M Hawk 2.

2
E M
ngine anagement
( Jan 2008)
S
ystem
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 Specifications Scorpio Vlx

Engine : M Hawk 2.2

Type : 4 cyl.Inline , Common rail direct injection

Clutch : Diaphragm

Transmission : NGT 530 R

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 (Tubeless)

Emission : BS3,EIII
 Specifications - M Hawk engine

Manufacturer : Mahindra & Mahindra Ltd., India

Bore : 85 mm
Stroke : 96 mm
Capacity : 2180 cc [2.2Litres]
Compression ratio : 18.5 : 1
Max. Power : 120 bhp @ 4000 rpm
Max. Torque : 29.5 kg-m @ 1800-2800 rpm
Idle speed : 800 rpm
Valve mechanism : Double overhead camshaft, 16 Valves ,
4 Valve / cyl. Camshafts with chain drive.
Fuel system : Common rail direct injection
Engine management : Bosch ECU, EDC16 C39, Controlling fuel
injection.
Diagnostics : 16 pin DLC, K-line diagnostics by using Smart
tester
 Mahindra M Hawk engine

Intercooler

EGR Valve

Auto belt tensioner

Viscous fan
 Oil separator
Electro hydraulic injectors
VGT
Oil filter

Oil cooler
 Maintenance - M Hawk
Engine oil
Specification : API CH4-SAE 15W 40
Recommended brand : Maximile supreme
Drain interval : 5000, 20000 , every 15000 kms / 9 month
Capacity : 6.5 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 indicator
Replacement interval : 40000 kms

Accessory belt (Alternator, PS, Fan & AC) & tensioner ( Auto & manual)
Type : 4 Groove, Poly V-belt
Replacement interval : 100000 kms
 Accessories belt layout

Alternator

Viscous fan

Water pump

Auto adjustor

AC compressor

Power steering
Main drive pulley
 Air intake system

Air Filter HFM Clean Side Air filter Intercooler Intercooler Boost
Air Hose service Inlet Hose Pressure
indicator Sensor

Intercooler
Outlet Hose

Intake
Pipe

Dirty Side Compressor VGT Cylinder Intake

Air Hose Inlet Elbow Head Manifold
Air cleaner

Replace element, if vehicle covered 40000 kms or

Air filter choking indicator shows Red band.

No cleaning of element is allowed

Ensure no dirt / dust or oil enters mass air flow

sensor while replacing air filter element
 Exhaust system

Exhaust Cylinder
Manifold Head

Muffler & Tail Pipe BSIII Front Catalytic VGT

Assembly Lower Pipe Converter
Fuel system layout
 Rail pressure sensor

Common rail

E
Electro-
C Sensors
hydraulic
U
Injectors

Map

Inlet
metering
unit

Tank
High pressure
Pump
Fuel temperature sensor

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

Fuel system layout
 Fuel filter

Priming pump
Fuel temperature
sensor

Water in fuel sensor

Indication in cluster

Spin-on filter element

Replace filter element at every 20000 kms

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

Bleed screw
In
 Fuel filter replacement

Remove the Fuel Filter element by rotating the Fuel Filter in direction 1.Remove the
Water in Fuel Sensor mounted at the bottom of the Element.
Fit the Water in Fuel Sensor ( Removed from old Fuel Filter Element) on the New
Fuel Filter Element. Fit the New Filter Element by rotating in direction 2.

NOTE : For replacing the Filter Element, Takeout the Filter Element only. Do not
take out the filter assembly. Do not remove the Fuel Lines. After replacing the Filter
Element, do the Air Bleeding.
Air bleeding ( Low pressure circuit) :
Loosen the Bleeding screw by 3-4 turns.
Switch ON the Ignition & remove the diesel Filling Cap
Do the bleeding by using the Hand Primer
Tighten the bleeding Screw.
Fit the diesel Filling Cap & Tighten.
 Oil separators

Labyrinth
oil separator

Cyclone
oil separator
Chain timing
 Camshaft
positioning tool

TDC Pin
 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 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.

