Mahindra Genio DC BS-IV Diagnostic Manual

Brand: Mahindra

Model: Genio DC BS-IV

Type: Diagnostic Manual

This manual is also suitable for

Genio DC BS-III

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, pillay.ajay@mahindra.com 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

o How to use this manual

o Overview of in-vehicle communication network

o Recommended troubleshooting process

o Warranty/Other information

o Key Assignment guideline

o Key Assignment process.

o Remote Learning

o EMS ECU replacement

o Immobilizer ECU replacement

o List of Unavailable Services

o Index of DTC codes

o Using diagnostic tool

o Troubleshooting chart

o Wiring 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

keysmith@mahindra.com

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

Code Description Code Description

1832 Immobilizer Authentication Failed

183F No ICU Response

Combination - 2 Page

ICU EMS

Code Description Code Description

8044 No ECM Challenge

Combination - 3 Page

ICU EMS

Code Description Code Description

8042 Wrong Transponder 1832 Immobilizer Authentication Failed

183F No ICU Response

Combination - 4 Page

ICU EMS

Code Description Code Description

8043 No Transponder is Learnt 1832 Immobilizer Authentication Failed

183F No ICU Response

Combination - 5 Page

ICU EMS

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

Code Description Code Description

8041 Invalid Transponder 1832 Immobilizer Authentication Failed

183F No ICU Response

Combination - 7 Page

ICU EMS

Code Description Code Description

8048 F() mismatch 1832 Immobilizer Authentication Failed

8045 ECM Authentication Failed

Combination - 8 Page

ICU EMS

Code Description Code Description

8044 No ECM Challenge 1832 Immobilizer Authentication Failed

183F No ICU Response

Combination - 9 Page

ICU EMS

Code Description Code Description

8049 No ECM Acknowledgement 1832 Immobilizer Authentication Failed

8045 ECM Authentication Failed

Combination - 10 Page

ICU EMS

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