Specifications Scorpio CRDe

Engine : Mahindra CRDe 2.6

Type : 4 cyl.Inline , Common rail direct injection

Clutch : Diaphragm

Transmission : NGT 530

Transfer case - Optional : Borg-Warner electric shift

Differential ratio : 4.3 : 1

Brakes : Twin pot caliper, tandem booster, vacuum reservoir

Tyre : 235 / 70 R 16 105 S

Emission : BS2, BS3,EII,EIII

 Specifications - Mahindra CRDe engine

Manufacturer : Mahindra & Mahindra , India

Bore : 94 mm
Stroke : 94 mm
Capacity : 2609 cc
Compression ratio : 18.5 : 1
Max. Power : 115 bhp @ 3800 rpm
Max. Torque : 28.3 kg-m @ 1700-2200 rpm
Idle speed : 850 rpm
Valve mechanism : Single camshaft in block , 8 Valves , 2
Valve / cyl. Camshafts with chain drive.
Fuel system : Common rail diesel injection
Engine management : Bosch ECU, Controlling fuel injection.
Diagnostics : 16 pin DLC, K-line diagnostics
 Mahindra CRDe engine

Electro-hydraulic Injectors
Oil separator

Common rail

EGR valve

High pressure
Pump
 Maintenance – Mahindra CRDe
Engine oil
Specification : API CH4-SAE 15W 40
Recommended brand : Maximile supreme
Drain interval : 5000, 20000 , every 15000 kms / 9 month
Capacity : 6 lit
Oil filter : Change with engine oil

Coolant
Recommended brand : Maximile coolant
Mix ratio : Pre-mixed
Replacement : 40000 kms or 2 years

Fuel filter
Type : Spin on with water sensor and diesel temperature
sensor
Replacement interval : 20000 kms

Air filter :
Type : Foam type with mechanical clogging indictor
Replacement interval : 40000 kms

Accessory belt
Type : 7 groove poly V-belt
Accessories belt layout
Air cleaner

Replace element, if vehicle covered 40000 kms or

Air filter choking indicator is on, in the cluster

No cleaning of element is allowed

Ensure no dirt / dust or oil enters mass air flow

sensor while replacing air filter element
 Fuel filter / fuel system

Priming pump
Diesel fuel temperature
sensor

Water in fuel sensor

Indication in cluster

Spin-on filter element (0305 DC 0161N)

Replace filter element after every 20000 kms

Unscrew the sensor body by few threads and water will drain out
 O
U
T

Bleed screw on
outlet banjo
[ Deleted in new vehicle ]

Bleed screw
[ New vehicle ]
In

8
Oil separator system

To air intake pipe

Labyrinth type oil separator

Balancer pipe
Oil filler cap Diaphragm

Wire mesh
To intake

From sump

Rocker chamber

One-way valve

Gas + oil

Gas

Oil
 Terminology's used in diesel engine

Diesel engine : An IC engine using diesel or heavy oils as fuel.

CI engine : Compression Ignition engine, an engine which uses the heat

to compression to self ignite the Air-Fuel mixture.

Direct injection
engine : An CI engine in which the fuel is injected directly on top of
the piston.

Indirect injection
engine : An CI engine in which the fuel is injected a separate
chamber located in the cylinder hard.
ECU – Known as Electronic Control Unit, receives information from various sensors on the
state of the engine / requirements and manipulates the engine functioning through
actuators. Other names – PCM (Powertrain Control Module), ECM (Engine Control
Module), EEC (Electronic Engine Control).

Sensors - Sensors are located strategically at various locations in the engine. These
sensors measure/sense the present operating conditions of the engine and pass on the
information to ECU for processing. Sensors can be of 3 types - Digital, Analog, Switch. Also
known as SENDER or SENDING UNIT.

Actuators - Actuators are manipulated by the ECU to change the operating condition of the
engine, based on the inputs received from Sensors and the logics/maps stored in the
engine.

Engine maps - In order to aid the ECU to make decisions based on inputs from sensors,
the desired operating condition of the engine is stored in the form of a MAP. Typical Maps in
a diesel engine are Airflow maps, EGR maps, Fuel quantity maps etc. Maps are stored
in a table for various discrete points in the operating range of the engine. Values falling in
between these points are interpolated by the ECU using various algorithms.

