Mahindra XUV 500 Diagnostic Manual

EMS DIAGNOSTIC MANUAL

MAN-00152

www.teknetmahindra.com

ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP-TO-DATE AT THE TIME OF PUBLICATION.
HOWEVER, SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE. THIS
MANUAL IS STRICTLY MEANT FOR RESTRICTED INTERNAL CIRCULATION WITHIN M&M AUTHORIZED
DEALER SERVICE CENTERS.

© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in
part, without the written permission of Mahindra & Mahindra Ltd.

RELEASED BY –

TECHNICAL PUBLICATION CELL
MAHINDRA & MAHINDRA LTD.

Rev1– OCTOBER 2011

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

CONTENTS

HOW TO USE THIS MANUAL 2

OVER VIEW OF THE VEHICLE COMMUNICATION NETWORK 3

EMS OVERVIEW 4

WARRANTY & OTHER INFORMATION 5

RECOMMENDED TROUBLE SHOOTING PROCESS 6

EMS ECU PIN DETAILS 7

EMS ECU CAN SIGNALS 10

IQA/IMA CODE PROGRAMMING 11

EMS ECU FLASHING 12

INDEX OF DTC CODES 20

EMS WIRING DIAGRAM 24

DTC BASED TROUBLESHOOTING 26

SYMPTOM BASED DIAGNOSIS- WITH NO DTC CODES 325

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

1

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

HOW TO USE THIS MANUAL

If the DTC code is known, then go to the Index of DTC code, and click on the group under which the

DTC appears. The codes/groups are hyperlinked to the respective trouble shooting chart/pages.

The following is the structure of the EMS Diagnostic Manual –

 DTC and its description
 Component location in the vehicle
 Normal operation of the system
 DTC detecting conditions
 Probable causes
 Lamp status
 DTC reaction on vehicle
 Healing Condition
 Connector layout
 Circuit Schematic
 Connector views and information
 Diagnostic tree

Always use the diagnostic manual along with the vehicle’s wiring manual (MAN-00149).

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

2

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

OVER VIEW OF THE VEHICLE COMMUNICATION NETWORK

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

3

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

EMS OVERVIEW

The EMS ECU uses the following sensors and actuators to govern all engine parameters for optimized

engine performance

Sensors/Switches

Hot Film Air Mass Flow Sensor

Engine Coolant Temperature Sensor

Ambient Air Pressure Sensor

Camshaft Position Sensor

Crankshaft Speed Sensor

Fuel Temperature Sensor

Gear Neutral Sensor

Boost Pressure Sensor

Rail Pressure Sensor

Accelerator Pedal Module

Tipple Pressure Switch

Vehicle Speed Sensor

Brake Switch

Clutch Sensor

Oil Pressure Switch

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

4

DIAGNOSTIC MANUAL MAN-00152

Actuators

EGR Actuator

Fan Control

Injectors

Fuel Metering Unit

Turbo charger actuator

Glow Plugs

A/C Compressor

Boost Pressure Actuator

EMS OCT 2011/Rev 1

WARRANTY & OTHER INFORMATION

All failures/complaints encountered on EMS ECU and other system components should be reported

through Service Complaint Report (SCR).Replacement of any of the EMS ECU and other system

components requires approval of the TEKline. Ensure that a TAR is raised# in the TEKnet website for

approval, attaching the SCR. While raising a warranty claim, the TAR no should be quoted on the warranty

claim.

# Only a trained and certified CoTEK can raise a TAR (in TEKnet website)

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

5

DIAGNOSTIC MANUAL MAN-00152



EMS OCT 2011/Rev 1

RECOMMENDED TROUBLE SHOOTINGPROCESS

Customer complaint

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

Record/Understand Customer Verbatim

 What happened?
 When it happened?
 What was the event before that?
 Does it happen all the time?

Does it happen only in some condition?

Search for Published quick solution in TEKnet.

