)
position sensor (RKL-E 5.9 NC)
G_R_CAS
O_T_TVAPOS
A10 Boost pressure sensor with temp.
A91 Intake throttle valve actuator and
sensor O_V_5VBPS
position sensor (RKL-E 5.9 NC)
A76 Boost pressure sensor with temp.
O_T_TVANEG
sensor I_A_BTS
A08 Intake throttle valve actuator and
position sensor (RKL-E 5.9 NC) A97 Boost pressure sensor with temp.
O_V_5VTVA sensor I_A_BPS
A50 Intake throttle valve actuator and A31 Boost pressure sensor with temp.
sensor G_R_BPS
position sensor (RKL-E 5.9 NC)
I_A_TVA A89 Boost Pressure Actuator Feedback
Sensor Signal O_T_EVGTPOS
A69 Intake throttle valve actuator and
position sensor (RKL-E 5.9 NC) A93 Boost Pressure Actuator Feedback
G_R_TVA Sensor Signal O_T_EVGTNEG
A94 EGR Actuator & Position Sensor A06 Boost Pressure Actuator Feedback
O_T_EGRPOS Sensor Signal O_V_5VEVGT
A90 EGR Actuator & Position Sensor A53 Boost Pressure Actuator Feedback
O_T_EGRNEG Sensor Signal I_A_EVGT
A07 EGR Position sensor O_V_5VEGR A34 Air Mass Flow METER O_V_5VSENT
A52 EGR Position sensor I_A_EGR A39 Air Mass Flow METER I_D_SENT2
A100 EGR Position sensor G_R_ETVA A38 Air Mass Flow METER I_D_SENT1
A92 Exhaust Throttle valve actuator and A29 Air Mass Flow METER G_R_SENT2
position sensor O_T_ETVAPOS A11 Rail pressure sensor O_V_5VRAILPS
A68 Exhaust Throttle valve actuator and A71 Rail pressure sensor I_A_RAILPS
position sensor O_T_ETVANEG A83 Rail pressure sensor G_R_RAILPS
A05 Exhaust Throttle valve actuator and A77 Fuel Temperature Sensor I_A_FTS
position sensor O_V_5VETVA A32 Fuel Temperature Sensor G_R_FTS
A74 Exhaust Throttle valve actuator and A58 Exhaust gas temp. sensor 1
position sensor I_A_ETVA I_A_THPEGRPOST
A37 Upstream DPF (T5) I_A_EGRCWTS A30 Exhaust gas temp. sensor 1
A99 Upstream DPF (T5) G_R_EGRCWTS G_R_THPEGRPOST
A59 Upstream DOC (T4) I_A_TBTS_UP A104 EGR temp sensor I_A_TEGR
A51 Coolant Temp. Sensor (Engine) A54 EGR temp sensor G_R_TEGR
I_A_CTS A41 SCR Warning Lamp O_S_SCRLP

8
EMS (3.3LNG BSVI)
Pin
Name
No.
A40 Gear Neutral Indicator O_S_GNSW
A14 E-Viscos Fan Visco Fan Drive EF 35
(BorgWarner MAHLE Behr)
O_V_5VFSS
A27 E-Viscos Fan Visco Fan Drive EF 35
(BorgWarner MAHLE Behr) I_T_FSS
A56 E-Viscos Fan Visco Fan Drive EF 35
(BorgWarner MAHLE Behr) G_R_FSS
A20 Starter relay O_S_STRTH
A21 Starter relay O_S_ O_S_STRTL
A62 Glow plug control unit O_T_GLW
A36 Glow plug control unit I_T_GLW
A105 Gear Neutral Switch I_S_GNSW
A42 Fuel heater relay O_S_FHRLY
A63 Electrical thermostat control relay
O_S_ETC
A98 Water in fuel sensor
A19 EGR cooling by-pass
A18 EGR Coolant Water Pump
A17 High pressure pump (CP4) with Fuel
metering unit
A23 Cyl. 1: O_P_INJVH11
A43 Cyl. 1: O_P_INJVL11
A22 Cyl. 4: O_P_INJVH12
A44 Cyl. 4: O_P_INJVL12
A64 Cyl. 3: O_P_INJVH21
A85 Cyl. 3: O_P_INJVL21
A65 Cyl. 2: O_P_INJVH22
A86 Cyl. 2: O_P_INJVL22

