Scorpio Crde - Wiring Manual - Rev3_reduced

SCORPIO CRDe All New – Lx, Dx, Slx

ELECTRICAL WIRING MANUAL Revision 3 MAN-00026 940XXXR031107EN-WM

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

RELEASED BY : TECHNICAL PUBLICATION CELL MAHINDRA & MAHINDRA LTD Rev 3 – NOVEMBER 2007

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

TABLE OF CONTENTS 1.

CONTROLLERS/FUSES/RELAYS – LOCATIONS ENGINE COMPARTMENT FUSE/RELAY BOX MAIN FUSE /RELAY BOX AUXILLARY/CRDe FUSE/RELAY BOX

2. 3. 4. 5. 6.

- EF – MF - AF

POWER FLOW DIAGRAM WIRING HARNESS LAYOUT INTERCONNECTORS – LOCATION/PINS/VIEWS GROUND/EARTHING POINTS – LOCATIONS INDIVIDUAL CIRCUITS ENGINE MANAGEMENT SYSTEM (CRDe) STARTING CIRCUIT CHARGING CIRCUIT HVAC CIRCUIT INSTRUMENT CLUSTER CIRCUIT POWER WINDOW CIRCUIT REMOTE LOCKING SYSTEM CIGAR LIGHTER/12 V POINT CIRCUIT HORN CIRCUIT DEMISTER CIRCUIT WIPER & WASHER – FRONT CIRCUIT WIPER & WASHER – REAR CIRCUIT HEADLAMP CIRCUIT HEADLAMP LEVELLING CIRCUIT FOLLOW-ME-HOME CIRCUIT PARKING/REGISTRATION PLATE CIRCUIT INTERIOR LAMPS CIRCUIT STOP LAMP/CLUTCH PEDAL CIRCUIT TURN AND HAZARD CIRCUIT REVERSE LAMP CIRCUIT FOG LAMP CIRCUIT VOICE MESSAGING SYSTEM CIRCUIT AUDIO CIRCUIT FUEL LID OPENER 4WD CIRCUIT

7. 8.

VEHICLE WIRING DIAGRAM APPENDIX Diode Checking Procedure Symbols and nomenclature Wire Colour coding chart

2 3 4 5

6 10 11 14 15 16 17 18 19 20 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 50

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CONTROLLERS/FUSE/RELAY BOX LOCATIONS – SCORPIO (All New) CRDe

FUESE & RELAY BOXES 1 2 3

ECUs & CONTROLLERS

ENGINE COMPARTMENT FUSE BOX - EF MAIN FUSE/RELAY BOX - MF AUX FUSE/RELAY BOX (CRDe) - AF

4 5 6

VMS CONTROLLER FOLLOW ME CONTROLLER 4WD CONTROLLER REMOTE LOCKING CONTROLLER/ SECURITY SYSTEM HAZARD CONTROLLER CRDe ENGINE CONTROLLER

7 8 9

RELAYS 10

STARTER RELAY

11

STARTER ENABLE RELAY

12

VMS DIODES (2 Nos)

12 8

4 5 6

M F

2

7 11

3 A F

10 1

EF

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ENGINE COMPARTMENT FUSE/RELAY BOX LOCATION

EF

– FRONT LEFT FENDER

3

60A 2

60A 1

30A 4

100A 12

5

7

6

15A 8

15A 9

15A 10

11

FUSE No

FUSE RATING

COLOUR

CIRCUIT

1

60A

YELLOW

MAXI FUSE 1

2

60A

YELLOW

MAXI FUSE 2

3

60A

YELLOW

GLOW PLUG

4

30A

PINK

CRDe ECU SUPPLY

8

15A

BLUE

HEADLAMP - HIGH

9

15A

BLUE

HEADLAMP - LOW

10

15A

BLUE

HORN/HAZARD

100A

BLUE

CHARGING SYSTEM

5

HEAD LAMP HIGH BEAM RELAY

HORN RELAY

15 A

20 A

HEAD LAMP LOW BEAM RELAY

A/C REQUEST RELAY

15 A

20 A

Important Note : The 100 Amps charging fuse (S N0 12) is fixed by bolts at the bottom. To remove the fuse , the bolts needs to be removed first.