Follow DTC based diagnosis

Contact TEKliner with TAR

(Technical Assistance Request)

6

DIAGNOSTIC MANUAL MAN-00152

7

EMS OCT 2011/Rev 1

EMS ECU PIN DETAILS

ECU

Connector

Pin no Function Connected To Pin no

1 GROUND GROUND G3
2 GROUND GROUND G3
3 POWER HIGH SIDE INJECTOR 1 - INJECTOR 4 1
4 POWER MAIN RELAY 87
6 POWER MAIN RELAY 87
6 POWER HIGH SIDE INJECTOR 3 - INJECTOR 2 1

7 POWER LOW SIDE INJECTOR 4 2
10 POWER CLUTCH SENSOR 4
11 GROUND COOLANT TEMPERATURE SENSOR 2
12 SIGNAL FUEL TEMPERATURE SENSOR 1
18 POWER ACCELERATOR PEDAL(APP1) 2
19 OIL PRESSURE SWITCH OIL PRESSURE SWITCH 1
20 SIGNAL-HIGH/LOW TRIPPLE PRESSURE SWITCH 2
22 SIGNAL VEHICLE SPEED SENSOR 3
23 85% SIGNAL CLUTCH SENSOR 1
23 POWER GEAR NEUTRAL SENSOR 1
24 REDUNDANT SIGNAL BRAKE SWITCH 4
25 SIGNAL-MIDDLE TRIPPLE PRESSURE SWITCH 3
29 POWER LOW SIDE INJECTOR 3 2
30 SHIELD CRANK SHAFT SPEED SENSOR 3
31 SIGNAL(AIR MASS) HOT FILM AIR MASS SENSOR 5
32 POWER RAIL PRESSURE SENSOR 3
33 SIGNAL COOLANT TEMPERATURE SENSOR 1
34 GROUND FUEL TEMPERATURE SENSOR 2
35 POWER BOOST PRESSURE SENSOR 3
40 POWER ACCELERATOR PEDAL(APP2) 1
41 15% SIGNAL CLUTCH SENSOR 2
41 SIGNAL GEAR NEUTRAL SENSOR 2
43 SIGNAL REVERSE SWITCH 2
44 GROUND CAM SHAFT POSITION SENSOR 1
45 POWER CAM SHAFT POSITION SENSOR 3
46 SIGNAL CAM SHAFT POSITION SENSOR 2
49 SIGNAL EXHAUST GAS RECIRCULATION ACTUATOR 2
50 SIGNAL MAIN RELAY 86
51 POWER LOW SIDE INJECTOR 2 2
52 SIGNAL (+) CRANK SHAFT SPEED SENSOR 1
53 GROUND HOT FILM AIR MASS SENSOR 1
54 SIGNAL RAIL PRESSURE SENSOR 2

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

ECU

Connector

Pin no Function Connected To Pin no

55 GROUND VEHICLE SPEED SENSOR 2
56 SIGNAL-P BOOST PRESSURE SENSOR 4
59 SIGNAL CLOCK SPRING 4
60 SIGNAL ACCELERATOR PEDAL (APP2) 6
61 SIGNAL ACCELERATOR PEDAL(APP1) 4
65 CAN LOW DLC CONNECTOR 14
66 CAN HIGH DLC CONNECTOR 6
68 SIGNAL COOLING FAN HIGH RELAY 86
71 POWER IGNITION SWITCH IG1
72 SIGNAL COOLING FAN LOW RELAY 86
73 POWER LOW SIDE INJECTOR 1 2
74 SIGNAL (-) CRANK SHAFT SPEED SENSOR 2