9
EMS (3.3LNG BSVI)
4. EMS SYSTEM SENSORS CONNECTOR DETAILS
A. CRANKK SPEED SENSOR

The crank speed sensor is a magnetic field PIN OUT DETAILS

sensitive transducer and generates a voltage PIN NO DESCRIPTION
output proportional to the rate of change of the
magnetic field near a "Missing tooth" configuration. PIN 1 Crank shaft sensor(+)
It monitors the rotating speed (rpm), the position of PIN 2 Crank shaft sensor(-)
crankshaft/ piston and speed fluctuations of the
engine and gives continuous feedback to the ECU. REMOVAL
In other words it gives engine speed and piston 1. Remove one mounting bolt.
position signal to the ECU. The sensor gap should
be 1.0±0.5mm. If the gap between the tone wheel 2. Take out the crank speed sensor.
and crank speed sensor is not correct, the engine NOTE
will not start or may misfire.  Rotation speed sensor must not be removed
LOCATION from its packaging until immediately prior to
The crank speed sensor is fitted on the cylinder installation in the vehicle or the test device.
crank case.  Grease O-ring prior to installation with a
mineral oil based grease.
INSPECTION
Measure resistance across the terminals pin 1 and
2 using Digital multimeter; it should be 525 Ω - 640
Ω.
REFITMENT
1. Locate the sensor on cylinder crankcase and fix
with partially self-sealing cylinder screw M6x12.
Tightening torque: 8 ±2Nm.
2. Connect wiring harness connector to the crank
speed sensor.
NOTE
 While fitment of crank speed sensor specified
TIGHTENING TORQUE air gap to be maintain. (Air gap 1.0mm
±0.5mm).
DESCRIPTION TORQUE
 Fix with partially self-sealing cylinder screw
Hex bolt M6 8 ±2Nm M6

13
EMS (3.3LNG BSVI)
B. CAM SHAFT POSITION SENSOR CONNETCOR DETAILS

The cam sensor is a magnetic field sensitive

transducer and generates a voltage output
proportional to the rate of change of the magnetic
field near a "camshaft lobe" configuration. The cam
sensor senses the position of the flag on the
Exhaust camshaft and gives feed back to the ECU
regarding the cylinder No.1 (90º BTDC). The
sensor gap should be 0.5mm to 1.5mm. If the gap
is not correct and also the position of camshafts
with respect to crank shaft (set during assembly),
the engine will not start or may misfire. While the
engine is running and the cam sensor fails then the
engine will continue to run till the engine is stopped,
but will not start again.

PIN DETAILS

PIN NO DESCRIPTION

Pin 1 Supply
Pin 2 Ground
Pin 3 Output

REMOVAL
LOCATION 1. Remove engine cover.
The cam sensor is fitted on cylinder head cover. 2. Disconnect the wiring harness connector from
cam shaft position sensor.
3. Remove one mounting bolt of sensor and take
out the cam position sensor from its location.
INSPECTION
Connect regulated 5V DC power supply to pin no.1
and Ground to pin no. 2 of the sensor.
Connect LED 1 with resistor 570Ω to the NPN
transistor collector. Emitter is grounded.
Connect another LED 2 along with a series resistor
(570Ω) between pin 3 and pin 1.
Connect the base of the transistor with resistors
(10kΩ and 100kΩ) as shown in the figure. Move a
ferromagnetic piece of material in front of the
TIGHTENING TORQUE sensor head.

DESCRIPTION TORQUE

Hex bolt M6 5 to 8 Nm

14
EMS (3.3LNG BSVI)
C. BOOST PRESSURE SENSOR
This sensor is fitted in the outlet of intake manifold
and gives the pressure of the air entering the intake
manifold to the EMS ECU.

