Mahindra Scorpio User manual

©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.



DIAGNOSTICMANUAL(SRS)



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

www.teknetmahindra.com

RELEASED BY -

TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.

Rev1 – JANUARY 2010

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.

MAN-00081



Vlx



©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 REPAIR MANUAL

The SRS Diagnostic manual outlines the detailed procedures to troubleshoot complaints related to

driver/co-driver airbags and pre-tensioning seat belts fitted on the Mahindra Scorpio Vlx/Mahindra

Scorpio Vlx Automatic vehicles.

This manual covers the diagnostic trouble shooting steps. The Defect Trouble codes (DTCs) need to be

retrieved using the SMART tester and the diagnostic steps followed as mentioned in the manual. The

Airbag Diagnostic software supplied with SMARTware CD version 1.0003 should be used in conjunction

with this manual.

The airbag /Pre-tensioning units are pyrotechnic components and needs to be handled and analysed

carefully to avoid any accidents in the workshop. It is recommended that only CoTEKs or authrosied

persons trained by CoTEKs handle these components.

In spite of our 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 or pillay[email protected].

Suggestions to improve the manual and make it more user-friendly are also welcome.

Diagnostic Manual- SRS MAN-00081-1

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

Contents

oHow to use this manual

oSystem Overview

oRecommended troubleshooting process

oWarranty/Other information

oImportant Terms

oImportant Instructions

oIndex of DTC codes

oUsing Scorpio Airbag Diagnostic Tester

oWiring Diagram

Diagnostic Manual- SRS MAN-00081-2

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

How to Use this manual

This manual is to be used along with the wiring manual (MAN 00076/MAN 00077)

If the DTC code is known, then go to the Index of DTC code, and click on the DTC.

The codes are hyperlinked and the respective page containing the trouble shooting

procedure for that DTC will be displayed.

The following is the structure of the Diagnostic Manual (Trouble shooting process).

•Error code

•Check lamp status

•Probable Cause

•Corrective Action

Diagnostic Manual- SRS MAN-00081-3

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

System Overview

Scorpio is equipped with Passive Safety systems, also known as Supplementary

Restraint System (SRS).The SRS system consists of Driver Airbag (DAB) located

in the Steering Wheel, a Passenger Airbag (PAB) located above the glove box

compartment and seat belt pre-tensioner units on the RH & LH B-Pillars. Airbag

locations can be identified by ‘SRS AIR BAG’ embossed on the air bag module

cover.

The purpose of airbag is to provide additional restraint that is designed to work in

conjunction with seat belts to reduce the severity of injuries to the occupants in

case of frontal collision. The deployment of airbag depends upon the severity and

direction of the frontal collision. This is done by the rapid inflation of a cushion by

non-toxic gas that is generated and/or released by an inflator in response to an

electrical signal from a collision detecting sensor inside the Airbag Control Unit

(ACU). The inflated cushion helps to absorb the energy of the driver or passenger

and prevent body contact with the vehicle structure. The seat belt pre-tensioner

unit removes the slack in the seat belts to avoid the passenger/driver from slipping

through below the belt.

When crash occurs, sensor in the ACU detects the vehicle deceleration and sends

an electrical signal and based on that the ACU decides whether to deploy the

airbag or not. An electrically activated initiator initiates a chemical reaction that

creates gases to fill the airbag. The inflator produces mostly nitrogen gas.

Diagnostic Manual- SRS MAN-00081-4

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

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- SRS MAN-00081-5

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

Warranty & Other Information

All failures/complaints encountered on Airbag Control Unit (ACU) and other system

components should be reported through Service Complaint Report (SCR).

Replacement of any of the Airbag Control Unit (ACU) 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.

The airbag /Pre-tensioning units are pyrotechnic components and needs to be

handled and analysed carefully to avoid any accidents in the workshop. It is

recommended that only CoTEKs or authrosied persons trained by CoTEKs handle

these components.

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

Diagnostic Manual- SRS MAN-00081-6

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

Important terms

These terms need to be understood before we start going through the diagnostic.

Loop Resistance: The resistance offered to current flow by the wiring from the

ACU to the individual components (Pretensioners & airbags) is called the loop

resistance of that particular circuit. For the effective functioning, each wiring circuit

in the SRS system should be having its resistance value within a certain limit. The

ACU will be monitoring the loop resistance continuously and will register DTCs if

the value is out of the defined range. The contacts are gold plated to prevent the

variation of resistance value due to oxidation.

•If the resistance is less than the lower limit, the error will be registered under

short circuit for that particular circuit, as the wiring offers less resistance

than required.

•If the resistance is more than the upper limit, the error will be registered

under open circuit for that particular circuit, as the wiring offers more

resistance than required.

Squib: Terminal connectors at the Airbag and Pretensioner ends are called

Squibs. They are provided with shunts, which does not allow current flow unless

and otherwise it is properly inserted in to the module. So it is impossible to

measure the continuity, voltage or resistance of these lines with multimeter.