SIGNAL REF

75

(TEMPERATURE) HOT FILM AIR MASS SENSOR 2

76 GROUND RAIL PRESSURE SENSOR 1

SIGNAL

77

(TEMPERATURE) HOT FILM AIR MASS SENSOR 4
78 GROUND BOOST PRESSURE SENSOR 1
80 MAIN SIGNAL BRAKE SWITCH 2
81 GROUND CLOCK SPRING 3
82 GROUND ACCELERATOR PEDAL(APP2) 5
83 GROUND ACCELERATOR PEDAL(APP1) 3
87 SIGNAL-T BOOST PRESSURE SENSOR 2
89 SIGNAL FUEL METERING UNIT 2
91 SIGNAL A/C CLUTCH RELAY 86
92 SIGNAL BOOST PROCEDURE ACTUATOR 2
93 SIGNAL GLOW PLUG RELAY 86

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

8

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

ABBREVIATIONS

EMS Engine Management System

ABS Antilock Braking System

ESP Electronic Stability Program

MBFM Mahindra Body Function Module

IC Instrument Cluster

SRS Supplementary Restraint System

IS Infotainment System

SAS Steering Angle Sensor

HVAC Heating Ventilation and Air Conditioning

SC Sensor Cluster

RPAS Reverse Park Assist System

ITM Interactive Torque Management

ECU Electronic Control Unit

EHCU Electronic Hydraulic Control Unit

R Receiver

T Transmitter

HDC Hill Descent Control

HHC Hill Hold Control

WSS Wheel Speed Sensor

EBD Electronic Brake Distribution

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

9

DIAGNOSTIC MANUAL MAN-00152

EMS ECU CAN SIGNALS

Sl

no Signal Name Reciever

1 Accelerator pedal position ESP,ITM,MBFM,IC,IS
2 Engine speed ESP,ITM,MBFM,IC,IS
3 Status of cruise control regulation ESP
4 Cruise On/Off status IC,ESP
5 Current gear ESP, MBFM,IC,IS,RPAS,SRS,ITM
6 Glow plug on/off control IC
7 Engine Oil Pressure IC,IS
8 Engine Coolant Temperature IC,HVAC
9 Vehicle Speed MBFM,IC,IS,RPAS,HVAC

10 Odometer Distance IC
11 Engine Torque ESC,ITM, MBFM

EMS OCT 2011/Rev 1

Signals Transmitted by EMS ECU

12 Clutch Status ESC,ITM, MBFM
13 ESS Start Request MBFM
14 ESS status Indication IC
15 System check lamp Indication IC
16 MIL Indication IC
17 VIN data All ECU's
18 Cruise Set Speed ESP
19 Brake Pedal Status ESP, MBFM

Signals Received by EMS ECU

Sl no Signal Name Transmitter

1 Torque Reduction Request _ESP ESP
2 Torque Increment Request ESP
3 Cruise Shut Off ESP
4 A/C Compressor ON Request HVAC
5 Water in Fuel Status IC
6 Torque Reduction Request_ITM ITM
7 Door Status MBFM
8 ESS Switch Status MBFM

9 Crash Status SRS

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

10

DIAGNOSTIC MANUAL MAN-00152

INTERMITTENT PROBLEMS

Check the following for intermittent problems

 Poor mating of the connector halves/damage of connector locking
 Terminals not fully seated in the connector body
 Damage of harness and terminals
 Connector pin separation from wire
 Corrosion on pin contact points

IQA/IMA CODE PROGRAMMING

EMS OCT 2011/Rev 1

An ECU controlled engine needs precise metering of fuel. Due to manufacturing tolerances, each

injector deviates slightly from its idealized behavior. Thus, each injector has a correction factor,

which is engraved on top of it, in the form of a 8-character alphanumeric code , out of which the

last character "W" is a dummy value. This is known as an IQA code/IMA code. For optimal

performance of the engine, the ECU needs to know the IQA code/IMA code of each injector. This

information is programmed into the ECU when the vehicle is manufactured. However, if you need

to replace an injector(s), then the IQA code/IMA code for that new injector has to be updated in

the ECU. The cylinder number starts from the right side of the vehicle.