Emissions - Any gaseous/solid/liquid material emitted form the engine are termed as
emissions. Emissions are broadly categorized as Tail pipe emission and Evaporative
emissions.
Pollutants : Components of Tail pipe emission or Evaporative emission , which are
considered to be harmful to Humans as well as environment are considered to be pollutants.
The acceptable pollutant levels are controlled by regulations of various countries.

Major pollutants in diesel engine

CO [Carbon Monoxide] : Colorless, odorless,Poisonous - Hemoglobin of blood has more

affinity for CO than Oxygen, leading to slow poising and death ,if exposed for very long
times.

HC [Hydrocarbons] : Partially burned or Unburned components of the fuel. Combines with

NOx , in the presence of sunlight to form photochemical smog.

NOx [Oxides of Nitrogen] : Brownish gas, poisonous - Once inhaled by humans mixes with
moisture in the lungs and forms Dilute Nitric acid which corrodes lung cells.

PARTICULATES : Components of Sulfur and unburned carbon. Sulfur is used in diesel to

improve lubricity.

CO2 [Carbon DI-Oxide] : Not considered as a pollutant as of now. However, it is termed as

a Green house gas leading to the phenomena of Global warming. Future regulations might
be introduced , indirectly as Fuel efficiency regulations. FE regulations exist in certain
countries.
Catalyst : A catalyst is an exhaust after-treatment device. A catalyst chemically converts
harmful exhaust pollutants to un-harmful gases. Generally referred to as CAT

Oxidation catalyst : Also Known as Oxi-cat. An Oxi-cat adds oxygen to harmful pollutants
such as CO, HC and converts to CO2 and Water. Generally fitted on Diesel engines.
Air-fuel ratio : A/F ratio is termed as the amount air (by mass) to the amount of fuel (by
mass), in a Air-Fuel mixture.

Stochiometric air-fuel ratio : Stochiometric A/F ratio is the amount of air required to mix a
certain amount fuel, in complete & chemically correct ratio. Stochimetric A/F ratio for
Gasoline (iso-octane) is 14.7 : 1 and for Diesel (N-Cetane) IS 15.1 : 1.

LAMBDA ( λ ) - Also known as equivalence ratio. It is the ratio of the actual A/F ratio to the
Stochiometric A/F ratio. λ=1 means a Stochiometric ratio.
Diesel engines operate with lean mixture varying between 200:1 (idle) to 22 : 1 (Full load).

Emission norms

EUROPE - Euro 1 , Euro 2 , Euro 3 , Euro 4 (2005), Euro 5 (2010)

USA - Tier 0, Tier 1, Tier 2 , LEV, ULEV, SULEV, ZEV
INDIA - INDIA 96, INDIA 2000, BS2, BS3

All the emissions norms specify a maximum limit for each pollutant component when tested
on a specified cycle.
ON BOARD DIAGNOSTICS (OBD) : In order to improve the emission & Fuel efficiency
performance the engine, an increasing number of electronic components are being added
to engine/Gear box control systems. However, it likely that some of these components
might fail and lead to the engines emitting abnormal levels of pollutants and deteriorated
fuel consumption. The vehicles may ply without even the driver knowing the deteriorated
engine performance as regards emission. OBD system was legislated by law in California
to inform the driver about the deteriorated condition of the engine.

OBD1 : When a critical electronic component fails which can have a effect on Tail pipe
emissions, the driver is indicated by a blinking “Check Engine” lamp. The driver has to
report to a workshop , where the technician can plug in a diagnostic tool/scanner and pull
out the defect codes from the ECU memory and do corrective action as required.

OBD2 : When a critical electronic component fail which can have a effect on Tail pipe
emissions , more than 1.5 times the legislated levels, the driver is indicated by a “Check
Engine” lamp. The driver has to report to the closest workshop within a specified time
period or else the motor vehicle dept, can impose a heavy fine, if caught. The time
between the defect and reporting to workshop can be pulled out from the ECU memory
using a normal scanner.(Kms driven with defect)

OBD3 : Similar to OBD2 , but the defect is automatically reported to the Motor vehicle dept,
through a satellite link from the vehicle’s GPS system.
OFF-BOARD DIAGNOSTICS

On-board diagnostics checks the operation of the ECU/sensors/ actuators and informs the
driver about the presence of a major fault in the engine management electronics, by lighting or
blinking the “check engine lamp”.