The LED 2 will be glow when the material in the

near the sensor head and the LED 1 will glow when
the material is away from the sensor head.
Fuel quantity and injection timing are optimized
NOTE
based on these inputs.
The above mentioned method does not check the
LOCATION
functionality of the sensor throughout its range. It
can only give a rough indication. To check the full This sensor is fitted on intake manifold outlet near
functionality, the sensors must be tested on a the pipe connecting intercooler to engine intake.
suitable test bench
REFITMENT
1. Locate the cam shaft position sensor and fit one
mounting bolt and tighten with specified torque.
Tightening torque for bolt – 5 to 8 Nm
2. Connect the wiring harness connector to the
cam shaft position sensor.
3. Fit engine cover.

TIGHTENING TORQUE

DESCRIPTION TORQUE
Hex screw M4 4 to 6 Nm

15
EMS (3.3LNG BSVI)
CONNECTOR DETAILS

PIN OUT DETAILS

PIN NO DESCRIPTION REFITMENT

Pin 1 GROUND 1. Locate the Booster Pressure sensor on intake
Pin 2 NTC manifold and fit one mounting bolt.

Pin 3 +5 V 2. Connect the electrical connection to the MAP

sensor.
Pin 4 U. (PRESSURE)
OUTPUT SIGNAL

REMOVAL
1. Disconnect the battery negative terminal from
battery.
2. Disconnect the electrical connection from
sensor.
3. Remove one mounting Bolt of sensor and take
out the sensor from its location.
INSPECTION
 Connect regulated 5V power supply to pin no.3
and Ground to pin no. 1 of the sensor.
 Check the output voltage at pin no. 4 with
respect to ground. At standard atmospheric
pressure pamb=935 mbar, the output voltage
should be Uout=1.165 V
Disconnect the power supply. Connect a
multimeter across connector pins 1 and 2 and
measure the resistance across it. It should show a
nominal resistance of 1.707 kΩ ±5% at 27˚C .The
circuit should not be open. It is enough to check the
resistance at room temperature.
NOTE
The above mentioned method does not check the
functionality of the sensor throughout its range.
It can only give a rough indication. To check the full
functionality, the sensors must be tested on a
suitable test bench.

16
EMS (3.3LNG BSVI)
D. PFM SENSOR CONNECTOR DETAILS

EMS measures the mass and temperature of air

entering intake by using this sensor. PFM sensor
has 4-pole connector and provides the frequency
input signal at A13 which corresponds to flow of air
and Analog input at A23 which corresponds to
temperature of air intake. It is mounted in the intake
air duct between the air cleaner and turbo charger.

PIN OUT DETAILS

PIN DESCRIPTION
NO

1 VDD (5V), Source

LOCATION 2 Sent 1, Dynamic Pressure P
This sensor is mounted between air filter and
turbocharger. 3 GND, Ground

4 Sent 2, Absolute Pressure P and

Air Temperature

REMOVAL
1. Disconnect the electrical connection from
sensor.
2. Remove two mounting bolts of sensor and take
out from its location.

TIGHTENING TORQUE

DESCRIPTION TORQUE
Hex screw M5 10.0 Nm

REFITMENT
1. Locate sensor assembly in the housing and fit
two mounting bolts.
2. Connect the wiring harness connector to the
sensor.

17
EMS (3.3LNG BSVI)
E. EGR TEMPERATURE SENSOR
PIN No. Description
The EGR Temperature Sensor detects the
temperature of the incoming Air stream. It is also 1 Sensor Signal
used for detecting ambient temperature on a cold
start and intake air temperature as the engine 2 Sensor Return
heats up the coming air.
Removal
1. Disconnect the wiring harness connector from
sensor.
2. Remove the sensor by loosening it with the help
of a spanner.
Inspection
Schematic Diagram

Location
The sensor is mounted on the air intake pipe,
Intake Manifold.

Test Circuit

Connector Details

18
EMS (3.3LNG BSVI)
Resistance to Temperature Table F. AMBIENT TEMPERATURE SENSOR
± ± This sensor gives Information about ambient
Resistance
T (°C) Tol. Tol. temperature of the air entering in the engine. This
(Ω)
(%) (K) input is used by the ECU for cutting of Adblue
-40 220348.8 16.7 3.4 dosing below specified ambient temperature.