Forceful insertion of the multimeter terminal will cause permanent damage to the

squibs.

Important instructions

•Never repair any wiring. It is always recommended to replace the wiring.

•Never try to probe the Airbag or Pretensioner with multimeter. The current

from the internal battery of the multimeter may fire the component and

deploy the airbags.

•Always lock the ACU through the diagnostic tester before doing any

diagnostic job related to Airbag system.

•Always lock the ACU and remove the battery negative terminal while doing

any body repair.

Note: Refer Annexure to understand the usage of diagnostic tester.

Diagnostic Manual- SRS MAN-00081-7

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

Index of DTCs

Error Code Label Page

No:

DTC STA

B1001 01 Line1(Co-Driver Pretensioner) leakage to open

circuit 8

B1001 02 Line1(Co-Driver Pretensioner) leakage to

ground 9

B1001 03 Line1(Co-Driver Pretensioner) leakage to plus 10

B1001 0C Line1(Co-Driver Pretensioner)leakage to short

circuit 11

B1002 01 Line2(Driver Pretensioner) leakage to open

circuit 12

B1002 02 Line2(Driver Pretensioner) leakage to ground 13

B1002 03 Line2(Driver Pretensioner) leakage to plus 14

B1002 0C Line2(Driver Pretensioner)leakage to short

circuit 15

B1003 01 Line3(DAB) leakage to open circuit 16

B1003 02 Line3(DAB) leakage to ground 17

B1003 03 Line3(DAB) leakage to plus 18

B1003 0C Line3(DAB)leakage to short circuit 19

B1004 01 Line4(PAB)leakage to open circuit 20

B1004 02 Line4(PAB) leakage to ground 21

B1004 03 Line4(PAB) leakage to plus 22

B1004 0C Line4(PAB) leakage to short circuit 23

B1042 12 Battery out of range 24

B100D Internal Fault 25

B1040 03 Warning lamp leakage to plus 26

B1040 02 Warning lamp leakage to ground 27

B1044 06 Wrong ACU configuration 28

Diagnostic Manual- SRS MAN-00081-8

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount



DTC STA

B1001 01

Error Code Label

Code(DTC) Status(STA)

B1001 01 Line1(Co-Driver Pretensioner) leakage to open circuit

Airbag warning lamp Status: ON.

Probable Causes:

•A cut in the wiring from ACU to Co – Driver Pretensioner.

•Pin Bent/Backout at ACU or Co – Driver Pretensioner connectors.

•Pin Bent/Backout at Interconnector.

•High wiring loop resistance of Co – Driver Pretensioner wiring.

•Pre-tensioner internal failure.

Corrective Action:

1. Disconnect the Pretensioner unit and connect the dummy resistor. Check for

the DTC. If DTC goes to healed condition, problem is with the Pretensioner,

and it should be replaced. If it is still present, the problem is with wiring.

Then follow step 2 onwards.

2. Check for pin bent/backout at ACU and Co – Driver Pretensioner.

3. Check for pin bent/backout at IC48 pin 1&2.

4. Check the loop resistance with the diagnostic tester. The value should be

between 1.9Ωto 4Ω. If not change the wiring harness.

U

Diagnostic Manual- SRS MAN-00081-9

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

Error Code Label

Code(DTC) Status(STA)

B1001 02 Line1(Co-Driver Pretensioner) leakage to ground

Airbag warning lamp Status: ON

Note: Both +ve and –ve supply to the Pretensioners are given by the ACU, and

that too only when a crash is detected. So if the ACU finds that any of the line is

grounded, it will register an error.

Probable Causes:

•Either +ve or –ve line of the Pretensioner is short to ground.

Corrective Action:

•Replace the wiring harness.

DTC STA

B1001 02

U

Diagnostic Manual- SRS MAN-00081-10

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

Error Code Label

Code(DTC) Status(STA)

B1001 03 Line1(Co-Driver Pretensioner) leakage to plus

Airbag warning lamp Status: ON

Note: Both +ve and –ve supply to the Pretensioners are given by the ACU, and

that too only when a crash is detected. So if the ACU finds that any of the line is

getting +ve supply, it will register an error.

Probable Causes:

•Either +ve or –ve line of the Pretensioner is short to any +ve line.

Corrective Action:

•Replace the wiring harness.

DTC STA

B1001 03

U

Diagnostic Manual- SRS MAN-00081-11

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

DTC STA

B1001 0C

Error Code Label

Code(DTC) Status(STA)

B1001 0C Line1(Co-Driver Pretensioner)leakage to short circuit

Airbag warning lamp Status: ON.

Probable Causes:

•+ve and –ve lines short in the wiring.

•Low loop resistance in the wiring.

•Pretensioner internal failure.

Corrective Action:

1. Disconnect the Pretensioner unit and connect the dummy resistor. Check for

the DTC. If DTC goes to healed condition, problem is with the Pretensioner,

and it should be replaced. If it is still present, the problem is with wiring.

Then follow step 2 onwards.