6 7

11 12

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MF

MAIN FUSE/RELAY BOX LOCATION

– BELOW STEERING WHEEL MAIN FUSE/RELAY BOX - FUSES/CIRCUITS/RATINGS

FUSE No

FUSE RATING

COLOUR

CIRCUIT

RED

INTERIOR LAMP/PARK LAMP/ ILLUMINATION/ AUDIO MEMORY/FOLLOW-ME/HEADLAMP LEVELLING/ HEAD LAMP/ VMS

20A

RED

FUEL LID OPERATION

20A

YELLOW

4WD - ELECTRIC SHIFT

30A

GREEN

1

10A

2 3 4

CONDENSER FAN

FUSE No

FUSE RATING

COLOUR

12

15A

BLUE

13 14 15

15A

BLUE

10A

RED

20A

YELLOW

CIRCUIT

CIGAR LIGHTER/ACCESSORIES

FRONT/REAR WIPER MOTOR REAR WIPER PARK MECHANISM CRDe ECU K28

5

15A

BLUE

FRONT FOG LIGHT

16

10A

RED

TURN SIGNAL/VMS/CHARGING LAMP/REVERSE LAMP

6

15A

BLUE

REAR FOG LIGHT

17

10A

RED

PARKING LIGHTS/FOLLOW-ME/ HEADLAMP LEVELLING

CRDe DIAGNOSTIC

18 19 20 21

10A

RED

AUDIO SYSTEM/FOLLOW-ME

-----

-----

-----

-----

40A

GREEN

POWER WINDOW

22

40A

GREEN

A/C BLOWER

5A 9

20A 10

7 8 9 10 11

FRONT FOG RELAY

5A

BROWN

15A

BLUE

5A

BROWN

SECURITY SYSTEM ECU (CDL-2)

20A

YELLOW

CENTRAL DOOR LOCKING (CDL-1)

15A

BLUE

10A 1

20A 2

DEMISTER

A/C COMPRESSOR /DEMISTER/HEADLAMP

20A 3

30A 4

15A 5

15A 6

5A 7

15A 8

---------

20 A

20 A 40A 21

REAR FOG

A/C COMPRESSOR RELAY

40A 22

PULLER

10A 18

10A 17

10A 16

20A 15

10A 14

15A 13

15A 12

15A 11

FUEL LID OPENER RELAY

20 A

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AUX. FUSE/RELAY BOX LOCATION

MAIN RELAY CRDe

– BEHIND GLOVE BOX/BLOWER MOTOR

DEMISTER CONTROLLER

WIPER CONTROLLER

BLOWER RELAY

CONDENSOR FAN RELAY

30 A

30 A

30 A 10A 1 10A 2

AF

15A 3 15A 4 15A 5 10A 6

AUX. FUSE/RELAY BOX - FUSES/CIRCUITS/RATINGS FUSE No 1 2 3 4 5 6

FUSE RATING

COLOUR

CIRCUIT

10A

RED

A/C REQUEST

10A

RED

HFM SENSOR SUPPLY

15A

BLUE

EGR/BRAKE LIGHT/CLUTCH SWITCH

15A

BLUE

CRDe ECU SUPPLY - K05

15A

BLUE

CHECK ENGINE LAMP

10A

RED

CRDe ECU SUPPLY - K01

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940XXXR031107EN-WM POWER FLOW DIAGRAM – SCORPIO CRDe (All New) – BS3 MAN-00026

STR

+

STARTER SOLENOID

BATTERY

-

CHARGING FUSE EF - 100 A

E1 E14 F(EF, 15A) – Horn Hazard

FROM START ENABLE RELAY

STARTER RELAY

FROM IGN “15”