As a first step, you need to select the cylinder number of the injector being replaced. After the

cylinder number is selected by clicking on the check-button next to the number, the IQA

code/IMA code should be entered in the box provided.

Caution

Even though on the injector, 8 character alphanumeric code is engraved , while writing

the IQA code only the first 7 digits need to be entered

Click the button to the right of the text box. If the Injector code is valid and accepted by the ECU,
a message is displayed, indicating that the operation is performed successfully.

A message “Invalid IQA code” will be displayed , if an incorrect IQA/IMA code is keyed in. IQA

codes are case sensitive.

Programming IQA codes is an extremely important activity. In order to ensure that the correct

code has been entered and that it has been entered in the correct cylinder, SMART tester allows

you to verify the codes that you have entered.

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

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DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

Select an injector, and click the button below the ”Verify” line in figure. The IQA codes present in

the ECU will be read back and displayed in the text box before this button. It is recommended

that you carry out the verification activity whenever you change an IQA code.

PLEASE ENSURE TO PROGRAM IQA/IMA CODES WHEN YOU REPLACE AN INJECTOR, ECU or ENGINE.

The following are the fonts of the alphanumeric characters of the IQA/IMA code, as etched on
the injectors.

EMS ECU FLASHING

The EMS ECU required to be flashed in the following conditions

BLANK ECU

1. Procure blank EMS ECU from spare part dept.

1805AAA01571N ECU WITHOUT ETK EDC17C55*

* Check for the correct/latest part no in parts catalogue/Technical Service Bulletins.

2. Flash the EMS ECU dataset with a latest dataset as per TSB or at the advice of TEKline.

Notes -

1. Flash the EMS ECU with the correct/latest dataset. The matrix of the vehicles and the related latest

dataset will be released through TSB - if in doubt ask the TEKline.

2. Wrong dataset flashing may result in vehicle not starting and can lead to ECU failure.

Software

Version

V44 EDC17C55 1037519721

ECU Type Dataset ID Type Model

Factory/

Reflashing

XUV500

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

12

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

3. Ensure that the there is no communication breakdown once the flashing begins. Check Python

connections are secure.

4. Ensure that the SMART tester has -

 Enough battery reserve/Connected to AC power
 Screen saver/Battery saver mode turned off
 Vehicle’s ignition is ON
 Battery terminals connected securely.
 Battery earth connection is good.

5. Never touch the ECU pins by hand/finger

FLASHING PROCEDURE

1. Connect using the "Python 1BConfig0404"

2. Click the “XUV

500 field flashing tool” icon present on the desktop

The following window appears

3. Click on "Connect" . The following window appears

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

13

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

4 . Click on " READ VIN NUMBER " . The following window appears

5. Manually enter the VIN NUMBER in the box as shown and the following window appears

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

14

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

6. Click on " READ MODEL NUMBER " . The following window appears

7. Manually enter the MODEL NUMBER in the box as shown and the following window appears

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

15

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

8. Select "EMS " from the drop down list. The following window appears

9. The current data set is selected by default in the browse tab .Click " START FLASHING " to start flashing
. The following window appears after the flashing is successful.

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

16

DIAGNOSTIC MANUAL MAN-00152

7

EMS OCT 2011/Rev 1

10. Once the EMS ECU is flashed successfully , follow the below sequence to write VIN NUMBER ,

MODEL NUMBER , VARIANT CODING.

