MAN-00159-IMMOBILISER Diagnostic Manual - XUV500

IMMOBILISER DIAGNOSTIC MANUAL
MAN-00159
RELEASED BY –
TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.
www.teknetmahindra.com Rev1 – OCTOBER 2011
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.
© 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.
DIAGNOSTIC MANUAL MAN-00159
IMMOBILISER OCT 2011/ Rev 1
CONTENTS
HOW TO USE THIS MANUAL 2
OVERVIEW OF IN-VEHICLE COMMUNICATION NETWORK 3
WARRANTY & OTHER INFORMATION 4
RECOMMENDED TROUBLESHOOTING PROCESS 4
KEY ASSIGNMENT GUIDELINE 5
KEY ASSIGNMENT PROCESS 6
REMOTE LEARNING 7
EMS ECU REPLACEMENT 10
MBFM REPLACEMENT 11
LIST OF UNAVAILABLE SERVICES 12
INDEX OF DTC’s 13
LIST OF COMBINATIONS 14
IMMOBILISER WIRING DIAGRAM 17
COMBINATION BASED TROUBLESHOOTING 18
USING DIAGNOSTIC TOOL 67
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
HOW TO USE THIS MANUAL
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 MBFM needs to be replaced. The second part outlines the trouble
shooting process.
The following is the structure of the Immobiliser Diagnostic Manual –
Combination of error codes

Reason for the combination
Probable Causes
SVS lamp status
Security lamp status
DTC reaction on vehicle
Connector layout
Circuit Schematic
Connector views and information
Diagnostic tree
The DTCs for Immobilser are generated at the MBFM as well as at the Engine Management System (EMS)
ECU. Hence it is essential that after looking at the DTC at MBFM , 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 MBFM and EMS ECU.
Always use the diagnostic manual along with the vehicle’s wiring manual (MAN- 00149).
2
OVERVIEW OF VEHICLE COMMUNICATION NETWORK
3
WARRANTY & OTHER INFORMATION
All failures/complaints encountered on EMS ECU, MBFM and transponder ring should be reported
through Service Complaint Report (SCR). Replacement of any of the EMS ECU, MBFM and transponder
ring 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)
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?
D i h l i di i ?
Search for Published quick solution in TEKnet.
Follow DTC based diagnosis
Contact TEKliner with TAR
(Technical Assistance Request)
4
KEY ASSIGNMENT GUIDELINE
Note - Only 2 keys/vehicle possible at any point of time
Key
Key lost / stolen/
Additonal key
failure
Reassign Existing
Not possible key
Order Mechanical
Key (DKR)
Assign New
Key
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.
5
DIAGNOST
TIC MANUA
AL MAN-00159
IMM
MOBILISER
R OCT 2011
1/ Rev 1
KEY ASSIG
GNMENT PR
ROCESS
Key • Custome
er Verification
Request
Key • Order neew key usingg the Dupliccate Key Request (DKR) process.
Order
• Select "Ke
ey Programm ming"
TPK1
•SMART tesster will gennerate Tool Programmin
P g Key-1 - Valid for 48 hours.
•Raise a TAAR along with
h Tool Prograamming Keyy – 1 (TPK1)
• TEKline will
w provide After Saless Code - 1 (A
ASC1) based on TPK1
ASC1 • ASC1 is valid
v until TPK1 is valid.
• Based onn the ASC1, reassign keey. SMART tester will geenerate Too
ol Programm
ming
Key – 2 (TPK2)
(
TPK2
• TPK2 to be provided
d to TEKlineer
ASC2 • TEKline will

w provide After Saless code -2 (A
ASC2)
• CoTEK will
w enter the ASC2 and complete the
t Key assiignmnet sesssion
Finish • Close TA
AR
Importa
ant Note -
Wheneveer the key is replaced and