However, the identification of the exact nature of the fault is done through off-board diagnostic
equipments like scanners, engine analyzers etc , at the dealer workshops.

Some of the off-board equipments like scanners are universal and pulls out the DTCs (Defect
Trouble Code) stored in the ECU’s memory. The technician has to apply his knowledge to
correct the same.

Most of the manufacturers supply a specialized diagnostic equipment, tailor-made for their
product. These diagnostic equipment provide “value added” service by describing the defect
in normal english and also provide trouble shooting guide. Even the shape the sensor outputs
can be viewed in a graphical form for better understanding.
 Evolution of fuel injection system

Fuel system Peak injection pressure Timing Governor

Inline without timer 800 Fixed Mechanical
Inline with timer 800 Variable Mechanical
Rotary pump -VE
1200 Variable Mechanical
[ Axial plunger ]
Rotary pump -VP21
1200 Variable Electronic
[ Axial plunger ]
Rotary pump -VP44
1200 Electronic Electronic
[ Radial plunger ]
CRDi 1600-3000 De-linked Electronic
 Injection control - Conventional

MI

IVC EVO

BDC FIRING BDC

TDC

Intake Compression Power Exhaust

 Injection control - CRDe

Noise Power Emission

Pil3 Pil2 Pil1 MI Po1 Po2

IVC EVO

BDC FIRING BDC

TDC

Intake Compression Power Exhaust

 Injection control - Mahindra CRDe

Noise Power

Pil2 Pil1 MI

IVC EVO

BDC FIRING BDC

TDC

Intake Compression Power Exhaust

21
 Basics of electronic engine management

In electronic engine management, the ECU receives information about the present
operating state of the engine from various sensors, assesses the situation with regard to
driver input (pedal request) , calculates the basic fuel quantity &, based on MAPs , does
minor corrections to suit the local conditions like ambient temp, coolant temp etc, and
controls the actuators to deliver the corrected quantity of fuel.

Sensors

ECU

Actuators

• Calculate fuel qty

• Do local correction
 Basic layout of Scorpio CRDe

Sensor input Actuator output

Fuel injector
• Engine speed Engine map
• Mass air flow
EGR modulator
• Manifold air temp
• Rail pressure
Pump metering unit
• Cam phase sensor
E • Temperature gauge
• Accl. Pedal sensor
• Cruise control switches *
C • High temp lamp

Tachometer
• Coolant temperature
• Vehicle speed
• Brake pedal position
U A/c compressor relay
• Clutch pedal position
Glow plug relay
• Diesel temperature Diagnostic (In export)
• A/c request switch executive /
Fault memory • Engine check lamp
• Diagnostic outlet
 Functions of ECU, sensors, actuators & relays
Electronic control unit [ ECU ] Critical

Location : Behind glove box

Type : EDC 16 C torque structure.

Function : Receives information from various sensors on the state of the

engine / requirements and manipulates the engine functioning
through actuators.

Purpose : To run the engine as per desired mapping

 Critical

TDC position sensor

Location : On the clutch housing - facing the toothed flywheel

Type : 2 wire, inductive voltage generator pickup

Function : Locates the TDC of no.1 or 4 cylinder

ECU calculates the speed based on no of TDC / unit time

Purpose : Flywheel outer face has 60 equally spaced teeth machined.

Two teeth, near tdc of no.1 or 4, is deliberately missed. The
sensor identifies the missing teeth & locates the TDC and the
ECU calculates the speed.
 Critical

Cam phase sensor

Location : On the timing cover - facing the camshaft sprocket

Type : 3 wire, hall effect switch

Function : Locates the firing tdc of no.1 cylinder

Purpose : Synchronization for sequence of fuel injection

 Critical

Rail pressure sensor

Location : On the fuel common rail

Function : Monitors rail pressure

Purpose : To decide on injector energizing time

 Important

Accelerator pedal sensor

Location : In the accelerator pedal

Type : 6 wire, double track potentiometer

Function : Informs ECU about driver’s pedal request.