-20 77418.1 14.4 3.1

0 29846.1 12.3 3

20 12868.3 10.7 2.9

25 10584.1 10.3 2.8

40 6091.2 9.3 2.8

60 3124.2 8.1 2.7

80 1717.4 7 2.6 Location

100 1002.4 5.8 2.3 This sensor is mounted in between air filter and
turbocharger.
120 615.3 4.7 2

140 394.2 3.5 1.6

160 261.1 3 1.5

180 178 3.3 1.8

200 124.6 4 2.3

220 88.2 4.7 2.8

240 63.4 5.3 3.5

260 46.3 6.1 4.1

Connector Details
280 34.3 6.9 4.8

300 25.7 7.9 5.3

Refitment
1. Locate sensor on the Intake manifold and fit the
adaptor.
2. Connect the wiring harness connector to the
sensor.
Tightening Torque
Description Torque (Nm)
Adaptor M12 x 1 20 ± 2 PIN No. Description
1 ECU Ground
2 NTC

19
EMS (3.3LNG BSVI)
Removal G. COOLANT TEMPERATURE SENSOR
1. Disconnect the wiring harness connector from This sensor is a made of semi conductor material
sensor. (NTC) which changes its resistance when exposed
to variable temperature source. Resistance
2. Remove the sensor by loosening it with the help
decreases as temperature increases. It provides
of a suitable spanner.
temperature signal to the HVAC controller. The
Inspection sensor mounted on the thermostat housing
provides signal to the EMS. Corrections for
1. Range of Intake Air temperature: injection parameters are done by the EMS based
Min. air Intake Temp. : -40°C on coolant temperature to run the engine with
maximum efficiency at all temperatures.
Max. air Intake Temp.: +110°C
2. Range of ambient Temperature (under hood
condition)
Min. ambient Temp. : -40°C
Max. ambient Temp. : +110°C
3. For supply voltage between 7.5V and 9V the
maximum airflow with guaranteed accuracy
100kg/h.

LOCATION
1. The sensor, which gives signal to EMS, is fitted
on thermostat housing.

20
EMS (3.3LNG BSVI)
CONNECTOR DETAILS NOTE
The above mentioned method does not check the
functionality of the sensor throughout its range. It
can only give a rough indication. To check the full
functionality, the sensors must be tested on a
suitable test bench.
REFITMENT
1. Tighten the coolant temperature sensor on
thermostat housing.
2. Connect the wiring harness connector to the
coolant temperature sensor.

PIN DETAILS
PIN NO DESCRIPTION

1 Sensor signal

2 Sensor return

REMOVAL
1. Drain the coolant. (Refer Engine Section)
2. Disconnect the wiring harness connector from
the sensor.
3. Loosen and remove sensor from the thermostat
housing.
INSPECTION
Connect a multimeter across the two terminals and
measure the resistance across it. It should show a
resistance of 1.160kΩ at 25˚C.The circuit should
not be open (high value of resistance).
Checking the resistance at room temperature is
sufficient.

21
EMS (3.3LNG BSVI)
H. EXHAUST TEMPERATURE SENSORS REMOVAL
WITH ROUTING T4, T5 and T6 1. Disconnect the electrical connection.
T4, T5, T6 are the exhaust gas temperature 2. Unscrew Hex. Nut M12X1.25 SW14 (T4)
sensors. M14X1.5 SW17 (T5 and T6) to remove the
LOCATION sensors.

T4 is mounted just before DOC, T5 is mounted REFITMENT

before DPF and T6 is mounted after DPF. 1. Tighten Hex. Nut M12X1.25 SW14 (T4)
M14X1.5 SW17 (T5 and T6) to fix the sensors.
2. Connect all the electrical connection of the
sensors.

CONNECTOR DETAILS

PIN DETAILS

PIN NO DESCRIPTION

1 + Signal. Grey Pin

2 - Ground. White Pin

22
EMS (3.3LNG BSVI)
I. DIFFERENTIAL PRESSURE SENSOR REMOVAL
(DPS) 1. Disconnect the electrical connection.
DPS senses the differential pressure across the 2. Unscrew Hex. FL screw M6X22 to remove the
after treatment component. The sensor provides DPS from mounting bracket.
the ECU with the differential pressure which is
used to determine the health of the trap. REFITMENT

LOCATION 1. Tighten Hex. FL screw M6X22 to fix the DPS

on mounting bracket.
DPS is placed across the DPF.
2. Connect all the electrical connection of the
DPS.