d if the vehiccle is with ke
eyless entry then
t the rem
mote learningg has to be
performed thru diagnostic tester
The repair methods give en by the manufacturer in this document are based on the technical spe ecifications, current at th
he time of release. The methods
m may be modifieed as a result of change es introduced by the
manufacturer in the prod duction of the various co
omponent units and acce essories from which the vehicles
v are manufacture ed. The reproduction, traanslation, transmission, in part of or whole of the
e present document,
are prohibited without the prior written consent off Mahindra & Mahindra Ltd.
L The use of this docu
ument by any person othe er than the trained perso
onnel, at the Authorized S
Service Centre of Mahind dra & Mahindra Ltd.,
will amount to unauthorizzed use and shall be liab
ble for penalty/prosecution© 2011 Mahindra & Ma ahindra Ltd.
6
REMOTE LEARNING
Remote learning needs to be performed in the following sequence whenever MBFM or key/s are changed
with a new one
1. Connect using the "Python 1BConfig0404"
2. Click the "XUV500 Diagnostic Tester " icon present on the desktop.
3. MBFM"
3. Click on "WRITE DATA". The following window appears.
If only keys are replaced first click on "CLEAR REMOTES" and clear the older RKE ID's
7
4. Click on "LEARN REMOTE" and follow the instructions as mentioned in the following window
8
5. Confirm the RKE ID is getting updated as shown in the below window
9
DIAGNOST
TIC MANUA
AL MAN-00159
IMM
MOBILISER
R OCT 2011
1/ Rev 1
EMS ECU
U REPLACEMENT
Order fo
or blank FLaash the ECU usiing the Flash Do thee ECU
ECU to
ool with the corrrect VIN no ment
assignm
and the correcct dataset. process
• Selectt "EMS Chan

nge"
• SMART tester will generate code - Valid for 48 hou
urs.
TPK1 • Raise a TAR alongg with Tool Programmiing Key – 1 (TPK1) generated from
m
SMART tester
• TEKline will provide After Saales Code - 1 (ASC1) based on Acceess Passworrd
ASC1 • ASC1 is
i valid until TPK1 is valid
• Based on the entry password d, learn EMS ECU. SMA

ART tester will
w generate
e
Tool Programmin
P ng Key – 2 (TPK2)
(
TPK2 • TPK2 to
t be provid
ded to TEKliiner
• TEKline will provide After Saales Code - 2 (ASC2)

ASC2
• CoTEK
K will enter the
t ASC2 an
nd complete
e the EMS learning sesssion
Finish • Close TAR
nt Note -
Importan
For EMS datasett flashing pro nual.

ocedure, refeer to EMS diaagnostic man
e present document,
10
DIAGNOST
TIC MANUA
AL MAN-00159
IMM
MOBILISER
R OCT 2011
1/ Rev 1
MBFM REEPLACEMENT
Ordeer for blank MBFM Do the Immob

biliser ECU
assignment process
• Select "Imm Chan

nge "
• SMARTT tester willl generate code - Valid
d for 48 hou
urs.
TPK1 • Raise a TAR alongg with Tool Programmi
P ng Key – 1 (TPK1) geneerated from
m
SMARTT tester
• TEKline will providde After Sales Code - 1 (ASC1) baased on TPK

K1
ASC1 • ASC1 is valid untill TPK1 is vallid
• Based on the ASCC1, learn ICU

U/Reassign keys. SMAR
RT tester will generate Tool
Prograamming Keyy – 2 (TPK2))
TPK2 • TPK2 to
t be provid
ded to TEKliner
• TEKline will provid

de After Sales Code - 2 (ASC2)
ASC2
• CoTEKK will enter the

t ASC2 an
nd complete
e the ICU leearning sesssion
Finish • Close TAR
T
e present document,
11
LIST OF UNAVAILABLE SERVICES
The following actions are not possible –
1. Replacement of EMS ECU when both keys are not available