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 vehicles 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 ECUs 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 - Bosch

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 1600-2250 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 M Hawk

Noise Power

Pil2 Pil1 MI

IVC EVO

BDC FIRING BDC

TDC

Intake Compression Power Exhaust

 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
 CRS layout of Scorpio M Hawk engine

Air Mass Flow

Pump metering
Accelerator
unit
Pedal Position Power
Stage
Coolant Temp. Injectors
Air Temp. Analog/Digital
Signal CPU Boost Pressure
Boost Pressure Actuator
Conditioner
Rail pressure Power EGR Actuator
AC clutch relay
Stage
Cam phase
Glow Plug Control
Battery
Immobilizer

Cruise control Program Analog Tachometer

Crankshaft Speed Memory signal
Temp gauge, High
Analog/Digital (EPROM) temp warning light
Signal
Brake Switch
Non-volatile Diagnostic
Conditioner Engine check lamp
Clutch Switch Memory &
Air-conditioning (E2PROM) Alarms Diagnostic Tester

Vehicle speed
Diesel temp.
 Functions of ECU, sensors, actuators & relays
Electronic control unit [ ECU ] Critical

Location : Behind glove box

Type : EDC 16 C 39 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 [Increment speed sensor]

Location : On the crankcase, Behind the high pressure pump.

Type : 3 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 : Trigger wheel which is mounted on crankshaft inside the

crankcase 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 drivers pedal request.

Purpose : To transmit drivers pedal request to ECU

 Important

Mass air flow sensor [ HFM 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
 Important

Boost pressure sensor

Location : On intercooler

Type : 3 wire, Piezoresistive

Function : Measure the boost pressure after intercooler & give

feedback to engine ECU.

Purpose : Based on feedback from boost pressure sensor, ECU will

control the VGT actuator to get desired pressure when
working in closed loop mode.
 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 drivers 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

Vacuum modulator - EGR

Location : Engine compartment, RHS fender

Type : Solenoid controlled vacuum modulator

Function : To supply desired level of vacuum to EGR valve

Purpose : To control EGR flow

 Important

Vacuum modulator - VGT Actuator

Location : Engine compartment, RHS fender

Type : Solenoid controlled vacuum modulator

Function : To supply desired level of vacuum to VGT actuator.

Purpose : To control the vacuum signal given to VGT actuator according

to PWM signal from ECU.
 Important

A/c compressor clutch relay

Location : On the main fuse box, Below steering wheel.

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 : Led

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, Fixed on the bracket

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 Smart tester ]

 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.
 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
 Correction 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

Injection quantity adjustment - IQA

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

To ensure vibration free & smooth engine operation

 Zero fuel calibration - ZFC
Most critical for noise is pilot injection
Pilot injections require extremely small opening times (ET)
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 [Learning time up to 3000Km]

When the vehicle is coasting

A
with foot off accelerator :
A
Opens 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 injected fuel
quantity resulting smooth engine speed for higher comfort & less deviation from mean fuel
quantity for better emission.

Measure the flywheel speed

fluctuation for each firing cylinder

Adjust fuel quantity to ensure

equal speed for all firing cylinders
 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 )

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.
Injected Quantity Adjustment (IQA) or IMA: Control the Injected quantity depending on the
flow Characteristic Variation of the Injector.
 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 injectors IQA code need to
be reflashed in to the ECU, using Mahindra smart tester.

7 digit alphanumeric IQA code

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.
 Comfort functions

Active surge damper - ASD

Ensures that torque fluctuations in driveline due to sudden acceleration are

damped out.
Smooth take off and comfort for passengers
Cruise control

Cruise control is a feature by which desired speed of the vehicle can be

maintained without pressing the accelerator pedal
Low idle governor

Engine low idle RPM is maintained irrespective of various load viz. Power
steering pump, AC compressor etc. Less vibration in idling.
 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.
 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 [+1.5 Km/hr]

Emergency shut-off

Set cruise
Reduce speed [- 1.5 Km /hr]
 Cruise control

Cruise switches

Clutch
Engine ECU
Brake
Accelerator

Vehicle speed sensor

Engine
Activating cruise
Drive to desired speed ( 2/3/4/5 gears & Engine RPM should be
more than 1200)
Leave the accelerator pedal
Press the SET + button
Further increase/decrease in speed can be obtained by
pressing either SET+ or SET [+/- 1.5 Km/hr for each press]

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, RPM should be

more than 1200.
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.
 Airconditioner control

Air conditioner (compressor clutch) is controlled by the ECU based on the input from A/C
request relay ( R) (A/C 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).