2. Check the loop resistance with the diagnostic tester. The value should be

between 1.9Ωto 4Ω. If not change the wiring harness.

U

Diagnostic Manual- SRS MAN-00081-12

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

DTC STA

B1002 01

Error Code Label

Code(DTC) Status(STA)

B1002 01 Line2(Driver Pretensioner) leakage to open circuit

Airbag warning lamp Status: ON.

Probable Causes:

•A cut in the wiring from ACU to Driver Pretensioner.

•Pin Bent/Backout at ACU or Driver Pretensioner connectors.

•Pin Bent/Backout at Interconnector.

•High wiring loop resistance of Driver Pretensioner wiring.

•Pretensioner internal failure.

Corrective Action:

1. Disconnect the Pretensioner unit and connect the dummy resistor. Check for

the DTC. If DTC goes to healed condition, problem is with the Pretensioner,

and it should be replaced. If it is still present, the problem is with wiring.

Then follow step 2 onwards.

2. Check for pin bent/backout at ACU and Driver Pretensioner.

3. Check for pin bent/backout at IC48 pin 3&4.

4. Check the loop resistance with the diagnostic tester. The value should be

between 1.9Ωto 4Ω. If not change the wiring harness.

U

Diagnostic Manual- SRS MAN-00081-13

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

Error Code Label

Code(DTC) Status(STA)

B1002 02 Line2(Driver Pretensioner) leakage to ground

Airbag warning lamp Status: ON.

Note: Both +ve and –ve supply to the Pretensioners are given by the ACU, and

that too only when a crash is detected. So if the ACU finds that any of the line is

grounded, it will register an error.

Probable Causes:

•Either +ve or –ve line of the Pretensioner is short to ground.

Corrective Action:

•Replace the wiring harness.

DTC STA

B1002 02

U

Diagnostic Manual- SRS MAN-00081-14

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

Error Code Label

Code(DTC) Status(STA)

B1002 03 Line2(Driver Pretensioner) leakage to plus

Airbag warning lamp Status: ON.

Note: Both +ve and –ve supply to the Pretensioners are given by the ACU, and

that too only when a crash is detected. So if the ACU finds that any of the line is

getting +ve supply, it will register an error.

Probable Causes:

•Either +ve or –ve line of the Pretensioner is short to any +ve line.

Corrective Action:

•Replace the wiring harness.

DTC STA

B1002 03

U

Diagnostic Manual- SRS MAN-00081-15

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

DTC STA

B1002 0C

Error Code Label

Code(DTC) Status(STA)

B1002 0C Line2(Driver Pretensioner)leakage to short circuit

Airbag warning lamp Status: ON.

Probable Causes:

•+ve and –ve lines short in the wiring.

•Low loop resistance in the wiring.

•Pretensioner internal failure.

Corrective Action:

1. Disconnect the Pretensioner unit and connect the dummy resistor. Check for

the DTC. If DTC goes to healed condition, problem is with the Pretensioner,

and it should be replaced. If it is still present, the problem is with wiring.

Then follow step 2 onwards.

2. Check the loop resistance with the diagnostic tester. The value should be

between 1.9Ωto 4Ω. If not change the wiring harness.

U

Diagnostic Manual- SRS MAN-00081-16

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

DTC STA

B1003 01

Error Code Label

Code(DTC) Status(STA)

B1003 01 Line3(DAB) leakage to open circuit

Airbag warning lamp Status: ON.

Probable Causes:

•A cut in the wiring from ACU to Driver Airbag.

•Pin Bent/Backout at ACU or Driver Airbag connectors.

•Pin Bent/Backout at Interconnector.

•High wiring loop resistance of Driver Airbag wiring.

•Driver Airbag internal failure.

Corrective Action:

1. Disconnect the Airbag unit and connect the dummy resistor. Check for the

DTC. If DTC goes to healed condition, problem is with the Airbag, and it

should be replaced. If it is still present, the problem is with wiring. Then

follow step 2 onwards.

2. Check for pin bent/backout at ACU and Driver Airbag.

3. Check for pin bent/backout at IC49 pin 3&4.

4. Check the loop resistance with the diagnostic tester. The value should be

between 1.9Ωto 5.5Ω. If not change the wiring harness.

U

Diagnostic Manual- SRS MAN-00081-17

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount

Error Code Label

Code(DTC) Status(STA)

B1003 02 Line3(DAB) leakage to ground

Airbag warning lamp Status: ON.

Note: Both +ve and –ve supply to the Airbags are given by the ACU, and that too

only when a crash is detected. So if the ACU finds that any of the line is grounded,

it will register an error.

Probable Causes:

•Either +ve or –ve line of the Driver Airbag is short to ground.

Corrective Action:

•Replace the wiring harness.

DTC STA

B1003 02

U

Diagnostic Manual- SRS MAN-00081-18

Scorpio mHawk January 2010/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 Authoirsed Service Centre of Mahindra & Mahindra Ltd., will amount