FROM COMBINATION SWITCH

F(EF, 15A) – Head Lamp High F(EF, 15A) - Head lamp Low

ALT

MAXI FUSE 1 EF - 60 A

MAXI FUSE 2 EF - 60 A

A

B

MAXI FUSE 3 EF -

MAXI FUSE 4 EF - 30 A

D Page 6Fusebox Legend : EF – Engine Compartment Fusebox ; MF – Main Fusebox ; AF – Auxilliary

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A

F(MF, 40A) – Blower Motor Relay +12V F(MF, 15A) – Demister Controller + 12 V F(MF, 20A) – Central Door Locking +12V F(MF, 5A) - Security System Controller F(MF, 15A) – Fog Lamp Relay +12V F(MF, 5A) – Diagnostic Link Connector +12V

POWER FLOW – SCORPIO CRDe (All New) BS3

D

Water in Fuel Sensor CRDe ECU Relay +12V F(AF, 10A) – ECU K01 F(AF, 15A) – ECU K05 F(AF, 15A) – Temp. Gauge +12V High Temp. Warning Lamp OBD Lamp Check Engine Lamp F(AF, 10A) A/c Compressor Clutch Relay Coil A/c Request Relay + 12V F(AF, 15A) - Clutch Switch Stop Lamp +12V Vacuum Modulator +12V

Legend : EF – Engine Compartment Fusebox ; MF – Main Fusebox ; AF – Auxilliary PageFusebox 7

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B

F(MF, 20A) – Fuel Lid Opener Relay/Switch +12V F(MF, 30A) – Condenser Fan Relay +12V F(MF, 20A) – 4WD Shift Motor F(MF, 10A) – Interior Lamp – Front Interior Lamp – Rear Footstep Lamp Ignition Key Ring Lamp Headlamp Controller (Door Open Signal) Head Lamp Low Relay Coil VMS Audio Memory HVAC Memory Cluster Memory F(MF, 10A) – Park Lamp – Lt/Rt Tail Lamp – Lt/Rt Reg Number Plate Lamp Headlamp Leveling Switch/Motor Headlamp Controller (Park Light Signal) Illumination – 4WD Selector Switch Illumination – HVAC Switches Illumination – Fuel Lid Switch Illumination – Demister Switch Illumination – Cigar Lighter Illumination – Cluster POWER FLOW – SCORPIO CRDe (All New) BS3

IGNITION SWITCH 30 KA P 15a

B.1

15 50

Legend : EF – Engine Compartment Fusebox ; MF – Main Fusebox ; AF – Page Auxilliary 8 Fusebox

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B.1 F(MF, 10A) – Audio Headlamp Controller (Key removal)

KA

P 50 F(MF, 15A) – Cigar Lighter F(MF, 15A) – Front Wipe/Wash Rear Wipe/Wash F(MF, 10A) – Rear Wiper Park Position F(MF, 40A) - Power Window Blower Relay Coil F(MF, 10A) – A/c Compressor Relay Condenser fan Relay Coil Demister Switch Demister Timer 4WD ECU

Note : Circuits 15a and 50 are mutually exclusive

POWER FLOW – SCORPIO CRDe (All New) BS3

Star Enable Relay Coil Start Enable Relay Starter Relay Coil

15a 15 F(MF, 10A) – Hazard Controller Reverse lamp HVAC Control Panel Fuel Gauge Tachometer VMS Speedometer/Tachometer PCB Tell Tale – Brake Fluid Tell Tale – Battery Charging Tell Tale – 4WD High Tell Tale – 4WD Low Tell tale – Low Oil Pressure Tell Tale – Seat Belt F(AF, 10A) – HFM Sensor + Ign F(AF, 20A) – CRDe ECU +Ign K28 Legend : EF – Engine Compartment Fusebox ; MF – Main Fusebox ; AF – Auxilliary PageFusebox 9

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WIRING HARNESS LAYOUT HARNESS No 1 2 3 4 5 6 7 8 9 10 11 12