CONNECTOR DETAILS

PIN DETAILS

PIN NO DESCRIPTION

1 Vcc

2 Ground

3 Vout

23
EMS (3.3LNG BSVI)
J. RAIL PRESSURE SENSOR INSPECTION

This sensor is fitted on the fuel rail and gives a 1. Check Battery Voltage (12.5±3 volts).
close loop control of the rail pressure. Fuel is 2. Check Rail pressure sensor pins for damage
maintained at a high pressure in the fuel rail
depending on requirement of the engine. 3. Check Rail pressure sensor connector for
damage.
LOCATION
4. Check Rail pressure signal lines for continuity.
The Rail Pressure Sensor mounted on the rail of
common rail fuel injection system, provides the
information of fuel pressure present in the rail to
ECU. This sensor consists of piezo-resistive
elements whose resistance changes with the
pressure acting on the piezo element.

PIN DETAILS

PIN NO DESCRIPTION

Pin 1 Rail Pressure

Pin 2 S-GND
Pin 3 V_SESNS2

CONNECTOR DETAILS

NOTE
The rail pressure sensor should not be removed
from the rail. In case the sensor is faulty consult
M/S BOSCH service Engineer.

24
EMS (3.3LNG BSVI)
K. WATER IN FUEL SENSOR CONNECTOR DETAILS

It measures the water percentage in fuel and gives

indication on the instrument cluster. The water
collected to be drained when the indicator glows in
Instrument panel.

PIN DETAILS

PIN NO DESCRIPTION
LOCATION
Pin 1 Ground (Brown)
Pin 2 Output (Blue)
Pin 3 Ignition (Red)

REMOVAL
1. Disconnect the electrical connection of water in
fuel sensor.
2. Rotate the sensor in anti-clockwise direction
and take out the sensor.

1. This sensor which gives the signal to EMS

ECU is fitted on fuel filter, near the intake
manifold.
2. Fuel filter mounted on chassis.

REFITMENT
1. Fit the sensor by rotating in clockwise direction.
2. Connect the electrical connection of the
sensor.

25
EMS (3.3LNG BSVI)
INSPECTION L. ACCELERATOR PEDAL SENSOR
 Connect a multimeter across the pin 2 and 3 This sensor is secured to the accelerator pedal
terminals and measure the resistance across it. inside it contains an axially-located shaft
It should show a resistance of 5.229 kΩ ±10% connected to two potentiometers: a main one and
at 27˚C.The circuit should not be open (high one safety one.
value of resistance).
A coil spring on the shaft ensures the correct
 Checking the resistance at room temperature is amount of resistance to pressure while a second
sufficient. spring ensures return following release.
Note: The above mentioned method does not The redundant signal reading makes it possible to
check the functionality of the sensor throughout its continuously monitor the plausibility of the readings
range. It can only give a rough indication. To check in order to guarantee complete safety whilst driving
the full functionality, the sensors must be tested on even if there is a failure.
a suitable test bench.
The accelerator pedal position is converted into an
NOTE electrical voltage signal and sent to the EMS ECU
In case the sensor is faulty consult M/S BOSCH by the potentiometer connected to the pedal. The
service Engineer. accelerator pedal position signal is processed
together with the information relating to the engine
rpm to produce the desired torque and engine
speed.

26
EMS (3.3LNG BSVI)
CONNECTOR DETAILS 2. Loosen and remove the 3 mounting bolts and
remove the accelerator pedal module.
INSPECTION
Check the resistance
 1.7K ohm +/- 0.8 between terminals 1 and 5
 1.2K ohm +/- 0.5 between terminals 2 and 3
REFITMENT
1. Locate accelerator pedal module and fit
mounting nuts.
2. Connect the accelerator pedal electrical
connector to the accelerator pedal module.