2. Replacement of MBFM when both keys are not available
3. Replacement of EMS ECU and MBFM when both keys are not available
4. Simultaneous replacement of EMS ECU and MBFM .
Contact TEKline for any advise/assistance
12
INDEX OF DTC CODES
Error codes in Immobiliser (MBFM)
DTC DESCRIPTION
B004D IMMO LIN cannot start
B0047 Invalid EMS Secret Key
B0040 Missing Transponder/ No Response
B0041 Invalid Transponder Secret Key
B0042 Wrong TxP
B0043 Transponder ID Table Empty
B0044 No EMS Challenge
B0045 EMS Authentication Failed
B0046 Transponder Data Format Error
B004B IMMO coil open/short
B0048 F() mismatch
B0049 No Acknowledgement
B004a Negative acknowledgement
B004C IMMO LIN communication interrupt
Error codes in EMS ECU
DTC DESCRIPTION
183F No Communication from MBFM
1832 Authentication Failed
183B EMS Locked
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.
13
LIST OF COMBINATIONS
COMBINATION 1
MBFM EMS
Page No
DTC DESCRIPTION DTC DESCRIPTION
P183F No Communication from MBFM
18
P1832 Authentication Failed
COMBINATION 2
MBFM EMS
Page No
20
COMBINATION 3
MBFM EMS
Page No
B0044 No EMS Challenge P183F No Communication from MBFM
22
COMBINATION 4
MBFM EMS
Page No
B004D IMMO LIN can not start P183F No Communication from MBFM
23
COMBINATION 5
MBFM EMS
Page No
B004B IMMO coil open/short P183F No Communication from MBFM
29
COMBINATION 6
MBFM EMS
Page No
B004C IMMO LIN communication interrupt P183F No Communication from MBFM
35
14
COMBINATION 7
MBFM EMS
Page No
B0040 Missing Transponder/ No Response P183F No Communication from MBFM
37
COMBINATION 8
MBFM EMS
Page No
B0041 Invalid Transponder Secret Key P183F No Communication from MBFM
39
COMBINATION 9
MBFM EMS
Page No
B0042 Wrong TxP P183F No Communication from MBFM
41
COMBINATION 10
MBFM EMS
Page No
B0043 Transponder ID Table Empty P183F No Communication from MBFM
43
B0042 Wrong TxP P1832 Authentication Failed
COMBINATION 11
MBFM EMS
Page No
B0046 Transponder Data Format Error P183F No Communication from MBFM
44
COMBINATION 12
MBFM EMS
Page No
B0048 F() mismatch P1832 Authentication Failed
45
B004F Random number block failure
15
COMBINATION 13
MBFM EMS
Page No
B004A Negative acknowledgement P1832 Authentication Failed
46
COMBINATION 14
MBFM EMS
Page No
B0047 Invalid EMS Secret Key P1832 Authentication Failed
B0045 EMS Authentication Failed 47
B0048 F() mismatch
COMBINATION 15
MBFM EMS
Page No
B004E MBFM internal EEPROM failure P183F No Communication from MBFM
B0045 EMS Authentication Failed P1832 Authentication Failed 48
B0048 F() mismatch
COMBINATION 16
MBFM EMS
Page No
49
16
IMMOBILISER WIRING DIAGRAM
17
COMBINATION 1
MBFM EMS
REASON FOR THE During Ignition ON , MBFM not communicating with EMS ECU
COMBINATION
Open CAN wires

PROBABLE Open/Short MBFM ignition power supply
CAUSES Open/Short MBFM battery power supply
Open MBFM ground
Malfunctioning MBFM
LAMP STATUS
SVS Lamp Blinks
Security lamp OFF
DTC REACTION Engine will not crank /start
18
19
COMBINATION 2
MBFM EMS
REASON FOR THE During Ignition ON , EMS ECU not communicating with MBFM
COMBINATION
Open CAN wires