Purpose : To transmit driver’s pedal request to ECU

 Important

Mass air flow sensor

Location : On the intake hose

Type : 3 (5 ) wire , Hot film mass flow sensor

Function : Monitors the air flow

Purpose : To correct air flow map and regulate EGR flow

 Correction

Intake air temperature sensor

Location : Integrated with MAF sensor

Type : 2 ( 5 ) wire, Resistor with negative temperature coefficient

Function : Monitors the intake air temperature

Purpose : Measures air temperature for density correction & maintaining

temperature of hot film
 Correction

Fuel temperature sensor

Location : In the fuel filter assembly

Type : Wire, resistor with negative temperature coefficient

Function : Monitors the fuel temperature

Purpose : Measures fuel temperature for density correction

 Correction

Coolant temperature sensor

Location : On the water outlet box, near thermostat

Type : 2 wire, resistor with negative temperature coefficient

Function : Monitors the coolant temperature

Purpose : To determine the temperature of the engine

 Information

A/c request relay

Location : On the main fuse box

Type : A/C on-off ( Low ) switch & relay

Function : Informs ECU about driver’s request for A/C.

Purpose : To prepare the engine, in advance, for A/C load.

 Critical

Fuel injector

Location : On the cylinder head

Type : 2 wire, solenoid operated , Electro-hydraulic injector

Function : Solenoid valve opens on receipt of signal from ECU.The

amount of time the injector open determines the amount of fuel
flow, as the rail pressure is monitored.

Purpose : To inject fuel in a fine mist inside the cylinder

 Critical

Metering unit

Location : On the high pressure pump

Function : To control the fuel inflow in to high pressure pump

 Important

EGR vacuum modulator

Location : On the firewall

Type : Solenoid controlled vacuum modulator

Function : To supply desired level of vacuum to egr valve

Purpose : To control EGR flow

 Important

A/c compressor clutch relay

Location : On the main fuse box

Type : Relay. Relay coil with diode to protect ECU against reverse
EMF.

Function : Relay coil is controlled by ECU

Purpose : To engage & disengage the A/C clutch based on information

from ECU.
 Information

Temperature gauge

Location : On the instrument cluster

Type : Analog dial

Function : Indicates the temperature of engine.

Purpose : To inform the driver about engine temperature.

 Information

High temperature warning lamp

Location : On the instrument cluster, end of temperature gauge red band

Type : Led

Function : Blinks when water temperature reaches 1100 C. Blinking

frequency will increase till temperature reaches 120 deg. At
1200 C, the lamp will remain on permanently.

Purpose : To inform the driver about engine overheating.

 Information

Check engine lamp

Location : On the instrument cluster

Type : Tell tale lamp.

Function : Lights up / Blink when a major fault is detected in engine

electronics.

Purpose : To inform the driver about engine status / fault status.

 Information

Tachometer

Location : On the instrument cluster.

Type : Analog dial

Function : To operate the tachometer based on engine speed.

Purpose : To inform the driver about engine speed.

 Critical

Engine management system relay

Location : On the firewall , behind glove box

Type : Relay. Relay coil with diode to protect ECU against reverse
EMF

Function : Relay coil is controlled by ECU.

Purpose : To supply 12v power to ECU

 Information

Data link connector ( DLC )

Location : Below the fuse block , near foot pedals

Type : 16 pin connector

Function : Communication to off-board diagnostic equipment

Purpose : Input to diagnostics.[ Mahindra insight ]

 Cruise control

Cruise control switches

Location : In the steering wheel.

Type : On-off type

Function : Activate, Deactivate cruise control

Increase or decrease speed in cruise control mode.

Purpose : To send the required input to ECU to drive the vehicle at

desired set speed.

44
 Cruise control

Vehicle speed sensor

Location : On the gear box output shaft

Type : Hall effect sensor , 8 pulses / rev

Function : Monitors the vehicle speed. ECU based on this information

can decide the gear in which vehicle is driven.