PIN OUT DETAILS

PIN NO DESCRIPTION

PIN1 APS Signal 1

PIN 2 GND 1

PIN 3 APS Supply 1

PIN 4 APS Supply 2

PIN 5 GND 2

PIN 6 APS Signal 2

REMOVAL
1. Disconnect the accelerator pedal electrical
connector from the accelerator pedal module.

27
EMS (3.3LNG BSVI)
M. NOx sensor (upstream/downstream) with CONNECTOR DETAILS
routing
There are two NOx sensors (upstream &
downstream). Upstream NOx gives the valve of
engine out NOx and downstream NOx gives the
value of tail pipe NOx in ppm. This sensors used
for NOx control calibration.

PIN OUT DETAILS

LOCATION
NOx sensor upstream is mounted before DOC. PIN NO DESCRIPTION
NOx sensor downstream is mounted after SCR. PIN1 UBATT

PIN 2 GND

PIN 3 CAN LOW

PIN 4 CAN HIGH

PIN 5 Ground/Open depending on sensor

position

REMOVAL
1. Disconnect electrical connections.
2. Apply <50 Nm torque while sensor loosening
(1). Remove Hex FL screws M6X14 (2 nos.)
from sensor bracket (2)

28
EMS (3.3LNG BSVI)
REFITMENT N. BRAKE SWITCH
1. Fit the sensor (1) with tightening torque 60 +10/-
20 Nm.
2. Tighten Hex FL screws M6X14 (2 nos.) on the
bracket (2).
NOTE
Tightening torque 60 +10/-20 Nm valid with
BOSCH recommended mounting boss.

The brake pedal is fitted with a Brake switch, which

provides the information to ECU about the brake
pedal application. It gives signal to tail lamp, EMS
and ABS ECU.
LOCATION

Brake switch fitted on brake light switch mounting

bracket.
TIGHTENING TORQUE

DESCRIPTION TORQUE

Hex screw M8 4 to 5 Nm

29
EMS (3.3LNG BSVI)
CONNECTOR DETAILS INSPECTION
Disconnect the connector and check the continuity
between the following pins. When the pedal is
depressed there should be connectivity and when
it is released to rest position there should not be
connectivity.
NOTE
For switch adjustment details, refer brake section.
REFITMENT
Fit the brake light switch on the mounting bracket
and tighten its mounting nut.
NOTE
Refer brake section for brake switch adjustment
details.
PIN OUT:

PIN No. DESCRIPTION

PIN 1 Ground
PIN 2 Brake pedal signal to EMS
PIN 3 Ground
Brake pedal signal to transfer
PIN 4
case ECU

REMOVAL
1. Disconnect electrical connections of brake
switch.
2. Loosen the mounting nut of brake switch and
take out the brake switch by rotating
anticlockwise direction.

30
EMS (3.3LNG BSVI)
O. CLUTCH SWITCH TIGHTENING TORQUE

It provides information to ECU before the gear DESCRIPTION TORQUE

change which helps in faster gear change
detection. Based on this input the ECU maintains Against steel
8 kgfm
optimum fuel supply. It also gives signal to Transfer face
case ECU.
For AL casting 1.5 to 3.0 kgfm

CONNECTOR DETAILS

PIN No. DESCRIPTION

PIN 1 Signal Output

PIN 2 Ground

REMOVAL
1. Disconnect the electrical connection from the
clutch switch.
2. Loose and remove lock nut of clutch switch and
take out the clutch switch.

LOCATION
It is fitted on clutch switch mounting bracket.

INSPECTION
Disconnect the connector and check the continuity
between the pins. When the pedal is depressed
there should be connectivity and when released to
rest position there should not be connectivity.
REFITMENT
NOTE
1. Fit the clutch light switch on the mounting
A faulty clutch switch may disable the semi cruise bracket and tighten its mounting nut.
functionality on Vehicle thus impacting fuel
economy to some extent. NOTE
Refer clutch section for clutch switch adjustment
details.
A faulty switch may disable the semi cruise
functionality on vehicle thus impacting fuel
economy to some extent.

