5.
Maintenance Section
9. Special Functions
Table of Contents
9.1 Flash Programming ........................................................................... 9.1
9.2 Calibration.......................................................................................... 9.14
9.3 ECU Replacement............................................................................. 9.19
9.4 K-factor value list.............................................................................. 9.26
Troubleshooting
Diagnostics Manual -
Special Functions
5. Maintenance Section
9.1 Flash Programming
• Flash programming is a diagnostic function of reprogramming a control module, to enhance its
functionality or to rectify a fault in the internal programming. Here there are two types of files which
are used for flashing.
1) HEX files - Flashing of parameters related to the engine.
2) DCM files - Flashing of parameters related to the vehicle.
Notice
Flash programming can be performed only under the following scenarios:
1. Whenever there is an upgrade in the flash-ware.
2. Engine Replacement (Only in V1.1.5 Release, V1.2 release will have seperate tab for Engine
replacement).
• Pre-Requisites
– Ensure that the VIN entered while logging on to the application is same as the one for which
flashing is to be performed. This is because the flash-ware data of the VIN entered in the initial
screen will be downloaded from the database (Online mode) or from the DVD (Offline mode).
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Troubleshooting
9-1 Diagnostics Manual -
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5. Maintenance Section
Start flash
HEX*
HEX DCM
or
DCM**
Satisfy Satisfy
Pre-conditions Pre-conditions
New HEX file New DCM file
is available do No is available do No
you want to you want to
flash with new flash with new
HEX file? DCM file?
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Yes Yes
Troubleshooting
HEX File DCM File
upgradation upgradation
Flashing process Flashing process
1) Protected area 1) EOL 1
2) Code area 2) EOL 2
3) Data area 3) EOL 3
Flashing
4) EOL 4
successful
Flashing
successful
* It is highly recommended to flash the HEX file first
** DCM alone is to be flashed only if the engine is replaced under the
assumption that the new float engine is coming with a pre-flashed ECU Stop flash
9-2 Diagnostics Manual -
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5. Maintenance Section
• Always flash the HEX file first and then proceed with the DCM file flashing. Select the file and click on
the “Flash” button.
Special Functions
Troubleshooting
9-3 Diagnostics Manual -
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Special Functions 5. Maintenance Section
Troubleshooting
• Ensure the above pre-conditions are satisfied and then click on “Yes, Checked” button.
9-4 Diagnostics Manual -
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5. Maintenance Section
• A window pops-up, as and when the ECUSpace detects an upgrade to the HEX file.
Notice
Ensure to upgrade the DCM file once the HEX file is been upgraded.
• Click on “Yes” to flash with the upgraded file.
Special Functions
Troubleshooting
Notice
User should not stop the flashing process in the middle. It might take minimum 5 minutes for the HEX
file to be flashed.
Notice
Upgradation of the HEX or DCM file in the offline mode will be effective only from the ECUSpace
release V1.2.
It is always recommended to do the flashing in the Online Mode.
9-5 Diagnostics Manual -
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Special Functions 5. Maintenance Section
Troubleshooting
• The flash programming proceeds in three areas
1. Protected Area
2. Code Area
3. Data Area
9-6 Diagnostics Manual -
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5. Maintenance Section
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Troubleshooting
• After the flash programming of HEX file is successful, the below screen will appear.
9-7 Diagnostics Manual -
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5. Maintenance Section
DCM Flashing
• Select DCM from the flash file type list.
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Troubleshooting
9-8 Diagnostics Manual -
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5. Maintenance Section
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Troubleshooting
• After satisfying the pre-conditions click on “Yes, Checked” button.
9-9 Diagnostics Manual -
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5. Maintenance Section
• A window pops-up, as and when the ECUSpace detects an upgrade to the DCM file.
Notice
Ensure to upgrade the HEX file once the DCM file is been upgraded.
• Click on “Yes” to flash with the upgraded file.
Special Functions
Troubleshooting
Notice
User should not stop the flashing process in the middle. It might take minimum 5 minutes for the DCM
file flashing to be completed.
Notice
Upgradation of the HEX or DCM file in the offline mode will be effective only from the ECUSpace
release V1.2.
9-10 Diagnostics Manual -
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5. Maintenance Section
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Troubleshooting
9-11 Diagnostics Manual -
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5. Maintenance Section
• The flash programming proceeds in a four step process.
1. EOL1 3. EOL3
2. EOL2 4. EOL4
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Troubleshooting
9-12 Diagnostics Manual -
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5. Maintenance Section
• The flash programming is successful, after all the four processes end.
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Troubleshooting
9-13 Diagnostics Manual -
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5. Maintenance Section
9.2 Calibration
• It is the process of calibrating the ECU with specified values for required set of parameters when a
specific component is replaced .
• Calibration process is performed under the following scenarios:
1. Injector replacement.
2. Engine replacement.
3. Max vehicle speed editing.
4. Rail replacement.
• To calibrate the ECU, following parameters are available:
1. Idle Speed.
2. IQA.
3. Engine Serial Number (ESN).
4. Torque value correction.
5. Max Speed Limit.
6. PRV reset.
• For Example: Calibration of the injectors with the IQA codes is done after performing the following
operations:
– Replacement of the Injectors.
Special Functions
– Engine Replacement.
Troubleshooting
• The IQA code is a 7 digit code present on the top of each injector (as shown in the illustration below).
9-14 Diagnostics Manual -
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5. Maintenance Section
• The Engine Serial Number (ESN) is located on the engine block above the starter motor (as shown in
the illustration below).
