Mahindra SCORPIO Vlx 2007 User manual

The reproduction, translation, transmission, in part of whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. © 2007 Mahindra & Mahindra Ltd
SCORPIO Vlx
DIAGNOSTIC MANUAL -
ABS
Revision 1
MAN-00030
922BRKR011107EN-DM
RELEASED BY :
TECHNICAL PUBLICATION CELL
MAHINDRA & MAHINDRA LTD
Rev 1 – NOVEMBER 2007
CONFIDENTIAL
• ONLY FOR INTERNAL CIRCULATION WITHIN
M&M AUTHORISED DEALERS & SERVICE CENTRES
• PASSING ON TO THRID PARTY IS NOT PERMITTED
•
ALWAYS CHECK FOR THE LATEST VERSION

TABLE OF CONTENTS
1. INDEX OF COMMONLY USED TERMS 3
2. INDEX OF DTC CODES 5
3. WIRING DIAGRAM 7
4. DTC BASED DIAGNOSTICS 8
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 3 of 62
Index of Common Terms Used
DTC: Diagnostic Troubleshooting Codes
ABS Lamp: Yellow lamp in cluster with the ABS written (photo to be inserted)
Parking Brake Lamp: The parking brake lamp & the FLWI lamp is a combined red
lamp. (Sketch required). The ABS errors will also be shown through this red lamp.
DRP: Dynamic Rear Proportioning
Note: DRP is equivalent to electronic LSPV. It is active only when the rear wheels
are tending to lock.
ABS : Anti Lock Braking System
Note: ABS is active only in the extreme condition when the front wheel lock is
taking place. In normal operation the braking does not activate the ABS
functionality. Also the brake pedal pulsation when the ABS is active is normal
Note: When the lock takes place normally the rear tend to lock first hence initially
the DRP kicks in. Then the second stage if the front is locking then the ABS also
becomes active.
Under severe panic braking the front wheels can lock first or all the four wheels
will tend to lock. Under this condition the ABS will come into operation
immediately.
WSS: Wheel Speed Sensor
Front Toner Wheel: Is mounted inside the disc for front wheel spped signal to ABS
ECU & serviced with disc & toner assembly & not serviced individually
Rear Toner Wheel: Is mounted on to differential case assembly & serviced with
differential case & not serviced individually for rear wheel speed signal to ABS ECU
EOL: End of the Line (Only in the assembly line)
Note: Clear all the DTC codes before giving the vehicle back to the customer. Any
unhealed code should be attended and then only the vehicle to be released.
It is recommended that when ever the vehicle reports to the workshop, the DTC
codes should be checked & using print command in software save the image of
error codes to maintain vehicle history.
The status of the code (healed or not present) when it came to the workshop as
well as before leaving the workshop, should be printed. (Use the print command in
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 4 of 62
the diagnostic, converts to a PDF file, later the PDF file to be printed. This record
should be kept in the vehicle history and can be useful later.)
After clearing all the ABS related errors drive the vehicle and do at least 5 ABS
braking application and check if any errors are recorded. Suggestion is that the
vehicle speed should not exceed 50 Km/hr when doing the panic braking to check
ABS performance.
