The reproduction, translation, transmission, in part of whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. 2007 Mahindra & Mahindra Ltd

SCORPIO CRDe All New Lx, Dx, Slx

ELECTRICAL WIRING MANUAL

Revision 3 MAN-00026

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

CONFIDENTIAL ONLY FOR INTERNAL CIRCULATION WITHIN

M&M AUTHORISED DEALERS & SERVICE CENTRES PASSING ON TO THRID PARTY IS NOT PERMITTED ALWAYS CHECK FOR THE LATEST VERSION

TABLE OF CONTENTS 1. CONTROLLERS/FUSES/RELAYS LOCATIONS 2

ENGINE COMPARTMENT FUSE/RELAY BOX - EF 3 MAIN FUSE /RELAY BOX MF 4 AUXILLARY/CRDe FUSE/RELAY BOX - AF 5

2. POWER FLOW DIAGRAM 6 3. WIRING HARNESS LAYOUT 10 4. INTERCONNECTORS LOCATION/PINS/VIEWS 11 5. GROUND/EARTHING POINTS LOCATIONS 14 6. INDIVIDUAL CIRCUITS 15

ENGINE MANAGEMENT SYSTEM (CRDe) 16 STARTING CIRCUIT 17 CHARGING CIRCUIT 18 HVAC CIRCUIT 19 INSTRUMENT CLUSTER CIRCUIT 20 POWER WINDOW CIRCUIT 24 REMOTE LOCKING SYSTEM 25 CIGAR LIGHTER/12 V POINT CIRCUIT 26 HORN CIRCUIT 27 DEMISTER CIRCUIT 28 WIPER & WASHER FRONT CIRCUIT 29 WIPER & WASHER REAR CIRCUIT 30 HEADLAMP CIRCUIT 31 HEADLAMP LEVELLING CIRCUIT 32 FOLLOW-ME-HOME CIRCUIT 33 PARKING/REGISTRATION PLATE CIRCUIT 34 INTERIOR LAMPS CIRCUIT 35 STOP LAMP/CLUTCH PEDAL CIRCUIT 36 TURN AND HAZARD CIRCUIT 37 REVERSE LAMP CIRCUIT 38 FOG LAMP CIRCUIT 39 VOICE MESSAGING SYSTEM CIRCUIT 40 AUDIO CIRCUIT 41 FUEL LID OPENER 42 4WD CIRCUIT 43

7. VEHICLE WIRING DIAGRAM 44 8. APPENDIX

Diode Checking Procedure 45 Symbols and nomenclature 46 Wire Colour coding chart 50

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

FUESE & RELAY BOXES

ECUs & CONTROLLERS

RELAYS

1 ENGINE COMPARTMENT FUSE BOX - EF 4 VMS CONTROLLER 10 STARTER RELAY 2 MAIN FUSE/RELAY BOX - MF 5 FOLLOW ME CONTROLLER 3 AUX FUSE/RELAY BOX (CRDe) - AF 6 4WD CONTROLLER 11 STARTER ENABLE RELAY

7 REMOTE LOCKING CONTROLLER/ SECURITY SYSTEM 12 VMS DIODES (2 Nos) 8 HAZARD CONTROLLER 9 CRDe ENGINE CONTROLLER

MF

EF

AF

1

3

2

8

7

5 4

11

10

9

12

6

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ENGINE COMPARTMENT FUSE/RELAY BOX LOCATION FRONT LEFT FENDER

60A 1

HEAD LAMP LOW BEAM

RELAY 15 A

HEAD LAMP HIGH BEAM

RELAY 15 A

6

7

15A 9

15A 8

15A 10

11

100A 12

5

HORN RELAY 20 A

A/CREQUEST

RELAY 20 A

60A 2

3 30A 4

FUSE No FUSE RATING COLOUR CIRCUIT1 60A YELLOW MAXI FUSE 12 60A YELLOW MAXI FUSE 23 60A YELLOW GLOW PLUG4 30A PINK CRDe ECU SUPPLY5678 15A BLUE HEADLAMP - HIGH9 15A BLUE HEADLAMP - LOW