DESCRIPTION INSTRUMENT PANEL (IP) ENGINE ROOM ENGINE FLOOR DOOR - FRONT RIGHT DOOR - FRONT LEFT DOOR - REAR RIGHT DOOR - REAR LEFT DOOR - BACK DOOR ROOF CENTRAL CONSOLE FOOTSTEP LAMP (Only TC4)

2

10

1 11

5

7

4

9 12

3

6

8

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INTER-CONNECTORS - LOCATIONS/PINS/VIEWS DESCRIPTION

LOCATION

IC No

PINS

M/F

IP to FLOOR

A-PILLAR RIGHT

1

21

F

IP to FLOOR

A-PILLAR RIGHT

2

20

F

IP to FLOOR

A-PILLAR RIGHT

3

13

F

IP to ENGINE FLOOR

A-PILLAR RIGHT

4

20

M

IP to ENGINE FLOOR

A-PILLAR RIGHT

5

5+2

M

IP to HVAC

BEHIND CENTER BEZEL

6

5+2

F

IP to TRANSFER CASE

A-PILLAR RIGHT

7

3

F

IP to TRANSFER CASE

A-PILLAR RIGHT

8

2

M

IP to TRANSFER CASE

A-PILLAR RIGHT

9

2

F

IP to ENGINE

A-PILLAR LEFT

10

21

M

CONNECTOR VIEW

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INTER-CONNECTORS - LOCATIONS/PINS/VIEWS DESCRIPTION

LOCATION

IC No

PINS

M/F

IP to ENGINE

A-PILLAR LEFT

11

20

M

ENGINE ROOM to FOG LAMP

WHEEL HOUSE PANEL -RIGHT

12

2

M

FLOOR to ROOF WIRING

A-PILLAR RIGHT

13

6

F

FLOOR to DRIVER DOOR

A-PILLAR RIGHT

14

8

M

FLOOR to REAR DOOR

B-PILLAR RIGHT

15

6

M

FLOOR to TRANSFER BELOW DRIVER CASE (Old 4WD ECU) SEAT

16

2

F

FLOOR to TRANSFER BELOW DRIVER CASE(New 4WD ECU SEAT

16

8

F

FLOOR to CONSOLE

17

12+2

F

FLOOR to CO-DRIVER A-PILLAR LEFT

18

6

F

FLOOR to BACK DOOR

D-PILLAR RIGHT

19

13

M

FLOOR to BACK DOOR

D-PILLAR RIGHT

20

2

F

BELOW CONSOLE

CONNECTOR VIEW

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INTER-CONNECTORS - LOCATIONS/PINS/VIEWS DESCRIPTION

LOCATION

IC No

PINS

M/F

FLOOR to CHASIS

Near FUEL TANK

21

2

F

FLOOR to REAR DOOR

B-PILLAR LEFT

22

6

M

ROOF to HM STOP LAMP

REAR ROOF PANEL

23

2

F

IP to ENGINE ROOM (Only in export models)

A-PILLAR RIGHT

24

3

M

CONNECTOR VIEW

M - MALE CONNECTOR WITH PINS F - FEMALE CONNECTOR

IC- 1, 2, 3, 4, 5, 7, 8, 9, 13, 14, 24

IC- 12

IC- 19, 20

IC- 15

IC- 23 IC- 16

IC- 21

IC- 6 IC- 17 IC- 22

IC - 10 , 11 ,18

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GROUND LOCATION CHART GROUND No E0 E1 E2 E3 E4

E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 E15

CIRCUITS CONTROLLED

LOCATION

CRDe ECU (K02, K04, K06), TEMPERATURE GAUGE, FUEL GAUGE, STARTER RELAY, VEHICLE SPEED SENSOR, WATER IN FUEL SENSOR, HEADLAMP ON BATTERY NEGATIVE POST RELAY BATTERY NEGATIVE TERMINAL TO BODY