Ac high switch Compressor clutch

E
R C C
U

+ 12 v
AC low switch

On sudden acceleration, the ECU will disengage the compressor clutch.

Relays used in the system are diode protected.

 Water in fuel sensor

Once the water is accumulated in the filter, This sensor will lit the water in fuel
warning light on instrument cluster.

Water in fuel Water in fuel warning light on

sensor instrument cluster

+
30A
ECU fuse

-
-
 Fuel injector

Injectors
Solenoid Operated
Fuelling controlled by the energizing time of the solenoid
 Limp home mode

The following are the most critical sensors / actuators in M Hawk 2.2 lit. 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 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

To vacuum modulator-VGT Vacuum modulator-EGR

Vac
Brake
Reservoir
booster EGR
[Brake]
valve

Mass air flow & Mass Air flow Engine map

Air temp sensor
Coolant E
Coolant temp.
temperature C
U Air
sensor cleaner
Boost
Speed
pressure
TDC sensor
sensor
 M Hawk EGR system

Cylinder Head
Intake Assembly
Pipe

Intake EGR Valve

Manifold

EGR
Elbow

EGR Pipe
Long
Exhaust
Manifold
 Vacuum line connection at vacuum modulator

From vacuum pump

To EGR valve

From air cleaner

Controlling of EGR : Actual Air Flow is higher than desired Air Flow

Boost Pressure Intercooler Air Flow Signal

Sensor
Fresh Air
Flow Rate
decreases
Boost Pressure
Sensor Signal Desired Fresh
Air Flow
EGR Flow
achieved
Turbocharger
Rate
increases Fresh Air
Intake Air
Flow HFM
Fuelling Sensor

Speed Engine
Exhaust

ECU
EGR Valve
EGR Flow opens more Vacuum
ECU Signal reservoir
demands higher
EGR valve Pressure
vacuum Modulated
Vacuum Modulator
delivers higher
EGR Actuator Signal
vacuum

Pressure Vacuum Pump

Modulator
Controlling of EGR : Actual Air Flow is lesser than desired Air Flow

Boost Pressure Intercooler Air Flow Signal

Sensor
Fresh Air
Flow Rate
increases
Boost Pressure
Sensor Signal Desired Fresh
Air Flow
EGR Flow
achieved
Turbocharger
Rate
decreases Fresh Air
Intake Air
Flow HFM
Fuelling Sensor

Speed Engine
Exhaust

ECU
EGR Valve
EGR Flow closes more Vacuum
ECU Signal reservoir
demands lesser
EGR valve Pressure
vacuum Modulated
Vacuum Modulator
delivers lesser
EGR Actuator Signal
vacuum

Pressure Vacuum Pump

Modulator
 Variable geometry turbine turbocharger [ VGT ]

Variable geometry turbocharger :

Control the specific energy of the exhaust gas flowing into the turbine to control
the boost
Synonyms: VTG- Variable Turbine Geometry, VNT- Variable Nozzle Turbine
 Specifications : BV43 2070 DCB 380.18 Turbocharger

BV43 : Turbine wheel diameter 43 mm.

2070 : Compressor inlet area 70% of 2 inch.
DCB : The surge line of the compressor is tailored in specified
manner.
380.18 : Turbine throat flow area.

The variable turbine geometry allows the turbine flow cross-section to be varied in
accordance with the engine operating point. This allows the entire exhaust gas
energy to be utilized and the turbine flow cross-section to be set optimally for each
operating point. As a result the efficiency of the turbocharger and hence that of the
engine is higher than that achieved with the by-pass control.

Today variable turbine geometry with variable guide vanes (VTG) is the state of the
art in modern passenger car diesel engines. As a result of the continuous turbine
cross-section adjustment to the engines driving condition, fuel consumption and
emission are reduced.
The high engine torque already at lower speed and an adequate control strategy
ensures a significant improvement of the dynamic performance.

Variable guide vanes between the volute housing and the turbine wheel have an
effect on the pressure build up behavior and therefore on the turbine power output.