PROBABLE Open/Short EMS ECU ignition power supply , Malfunctioning Main Relay
CAUSES Open/Short EMS ECU battery power wire
Open EMS ECU ground
Malfunctioning EMS ECU
LAMP STATUS
SVS Lamp OFF
Security lamp OFF
DTC REACTION Engine will crank but will not start
20
21
COMBINATION 3
MBFM EMS
B0044 No EMS Challenge P183F No Communication from MBFM
REASON FOR THE During Ignition ON , the signal from the EMS ECU is not received by MBFM
COMBINATION
PROBABLE Attempt to start the vehicle before EMS ECU after run completed
CAUSES Disturbance in CAN wires between MBFM and EMS ECU
LAMP STATUS
SVS Lamp blinks
Security lamp Off
DTC REACTION Engine will not start
Corrective Action
Turn Off the ignition .Wait for 2 minutes and let the after run complete. Try to start the engine. If it
starts clear the DTC and deliver the vehicle
If the DTC still exists ,check as per the procedure given for U1101 and U1104 in the last section of this
manual
22
COMBINATION 4
MBFM EMS
IMMO LIN cannot start P183F No Communication from MBFM
REASON FOR THE During Ignition ON , no LIN communication between transponder ring and
COMBINATION
MBFM
Key IN fuse blown

PROBABLE Open/short LIN BUS
CAUSES Open /short transponder ring power wire
Open transponder ring ground wire
Faulty transponder ring
LAMP STATUS
SVS Lamp blinks
Security lamp blinks for 30 seconds
23
CIRCUIT SCHEMATIC
CONNECTOR VIEWS AND INFORMATION
24
25
CONNECTOR
NOMENCLATURE PIN NO FUNCTION
1 POWER
P7 2 GROUND
3 LIN BUS
4 LED SIGNAL
P6 K1 KEY IN POWER
K2 KEY OUT POWER
P26 J2-37 LIN BUS
P28 J4-12 GROUND
26
27
28
COMBINATION 5
MBFM EMS
B004B IMMO coil open/short P183F No Communication from MBFM
REASON FOR THE During Ignition ON , transponder ring power fluctuation or impedance
COMBINATION
mismatch
Intervention of local electromagnetic field in transponder ring

PROBABLE Open/short LIN BUS
CAUSES Open /short transponder ring power wire
Open transponder ring ground wire
Faulty transponder ring
LAMP STATUS
SVS Lamp blinks
29
CIRCUIT SCHEMATIC
30
31
CONNECTOR
NOMENCLATURE PIN NO FUNCTION
1 POWER
P7 2 GROUND
3 LIN BUS
4 LED SIGNAL
P6 K1 KEY IN POWER
K2 KEY OUT POWER
P26 J2-37 LIN BUS
P28 J4-12 GROUND
32
33
STEP 4
Ignition OFF
Transponder ring wiring
harness connector
DISCONNECTED(P7)
MBFM wiring harness
connector DISCONNECTED(P26)
Check the resistance between
pin 3 of the transponder ring
wiring harness connector and
pin J2-37 of the MBFM wiring
harness connector
YES Is the value <1Ω? NO
STEP 5 Examine the open circuit of

Ignition OFF transponder ring to MBFM LIN
Transponder ring wiring bus
harness connector Replace the wiring harness
DISCONNECTED(P7) Clear the DTC and verify
MBFM wiring harness
battery ground
YES Is the value =∞Ω? NO
STEP 6 Examine the short circuit to

Ignition OFF ground of immobiliser to MBFM
Transponder ring wiring LIN bus
harness connector Replace the wiring harness
DISCONNECTED(P7) Clear the DTC and verify
MBFM wiring harness
pin J4-12 of the MBFM wiring
harness connector
YES Is the value <1Ω? NO
Suspect transponder ring Examine the open circuit of

internal failure transponder ring ground wire
Replace the transponder ring to MBFM
with a new one Replace the wiring harness
Clear the DTC and verify Clear the DTC and verify
If the DTC still exists , replace
the MBFM with a new one
Check for any new DTC’s
34
COMBINATION 6
MBFM EMS
B004C IMMO LIN communication interrupt P183F No Communication from MBFM
REASON FOR THE During Ignition ON , LIN communication between transponder ring and
COMBINATION
MBFM interrupted
PROBABLE Loose connections in transponder ring circuit