Purpose : Gear recognition is useful in low speed governing & cruise

control
 Cruise control

Brake pedal switch

Location : In the brake pedal

Type : 4 wire, make-break switch

Function : Informs ECU about position of brake pedal. Operates brake

lamp / stop lamp

Purpose : Help ECU to identify brake actuation for cruise control

 Cruise control

Clutch pedal switch

Location : In the clutch pedal

Type : 4 wire, make-break switch

Function : Informs engine ECU about position of clutch pedal. Informs

4WD ECU about position of clutch pedal

Purpose : Help engine ECU to identify clutch actuation for cruise control
 Layout of Fuel injection system
Rail pressure sensor

Common rail

E
Electro-
C Sensors
hydraulic
U
Injector

Map

Inlet
metering
unit

Tank
High pressure
Pump
Fuel temperature sensor

Fuel filter with primer Water in fuel sensor, Indication in cluster

 Comfort functions
Zero fuel calibration - ZFC

Ensures that deterioration in injector response times are monitored, learnt and
reprogrammed in to ECU automatically.

To ensure consistent pilot injection and noise quality for long period of use.

Fuel balance control - FBC

Ensures that cylinder to cylinder variation in torque are monitored and corrected

To ensure vibration free & smooth engine operation

Active surge damper - ASD

Ensures that torque fluctuations in driveline due to sudden acceleration are damped out

Smooth take off and comfort for passengers

 Zero fuel calibration - ZFC
• Most critical for noise is pilot injection
• Pilot injections require extremely small opening times (etc)
• Nozzles have minimum response time
• some times response times are greater than pilot injection time
• This happens as the engine/nozzle ages in operation

Consequence : Pilot injection “disappears” and noise increases

ZFC ensures that the response times of each injector is monitored continuously and if found
more, adjusts the pilot injection opening times accordingly

When the vehicle is coasting

A
with foot off accelerator :
A
• Open a specific nozzle for a small
period of time - A
• Watch the flywheel for speed
change - B
• If not , increase the opening time
further - A
B
• Watch for speed change at
flywheel - B B
• Repeat till a speed change is
recorded
 Fuel balance control - FBC
• Most critical for vibration is cylinder to cylinder variation in torque
• Cylinder to cylinder variation could be due to :

Variation in difference between injectors ( ref IQA )

Variation in mechanical components of each cylinder /friction etc

Consequence : Torque fluctuation leading to engine “vibration”

FBC ensures that the torque output of each cylinder is equal , by adjusting the fuel injected
quantity.

• Measure the flywheel speed

fluctuation for each firing cylinder

• Adjust fuel quantity to ensure

equal speed for all firing cylinders
 Active surge damper - ASD
• Sudden acceleration leads to engine speed fluctuations
• Engine speed fluctuations are transmitted to driveline
• Driveline components “vibrate” as they flex and unflex

Consequence : Engine speed fluctuation leading to passenger discomfort as well loading of

driveline components
ASD dampens the engine speed fluctuations in driveline after sudden acceleration or
deceleration.
 Injector quantity adjustment - IQA
• Every injector has production variation
• These variations lead to difference in actual injected quantity (mg/injection) for the same
injector current

Consequence - excessive unbalance between cylinders and excessive correction by FBC

system.

IQA ensures that individual injector characteristics are mapped and stored in the ECU for
reference/correction.

IQA code for service

( Alphanumeric for manual entry )
ADF4567

• Injectors are checked at production and coded

• Injector codes are etched on the top face of
each injector
• Injector codes are fed in to the ECU with
cylinder nos. during engine assy.
 Airconditioner control
Air conditioner (compressor clutch) is controlled by the ECU based on the input from A/C
request relay ( R) (A/C on-off switch). On receipt of A/C request, the ECU checks the
acceleration phase, coolant temp. Adjusts the idle speed and then activates the compressor
clutch relay (C).

De-icing switch Compressor clutch

A/c on-off switch
Ac high
E
R C C
U

+ 12 v
De-icing switch
AC low

On sudden acceleration, the ECU will disengage the compressor clutch

 Cruise control
Cruise control is a feature by which desired speed of the vehicle can be maintained
without pressing the accelerator pedal.