ISO : Isolation valve
DUMP : Dump valve
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 5 of 62
Index of DTC Codes
Code Description Page #
1800 WSS Open – Front Left 8-9
1801 WSS Open – Front Right 8-9
1802 WSS Open – Rear 8-9
1803 WSS Short – Front Left 10-11
1804 WSS Short – Front Right 10-11
1805 WSS Short – Rear 10-11
1806 WSS Missing – Front Left 12-13
1807 WSS Missing – Front Right 12-13
1808 WSS Missing – Rear 12-13
1809 WSS Erratic – Front Left 14-15
180A WSS Erratic – Front Right 14-15
180B WSS Erratic – Rear 14-15
180C WSS Drop Out – Front Left 16-17
180D WSS Drop Out –Front Right 16-17
180E WSS Drop Out – Rear 16-17
180F Mismatch Tyre 18-19
1810 Solenoid Open–ISO Front Left 20-21
1811 Solenoid Open–ISO Front Right 20-21
1812 Solenoid Open – ISO Rear 20-21
1813 Solenoid Open–Dump Front Left 20-21
1814 Solenoid Open–Dump Front Right 20-21
1815 Solenoid Open – Dump Rear 20-21
1816 ISO Front Left Solenoid -Driver Shorted 20-21
1817 ISO Front Right Solenoid -Driver Shorted 20-21
1818 ISO Rear Solenoid -Driver Shorted 20-21
1819 Dump valve Front Left Solenoid -Driver
Shorted 20-21
181A Dump valve Front Right Solenoid -Driver
Shorted 20-21
181B Dump valve Rear Solenoid -Driver Shorted 20-21
181C Valve solenoid ISO valve Front Left 22-23
181D Valve solenoid ISO valve Front Right 22-23
181E Valve solenoid ISO valve -Rear 22-23
181F Valve Solenoid Dump–Front Left-Shorted 22-23
1820 Valve Solenoid Dump–Front Right-Shorted 22-23
1821 Valve Solenoid –Rear Dump-Short 22-23
1822 Valve Solenoid-ISO Front Left- Over
temperature 24-25
1823 Valve Solenoid-ISO Front Right- Over
temperature 26-27
1824 Valve Solenoid-ISO Rear- Over temperature 26-27
1825 Valve Solenoid - Dump Front Left - Over 26-27
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 6 of 62
Temperature
Code Description Page #
1826 Valve Solenoid - Dump Front Right - Over
Temperature 26-27
1827 Valve Solenoid - Dump Rear - Over
Temperature 26-27
1829 Power Switch - Shorted 28-29
182A ABS Motor - Open 30-31
182B ABS Motor - Locked 32-33
182C ABS Motor – Open Fuse 34-35
182D Microprocessor ROM Failure 36-37
182E Microprocessor RAM Failure 36-37
182F Microprocessor Stack Failure 36-37
1830 Microprocessor Schedule Overrun Failure 36-37
1831 Microprocessor External watchdog Failure 36-37
1832 Base brake fluid sensor – open
Base brake failure 38-39
1833 Ignition Voltage Supply low 40-41
1834 Ignition Voltage Supply High 42-43
1835 Ignition Voltage Supply – Excessive High 44-45
1836 Microprocessor Unimplemented Interrupt. 46-47
1837 Microprocessor Unexpected Exception. 46-47
1838 Microprocessor Solenoid Timeout Failure 46-47
1839 Microprocessor HET Periodic Interrupt
Failure. 46-47
183A Microprocessor SPI Failure. 46-47
183B Microprocessor SPI Queue Overflow 46-47
183C Brake Pedal Switch Failed – Never Active 48-49
183D Brake Pedal Switch Failed–Always Active 48-49
183E Tooth count Failure (Out of Range) 50-51
183F Tyre Size Failure ( Mismatch/ out of range) 52-53
1840 Emission Rollers Mode Active 54-55
1841 Invalid Drive-train configuration 56-57
1842 Communication Missing Transfer Case
Status 58-59
1843 Communication General K-Line Fault 60-61
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 7 of 62
Circuit Diagram –
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 8 of 62
ABS Trouble Shooting
Description –
DTC Error
Description Effect of DTC
1800
1801
WSS Open – Front Left
WSS Open – Front Right
ABS Lamp : ON
Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active
1802 WSS Open –
Rear ABS Lamp : ON
Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive
Performance Condition Possible Causes
Proper Performance:
Under normal condition the Wheel
speed signal are proportional and
can be used for the ABS & DRP
functionality
Malfunction:
WSS output signals out-of-range
•Defective wheel speed sensor
•Defective wiring harness to wheel speed
sensor
•Defective Microprocessor or Printed
Circuit Board in the ECU.
•Electrical Pins bent of ECU or WSS
1800
1801
1802
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 9 of 62
Trouble Shooting –
1800
1801
1802
After replacement of the required component, connect the wiring harness to Sensor
& EHCU.
Switch on the I
g
nition & confirm if the error is healed.
Change the wiring harness.
(Wiring Harness Part # -
Refer Table A
)
Check continuity in wiring harness - between
sensors’s mating connector to EHCU mating
connector (Low to Low & High to High).
If Yes If No
The problem exists
e
i
t
h
e
r in E
CU o
r
WSS
.
Change the respective WSS as
per the DTC codes.
(Front WSS Part # - Refer Table A
Rear WSS Part # - Refer Table A).
If Yes If No
The
problem is
with WSS.
The problem is with ECU. Switch ignition
Off; Detach EHCU connector;
Replace the ECU Assembly.