CAUSES Faulty transponder ring
LAMP STATUS
SVS Lamp blinks
35
36
COMBINATION 7
MBFM EMS
B0040 Missing Transponder/ No Response P183F No Communication from MBFM
Note-
Ensure that the key blade and key base cover is in 180 degree with the ignition switch
REASON FOR THE During Ignition ON , no signal from transponder (key) to MBFM
COMBINATION
PROBABLE Wrong key used

CAUSES Damaged Transponder
Transponder missing in the key
LAMP STATUS
SVS Lamp blinks
37
STEP 1
Connect the smart tester
Turn the ignition ON
Initialise the diagnostic tool
Record the DTC and clear
Turn ignition OFF
Wait for 2 minutes
Turn ignition ON
Start the engine
Does the engine

YES NO
starts?
STEP 2 Replace the key

Perform key learning
With the other allocated key to Clear the DTC in EMS and MBFM
the vehicle, start the engine Confirm the proper functioning
of the new key
Does the engine

YES NO
starts?
Replace the key
Inform the customer about a Perform key learning
possible theft attempt with a Clear the DTC in EMS and MBFM
mechanical replica Confirm the proper functioning
of the new key
Note-
With DTC B0040 present and If both the keys failed to start the engine , suspect internal failure of transponder ring
Replace the the transponder ring with a new one
38
COMBINATION 8
MBFM EMS
B0041 Invalid Transponder Secret Key P183F No Communication from MBFM
REASON FOR THE During Ignition ON , the signal from transponder (key) to MBFM is not valid
COMBINATION
Wrong key used

PROBABLE
CAUSES Damaged Transponder
Transponder missing in the key
Interruption in key and transponder ring communication due to local magnetic
field
LAMP STATUS
SVS Lamp blinks
Note -
Before proceeding for the steps given below, ensure that no local magnetic field near the transponder
ring
39
STEP 1
Turn ignition OFF
Wait for 2 minutes
Turn ignition ON
Start the engine
Does the engine

YES NO
starts?

With the other allocated key to Clear the DTC in EMS and MBFM
of the new key
Does the engine

YES NO
starts?
Replace the key
Inform the customer about a Perform key learning
possible theft attempt with a Clear the DTC in EMS and MBFM
mechanical replica Confirm the proper functioning
of the new key
Note-
With DTC B0041 present and If both the keys failed to start the engine , suspect internal failure of transponder ring
Replace the the transponder ring with a new one
40
COMBINATION 9
MBFM EMS
B0042 Wrong TxP No Communication from MBFM
Authentication Failed
REASON FOR THE During Ignition ON , the signal from transponder (key) to MBFM is valid but
COMBINATION
the key does not belong to this particular vehicle
PROBABLE Attempt to start the vehicle with a new key before programming
CAUSES Attempt to start the vehicle with a key programmed for another vehicle
LAMP STATUS
SVS Lamp blinks
41
STEP 1
Turn ignition OFF
Wait for 2 minutes
Turn ignition ON
Start the engine
Does the engine

YES NO
starts?

With the other allocated key to
Clear the DTC in EMS and MBFM
of the new key
Does the engine

YES NO
starts?
Replace the key
Error would have occurred Perform key learning
because of usage of another Clear the DTC in EMS and MBFM
vehicles key Confirm the proper functioning
Clear the DTC and verify of the new key
42
COMBINATION 10
MBFM EMS
B0043 Transponder ID Table Empty P183F No Communication from MBFM
B0042 Wrong TxP P1832 Authentication Failed
REASON FOR THE