Resume cruise

Set cruise
Increase speed

Emergency shut-off

Set cruise
Reduce speed
Activating cruise
Drive to desired speed ( Above 25 kms/hr in 2/3/4/5 gear )
• Leave the accelerator pedal
• Press the “SET +” or “ RES COAST” button
• Further increase/decrease in speed can be obtained
by pressing either SET+ or SET -

De-activating cruise
Press either the brake pedal or clutch pedal
Or
Lift the “CRUISE” switch on steering pad

• Cruise control will work only in 2/3/4/5 gears, above vehicle

speeds of 25 kms/hr
• While in cruise mode, temporary increase in speed (for
overtaking) can be obtained by pressing the accelerator pedal
further down. If the accelerator pedal is not released within 30
sec, the cruise mode will get deactivated automatically.
• The “RES COAST” button can be pressed to reactivate the
previous cruise settings
• The previous settings will be erased from memory once the
ignition is switched off.
 Controls & strategies
Precautions during starting

While starting the engine, follow the following precautions :

When the ignition is switched on, the “Check engine” lamp will come and then switch off if
all electronics are OK. It is recommended to crank the engine after the check lamp switches
off.
During the “check engine” lamp on phase, the ECU gets initialized , checks all sensors and
actuators for any defects like open / short etc.
If the check engine lamp remains on permanently or blinks, the vehicle needs to be checked
by a technician.

Interpretation of “check engine lamp”

Normal conditions : Once the ignition is turned on, the engine check lamp will come on,
and will remain on for a second and then goes off.

Abnormal conditions [Continuously on / blinking] : A continuously on / blinking lamp

indicates that there is a defect in the engine electronics . The defect code will be stored in
the ECU's memory and can be read through Mahindra insight.
The following are the most critical sensors / actuators in Cruz 2.6 engine and the effect of
failures are :

Engine speed sensor / TDC sensor : Engine does not start

Cam phase sensor : Engine does not start
Rail pressure sensor : Engine does not start
Metering unit : Engine does not start
Fuel injectors ( 2 nos) : Engine does not start
Accelerator pedal sensor [APS] : Engine goes to limp home mode

Limp home modes :

Limp home mode is an “emergency” situation declared by the ECU due to failure of APS.

In limp home mode, due to failure of APS , the ECU will revert to basic minimum
requirements (Fuel q ty) to aid the driver to bring back the vehicle to a nearest workshop.

In limp home mode, the engine speed will be set at 1150 - 1200 rpm. The accelerator pedal
will be inoperative

Driver has to drive the vehicle with gear, clutch & brakes
 Catalytic converter
Bharat stage 2 - No catalytic converter
Bharat stage 3 - Oxidation catalyst

Converts Unburned hydrocarbons ( HC) and carbon monoxide(CO) to carbon Di-oxide(CO2 )

and water H20)

Oxidation catalytic converter

Substrate : Ceramic cordierite

Washcoat : Alumina
Noble metal : Palladium
Cell shape : Square
Density : 400 cpsi
Operating temp : 4000 C to 10000 C
 Layout – EGR system
Vacuum Pump

Vacuum modulator

Vac
Brake
Reservoir
booster EGR
[Brake]
valve

Mass air flow & Mass Air flow Engine map

Air temp sensor
Coolant E
Coolant temp. C
temperature Air
sensor U
cleaner
Speed
TDC sensor

60
 Vacuum line connection at vacuum modulator

From vacuum pump

To EGR valve

From air cleaner

61
 Layout of timing chain
CRUZ 2.6 SZ 2600 PLUS

28
38

38 38
22 20
19
19

No. Of chain links - 98 No. Of chain links - 102

No. Of teeth in pump sprocket - 28 No. Of teeth in fip sprocket - 38
Speed of pump w r t crankshaft - 66 % Speed of FIP w r t crankshaft - 50 %
Cluster layout

26

1. Tachometer 08. Water in fuel 15. 4wd low 22. High beam
2. Speedometer 09. Driver seat belt 16. Low oil pressure 23. Fuel gauge
3. Odometer 10. Timing belt 17. Temperature gauge 24. Turn indicator-RH
4. Trip a/trip b/clock 11. Low batt. Charge 18. Door ajar 25. Turn indicator-LH
5. Set knob 12. Security system 19. Glow plug 26. High temp lamp
6. Mode knob 13. Low brake fluid/hand brake 20. Engine check lamp
7. Air filter choked 14. 4wd high 21. OBD check lamp
Layout of engine management system fuses
(Behind glove box)