(ECU assembly Part # - Refer Table A)
Connect the wiring harness to
Sensors & EHCU.
Switch on the ignition &
check if the error is healed.
Remove EHCU connector (H-3) & sensor connector
(FL: H-5; FR: H-6; RR: H-7).
Switch Off the Ignition
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 10 of 62
ABS Trouble shooting
Description –
DTC Error
Description Effect of DTC
1803
1804
WSS Short – Front Left
WSS Short – Front
Right
ABS Lamp : ON
Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active
1805 WSS Short –
Rear ABS Lamp : ON
Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive
Performance Condition Possible Causes
Proper Performance:
Under normal condition the Wheel
speed signal are proportional and
can be used for the ABS & DRP
functionality
Malfunction:
WSS output signals out-of-range
•Defective wheel speed sensor
•Defective wiring harness to wheel speed
sensor
•Defective Microprocessor or Printed
Circuit Board in the ECU.
•Electrical Pins bent of ECU or WSS
1803
1804
1805
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 11 of 62
Trouble Shooting –
1803
1804
1805
Change the wiring harness.
(Wiring Harness Part # - Refer
Table A)
After replacement of the required component, connect the wheel harness to Sensor
& EHCU.
Switch on the I
g
nition & confirm if the error is healed.
Check continuity in wiring harness - between
sensors’s mating connector to EHCU mating
connector (Low to Low & High to High).
If Yes If No
The problem exists
e
i
t
h
e
r in E
CU o
r
WSS
.
Change the respective WSS as per
the DTC codes.
(Front WSS Part # - Refer Table A
Rear WSS Part # - Refer Table A)
If Yes If No
The
problem is
with WSS.
The problem is with ECU. Switch Off
ignition; Detach EHCU connector;
Replace the ECU Assembly.
(ECU assembly Part # - Refer Table A)
Connect the wheel wiring
harness to Sensors & EHCU.
Switch on the ignition &
check if the error is healed.
Remove EHCU connector (H-3) & sensor connector
(FL: H-5; FR: H-6; RR: H-7).
Switch Off the Ignition
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 12 of 62
ABS Trouble shooting
Description –
DTC Error
Description Effect of DTC
1806
1807
WSS Missing – Front
Left
WSS Missing – Front
Right
ABS Lamp : ON
Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active
1808 WSS Missing – Rear ABS Lamp : ON
Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive
Performance Condition Possible Causes
Proper Performance:
Under normal condition the Wheel
speed signal are proportional and
can be used for the ABS & DRP
functionality
Malfunction:
WSS output signals out-of-range
•Wheel speed sensor not mounted
correctly.
•Wheel speed sensor to toner-wheel gap
out of tolerance.
•Excessive run-out at vehicle level on
toner ring teeth
1806
1807
1808
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 13 of 62
Trouble Shooting –
1806
1807
1808
Check the WSS mounting. Retighten to the
specified torque. ( 20 ±3 Nm ).
If the toner wheel appears to have come out of
the disc or there is more run out of the disc.
Check Toner wheel visually for any damage.
Switch Off the Ignition
Any damage/ visual defect
Replace the affected
Components Remove the wheel
assembly. Check the
bearing & races.
Reassemble.
Switch on the
ignition, clear all
errors.
If complaint re-occurs then
only replace the affected
toner wheel assembly.
Switch on the ignition,
clear all errors.
If Yes If No
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 14 of 62
ABS Trouble shooting
Description –
DTC Error
Description Effect of DTC
1809
180A
WSS Erratic – Front
Left
WSS Erratic – Front
Right
ABS Lamp : ON
Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active
180B WSS Erratic – Rear ABS Lamp : ON
Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive
Performance Condition Possible Causes
Proper Performance:
Under normal condition the Wheel
speed signal are proportional and
can be used for the ABS & DRP
functionality
Malfunction:
WSS output signals out-of-range
•Wheel speed sensor not mounted
correctly.
•Missing Tooth or Teeth on the wheel
speed sensor tone – wheel.
•Excessive run-out at vehicle level on
toner ring teeth
1809
180A
180B
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 15 of 62
Trouble Shooting –
1809
180A
180B
Check the WSS mounting. Retighten to the
specified torque. ( 20 ±3 Nm ).
I. If the toner wheel appears to have come
out of the disc or there is more run out of
the disc.