COMBINATION No key is assigned to MBFM
PROBABLE Attempt to start the vehicle after MBFM replacement without doing
CAUSES
Immobiliser learning
LAMP STATUS
SVS Lamp blinks
Corrective Action
Perform Immobiliser programming with the same MBFM in the vehicle
43
COMBINATION 11
MBFM EMS
B0046 Transponder Data Format Error P183F No Communication from MBFM
Note-
Ensure that the key blade and key base cover is in 180 degree with the ignition switch
REASON FOR THE Transponder format not matches with the MBFM format
COMBINATION
PROBABLE
CAUSES Wrong key used
LAMP STATUS
SVS Lamp blinks
DTC REACTION
Engine will not crank /start
Corrective Action
Relearn the key

If the DTC still exists, replace the key with a new one and perform key learning.
Clear the DTC in MBFM and EMS ECU
44
COMBINATION 12
MBFM EMS
F() mismatch
B0048
B004F Random number block failure
REASON FOR THE EMS codes mismatch with Immobiliser codes

COMBINATION
PROBABLE MBFM block corrupted during writing

CAUSES
LAMP STATUS
SVS Lamp blinks
Security lamp OFF
Corrective Action
Perform Immobiliser programming with the same MBFM in the vehicle

If the DTC still exists, replace the MBFM with new one
45
COMBINATION 13
MBFM EMS
B004A Negative acknowledgement
The signal from the MBFM is not as expected by EMS ECU for successful
REASON FOR THE MBFM authentication
COMBINATION
Disturbance in CAN wiring

PROBABLE EMS ECU and MBFM gone out of synchronisation due to disturbance in power
CAUSES supply to any of the component
LAMP STATUS
SVS Lamp blinks
Security lamp off
Corrective Action
Check and rectify CAN loose connections, MBFM and EMS ECU power supply and ground
as the procedure given in MBFM node absent (U1104) and EMS node absent (U1101)
DTC's in last section of this manual
If the DTC still exists, perform EMS programming.
Clear the DTC in MBFM and EMS ECU
46
COMBINATION 14
MBFM EMS
B0047 Invalid EMS Secret Key
B0048 F() mismatch
REASON FOR THE EMS ECU and MBFM are not paired and will have default DTC's
COMBINATION
PROBABLE EMS ECU and MBFM are not paired

CAUSES
LAMP STATUS
SVS Lamp blinks
Security lamp off
Corrective Action
Perform Immobiliser programming
47
COMBINATION 15
MBFM EMS
B004E MBFM internal EEPROM failure
REASON FOR THE Immobiliser security code incorrect while learning key
COMBINATION
PROBABLE MBFM EEPROM failure

CAUSES
LAMP STATUS
SVS Lamp blinks
Security lamp off
Corrective Action
Replace the MBFM with a new one
48
COMBINATION 16
MBFM EMS
P183B EMS Locked
Vehicle getting immobilised continuously for more than 20 times

REASON FOR THE
COMBINATION
PROBABLE ECU locked

CAUSES
LAMP STATUS
SVS Lamp blinks
DTC REACTION Engine will crank but will not start if the correct key is used
Engine will not crank if wrong key is used
Corrective Action
Clear the DTC using dealer security tool

Perform Immobiliser programming
Check and verify that engine is starting
49
U1101 - EMS Node Absent
EMS NODE ABSENT
COMPONENT LOCATION
NORMAL
OPERATION
DTC DETECTING
CONDITION
PROBABLE
CAUSES
LAMP STATUS
DTC REACTION
HEALING
CONDITION
50
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
51
Connector
Nomenclature Pin No Function
65 CAN LOW
66 CAN HIGH
E18 71 IGNITION POWER
1 ECU GROUND
2 ECU GROUND
4 ECU POWER
6 ECU POWER
P1 14 CAN LOW
6 CAN HIGH
52
53
54
55
Ignition OFF
EMS ECU Wiring harness
connector DISCONNECTED
YES NO
56
U1104 - MBFM Node Absent
MBFM NODE ABSENT
COMPONENT LOCATION
NORMAL
OPERATION
DTC DETECTING
CONDITION
PROBABLE
CAUSES
LAMP STATUS
DTC REACTION
HEALING
CONDITION
57
CONNECTOR LAYOUT
CIRCUIT SCHEMATIC
58
59
60
Connector
Nomenclature Pin No Function
P25 J1-55 CAN LOW
J1-56 CAN HIGH
P26 J2-11 IGNITION POWER
J3-12 MBFM GROUND 2
J3-15 MBFM GROUND 3
P27 J3-13 BATTERY 1
J3-07 BATTERY 3
P28 J4-03 MBFM GROUND 1
J4-11 MBFM GROUND 1
J4-13 BATTERY 2
P1 14 CAN LOW
6 CAN HIGH
61
62
63
Ignition OFF
MBFM wiring harness