During vehicle acceleration from lower speeds the guide vanes close to gain
maximum energy of the exhaust gas. With increasing speed the vanes open and
adapt to the corresponding operating point.
At low engine speeds the cross-section is reduced by closing the guide vanes. The
boost pressure and hence the engine torque rise as a result of higher pressure drop
between turbine inlet and outlet.
At high engine speeds, the guide vanes gradually open. The required boost pressure
is achieved at a low turbine pressure ratio and engine fuel consumption is reduced.
 BV43 2070 DCB 380.18 Turbocharger - Actuator Assembly

Do not disturb this setting

Turbine Housing

Compressor
Housing
Actuator Mounting
Bracket

Actuator Actuator Cup Vacuum Nozzle

Actuator Working
 Boost pressure controller
What does boost pressure controller do?

Adjusts the boost pressure required for clean combustion at desired speed-load
condition

Limits the boost pressure to protect engine and turbocharger

Builds the boost pressure rapidly against demand to improve the dynamic
response of the engine

What are the basic inputs?

Current injection quantity
Engine speed
Actual boost pressure

Boost pressure controller concept

Open loop control - which is always active

Close loop control - Activated in particular operating states

PID controller concept

Closed Loop control :

Decided by Speed & Fuelling.

Controller takes the VGT initially to preset vane position through Pre Control Map.
In Closed Loop Regime VGT takes feedback of the Actual Boost Pressure Value &
achieves the Desired Boost Pressure exactly.

The PID Controller works to eliminate the process deviation after the Pre Control
Setting. The PID Parameters are optimised to reach the Desired Value in shortest
possible time without instability in the system.
Case 1: PCR in Closed Loop. Actual pressure is less than the desired pressure.

Boost Pressure Intercooler

TC accelerates
Sensor increasing the
Boost Pressure
Sensor Signal
Boost
TC Closes
the Vanes
to reduce
Desired
Turbocharger the flow
boost Met
area
Intake Air
Fuelling

Speed Engine
Vacuum
Exhaust
reservoir
ECU Modulated
Modulator
Vacuum
delivers higher
vacuum to the
ECU Signal actuator
demands higher
vacuum Boost Pressure
Actuator Signal Pressure
Modulator

Vacuum Pump
Case 2: PCR in Closed Loop. Actual pressure is more than the desired pressure.

Boost Pressure Intercooler

TC decelerates
Sensor reducing the
Boost Pressure
Sensor Signal
Boost
TC opens
the Vanes
Desired to increase
Turbocharger the flow
boost Met
area
Intake Air
Fuelling

Speed Engine Vacuum

Exhaust
reservoir
ECU Modulated
Modulator
Vacuum
delivers lesser
vacuum to the
ECU Signal actuator
demands lesser
vacuum Boost Pressure
Actuator Signal Pressure
Modulator

Vacuum Pump
Open Loop control :

Decided by Speed & Fuelling

Controller takes the VGT to preset vane position through precontrol Map. In open
loop regime VGT operates only with Precontrol values without feedback of the
boost pressure value. There can be deviation between the desired Value &
the process Value.
Case 1: PCR in Open Loop. Process value can deviate from desired value

Boost Pressure Intercooler

TC can
Sensor accelerate/decelerate
Boost Pressure
Sensor Signal

TC takes
the vanes
Boost developed to preset
Turbocharger position
depending on
energy input to
the turbine Intake Air
Fuelling

Speed Engine Vacuum

Exhaust
reservoir
ECU Modulated
Modulator
Vacuum
delivers preset
vacuum to the
ECU Signal actuator
demands preset
vacuum Boost Pressure
Actuator Signal Pressure
Modulator

Vacuum Pump
 Engine immobilizer
Central door locking ECU confirm the right RF (Radio Frequency) signal and
communicates the Lock or Unlock Status of the vehicle to the Engine ECU (Refer
sketch showing signal flow from Security System). As per the Remote Lock (Arm) or
Remote Unlock (Dis-arm) status,
Security System ECU gives signal to engine ECU to activate or de-activate
the engine immobilizer feature.
Senses intrusion signal. If intrusion is sensed in armed condition, security
system ECU will disconnect the starter circuit apart from triggering the alarm.

Security System Engine Management

ECU System ECU

Communication Signal

Starter Software
Battery
Motor Immobilization

RF Signal Relay
NOTE(S) :

If remote is not functioning after locking the vehicle, follow the Emergency dis-arm
procedure to de-activate the Security System.

If wrong attempts made to unlock the vehicle for more than 3 times, then vehicle will
be immobilized permanently.

Number of wrong entries can be viewed in Mahindra Secure program given in

Smart Tester.