31
EMS (3.3LNG BSVI)
P. FUEL TEMPERATURE SENSOR 5. EMS SYSTEM ACTUATORS
The fuel temperature sensor, mounted on the fue A. ELECTRIC ACTUATOR FOR eVGT
filter assembly, provides information to the ECU
regarding fuel temperature. EVGT turbocharger is an electronic device that
controls the boost pressure depending on input
from ECU. It has electronic actuator along with an
internal stopper which restricts the actuator
movement in desired zones.

LOCATION

32
EMS (3.3LNG BSVI)
B. GRID HEATER 24VOLT: (If Applicable) C. INJECTORS
It is a simple heating coil fitted on the intake Fuel injectors are normally closed solenoid valves
manifold of the engine to aid for start-ability of the which operate when the electromagnetic core is
engine in extreme cold ambient conditions. energized by the ECU. Based on the Engine
operating conditions, ECU adjust the injection
pulse width to inject the precise amount of fuel
injected.

CONNECTOR DETAILS
It has a supply and ground connections through the
wiring harness.
INJECTOR FUNCTION
The duration of grid heater to be in 'ON' of 'OFF'
state is controlled by grid heater relay and  Injector not triggered:
calibration data in the ECU
The fuel, which comes from the rail* under high
pressure, reaches the control chamber and the
high pressure chamber of the jet via the high
pressure fuel feed. The bore to the fuel return line
is closed via the valve mushroom, which is
actuated by a spring.
The hydraulic force (F1), which will be exerted
through the high pressure of the fuel on the nozzle
needle in the control chamber, is greater than
hydraulic force (F2) which is effected on the tip of
the nozzle, since the surface of the control piston
in the control chamber is larger than the surface of
the tip of the nozzle.
The nozzle of the injector is closed.
 Injector triggered:
Solenoid operated actuator presses on the valve
piston and the valve mushroom opens a hole that
connects the control chamber with the fuel return
line.
That causes a pressure drop in the control
chamber and the hydraulic force (F2x), which
affects the nozzle needle, is larger than the force
(F1x) on the control piston in the control chamber.

33
EMS (3.3LNG BSVI)
The nozzle needle moves upwards and the fuel D. HIGH PRESSURE FUEL PUMP
reach the combustion chamber via the 7 spray
holes. The high pressure fuel pump is a demand
controlled radial piston pump.
When the engine is no longer running, the valve,
which connects the control chamber with the fuel The high pressure Pump supplies the volume flow
return line and the injector nozzle, is closed for the generation of the high pressure of the fuel
through the spring force. A small amount of fuel will in the rail*, providing the necessary fuel quantity to
be directed for lubrication purposes between the the injectors for all operating conditions of the
nozzle needle and the guide from the high pressure engine.
side directly into the return line. High pressure pump (CP4) is used to raise the fuel
NOTE pressure upto 2000 bar. It has an internal transfer
pump which raises the pressure upto 5 bar and this
The above mentioned method does not check the
is provided to high pressure section. It has three
functionality of the sensor throughout its range. It
ports, inlet, high pressure outlet and fuel return.
can only give a rough indication. To check the full
The High Pressure Pump is integrated with a
functionality, the sensors must be tested on a
Metering unit.
suitable test bench.
LOCATION
Injectors are mounted in cylinder head and
connected with HP pipes and back leak tube.

TIGHTENING TORQUE

DESCRIPTION TORQUE

Injector claw bolt

3.5 Kgfm
M8

34
EMS (3.3LNG BSVI)
E. METERING UNIT F. DeNOx SYSTEM
Metering unit regulates the delivery of fuel from the DeNOx system consists of the below parts:
internal low pressure transfer pump (ITP), which is 1. Supply Module
integrated into the diesel common rail pump (DCP),
2. Dosing Module
to the high pressure pump elements.
3. Level & temperature sensors
With that, the amount of fuel delivered by the high
Supply consists of pump with integrated level
pressure pump can already be adjusted to the
sensor. This is used to supply adblue at desired
requirements of the engine on the low pressure
pressure to the supply module.
side of the system.
Supply module is used to generate the necessary
The power consumption of the high pressure pump DEF pressure (approx. 6bar). It also consists of a
is reduced, improving the efficiency of the engine. purge pump, which sucks the adblue back into the
The volumetric control valve is directly screwed to tank once the engine is shut off. It has integrated
the diesel common rail pump (DCP). level & adblue temperature sensor.
Dosing module consists of a DEF injector with 3
equispaced holes to inject urea inside the mixer. It
is mounted over the exhaust mixer. As its tip comes
into contact with exhaust gas, it needs coolant to
control the tip temperature.