4D34i - XXX
4XX.9XX X XXXXXXX
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Troubleshooting
DICV-ENG-0358
Notice
Ensure the ignition is ON and engine is in OFF condition.
9-15 Diagnostics Manual -
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5. Maintenance Section
• Click ‘Forward’ to read the calibration parameters.
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Troubleshooting
9-16 Diagnostics Manual -
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5. Maintenance Section
• Enter the relevant field values when performing the following operations.
1. Injector Replacement.
a) IQA codes 7 digit alphanumeric code present on individual injectors
2. Engine Replacement.
a) Idle speed ± 100
b) ESN (Engine Serial Number) Present in the engine block
c) IQA codes 7 digit alphanumeric code present on individual injectors
d) Torque Value 1
3. Max vehicle speed limit adjustment.
a) Speed Limit As required (should not exceed the default value)
4. Common rail Replacement.
a) PRV Count 0
b) PRV Time 0
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Notice
Troubleshooting
PRV count and time needs tobe set to ‘0’ even during engine replacement.
9-17 Diagnostics Manual -
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5. Maintenance Section
Notice
Even if one injector is being replaced the user needs to enter IQA codes of all the injectors.
• Click on ‘Calibrate ECU’ to initiate the calibration process.
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Troubleshooting
9-18 Diagnostics Manual -
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5. Maintenance Section
9.3 ECU Replacement
Notice
ECU replacement process is performed under the following scenarios.
1. ECU replacement
2. Engine replacement (Only in V1.1.5 Release, V1.2 release will have seperate tab for Engine
replacement)
• When replacing the existing ECU with a new one, enter the ECU Part number and click on ‘Start’.
• The ECU part number is A4001530479.
Special Functions
Troubleshooting
9-19 Diagnostics Manual -
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5. Maintenance Section
• The process starts with the flashing of HEX and DCM files.
Notice
User should not stop the ECU replacement process in the middle. It might take minimum 10~15
minutes for the process to be completed.
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Troubleshooting
• After the HEX and DCM files are flashed the ECU automatically detects and writes in its memory
parameters such as:
– Engine Serial No. – IQA for injector 2
– VIN – IQA for injector 3
– Calibration ID for Engine – IQA for injector 4
– Calibration ID for Vehicle – Torque Limit Adjust Value
– IQA for injector 1
• All the parameters except the ‘Vehicle Speed Limit’ parameter gets written.
9-20 Diagnostics Manual -
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5. Maintenance Section
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9-21 Diagnostics Manual -
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• A window pops-up, stating the ‘vehicle speed limit’ parameterization needs to be done in the
calibration menu.
• Click OK.
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Troubleshooting
9-22 Diagnostics Manual -
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5. Maintenance Section
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9-23 Diagnostics Manual -
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5. Maintenance Section
• Go to the calibration window, set the speed limit and click on “Calibrate ECU”.
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Troubleshooting
9-24 Diagnostics Manual -
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5. Maintenance Section
• After the ECU calibration is successful, the below screen will appear.
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Troubleshooting
9-25 Diagnostics Manual -
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5. Maintenance Section
9.4 K-Factor Value
Gear Box Axle Tyre
K- Factor
S.No Model
TRAN CODE RAR CODE TYRE SIZE CODE TYPE Value
1 M036 GD8 5.13 AF9 8.25R16 WX0 Radial 4805
2 M036 GD8 5.13 AF9 8.25X16 I17 Crossply 4805
3 M036 GD8 5.13 AF9 235/75R17.5 WW2 Tubeless 5183
914R
4 M036 GD8 4.56 AO1 8.25R16 WX0 Radial 4272
5 M036 GD8 4.56 AO1 8.25X16 I17 Crossply 4272
6 M036 GD8 4.56 AO1 235/75R17.5 WW2 Tubeless 4607
7 1017R G85 GC6 4.56 AO1 235/75R17.5 WW2 Tubeless 9119
8 G85 GC6 6.33 AI8 8.25R20 WX1 Radial 10213
9 G85 GC6 6.33 AI8 8.25X20 I08 Crossply 10213
10 G85 GC6 5.13 AF9 8.25R20 WX1 Radial 8276
1214R
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11 G85 GC6 5.13 AF9 8.25X20 I08 Crossply 8276
12 G85 GC6 6.33 AI8 255/70R22.5 WW1 Tubeless 10859
Troubleshooting
13 G85 GC6 5.13 AF9 255/70R22.5 WW1 Tubeless 8800
14 G85 GC6 5.13 AF9 8.25X20 I08 Crossply 8276
15 G85 GC6 6.33 AI8 8.25X20 I08 Crossply 10213
1214R(12.8T)
16 G85 GC6 5.13 AF9 8.25R20 WX1 Radial 8276
17 G85 GC6 6.33 AI8 8.25R20 WX1 Radial 10213
18 G85 GC6 6.33 AI8 8.25R20 WX1 Radial 10213
19 1217C G85 GC6 6.33 AI8 8.25X20 I08 Crossply 10213
20 G85 GC6 6.33 AI8 255/70R22.5 WW1 Tubeless 10859
21 G85 GC6 5.57 AU0 10X20 I09 Crossply 8309
22 G85 GC6 5.57 AU0 10R20 I30 Radial 8309
23 1617R G85 GC6 5.57 AU0 295/80R22.5 I64/I65 Tubeless 8309
24 G85 GC6 6.17 AC8 10R20 I30 Radial 9266
25 G85 GC6 6.17 AC8 295/80R22.5 I64/I65 Tubeless 9266
9-26 Diagnostics Manual -
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