If the vehicle is immobilized,

Use the Emergency Drive Away feature given in Mahindra Secure and Enable this
feature. Drive the vehicle upto the dealership and rectify the fault(s). Disable the
Emergency Drive Away feature.
Mahindra Secure :

To find out the No. of wrong entries for immobilizer and use drive away feature,
Mahindra Secure program given in Smart Tester is to be used. Immobilizer type
selection is not required. SMART will read the type of Immobilizer (i.e., loop type or
analog type)

Refer the details given for these buttons.

To enter in Mahindra Secure program,

Double click on Mahindra Smart icon

Select Immobilizer & click on OK.

This will open the Mahindra Secure

program.
Following data can be retrieved from Mahindra Secure program

Read Immobilizer Data : This will display the immobilizer data.

Enable / Disable Emergency Drive Away : If the vehicle is immobilized, vehicle can
be driven upto the dealership by enabling Emergency Drive Away.

If the vehicle is immobilized & Emergency Drive Away mode is disabled, vehicle can
not be driven.

CAUTION : Emergency Drive Away mode should be disabled after rectifying the
fault(s).

Selection of immobilizer type : Show the type of immobilizer. Do not change the
type. For M Hawk Engine, immobilizer type is Analog immobilizer.

Clear Immobilizer errors: DTCs for the immobilizer can be cleared through
Immobilizer (i.e., Mahindra Secure) program or Engine ECU program.

Note : DTC of the immobilizer can be viewed in Engine ECU program only.
To enable / disable the emergency drive away feature , enter 1 / 0, as per the
instruction on screen, switch off the ignition & wait for min. 1 min. To confirm
the status reconnect the Mahindra Secure, click on read immobilizer data.
 Cluster layout

26

01 TACHOMETER 02 SPEEDOMETER 03 ODOMETER 04 TRIP A/TRIP B/CLOCK

05 MODE KNOB 06 SET KNOB 07 ABS FAULT LAMP 08 ENGINE CHECK LAMP
09 REAR FOG 10 GLOW PLUG 11 BATTERY CHARGING 12 SECURITY SYSTEM
13 HIGH BEAM 14 LOW OIL PRESSURE 15 LOW BRAKE FLUID/
HAND BRAKE/ABS
17 TEMPERATURE GAUGE 16 DOOR AJAR 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 TPMS DISPLAY 27 TPMS KNOB 28 HIGH TEMPERATURE LAMP
Engine compartments fuse box
Main fuse box
Auxiliary fuse / Relay box
 Smart tester

Purpose

Windows based diagnostic tool is use to diagnose :-

Scorpio CRDe 2.60 vehicle (with EDC 16C8 & EDC 16C39 ECU).
Scorpio CRDe 2.49 vehicle (with EDC 16C39 ECU).
Scorpio CRDe 2.20 vehicle (with EDC 16C39 ECU).

Scorpio Vlx Features such as : ABS & Immobilizer

Components of smart tester

Following are the components of SMART Tester :

Programmable CD : Containing Diagnostic Program, which needs to be

loaded in Laptop. This CD is suitable for Scorpio CRDe
2.6 BS III models.
USB lock : Key to enter in Diagnostic Program
Laptop : To run the program and view vehicle live parameters
Smart Interface Tool : Tool to communicate message from ECU to Laptop
Cables : For communication between DLC (Data Link
Connector), Smart Interface Tool and Laptop.
Components of smart tester
Python interface unit

Link Status :
When Interference Tool is connected and
Diagnostic Tester is
Not communicating, Red colour LED
will blink
Communicating, Green colour LED
will blink

Power :
Red colour LED will be ON when
Interference Tool is connected to DLC.

USB :
Green colour LED will be ON when USB
connector is connected to laptop.
 Installation of CD V 1.1

Insert the CD having Mahindra Smart V1.1 (Nov. 2007) in Laptop and follow the
stepwise procedure given below to upload the CD data in laptop.

Step - 1 : Open the folder EMS Diagnostic Tool V1.1

Step - 2 : Click and install Mahindra Diagnostic Tester_1_1
Step - 3 : Open the folder ABS Diagnostic Tool V1.0
Step - 4 : Click on file Setup to install the program.
Step - 5 : Open the folder Immobilizer Diagnostic Tool V1.0 and install dotnetfx.
Step - 6 : After installing dotnetfx from Immobilizer Diagnostic Tool V1.0 folder,
install Mahindra Secure V1.0
Step - 7 : Install Mahindra SMART V1.1

NOTE(S) : There is no need to remove the old program installed in laptop.