ECU supply - K01 : 10 A

[Engine will not start]

Engine check lamp

High temperature lamp : 15 A
Temperature gauge

ECU supply - K05 : 15 A

[Engine will not start]

VAC. Modulator
Brake switch
Clutch switch : 15A
A/c compressor relay
A/c switch

HFM supply : 10 A

EMS relay supply : 30 A

[Engine will not start]
 Unlocking of ECU connectors

1 2

3 4
 Locking of ECU connectors

1 2

3 4
 Off-board diagnostics
Off-board diagnostics in Mahindra Cruz 2.6 engine is done using the Mahindra insight

Mahindra insight

Insight is a simputer based diagnostic tool which connect to the engine management ECU.
The defects stored & present in the ECU are retrieved and displayed in normal English
language. The diagnostic trouble code [DTC] are retrieved through the DLC located below
the fuse console near the foot pedals.

Simputer

DLC

E
Interface C
U
 Mahindra insight

Installation on vehicle

Connect the data link cable between the

interface and the diagnostic outlet.

After successful connection, interface

light will turn to green.
Connect the other cable between interface &
simputer
[ Ensure that HRS marked on Simputor cable face
upward while connecting to Simputor ]

It is recommended not to remove cables from

Interface unit once connected. Frequent removal
may damage interface connector pins.

• Start the simputer. Switch on the ignition.

• Click on “connect” icon to communicate with
vehicle ECU.
• Once successfully connected, the word
“connected!” will appear in the bottom

69
Connect to vehicle ECU
Connected to vehicle ECU

ECU details
• General
( ECU information )

• Fault test
( Fault codes & descriptions )

• Live data
( Sensor & actuator values )

• Adjust
( Idle speed )

• IQA
( Injector data reflashing )

Scroll up Scroll down Power switch Select /

Enter
 IQA
(Injector data reflashing)
Adjust
(idle speed)
Live data
(sensor & actuator values)
Faults
(Fault codes & descriptions)
General
(ECU information)
 Output of insight

The following information can be obtained from the insight

1. Fault test

The insight retrieves DTCs codes stored or present in the system and displays them in the
screen, in normal English, narrowing down the area to be attacked first. DTCs are as per
OBD2 standards

2. Parameter data - live

The insight also displays the sensor/actuator readings, in real time. Theoretical understanding
of the engine management system is required to interpret these readings.

3. Injector code (IQA) flashing

This is used to reflash the ECU with injector data, whenever an injector is changed / replaced.

4. Adjust

Used to adjust the idle speed upto +/- 25 rpm

 Fault test

Description of the
highlighted fault codes

Fault codes :
Erase green faults
Green - stored fault
Red - present fault
 Live data

Selection of more
parameters

Unit
Live value

Parameter
 Click on check boxes to select

Clear all checks

Return to previous screen

Or used scroll up & down button & select button of simputor to select parameters .
 Adjust idle speed

Click enter

Enter idle speed

To maximise / minimise key board on screen,
click this icon.

To get CAPS letter , click this icon.

79
 IQA management - Field service
Precautions to be followed in field

• Never interchange injectors between engines / ECU's

• Never change ECU's between vehicles
• Never interchange injectors between cylinders in same engine

Whenever an injector or ECU need to be replaced, the new injector’s IQA code need to
be reflashed in to the ECU, using Mahindra insight

ADF4567

7 digit alphanumeric IQA code

 IQA code flashing

1] Select injector

3] Enter to flash

2] Enter IQA code

 IQA code-Verification

1] Select injector

2] Click to retrieve IQA code

ADF4567

3] 7 digit IQA code will appear here

IQA code is engrave on the top of the injector.
It is a 7 character alphanumeric code.

Snap shot of the letters in ascending order to avoid the reading the fonts / letters
wrongly.

83
To switch off the simputor

Click ‘X’ icon on top right corner.

Screen will go off

Press power button for ~ 4 Sec.