connector
DISCONNECTED(P26)
YES NO
Ignition OFF
MBFM wiring harness
connector
DISCONNECTED(P26)
YES NO
64
65
66
HOW TO USE THE DIAGNOSTIC TOOL
Home Screen
To start EMS/ICU/Key
assignment or to enter
ASC1 or ASC2 for an
existing session click
here
To check error codes

click here
To check the details of

an existing session click
here
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.
67
Checking DTCs
After clicking on CHECK ERROR CODES tab the following window will appear.
Select Python 1B
from the drop down
menu
68
After selecting Python 1B the following window will appear.
To read errors in EMS

ECU click here
To read errors in ICU click

here
69
After selecting Read EMS Error Codes the following window will appear. Similar window will come up for Read Immobiliser Error Codes also.
To refresh error code

screen click here
To clear error codes

click here
To close the error

code window click
here
70
High Security Programming
After selecting High security programming in the home screen, the following window will appear.
Click here to start

session
71
After clicking start session, the following window will appear.
Select Python 1B
from the drop down
menu
72
After selecting Python 1B, the following window will appear.

To create a new
session to generate
TPK1 select this
option
To enter ASC1
received from
TEKline select this
option
To enter ASC2
received from
TEKline select this
option
73
Creating new session to generate TPK1
After selecting the above option, the following window will appear.
Enter the dealer

code which was
entered during
installation of the
software here
74
After entering the dealer code, the following window will appear.
Select the service to be

done from the three
options. For the
purpose of
demonstration EMS
change is taken as the
service
75
After selecting operation, the following window will appear.
Select one or two based

on the number of old keys
presented by the
customer
NOTE: in case of key assignment, the combinations to be chosen are as follows.
To erase an old key: Old keys 1, New Keys 0

To assign 1 new key: Old keys 1, New Keys 1
To assign 2 new keys: Old keys 0, New Keys 2
76
After selecting the number of old keys , the following window will appear.
The tool will guide you

through further
procedure. Follow the
instructions coming in
this tab until the
TPK1is generated
Before clicking next and

starting the coding
procedure verify the
selections made are
correct from those
displayed here
77
Sending TPK1 & TPK2 to TEKline
At the end of the procedure the tool will generate a file XXXXXXXXXXXXXX.tpk1 in the location C:\codes
Attach the file to the TAR and send it to the TEKline.

TPK2 also will be generated in the same folder after entering ASC1 received from TEKline, which again should be sent to TEKline.
78
How to identify TPK1 & TPK2
The name of the TPK1 or TPK2 file generated carries a bunch of information as given below
MA1YE2JEKA6H50005_K295.tpk1
Vin Number of the Operation Carried Out Session ID: Type of code
vehicle running serial
K – Key Assignment .tpk1 – TPK1
number in the tool
C – ICU Change .tpk2 – TPK2
E – EMS Change .asc1 – ASC1
.asc2 – ASC2
79
Adding ASC1 or ASC2 to an existing session
Download the file XXXXXXXXXXX.asc1/XXXXXXXXXX.asc2 received from the TEKline and save it in any convenient location in your laptop.
After selecting high security programming in the home screen, select Add ASC1/ASC2 for existing session depending on the code you have to add.
The following window will open up
80
Browse and select the