For writing the VIN click on "WRITE VIN NUMBER". The following window appears

11. For writing MODEL NUMBER click "WRITE MODEL NUMBER ". The following window

appears

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

1

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

12. For writing VARIANT CODING click "WRITE VARIANT CODING ". The following window

appears

Confirm VIN NUMBER , MODEL NUMBER and VARIANT CODING are successfully written in the

task bar

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

18

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

13. Click on "CONFIG" . The following window appears

14. Enter carefully the 7 digit "IQA code" against each cylinder as shown.

Click on "WRITE IQA Values" to write the IQA values

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

19

DIAGNOSTIC MANUAL MAN-00152

INDEX OF DTC's

GROUP DTC DESCRIPTION

HFM SENSOR- AIR

FLOW

BATTERY

COOLANT

TEMPERATURE

SENSOR

EEPROM

MONITORING

EGR

ENVIRONMENT

PRESSURE SENSOR

CAM PHASE

SENSOR

CRANKSHAFT

SPEED SENSOR

EMS OCT 2011/Rev 1

PAGE

NO

Signal range check for HFM7 sensor signal above

P0103

maximum limit

26

Signal range check for HFM7 sensor signal below

P0102
P1100 Signal Error for HFM7 sensor

P0100 Battery voltage error of HFM6 sensor

minimum limit

30

35

39

HFM7 sensor drift Compensation beyond the limit at Low

P0101

Idle.

41

HFM7 sensor drift Compensation beyond the limit at

P1101
P0563 Battery voltage high error
P0562 Battery voltage low error

loaded condition.

41

43

45

Coolant Temperature Sensor Absolute Test non plausible

P1128

error

50

Coolant Temperature Sensor Dynamic Test non plausible

P1126

error

Signal Range Check for coolant temperature sensor

P0118

above maximum limit

52

Signal Range Check for coolant temperature sensor

P0117
P062F ECU EEPROM error
P162F ECU EEPROM error
P1630 ECU EEPROM error
P062B ECU monitoring error for Injector cut off demand
P0403 EGR Valve open load error
P1403 EGR Valve over temperature error
P0406 EGR Valve short to battery error
P0405 EGR Valve short to ground error

below minimum limit

57

62

64

66

68

70

74

76

80

Signal Range Check for Environmental pressure sensor

P2229

above maximum limit

84

Signal Range Check for Environmental pressure

P2228

P0340 Camshaft sensor no signal error
P0341 Camshaft sensor signal error
P1341 Camshaft sensor signal offset error
P0336 Crankshaft sensor signal error
P0335 Crankshaft sensor no signal error

sensor below minimum limit 86

88

93

97

99

104

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

20

DIAGNOSTIC MANUAL MAN-00152

GROUP DTC DESCRIPTION

COOLING FAN RELAY

FUEL TEMPERATURE

SENSOR

IQA CODE

MONITORING

INJECTORS

METERING UNIT

BOOST PRESSURE

SENSOR

BOOST TEMPERATURE

SENSOR

RAIL PRESSURE

SENSOR

EMS OCT 2011/Rev 1

PAGE

NO

P0480 Low speed fan open load
P0481 High speed fan open load
P0692 Low speed fan short to battery
P0694 High speed fan short to battery
P0691 Low speed fan short to ground
P0693 High speed fan short to ground

109

112

115

119

123

126

Signal range check for fuel temperature sensor above

P0183

maximum limit

129

Signal range check for fuel temperature sensor below

P0182
P268C Cylinder1 injector adjustment code incorrect error
P268D Cylinder2injector adjustment code incorrect error
P268E Cylinder 3 injector adjustment code incorrect error
P268F Cylinder4 injector adjustment code incorrect error
P0201 Cylinder1 injector open load error
P0202 Cylinder2 injector open load error
P0203 Cylinder3 injector open load error
P0204 Cylinder4 injector open load error
P0261 High side - Low side short circuit for cylinder1 injector
P0264 High side - Low side short circuit for cylinder2 injector
P0267 High side - Low side short circuit for cylinder3 injector
P0270 High side - Low side short circuit for cylinder4 injector
P2146 Short circuit in bank 0
P0001 Metering unit open load error
P0004 Metering unit output short circuit to battery error
P0003 Metering unit output short circuit to ground error