METERING UNIT FUNCTION

METERING UNIT not triggered:
The piston closes the link between the two
connections by means of the force generated by
the spring, without utilizing electrical current.
The fuel delivery to the high pressure pump is
interrupted.
METERING UNIT triggered:
The force exerted by the anchor is proportional to Reagent Used: Adblue which is a 32.5% urea
the electrical current and works against the force of solution is being used as reagent for SCR system.
the spring. Driver Warning System: Necessary attributes of
driver warning system have been accounted
Thus, the opening between the two connections is
through below methodology.
proportional to the electrical current (proportional
directional control valve). Low Reagent level: There is an indication in the
cluster for current reagent level as shown in the
below picture. Whenever the adblue level is less
than a specified threshold, driver warning &
corresponding inducements are set.

35
EMS (3.3LNG BSVI)
EGR valve tampering: If any error triggering EGR
to go off would attract MIL & warning lamp to be on.
MIL location:
The MIL is to be seen in the instrument pack .The
symbol confirms to ISO 2575, 1982 Symbol 4.36
(See picture below). It is located in the vehicle
instrument panel.

Low quality urea indicator: The DeNOx system

is equipped with urea quality sensor. Whenever the
quality is less than specified threshold (27%),
corresponding fault gets triggered & MIL gets
popped up.

Low / High Urea consumption: With the help of

UREA level sensor, whenever the adblue
consumption is deviated beyond specified
tolerance, error gets triggered & MIL gets popped
up.
DeNOx system tampering: If any of the critical
components of DeNOx system including dosing
module, supply module, pipe etc. are damaged or
removed, corresponding faults get triggered, MIL &
warning lamp gets popped up and corresponding
inducements are triggered.

36
EMS (3.3LNG BSVI)
G. EXHAUST GAS RECIRCULATION VALVE TIGHTENING TORQUE
(EGR)
DESCRIPTION TORQUE
The EMEGR valve (electric motor driven exhaust
gas recirculation valve) employs an electric DC Allen bolt M8 20 Nm
Motor and gear box
An eccentric drive translates the gear box output H. COMMON RAIL
from rotating motion to linear stroke
An angle sensor located on the output shaft of the
gear box detects the indirect position of valve
poppet. The position sensor is programmed such
that at valve stroke of typically 6mm results into
voltage difference of 3V. A return spring ensures
that the valve returns back to its closed position
The EMEGR valve has to be driven by closed loop
system. It is impossible to use EMEGR valve
without using the feedback sensor signal.
The EGR Cooler is a exchanger that is used to cool Its function is to maintain the desired high pressure
the exhaust gases before they are recirculated to inside. It has a rail pressure sensor to provide the
the intake manifold. The hot exhaust gases are pressure feedback to ECU. It also has a relief valve
routed into the EGR cooler from the exhaust pipes which allows the fuel to leak if the pressure
through metal tubes that are surrounded by engine exceeds beyond the desired set point. Rail
coolant. The cooled exhaust gas is more effective pressure control is a closed loop control operated
to help to reduce the pollutants. through ECU PID governing. It is critical to maintain
the desired rail pressure to achieve the emission
legislative limits.
I. EXHAUST THROTTLE VALVE

LOCATION
EGR valve fitted with EGR cooler. And both
assemblies mounted in the cylinder block. Exhaust throttle valve is a butterfly valve with an
electrical actuator and motor. It is used as a part of
engine thermal management strategy for 3.3L
BSVI engine. It is majorly operated during cold
phase for improving the exhaust temperatures
through throttling, creating additional restriction to
the exhaust flow and reducing A/F ratio up to the
desired extent.
It is again controlled by PIDs calibrated inside the
ECU. Actual & desired positions of the butterfly
valve are compared & corresponding to the error,
actuator position is commanded to meet the set
point.

37