10 15A BLUE HORN/HAZARD1112 100A BLUE CHARGING SYSTEM

EF

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

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MAIN FUSE/RELAY BOX LOCATION BELOW STEERING WHEEL

MAIN FUSE/RELAY BOX - FUSES/CIRCUITS/RATINGS FUSE No FUSE RATING COLOUR CIRCUIT

FUSE No

FUSE RATING COLOUR CIRCUIT

1 10A RED INTERIOR LAMP/PARK LAMP/ ILLUMINATION/ AUDIO MEMORY/FOLLOW-ME/HEADLAMP LEVELLING/ HEAD LAMP/ VMS

12 15A BLUE CIGAR LIGHTER/ACCESSORIES

2 20A RED FUEL LID OPERATION 13 15A BLUE FRONT/REAR WIPER MOTOR 3 20A YELLOW 4WD - ELECTRIC SHIFT 14 10A RED REAR WIPER PARK MECHANISM 4 30A GREEN CONDENSER FAN 15 20A YELLOW CRDe ECU K28

5 15A BLUE FRONT FOG LIGHT 16 10A RED TURN SIGNAL/VMS/CHARGING LAMP/REVERSE LAMP

6 15A BLUE REAR FOG LIGHT 17 10A RED PARKING LIGHTS/FOLLOW-ME/ HEADLAMP LEVELLING 7 5A BROWN CRDe DIAGNOSTIC 18 10A RED AUDIO SYSTEM/FOLLOW-ME 8 15A BLUE DEMISTER 19 ----- ----- ----- 9 5A BROWN SECURITY SYSTEM ECU (CDL-2) 20 ----- ----- ----- 10 20A YELLOW CENTRAL DOOR LOCKING (CDL-1) 21 40A GREEN POWER WINDOW

11 15A BLUE A/C COMPRESSOR /DEMISTER/HEADLAMP 22 40A GREEN A/C BLOWER

10A 1

FUEL LID OPENER RELAY 20 A

A/C COMPRESSOR

RELAY 20 A

20A 2

10A 18

10A 16

10A 17

20A 15

10A 14

15A 13

15A 12

20A 3

30A 4

15A 5

15A 6

5A 7

15A 8

5A 9

15A 11

20A 10

FRONT FOG

RELAY 20 A

REAR FOG

40A 21

40A 22 PULLER

MF

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AUX. FUSE/RELAY BOX LOCATION BEHIND GLOVE BOX/BLOWER MOTOR

10A 1

WIPER CONTROLLER

BLOWER RELAY 30 A 10A

2

15A 3

15A 5

15A 4

10A 6

MAINRELAY CRDe 30 A

DEMISTER CONTROLLER

CONDENSOR FAN

RELAY 30 A

FUSE No FUSE RATING COLOUR CIRCUIT1 10A RED A/C REQUEST2 10A RED HFM SENSOR SUPPLY3 15A BLUE EGR/BRAKE LIGHT/CLUTCH SWITCH4 15A BLUE CRDe ECU SUPPLY - K055 15A BLUE CHECK ENGINE LAMP6 10A RED CRDe ECU SUPPLY - K01

AUX. FUSE/RELAY BOX - FUSES/CIRCUITS/RATINGS

AF

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BATTERY+ -

MAXI FUSE 1EF - 60 A

MAXI FUSE 2EF - 60 A

MAXI FUSE 3EF -

MAXI FUSE 4EF - 30 A

CHARGING FUSEEF - 100 A

ALT

STARTER RELAY

STARTER SOLENOIDSTR

E1E14

FROM IGN 15

FROM STARTENABLE RELAY

POWER FLOW DIAGRAM SCORPIO CRDe (All New) BS3

F(EF, 15A) HornHazard

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

FROM COMBINATIONSWITCH

A B D

Legend : EF Engine Compartment Fusebox ; MF Main Fusebox ; AF Auxilliary Fusebox

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

D

Water in Fuel Sensor CRDe ECU Relay +12VF(AF, 10A) ECU K01F(AF, 15A) ECU K05F(AF, 15A) Temp. Gauge +12V

High Temp. Warning LampOBD LampCheck Engine Lamp

F(AF, 10A) A/c Compressor Clutch Relay CoilA/c Request Relay + 12V

F(AF, 15A) - Clutch Switch Stop Lamp +12VVacuum Modulator +12V

Legend : EF Engine Compartment Fusebox ; MF Main Fusebox ; AF Auxilliary FuseboxPOWER FLOW SCORPIO CRDe (All New) BS3

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BF(MF, 20A) Fuel Lid Opener Relay/Switch +12VF(MF, 30A) Condenser Fan Relay +12VF(MF, 20A) 4WD Shift MotorF(MF, 10A) Interior Lamp Front