ASC1/ASC2 received
from TEKline based on
the Vin number,
operation, session id
and TPK1/TPK2 and
click open at the
bottom
Follow the instructions coming up in the window
Until TPK2 is generated if entering ASC1

Until the assignment process is completed
successfully if entering ASC2
81
Checking session details

STAGE 1: Waiting for
After selecting Check Session Details on the home screen the following window will appear ASC1 from TEKline
after generation of
TPK1
STAGE 2 SESSION:
waiting for ASC2 from
TEKline for
completion of the
service after
generation of TPK2
Session ID: running Vin number of the Start date of the operation Service: type of service Time remaining till the
serial number for the vehicle in which the (EMS/ICU/KEY expiry of TPK1/TPK2
assignment Service is being assignment) being
procedure from the carried out carried out.
beginning of
installation of tool
82

MAN-00159-IMMOBILISER Diagnostic Manual - XUV500

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IMMOBILISER DIAGNOSTIC MANUAL

TECHNICAL PUBLICATION CELL

www.teknetmahindra.com Rev1 – OCTOBER 2011

IMMOBILISER OCT 2011/ Rev 1

HOW TO USE THIS MANUAL 2

OVERVIEW OF IN-VEHICLE COMMUNICATION NETWORK 3

WARRANTY & OTHER INFORMATION 4

RECOMMENDED TROUBLESHOOTING PROCESS 4

KEY ASSIGNMENT GUIDELINE 5

KEY ASSIGNMENT PROCESS 6

EMS ECU REPLACEMENT 10

LIST OF UNAVAILABLE SERVICES 12

IMMOBILISER WIRING DIAGRAM 17

COMBINATION BASED TROUBLESHOOTING 18

USING DIAGNOSTIC TOOL 67

IMMOBILISER OCT 2011/ Rev 1

HOW TO USE THIS MANUAL

The following is the structure of the Immobiliser Diagnostic Manual –

Combination of error codes

IMMOBILISER OCT 2011/ Rev 1

OVERVIEW OF VEHICLE COMMUNICATION NETWORK

IMMOBILISER OCT 2011/ Rev 1

WARRANTY & OTHER INFORMATION

RECOMMENDED TROUBLE SHOOTING PROCESS

Customer complaint Record/Understand Customer Verbatim

Search for Published quick solution in TEKnet.

Follow DTC based diagnosis

Contact TEKliner with TAR

(Technical Assistance Request)

IMMOBILISER OCT 2011/ Rev 1

KEY ASSIGNMENT GUIDELINE

Note - Only 2 keys/vehicle possible at any point of time

1. Duplicate key should be ordered after customer verification by the dealer

ASC2 • TEKline will

Wheneveer the key is replaced and

IMMOBILISER OCT 2011/ Rev 1

1. Connect using the "Python 1BConfig0404"

3. Click on "WRITE DATA". The following window appears.

IMMOBILISER OCT 2011/ Rev 1

IMMOBILISER OCT 2011/ Rev 1

5. Confirm the RKE ID is getting updated as shown in the below window

• Selectt "EMS Chan

• Based on the entry password d, learn EMS ECU. SMA

• TEKline will provide After Saales Code - 2 (ASC2)

For EMS datasett flashing pro nual.

Ordeer for blank MBFM Do the Immob

• Select "Imm Chan

• TEKline will providde After Sales Code - 1 (ASC1) baased on TPK

• Based on the ASCC1, learn ICU

• TEKline will provid

• CoTEKK will enter the

IMMOBILISER OCT 2011/ Rev 1

LIST OF UNAVAILABLE SERVICES

The following actions are not possible –

1. Replacement of EMS ECU when both keys are not available

Contact TEKline for any advise/assistance

IMMOBILISER OCT 2011/ Rev 1

INDEX OF DTC CODES

Error codes in Immobiliser (MBFM)