minimum limit

133

138

140

142

144

146

150

154

158

162

166

170

174

178

181

185

189

Signal range check for manifold absolute pressure sensor

P0238

above maximum limit

193

Signal range check for intake manifold absolute pressure

P0237

sensor below minimum limit

198

Signal range check for intercooler downstream

P007D

temperature sensor above maximum limit

203

Signal range check for intercooler downstream

P007C

temperature sensor below minimum limit

208

Signal range check for rail pressure sensor above

P0193

maximum limit

212

Signal range check for rail pressure sensor below

P0192
P0191 Rail pressure offset value above maximum limit
P1191 Rail pressure offset value above minimum limit
P169F Rail pressure raw value is intermittent

minimum limit

217

222

225

228

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

21

DIAGNOSTIC MANUAL MAN-00152

GROUP DTC DESCRIPTION

ACCELERATOR PEDAL

MODULE

HFM SENSOR-

TEMPERATURE

BOOST PRESSURE

MODULATOR

VEHICLE SPEED

SENSOR

SENSOR SUPPLY

MONITORING

EMS OCT 2011/Rev 1

PAGE
NO

Signal range check for APP sensor1 above maximum

P2123

limit 231
Signal range check for APP sensor2 above maximum

P2128

limit 236

P2138 Plausibility error between APP signal1 and signal2 241

Signal range check for HFM 7 temperature sensor

P0113

above maximum limit 248

Signal range check for HFM 7temperature sensor

P0112

below minimum limit 253
P0045 Boost pressure modulator open load error 257
P0048 Boost pressure modulator short circuit to battery 261
P0047 Boost pressure modulator short circuit to ground 265
P1645 Boost pressure modulator over temperature error 269

P0501 Vehicle speed sensor plausibility error 273
P0641 Sensor supply voltage1 monitoring error 278

P0651 Sensor supply voltage2 monitoring error 282

P0697 Error Sensor supplies 3 284

RAIL PRESSURE

GOVERNOR

MAIN RELAY

BRAKE SWITCH

CLUTCH SENSOR

GEAR NEUTRAL

Rail pressure positive governor deviation error in
P1B87

Metering Unit mode 286

Positive governor deviation and setpoint value of the
P1C87

fuel volume flow through the metering unit. 289

Rail pressure negative governor deviation error in
P1B88

Metering Unit mode 292

Rail pressure below minimum limit error in Metering
P1D87

Unit mode 294

Rail pressure above maximum limit error in Metering
P1C88

Unit mode 295
P068A Main relay early opening error 297
P068B Main relay struck error 297
P0504 Brake Signal plausibility error. 303
P0704 Clutch non plausible error 308

SENSOR P1704 Gear Neutral Signal is not plausible 313

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

22

DIAGNOSTIC MANUAL MAN-00152

GROUP DTC DESCRIPTION

CONTINUOUS

TORQUE

MONITORING

IMMOBILISER

EMS OCT 2011/Rev 1

PAGE
NO

P1900 ECU Monitoring: ADC NTP error
P163B ECU Monitoring: ADC test error
P163C ECU Monitoring: Voltage ratio error in ADC
P1621 ECU Monitoring: Query response communication error
P1622 ECU Monitoring: SPI communication error
P0605 ECU Monitoring: ROM memory error

318

P1623 ECU Monitoring: CPU error
P1625 ECU Monitoring: Response time error in ECU

ECU Monitoring: Shut off path test SPI communication

P1626

error
P1628 ECU Monitoring: Shut off path under voltage error
P1629 ECU Monitoring: WDA not working
P162A ECU Monitoring: Time out error

319

P162C ECU Monitoring: Positive test failure error
P162D ECU Monitoring: Time out error for shut off path test
P060D ECU Monitoring: Accelerator position error
P061C ECU Monitoring: Engine speed error

320

P1638

ECU Monitoring: Rail pressure monitoring plausibility

error
P060A ECU Monitoring: Energising time plausibility error
P1631 ECU Monitoring: Start of Injection plausibility error
P1632 ECU Monitoring: ZFC non plausibility error

