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

Diagnostic Manual (Immobiliser) MAN-00138-11
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.
Immobilizer ECU (ICU) Replacement
Order for blank
Immobilizer ECU Do the Immobilizer ECU
assignment process
TPK1
•Select "Immobiliser 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 TPK1
•ASC1 is valid until TPK1 is valid
TPK2
•Based on the ASC1, learn ICU/Reassign keys. 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 ICU learning session
•Close TAR

Diagnostic Manual (Immobiliser) MAN-00138-12
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.
List of Unavailable Services
The following actions are not possible –
1. Replacement of EMS ECU when both keys are not available
2. Replacement of Immobilizer ECU (ICU) when both keys are not available
3. Replacement of EMS ECU and Immobilizer ECU (ICU) when both keys are
not available
4. Simultaneous replacement of EMS ECU and ICU.
Contact TEKline for any advise/assistance

Diagnostic Manual (Immobiliser) MAN-00138-13
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.
Index of DTCs
Error Codes In ICU
Code
Label
8040 Transponder Missing/No Transponder
8041 Invalid Transponder
8042 Wrong Transponder
8043
No Transponder is Learnt
8044
No ECM Challenge
8045
ECM Authentication Failed
8048
F() mismatch
8049
No ECM Acknowledgement
804A
Negative Acknowledgement
Error Codes In EMS
Code
Label
P1832
Immobilizer Authentication Failed
P183F
No ICU Response
P183B
Locked State
NOTE: Error codes come in combinations and each combination has its own
interpretation which is given in the following pages according to priority. At any
time if there are more codes than any combination given below, the first
combination to be attended will be the one higher in the below table and then
proceed to the next one. Contact your TEKline in case you come across any
difficulty.
A troubleshooting chart, which is the tabular form of this entire manual, is given in
page 20 & 30. Suggest using that along with the wiring diagram of the vehicle to
develop troubleshooting skill.

Diagnostic Manual (Immobiliser) MAN-00138-14
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.
Combination - 1 Page
ICU EMS
16
Code Description Code Description
1832 Immobilizer Authentication Failed
183F No ICU Response
Combination - 2 Page
ICU EMS
17
Code Description Code Description
8044 No ECM Challenge
Combination - 3 Page
ICU EMS
18
Code Description Code Description
8042 Wrong Transponder 1832 Immobilizer Authentication Failed
183F No ICU Response
Combination - 4 Page
ICU EMS
19
Code Description Code Description
8043 No Transponder is Learnt 1832 Immobilizer Authentication Failed
183F No ICU Response
Combination - 5 Page
ICU EMS
20
Code Description Code Description
8040 Transponder Missing/No
Transponder 1832 Immobilizer Authentication Failed
183F No ICU Response

Diagnostic Manual (Immobiliser) MAN-00138-15
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.
Combination - 6 Page
ICU EMS
22
Code Description Code Description
8041 Invalid Transponder 1832 Immobilizer Authentication Failed
183F No ICU Response
Combination - 7 Page
ICU EMS
24
Code Description Code Description
8048 F() mismatch 1832 Immobilizer Authentication Failed
8045 ECM Authentication Failed
Combination - 8 Page
ICU EMS
25
Code Description Code Description
8044 No ECM Challenge 1832 Immobilizer Authentication Failed
183F No ICU Response
Combination - 9 Page
ICU EMS
26
Code Description Code Description
8049 No ECM Acknowledgement 1832 Immobilizer Authentication Failed
8045 ECM Authentication Failed
Combination - 10 Page
ICU EMS
27
Code Description Code Description
804A Negative Acknowledgement 1832 Immobilizer Authentication Failed
8045 ECM Authentication Failed

Diagnostic Manual (Immobiliser) MAN-00138-16
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.
Combination – 1
ICU EMS
Code Description Code Description
1832 Immobilizer Authentication Failed
183F No ICU Response
Reason:This combination is registered when the signal from the EMS ECU is not
received by the ICU and the ICU is not getting powered on.
Check lamp Status: Blinking.
Vehicle Behavior: Engine not starting.
Probable Causes:
1. ICU not getting powered on after ignition is turned on.
2. Defective ICU.
Corrective Action:
•Check the power supply and ground to the ICU (Click here for procedure).
If everything found ok,
•Replace the ICU and do the ICU learning. Clear codes, ensure proper
functioning and deliver the vehicle.

Diagnostic Manual (Immobiliser) MAN-00138-17
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.
Combination – 2
ICU EMS
Code Description Code Description
8044 No ECM Challenge
Reason:This combination is registered when the signal from the EMS ECU is not
received by the ICU and the EMS is not getting powered on.
Check lamp Status: Off.
Vehicle Behavior: Engine not starting.
Probable Causes:
1. Disturbance in CAN wiring between EMS and ICU as well as EMS and
diagnostic connector (DLC).
2. EMS not getting powered on after ignition is turned on.
3. Defective EMS ECU.
Corrective Action:
•Check the CAN wiring between ICU and EMS ECU (Click here for
procedure).
•Check the CAN wiring between EMS ECU and DLC (Click here for
procedure).
If everything found ok,
•Check the power supply and ground to the EMS ECU (Click here for
procedure).
•Make sure the main relay and complete wiring is thoroughly checked before
going to next step.
If everything found ok,
•Replace the EMS ECU, flash it and do the EMS learning. Clear codes,
ensure proper functioning and deliver the vehicle.

Diagnostic Manual (Immobiliser) MAN-00138-18
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.
Combination – 3
ICU EMS
Code Description Code Description
8042 Wrong Transponder 1832 Immobilizer Authentication Failed
183F No ICU Response
Reason:The response received by the ICU from the keys is understandable to the
ICU. But the key does not belong to this particular vehicle.
Check lamp Status: Blinking.
Vehicle Behavior: Engine not starting.
Probable Causes:
1. Attempt to start the vehicle with new key before doing key programming.
2. Attempt to start the vehicle with key programmed for another vehicle.
Corrective Action:
•Try starting the vehicle with both keys originally allocated to the vehicle. If
vehicle starts with both keys, clear the error codes, and deliver the vehicle.
•If not replace the key with which it is not starting, do the learning, clear the
error codes and deliver the vehicle.

Diagnostic Manual (Immobiliser) MAN-00138-19
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.
Combination – 4
ICU EMS
Code Description Code Description
8043 No Transponder is Learnt 1832 Immobilizer Authentication Failed
183F No ICU Response
Reason:This error will be registered when there is no key is learned to the ICU.
Check lamp Status: Blinking.
Vehicle Behavior: Engine not starting.
Probable Causes:
1. Attempt to start vehicle after ICU replacement without doing ICU learning.
Corrective Action:
•Perform ICU learning.

Diagnostic Manual (Immobiliser) MAN-00138-20
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.
Combination – 5
Reason:ICU not receiving any signal from the key
Check lamp Status: Blinking.
Vehicle behaviour: Engine does not start.
Probable Causes:
1. Physical/electrical damage to the transponder chip inside the key.
2. Damaged transponder ring.
Corrective Action:
•Try starting the vehicle with both keys originally allocated to the vehicle. If
vehicle starts with both keys, inform the customer about a possible theft
attempt with mechanical replica, clear the error codes, and deliver the
vehicle.
•If not
Scenario 1: Vehicle is not starting with any of the two keys.
•Replace the key.
•Perform KEY learning.
•Clear the DTCs in ICU and EMS ECU. Check proper functioning with
the newly learnt key and deliver the vehicle.
ICU
EMS
Code Description Code Description
8040 Transponder Missing/No
Transponder 1832 Immobilizer Authentication Failed
183F No ICU Response