FRONT WHEEL HOUSE PANEL - LEFT

UNUSED FRONT WHEEL HOUSE PANEL - LEFT TURN LEFT, SIDE MARKER LEFT , HEADLAMP/LEVELLING MOTOR - LEFT, FRONT WASHER MOTOR, HORN, CONDENSOR FAN, A/C PRESURE SWITCH, FRONT WHEEL HOUSE PANEL - LEFT SIREN FRONT FOG LAMP, PARK LEFT/RIGHT, TURN RIGHT, SIDE MARKER RIGHT , HEADLAMP/LEVELLING MOTOR - RIGHT, FRONT WIPER MOTOR, TAIL LAMP FRONT WHEEL HOUSE PANEL - RIGHT - LEFT, FLWI CIGAR LIGHTER, DEMISTER RELAY, DLC, FOG LAMP RELAY,BLOWER RELAY, CONDENSOR FAN RELAY,INETRIOR LAMP- FRONT/REAR, ILLUMINATION, HAZARD CONTROLLER, HAZARD SWITCH, COMBINATION SWITCH, VMS RESET SWITCH, HEAD LAMP LEVELLING SWITCH,

A-PILLAR RIGHT

AUDIO

A-PILLAR RIGHT

HVAC

A-PILLAR LEFT

UNUSED CLUTCH SWITCH (4WD), DRIVER DOOR LOCK, FOLLOW ME HOME CONTROLLER,POWER WINDOW, SECURITY SYSTEM, CENTRAL DOOR LOCKING, SEAT BELT SWITCH, VMS UNIT, TANK UNIT UNUSED DEMISTER, REAR FOG LAMP, REGISTRATION PLATE, TAIL LAMP RIGHT, CHSML, STOP LAMPS, REAR WIPER, REAR WASHER, REVERSE LAMP, TURN REAR - LEFT/RIGHT UNUSED

A-PILLAR LEFT BELOW CETRE CONSOLE

D-PILLAR RIGHT D-PILLAR LEFT

UNUSED BATTERY NEGATIVE TERMINAL TO ENGINE

ENGINE BLOCK - LEFT

CRDe ECU, FLWI - BRAKE FLUID LEVEL WARNING INDICATOR CHMSL - CENTRAL HIGH MOUNTED STOP LAMP

A-PILLAR LEFT

E5, E6 E4

E11 E4 E9

E13 E14 E10

E2 E3

E1

E15 E12

E0 E7, E8

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INDIVIDUAL CIRCUITS

ENGINE MANAGEMENT SYSTEM (CRDe) STARTING CIRCUIT CHARGING CIRCUIT HVAC CIRCUIT INSTRUMENT CLUSTER CIRCUIT POWER WINDOW CIRCUIT REMOTE LOCKING SYSTEM CIGAR LIGHTER/12 V POINT CIRCUIT HORN CIRCUIT

DEMISTER CIRCUIT WIPER & WASHER – FRONT CIRCUIT WIPER & WASHER – REAR CIRCUIT HEADLAMP CIRCUIT HEADLAMP LEVELLING CIRCUIT FOLLOW-ME-HOME CIRCUIT PARKING/REGISTRATION PLATE CIRCUIT INTERIOR LAMPS CIRCUIT STOP LAMP/CLUTCH PEDAL CIRCUIT TURN AND HAZARD CIRCUIT REVERSE LAMP CIRCUIT FOG LAMP CIRCUIT VOICE MESSAGING SYSTEM CIRCUIT AUDIO CIRCUIT FUEL LID OPENER 4WD CIRCUIT

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INSTRUMENT CLUSTER - SCORPIO (All New) CRDe 1