321

322

P1633 ECU Monitoring: PoI2 qty error
P1634 ECU Monitoring:PoI2 shut off error
P1635 ECU Monitoring:PoI3 efficiency factor error
P1636 ECU Monitoring: Overrun monitoring error
P1637 ECU Monitoring: Injection quantity correction error
P061B ECU Monitoring: Torque comparison error

323

P163E ECU Monitoring: Torque monitoring level2 error
P1639 ECU Monitoring: Lead torque monitoring level2 error
P163D ECU Monitoring: Set torque monitoring level2 error
P1832 Immobiliser authentication error
P183F Immobiliser not present in vehicle

324

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

23

DIAGNOSTIC MANUAL MAN-00152

EMS ECU WIRING DIAGRAM

EMS OCT 2011/Rev 1

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

24

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

25

DIAGNOSTIC MANUAL MAN-00152

EMS OCT 2011/Rev 1

P0103 - Signal range check for HFM7 sensor signal above maximum limit

HOT FILM AIR MASS SENSOR (HFM)

Mass air flow rate is measured by detection of heat transfer from a hot film probe because the change of

the mass air flow rate causes change in the amount of heat being transferred from the hot film probe

surface to the air flow. The airflow sensor generates a pulse so it repeatedly opens and closes between

the 5V voltage supplied from the engine control module. This results in the change of the temperature of

the hot film probe and in the change of resistance.

COMPONENT LOCATION

NORMAL

OPERATION

DTC DETECTING

CONDITION

PROBABLE

CAUSES

LAMP STATUS

DTC REACTION

HEALING

CONDITION

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

 During ignition ON , HFM sensor outputs a voltage with respect to the intake

air flow to EMS ECU and is within the range

 The measured output voltage of the sensor is more than 5.25 V for 0.5 Second

 HFM (air mass) signal wire short to battery
 HFM sensor internal failure

 OBD lamp ON

 EGR switches OFF
 Ignition Off/On

26

DIAGNOSTIC MANUAL MAN-00152

7

CONNECTOR LAYOUT

EMS OCT 2011/Rev 1

CIRCUIT SCHEMATIC

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

2

DIAGNOSTIC MANUAL MAN-00152

CONNECTOR VIEWS AND INFORMATION

EMS OCT 2011/Rev 1

CONNECTOR

NOMENCLATURE

E1

PIN NO

5

FUNCTION

SIGNAL(AIR MASS)

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

28

DIAGNOSTIC MANUAL MAN-00152

STEP 2

Ignition OFF
HFM sensor wiring harness
connector DISCONNECTED
Ignition ON

Check the voltage between pin
5 of the HFM sensor wiring
harness connector and battery
ground

Connect the smart tester

Turn the ignition ON

Initialise the diagnostic tool

Record the DTC and clear

Turn ignition OFF

Turn ignition ON

Verify if P0103 is present?

YES

EMS OCT 2011/Rev 1

STEP 1

Is P0103 present?

NO

Intermittent problem exists
Refer the intermittent problem
inspection procedure

YES NO

Suspect internal failure of HFM
sensor
Replace the HFM sensor with a
new one
Clear the DTC and verify

Is the value >5.25 V?

Examine the short circuit of
HFM sensor air mass signal wire
to battery
Repair/replace the wiring
harness
Clear the DTC and verify

The repair methods given by the manuf acturer in this document are based on the tec hnical specifications , current at the time of release. T he methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component u nits and acces sories from which th e vehicles are m anufactured. T he reproduction, transl ation, transm ission, in part of or who le of the present doc ument,
are prohibited without the prior written c ons e nt of Ma hi ndra & Ma hi ndra L t d. The us e of this d ocument by any person other than the trained p er sonn el, at the Authorized Service Centre of Mahindr a & M ahi ndra Ltd. ,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

29