New programs in CD gets installed automatically deleting the old programs.

Do not skip any step/steps. Follow all the steps mentioned above.

The Diagnostic Laptop should not be used for any other activity other than a
Diagnostic Tester.
Screen shots showing the selection to be made during CD installation
 How to use smart tester

How to learn USB Ports

Connect the Smart interface tool

Insert Smart Lock
Switch ON the ignition
Click on icon PythonIBConfig in Desktop.
Select Python Interface as USB
Select the Baud rate 57600.
Click on Auto detect
Click on OK
Click on OK

NOTE :

Remember the USB position of Python interface & USB lock. Do not change this
position whenever using smart tester or else reconfiguration of python is required.
 How to use smart tester

Diagnostic details given in Mahindra Smart V1.1 program :

Open the diagnostic program by clicking the Mahindra SMART V1.1

icon.

Select the required field i.e. Engine ECU and click on OK

Click on Mahindra & Mahindra Click on Scorpio 2.2 litre

Click on EDC 16C39 Click on India

If error is recorded in ECU memory, program will ask user action to select Yes to
see the DTC information.
Diagnostic Tester opens the Screen showing Diagnostic Trouble Codes Refer fig.

Diagnostic Trouble Codes

 Guideline to use smart tester
Blinking
Colour
Status Description
Code
Indicator
Communication error. e.g., Ignition is not
Connection Red
Switched ON
Status
Indicator Communication from vehicle to computer is
Green
proper and there is no communication error.
 Blinking
Colour
Status Description
Code
Indicator
Defect Code Yellow Healed DTC
Status
Indicator Red Present DTC
RESOLUTION :
By selecting this button, we can put comments for the solution to the error code's.
There are total 5-lines and total 90-characters can be entered on each line.It is
suggested that if any particular reason is found while identifying any error, then it can
be written in this field. So that when another technician uses Smart Tester, reasons
written in resolution field can be used as a guide. This resolution file is local & specific
to Dealer / Laptop.
STATUS
By selecting this button, we can understand current status of the error code i.e.,
State of the DTC code, System Lamp status, MIL status and MIL Blinking status.
There are total 4 states of the DTC code
State 1 & 2 : Error present and is stored in ECU memory
State 3 : ECU has noticed that the error has occurred more than once
and is confirming that it is present and is not a random error.
State 4 : Error is healed
FREEZE FRAME
By selecting this button, we can note 8-vehicle parameters as follows :
Calculated load value
Engine coolant Temperature
Boost Pressure sensor value
Engine RPM
Vehicle Speed sensor value
Intake Manifold pressure
Air flow rate from Air mass sensor
Max. rail pressure of last 10 ms
ENVIRONMENTAL CONDITIONS:
By selecting this button, we can note the Environmental Conditions for the Error
Code.
CLEAR ALL:
Healed errors in ECU memory can be cleared by selecting this button.
MANUAL
By selecting this button, we can see details for the error code in Diagnostic Guide.
Follow the procedure given in the manual to solve the complaint.
Test Actuators :

With Test Actuators, we can see the operation of Lamps and Actuators. There are
total 5-groups defined in Test Actuators as :

Group 1 : To check operations of system Lamp (Engine Check Lamp).

Group 2 : To check coolant overheat indicator lamp & Air Conditioning Actuator.
Group 3 : To check operations of Exhaust Gas Recirculation Actuator and Metering
Unit Actuator.
Group 4 : To check operation of boost pressure actuator.
Group 5 : Glow lamp & Glow relay.[ Not active]

Engine Test : Not active

ACT # 1 - System Lamp
Test condition : Ignition ON
Actuate : Click on the System Lamp ON.
Click on the release to release the lamp
Expected Result : The system lamp in the cluster will come ON
ACT # 2- Coolant Overheat Lamp Test
Test condition : Engine Running
Actuate : Click the switch ON.
Expected Result : The coolant overheat lamp at the end of the temperature scale will
light up.
It will remain ON for 20 seconds or until is Released
ACT # 3- Air Conditioning Actuator
Test condition : Engine at Idle or With Ignition ON Actuate
Expected result : The air condition actuator will become ON, you can hear the
compressor engage
Note: This actuator does not get released automatically. You have to manually release
ACT #4 - EGR Actuator
Test condition : Engine Running at Idle
Note the quantity of the injection and the air mass.
Action : Put EGR quantity >80%. In the Enter duty cycle. Actuate
Expected result : The actual duty cycle will change.