9

18

25

19 7 11

24

2

12

6

3

4

5

23

15 20 21

14

13 22 8

10

17 26

16

1. TACHOMETER 2. SPEEDOMETER 3. ODOMETER 4. TRIP A/TRIP B/CLOCK 5. MODE KNOB 6. SET KNOB 7. REAR FOG 8. ENGINE CHECK LAMP 9. ABS FAULT LAMP 10. GLOW PLUG 11. BATTERY CHARGING 12. SECURITY SYSTEM 13. HIGH BEAM 14. LOW OIL PRESSURE 15. LOW BRAKE FLUID/ HAND BRAKE 16. DOOR AJAR 17. TEMPERATURE GAUGE 18. WATER IN FUEL 19. DRIVER SEAT BELT 20. 4WD HIGH 21. 4WD LOW 22. OBD CHECK LAMP 23. FUEL GAUGE 24. DIRECTION INDICATOR 25. DIRECTION INDICATOR 26. HIGH TEMPERATURE LAMP

UPTO VIN – 72D75112

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INSTRUMENT CLUSTER - SCORPIO (All New) CRDe 1. TACHOMETER 2. SPEEDOMETER 3. ODOMETER 4. TRIP A/TRIP B/CLOCK 5. MODE KNOB 6. SET KNOB 7. ABS FAULT LAMP 8. ENGINE CHECK LAMP 9. REAR FOG 10. GLOW PLUG 11. BATTERY CHARGING 12. SECURITY SYSTEM 13. HIGH BEAM 14. LOW OIL PRESSURE 15. LOW BRAKE FLUID/ HAND BRAKE 16. DOOR AJAR 17. TEMPERATURE GAUGE 18. WATER IN FUEL 19. DRIVER SEAT BELT 20. 4WD HIGH 21. 4WD LOW 22. OBD CHECK LAMP 23. FUEL GAUGE 24. DIRECTION INDICATOR 25. DIRECTION INDICATOR 26. HIGH TEMPERATURE LAMP FROM VIN – 72D75113

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ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM SYMBOL Y-R Y-R

EXPLANATION WIRE WITH COLOUR OF WIRE Y- BASE COLOUR ; R - TRACER COLOUR (Refer colour chart for colour codes) WIRES - NOT JOINED

WIRES - JOINED

SHILEDED WIRE

TWISTED WIRE

>>

CONNECTOR

IC12/17

IC12 - CONNECTOR NO 17 - PIN NO IN CONNECTOR 12

EARTH / GROUND

GROUND ON COMPONENT

POWER SOURCE - BATTERY

POWER SOURCE - DC

POWER SOURCE - AC

10 A

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ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM SYMBOL

EXPLANATION COIL / INDUCTOR

RESISTANCE/RESISTOR

VARIABLE RESISTOR/RHEOSTAT

POTENTIOMETER

SWITCH - PUSH TO MAKE

SWITCH - TOGGLE

SWITCH - PUSH TO BREAK SWITCH - ON/OFF

CAPACITOR

VARIABLE CAPACITOR

LAMP

INDICATOR LAMP

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ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM SYMBOL

EXPLANATION MOTOR

DIODE

ZENNER DIODE

LIGHT EMITTING DIODE (LED)

TRANSISTOR (NPN)

TRANSISTOR (PNP)

30

85

87

4-POINT, NO (NORMALLY OPEN) RELAY

86

30

87

85

86

30

87

85

86

4-POINT, NC (NORMALLY CLOSED) RELAY

4-POINT, NO (NORMALLY OPEN) RELAY WITH DE-SPIKING DIODE

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ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM SYMBOL

30

85

EXPLANATION

87

4-POINT, NC (NORMALLY CLOSED) RELAY WITH DE-SPIKING DIODE

86

87 30 87a 85

30

86

87 87a

85

5 POINT RELAY (CHANGE OVER RELAY)

5 POINT RELAY (CHANGE OVER RELAY) WITH DE-SPIKING DIODE

86

SOLENOID

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WIRE COLOUR CODES WIRE COLOUR

WIRE CODE

B BL/L G Gr O P R Sb/S V W Y Br

BLACK BLUE GREEN GRAY ORANGE PINK RED SKY BLUE VIOLET WHITE YELLOW BROWN

DECODING WIRE COLOUR Y-R

BASE COLOUR TRACER COLOUR

– Y – YELLOW – R - RED

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