II. Check Toner wheel visually for any
damage.
Switch Off the Ignition
Any damage/ visual defect
Replace the affected
Components Remove the wheel
assembly. Check the
bearing & races.
Reassemble.
Switch on the
ignition, clear all
errors.
If complaint re-occurs then
only replace the affected
toner wheel assembly.
Switch on the ignition,
clear all errors.
If Yes If No
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 16 of 62
ABS Trouble shooting
Description –
DTC Error
Description Effect of DTC
180C
180D
WSS Drop Out – Front
Left
WSS Drop Out –Front
Right
ABS Lamp : ON
Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active
180E WSS Drop Out – Rear ABS Lamp : ON
Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive
Performance Condition Possible Causes
Proper Performance:
Under normal condition the Wheel
speed signal are proportional and
can be used for the ABS & DRP
functionality
Malfunction:
WSS output signals out-of-range
•Defective wheel speed sensor
•Defective harness to wheel speed sensor
•Defective terminals of WSS or wiring
harness
•Wheel speed sensor not mounted
correctly.
180C
180D
180E
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 17 of 62
Trouble Shooting –
180C
180D
180E
Replace Wheel speed sensor & Check
Replace the disc & toner wheel assembly in
the front and the toner wheel in the rear.
(Disc & Toner wheel Part # - Refer Table A
Rear Toner wheel assembly Part # - Refer
Table A)
Switch on the Ignition & check if the
error is healed.
Switch Off the Ignition
If sus
p
ect
Replace the WSS
wiring harness
suitably.
(Wiring harness Part
# - Refer Table A)
If found O
K
Check WSS mounting.
Tighten to the specified
torque (20 ± 3 Nm).
If found faulty
Check Toner wheel Visually for
Damaged/Missing tooth (No. of
Teeth=60
)
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 18 of 62
ABS Trouble shooting
Description –
DTC Error
Description Effect of DTC
180F Mismatch Tyre
ABS Lamp : ON
Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive
Performance Condition Possible Causes
Proper Performance:
Under normal condition the Wheel
speed signal are proportional and
can be used for the ABS & DRP
functionality
Malfunction:
High variation in wheel speed
•Anything that generates consistent
differences in apparent wheel
rotational speed.
•Significantly different size tyres
installed on the vehicle.
•Rear toner wheel come out of the
diff case or free to rotate on diff case
assembly.
180F
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 19 of 62
Trouble Shooting –
To get an indication go to the live data screen in the Diagnostic tool.
Drive the vehicle and check the wheel speed (individual) and the see the
difference.
Check toner wheel visually for damaged / missing
tooth / teeth. (No. of teeth 60)
Replace the disc & toner wheel
assembly on the front and toner wheel
on the rear.
(Disc & toner wheel assembly Part # -
Refer Table A
Differential Case & Rear Toner wheel
Assembly Part # - Refer Table A )
Check if only
recommended tyres
are installed on the
vehicle.
If found faulty If found OK
If No
Replace with the
recommended size tyres.
Switch on the Ignition & check if the error is healed.
Switch Off the Ignition
180F
MAN-00030
922BRKR011107EN-DM

Automotive Sector
All copyrights reserved by
Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS
Confidential- For Internal Circulation Only Ver 1 Nov 07
Page 20 of 62
ABS Trouble shooting
Description –
DTC Error Description Effect of DTC
1810
1811
Solenoid Open–ISO Front
Left
Solenoid Open–ISO Front
Right
ABS Lamp : ON
Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active
1812 Solenoid Open – ISO Rear ABS Lamp : ON;
Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive
1813
1814
Solenoid Open–Dump Front
Left
Solenoid Open–Dump Front
Right
ABS Lamp : ON
Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active
1815
Solenoid Open – Dump
Rear
ABS Lamp : ON
Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive
1816
1817
1818
1819
181A
181B
ISO Front Left Solenoid -
Driver Shorted
ISO Front Right Solenoid -
Driver Shorted
ISO Rear Solenoid -Driver
Shorted
Dump valve Front Left
Solenoid -Driver Shorted
Dump valve Front Right
Solenoid -Driver Shorted
Dump valve Rear Solenoid
-Driver Shorted
ABS Lamp : ON
Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive
1810
1811
1812
1813
1814
1815
1816
1817
1818
1819
181A
181B
MAN-00030
922BRKR011107EN-DM