The air mass quantity and the injection quantity should change. The value are very
small Air mass by around 4 and fuel quantity change of around 0.47.
Note: If not released manually, the system will automatically release the entered duty
cycle after 30 seconds
ACT #5 - Boost Pressure Actuator ( BPA) Test
Test Condition : Engine running - at idle
Enter duty cycle : Between 0 to 100%.
Click on Test
Expected result : There is a change in Engine RPM and also the air mass quantity
changes. The engine noise change is also clearly audible
Write Parameters :

With Write Parameters, we can

Change IQA value for the cylinders.
Change engine idle speed.
Exchange of the old ECU Learning values to the new ECU if old ECU is readable.

To enter IQA :

Select the injector no

Enter the IQA code.
Click on Set IQA For
Selected Cylinders
 (Enter +/-25)

To change Idle speed : Set idle speed for the engine is 800 rpm. Idle speed can be
adjusted anywhere between 775 rpm to 825 rpm (+ / - 25 rpm )
ECU Replacement : When replacing the new ECU, If old ECUs learning values [IQA
Code, ZFC values] are available. Then click on Read , Replace the old ECU & then
click on write. Smart tester will write the stored values in the New ECU.
Read Data Packets :
With the Read Data Packets, we can read standard data packets given in program.
There are total 23-groups of Data Packets and in each group different signals are
selected with colour code. Colour code is given for each signal to identify the live
performance of the parameter in graph for the selected error code.
 Select the data
Packets for live values

Right click on mouse to change

Timer speed : To take dynamic reading from 100ms to 10000ms.

Modify : Line style, Line width & Scale range [0% to 100%]
Kill timer : To note the observation for analysis at any point of time when the
live data is being viewed.
Restore timer : Re-store timer to continue the observations
Dynamically Defined LIDs
We can randomly select the required User Defined Signals for the selected error
code. Total 2-groups F1 & F2 of User Defined Signals are given in Smart Tester
program and in each group maximum 12-signals can be selected from the list of
signals.Colour code is given for each signal to identify the live performance of the
parameter in graph for the selected error code.
Note : Once User Defined Parameters are selected, the application is need to be
closed and then restarted to work the user defined parameters.
Click on Configure
Click on Dynamically Define Sets
Selected Signal
Tab for signal removal

Tab for signal adding

 Tutorial mode in Smart tester
Tutorial mode is feature of smart tester which enable to run the smart tester without
Connecting the vehicle. This mode can be use for training to explain the smart
Tester features.

Connect the python interface & USB lock to computer.

Double Click on Mahindra Smart Icon Double Click on Engine ECU Mahindra
& Mahindra Scorpio 2.2Litre EDC16C39India.

Pop up screen will appear : Failed to connect

Click on Yes to enter tutorial mode.

All features of Smart tester will run in tutorial mode.
[ In tutorial mode ECU will not interact with Engine ECU, All the code appearing on
Screens are selected only for demonstration purpose. While working on vehicle with
smart tester, if python failed to connect, It will ask for Tutorial mode. If we enter
Yes, Smart tester will run in Tutorial mode which further misguide to technicians]
Tutorial mode

Connected with Engine ECU

 Unlocking of ECU connectors

1 2

3 4
 Locking of ECU connectors

1 2

3 4
 Injector checking procedure
Possible customer complaints / symptoms
Engine Not Starting
Engine Vibrations / Engine Noise
Engine Knocking
Cylinder Misfiring

Other observations
No error codes registered.
In the live data the status of torque limitation, synchronization status and the state
of staring system are correct.
If HPP is removed at the rail end then fuel can be observed.

Parts Required :
Test tube with graduations, capacity 30 to 75 ml (Quantity : 04 Nos.).
Engine Tube Connection Injection Pump, Part Number : 9350042680, Length 310
mm (Quantity : 04 Nos.).
Caution : The ID of the tube is important hence use only the part number specified.

