Mahindra XUV500 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.
EMS DIAGNOSTIC MANUAL
MA
N
-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.
RELEASED BY –
TECHNICAL PUBLICATION CELL
MAHINDRA & MAHINDRA LTD.
Rev1
–
OCTOBER 2011

DIAGNOSTIC MANUAL MAN-00152
EMS OCT 2011/Rev 1
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 of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
1
CONTENTS
HOWTOUSETHISMANUAL 2
OVER VIEW OF THE VEHICLE COMMUNICATION NETWORK 3
EMSOVERVIEW 4
WARRANTY&OTHERINFORMATION 5
RECOMMENDED TROUBLE SHOOTING PROCESS 6
EMSECUPINDETAILS 7
EMSECUCANSIGNALS 10
IQA/IMACODEPROGRAMMING 11
EMSECUFLASHING 12
INDEXOFDTCCODES 20
EMSWIRINGDIAGRAM 24
DTCBASEDTROUBLESHOOTING 26
SYMPTOM BASED DIAGNOSIS- WITH NO DTC CODES 325

DIAGNOSTIC MANUAL MAN-00152
EMS OCT 2011/Rev 1
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 of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
2
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).

DIAGNOSTIC MANUAL MAN-00152
EMS OCT 2011/Rev 1
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 of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
3
OVER VIEW OF THE VEHICLE COMMUNICATION NETWORK

DIAGNOSTIC MANUAL MAN-00152
EMS OCT 2011/Rev 1
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 of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
4
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

DIAGNOSTIC MANUAL MAN-00152
EMS OCT 2011/Rev 1
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 of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
5
Actuators
EGR Actuator
Fan Control
Injectors
Fuel Metering Unit
Turbo charger actuator
Glow Plugs
A/C Compressor
Boost Pressure Actuator
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)

DIAGNOSTIC MANUAL MAN-00152
EMS OCT 2011/Rev 1
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 of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
6
RECOMMENDED TROUBLE SHOOTINGPROCESS
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 ha
pp
en onl
y
in some condition?
Search for Published quick solution in TEKnet.
Follow DTC based diagnosis
Contact TEKliner with TAR
(Technical Assistance Request)

DIAGNOSTIC MANUAL MAN-00152
EMS OCT 2011/Rev 1
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 of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
7
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

DIAGNOSTIC MANUAL MAN-00152
EMS OCT 2011/Rev 1
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 of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
8
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
75
SIGNAL REF
(TEMPERATURE) HOT FILM AIR MASS SENSOR 2
76 GROUND RAIL PRESSURE SENSOR 1
77
SIGNAL
(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

DIAGNOSTIC MANUAL MAN-00152
EMS OCT 2011/Rev 1
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 of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
9
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