Red LED will goes off.

84
 Maintenance
Battery specifications :
Rechargeable Nickel hydride battery 2 nos
1.2 volt, 2100 mAh
Size - AA R6
SANYO Electric Co. Ltd.,Japan
Model HR - 3U 1.2V

Charging specifications :
Charger : I/P 100-240V~50-60Hz 0.40 A
O/P 6.5V 2.0A DC
Click this icon to get battery
Charged the battery once in a week when not in used. life in percentage.
Fully charged battery lasts for 4 hrs.
Simputer shuts off when battery life remaining is 20 min.

Charging procedure :
Charge the battery by using charger provided with the kit.
Charge till the green LED on simputor goes off.
 Electrical connector

Check all electrical connectors for proper connection connecting engine wiring harness &
main wiring & IP wiring harness.

Interconnection main wiring harness

Location: Near Battery

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 ECU relay connector Instruments cluster connection
Location: Near ECU Location: Behind cluster

C2 C24
2 1 2 3 4 5 6 7 8 9 10 11 12
3 1

Interconnection main wiring harness

Interconnection IP wiring Location: Near main fuse box
Location: Near ECU
C26
C3
8 9 10 11 12 11 12 13 14 15 16 17 18
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10

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 15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54
8 23 38 53
7 22 37 52
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
A-connector 1 16 31 46

Location : Above ECU

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 28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84
17 39 61 83
16 38 60 82
15 37 59 81
14 36 58 80
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73
K-connector
2 4 6
1 3 5

Location : Above ECU

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Continuity test can be perform by using digital multimeter for each sensor. For detail ,
refer EMS circuit diagram.

Example 1 : For fuel temperature sensor [ Refer EMS circuit diagram ]

Switch off the ignition.
Remove ‘A’ terminal of ECU & Fuel temperature sensor connector.
Check continuity in-between Fuel temperature sensor Pole 1 & A 52 pole of ECU A terminal.
Check continuity in-between Fuel temperature sensor Pole 2 & A 51 pole of ECU A terminal.
If continuity is OK means wiring harness is OK for FTS.

w
A 52

1 2
G-P
A 51
FTS

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Example 2 : For Rail pressure sensor [ Refer EMS circuit diagram ]
Switch off the ignition.
Remove ‘A’ terminal of ECU & Rail pressure sensor connector.
Check continuity in-between Rail pressure sensor Pole 1 & A 08 pole of ECU ‘A’ terminal.
Check continuity in-between Rail pressure sensor Pole 2 & A 43 pole of ECU ‘A’ terminal.
Check continuity in-between Rail pressure sensor Pole 3 & A 28 pole of ECU ‘A’ terminal.
If continuity is OK means wiring harness is OK for RPS.

O
1 A 08
R
2 A 43
O-B
3 A 28

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Digital multimeter

For checking Continuity, Resistance &

DC Voltage, use digital multimeter.

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 To check continuity

Insert the terminal pin here to Keep knob position here to

check the continuity. check the continuity.If the
continuity is OK it will give beep.

93
 To check Resistance

Insert the terminal pin here to

check the Resistance.
Keep knob position here to
check the resistance. Keep the
knob position as per the
resistance value.

Resistance value will appear on

screen. 94
 To check DC Voltage

Insert the terminal pin here to

check the DC voltage.

Keep knob position here to

check the Voltage.

Voltage value will appear on screen.

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Following test can be done by using digital multimeter

Coolant temperature sensor / Fuel temperature sensor

Temperature Min. resistance Max. resistance
10 8.244KΩ 10.661KΩ
20 2.262KΩ 2.76 KΩ
80 0.304KΩ 0.342KΩ
100 0.178KΩ 0.196KΩ
Accelerator pedal
Potentiometer-1 Potentiometer-2
0 % Pressed 2.160 KΩ 2.672 KΩ
100 % Pressed 1.321 KΩ 2.112 KΩ
Injector solenoid coil [ 20-70 degree C ]
Nominalvalue 0.255 Ω
Minimum value 0.215 Ω
Maximum value 0.295 Ω
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 Metering unit [ 20 degree C ]
Minimum value 2.600 Ω
Maximum value 3.150 Ω

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