Mahindra Genio DC BS-III User manual

© 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.
DIAGNOSTIC MANUAL (IMMOBILISER)
BS-III / BS-IV
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 RESTRICT
ED INTERNAL CIRCULATION WITHIN M&M AUTHORIZED
DEALER SERVICE CENTERS.
RELEASED BY –
TECHNICAL PUBLICATION CELL
MAHINDRA & MAHINDRA LTD.
Rev1 – AUGUST 2011
MAN-00138

©2010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.
About the Diagnostic Manual
The diagnostic manual outlines the detailed pr ocedures to troubleshoot complaints related to the
Immobiliser System in GENIO BS III & BS IV vehicle. Since Immobiliser system is related to vehicle
security; on ly a t rained aut horized per sons can work on t he Immo biliser system in con junction
with M&M diagnostic tool.
The manual consists of –


Trouble shooting and diagnosis of DTCs (Defect Trouble Codes)
Use of the Genio immobiliser diagnostic tool.
Trouble shooting chart.
Inspiteofbesteffortstomakethemanualerrorfree,afewerrorscouldhaveinadvertentlycreptin.

Ifyou

identifyerrors,functionalortypographical,pleaseinformyourTEKline,[email protected]or
[email protected]om.Suggestionstoimprovethemanualandmakeitmoreuserfriendlyarealso
welcome.


Diagnostic Manual (Immobiliser) MAN-00138-3
Genio DC - BS III & BS IV August 2011/Rev 1
All copyrights reserved by
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced
by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the
present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd.
Contents
oHow to use this manual
oOverview of in-vehicle communication network
oRecommended troubleshooting process
oWarranty/Other information
oKey Assignment guideline
oKey Assignment process.
oRemote Learning
oEMS ECU replacement
oImmobilizer ECU replacement
oList of Unavailable Services
oIndex of DTC codes
oUsing diagnostic tool
oTroubleshooting chart
oWiring Diagram

Diagnostic Manual (Immobiliser) MAN-00138-4
Genio DC - BS III & BS IV August 2011/Rev 1
All copyrights reserved by
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced
by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the
present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd.
How to Use this manual
.
This is a combined Immobiliser diagnostic manual for GENIO SC as well as DC models.
The manual is divided in to 2 parts. The first part outlines the procedure to be followed
when any of the components, viz Keys, EMS ECU or Immobilser ECU (ICU), needs to be
replaced. The second part outlines the trouble shooting process.
The following is the structure of the Diagnostic Manual (Trouble shooting process) –
•Combination of Error Codes
•Reason
•Check lamp status
•Vehicle Behavior
•Probable Cause
•Trouble shooting steps
The DTCs for Immobilser are generated at the ICU as well as at the Engine Management
System(EMS) ECU. Hence it is essential that after looking at the DTC at ICU, the DTC at
the EMS ECU should also be checked. Based on the combination of DTCs, the possible
causes and the corrective actions to be taken.
It is also essential to clear the DTCs in both ICU and EMS ECU. The diagnostic manual
should always be used along with the vehicle’s wiring manual (MAN – 00137).

Diagnostic Manual (Immobiliser) MAN-00138-5
Genio DC - BS III & BS IV August 2011/Rev 1
All copyrights reserved by
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced
by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the
present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd.
Overview of the in-vehicle communication network
DLC
EMS ICU
CAN

Diagnostic Manual (Immobiliser) MAN-00138-6
Genio DC - BS III & BS IV August 2011/Rev 1
All copyrights reserved by
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced
by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the
present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd.
Recommended Trouble Shooting Process
Customer complaint
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)

Diagnostic Manual (Immobiliser) MAN-00138-7
Genio DC - BS III & BS IV August 2011/Rev 1
All copyrights reserved by
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced
by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the
present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd.
Warranty & Other Information
All failures/complaints encountered on EMS ECU and/or ICU controllers need to be
reported through a Common Rail Failure Report (CrFR)/Service Complaint Report
(SCR).
Replacement of any of the EMS ECU or ICU controller requires approval of the
TEKline. Ensure that a TAR is raised#in the TEKnet website for approval, attaching
the CrFR/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)

Diagnostic Manual (Immobiliser) MAN-00138-8
Genio DC - BS III & BS IV August 2011/Rev 1
All copyrights reserved by
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced
by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the
present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd.
Key assignment guideline
Note - Only 2 keys/vehicle possible at any point of time
Notes –
1. Duplicate key should be ordered after customer verification by the dealer
2. Fill up the DKR format (Duplicate Key Request) and mail it to
[e-mail]
3. Once the new key is received, follow the key assignment process as below.
Key
Additonal key
Not possible
Key lost / stolen/
failure
Reassign Existing
key
Order Mechanical
Key (DKR)
Assign New
Key

Diagnostic Manual (Immobiliser) MAN-00138-9
Genio DC - BS III & BS IV August 2011/Rev 1
All copyrights reserved by
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced
by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the
present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd.
Key Assignment Process
Important Note -
1. Whenever the key is replaced and if the vehicle is with keyless entry then
the remote learning has to be performed
Key
Request
•Customer Verification
Key
Order
•Order new key using the Duplicate Key Request (DKR) process.
TPK1
•Select "Key Programming"
•SMART tester will generate Tool Programming Key-1 -Valid for 48 hours.
•Raise a TAR along with Tool Programming Key –1 (TPK1)
ASC1
•TEKline will provide After Sales Code -1 (ASC1) based on TPK1
•ASC1 is valid until TPK1 is valid.
TPK2
•Based on the ASC1, reassign key. SMART tester will generate Tool Programming
Key –2 (TPK2)
•TPK2 to be provided to TEKliner
ASC2 •TEKline will provide After Sales code -2 (ASC2)
Finish
•CoTEK will enter the ASC2 and complete the Key assignmnet session
•Close TAR

Diagnostic Manual (Immobiliser) MAN-00138-10
Genio DC - BS III & BS IV August 2011/Rev 1
All copyrights reserved by
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced
by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the
present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd.
EMS ECU Replacement
Important Note -
1. For EMS dataset flashing procedure, refer to EMS diagnostic manual.
Order for blank
ECU
FLash the ECU using the Flash
tool with the correct VIN no
and the correct dataset.
Do the ECU
assignment
process
TPK1
•Select "EMS ECU Programming"
•SMART tester will generate code -Valid for 48 hours.
•Raise a TAR along with Tool Programming Key –1 (TPK1) generated from
SMART tester
ASC1
•TEKline will provide After Sales Code -1 (ASC1) based on Access Password
•ASC1 is valid until TPK1 is valid
TPK2
•Based on the entry password, learn EMS ECU. SMART tester will generate
Tool Programming Key –2 (TPK2)
•TPK2 to be provided to TEKliner
ASC2
•TEKline will provide After Sales Code -2 (ASC2)
Finish
•CoTEK will enter the ASC2 and complete the EMS learning session
•Close TAR