[ Refer circular :2007-112-TNO- 00248, Same can be use for M Hawk]

Blow air around the injectors to remove the dust. Remove injector overflow
connector holder clips from all the four injectors. Remove injector overflow
connections from all the four injectors. Keep the removed overflow pipes behind
injectors. Do not remove overflow tube connection from the fuel return line T joint.
Insert injector overflow pipe firmly in Each Injector. Refer to the photographs.
 Insert pipe open end in test tubes as shown in photograph number (Use
Rubber Band to hold the test tubes in stand). Start engine and keep it in idle.
Collect fuel in Test Tube for one minute. Stop the engine. Ignore first reading.
Empty the test tubes & reconnect.
If any test tube gets filled during the test, STOP the test and Replace that
cylinder injector. Start engine & repeat test for exactly one minute.
If collected fuel quantity is 5 to 20 ml, all injectors are OK.
If the fuel quantity in any test tube is more than 20 ml, then the corresponding
injector's is defective. Replace the injector.

For engine not starting complaint, crank the engine for 30 seconds, the faulty
injector's will show more than 20 ml overflow quantity. Replace the defective
injector's. Repeat the test with new replaced injector (s) & confirm the resolution of
for starting problem

All injectors are O K Injector is not O K

 Mass airflow sensor cleaning
Possible customer complaints / symptoms
Poor pickup
Black smoke

Root cause :
Wrong indication of the air flow to the ECU from the HFM sensor. This is
due to the deposition of oil & dust particles on sensor element.

Logic :
Under normal driving conditions, if required boost pressure is not generated
by the turbocharger, the smoke limitation map limits the fuelling to avoid smoke due
to lack of air.
If oil / other soot particles are deposited on the HFM sensor element, the
HFM sensor will not read the actual airflow and may report a lesser value to the
ECU, thereby limiting the fuelling. This brings down the vehicle performance below
acceptable limits. In such cases, the HFM sensor performance can be restored by
cleaning the sensor with Petrol thoroughly as per the procedure given below. [ Refer
circular :2007-123-TNO- 00294 , Same can be use for M Hawk]
 Take Petrol in a container such that HFM sensor unit can be immersed
completely. [Ensure that the electrical connector is not immersed in the petrol bath.]
Allow the HFM sensor unit to immerse in Petrol for about 5-10 min.[ Petrol once
used should not be re-used for cleaning the HFM sensor.]
Shake the HFM Sensor thoroughly keeping it inside the Petrol bath, such
that any oil content stuck to the sensor can be flushed out.Remove the sensor
assembly from the Petrol bath and remove the Petrol completely from the sensor.
Allow the sensor to get dry. Blow pressurized air jet ( Pressure between 3
to 5 bars) from a distance of 10 cms to 15 cms from one end of the sensor so as to
remove any Petrol content present in the mesh. Clean the electrical connector using
pressurized air to remove any liquid content on it.
 Wiring harness connector - ECU

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

 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

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
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
Digital multimeter

For checking Continuity, Resistance & DC

Voltage, use digital multimeter.
[ Please refer instruction manual from supplier]
 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.
 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.
 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.

 Following test can be done by using digital multimeter

Coolant temperature sensor / Fuel temperature sensor

Temperature Min. resistance Max. resistance
10 8.244 K 10.661K
20 2.262 K 2.76 K
80 0.304 K 0.342 K
100 0.178 K 0.196K
Accelerator pedal
Potentiometer-1[Pin 2 & 4] Potentiometer-2[Pin 1 & 6]
0 % Pressed 2.160 K 2.672 K
100 % Pressed 1.321K 2.112K
Injector solenoid coil [ 20-70 degree C ]
Nominalvalue 0.255
Minimum value 0.215
Maximum value 0.295
 Metering unit [ 20 degree C ]
Minimum value 2.600
Maximum value 3.150
Following documents need to be refer while working on M Hawk engine.
{Always ask for updated version}

Scorpio Vlx maintenances schedule : For maintenance schedule.

Scorpio Vlx repair manual : For dismantling , Assembly & detailed repair of
M Hawk engine.

Scorpio Vlx- Wiring manual : For referring the circuit diagram of engine
management system & related circuits.

M Hawk BSIII Diagnosis manual : For diagnosing the DTC code. Incorporated in
Smart Tester.