Interior Lamp RearFootstep LampIgnition Key Ring LampHeadlamp Controller (Door Open Signal)Head Lamp Low Relay CoilVMSAudio MemoryHVAC MemoryCluster Memory

F(MF, 10A) Park Lamp Lt/RtTail Lamp Lt/RtReg Number Plate LampHeadlamp Leveling Switch/MotorHeadlamp Controller (Park Light Signal)Illumination 4WD Selector SwitchIllumination HVAC SwitchesIllumination Fuel Lid SwitchIllumination Demister SwitchIllumination Cigar LighterIllumination Cluster

IGNITION SWITCH

B.1

KA

P

15a

15

50

Legend : EF Engine Compartment Fusebox ; MF Main Fusebox ; AF Auxilliary FuseboxPOWER FLOW SCORPIO CRDe (All New) BS3

30

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F(MF, 15A) Cigar LighterF(MF, 15A) Front Wipe/Wash

Rear Wipe/WashF(MF, 10A) Rear Wiper Park PositionF(MF, 40A) - Power Window

Blower Relay CoilF(MF, 10A) A/c Compressor Relay

Condenser fan Relay CoilDemister SwitchDemister Timer4WD ECU

F(MF, 10A) AudioHeadlamp Controller

(Key removal)

F(MF, 10A) Hazard ControllerReverse lampHVAC Control PanelFuel GaugeTachometerVMSSpeedometer/Tachometer PCBTell Tale Brake FluidTell Tale Battery ChargingTell Tale 4WD HighTell Tale 4WD LowTell tale Low Oil PressureTell Tale Seat Belt

F(AF, 10A) HFM Sensor + IgnF(AF, 20A) CRDe ECU +Ign K28

Star Enable Relay CoilStart Enable RelayStarter Relay Coil

B.1

Legend : EF Engine Compartment Fusebox ; MF Main Fusebox ; AF Auxilliary Fusebox

KA

P

15a15

50

POWER FLOW SCORPIO CRDe (All New) BS3

Note :Circuits 15a and 50 are mutually exclusive

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HARNESS No DESCRIPTION

1 INSTRUMENT PANEL (IP)2 ENGINE ROOM3 ENGINE 4 FLOOR5 DOOR - FRONT RIGHT6 DOOR - FRONT LEFT7 DOOR - REAR RIGHT8 DOOR - REAR LEFT9 DOOR - BACK DOOR

10 ROOF11 CENTRAL CONSOLE12 FOOTSTEP LAMP (Only TC4)

WIRING HARNESS LAYOUT

1

2

3

86

9

75

4

10

11

12

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DESCRIPTION LOCATION IC No PINS M/F CONNECTOR VIEW

IP to FLOOR A-PILLAR RIGHT 1 21 F

IP to FLOOR A-PILLAR RIGHT 2 20 F

IP to FLOOR A-PILLAR RIGHT 3 13 F

IP to ENGINE FLOOR A-PILLAR RIGHT 4 20 M

IP to ENGINE FLOOR A-PILLAR RIGHT 5 5+2 M

IP to HVAC BEHIND CENTER BEZEL 6 5+2 F

IP to TRANSFER CASE A-PILLAR RIGHT 7 3 F

IP to TRANSFER CASE A-PILLAR RIGHT 8 2 M

IP to TRANSFER CASE A-PILLAR RIGHT 9 2 F

IP to ENGINE A-PILLAR LEFT 10 21 M

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DESCRIPTION LOCATION IC No PINS M/F CONNECTOR VIEWINTER-CONNECTORS - LOCATIONS/PINS/VIEWS

IP to ENGINE A-PILLAR LEFT 11 20 M

ENGINE ROOM to FOG LAMP

WHEEL HOUSE PANEL -RIGHT 12 2 M

FLOOR to ROOF WIRING A-PILLAR RIGHT 13 6 F

FLOOR to DRIVER DOOR A-PILLAR RIGHT 14 8 M

FLOOR to REAR DOOR B-PILLAR RIGHT 15 6 M

FLOOR to TRANSFER CASE (Old 4WD ECU)

BELOW DRIVER SEAT 16 2 F

FLOOR to TRANSFER CASE(New 4WD ECU

BELOW DRIVER SEAT 16 8 F

FLOOR to CONSOLE BELOW CONSOLE 17 12+2 F

FLOOR to CO-DRIVER A-PILLAR LEFT 18 6 F

FLOOR to BACK DOOR D-PILLAR RIGHT 19 13 M

FLOOR to BACK DOOR D-PILLAR RIGHT 20 2 F

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DESCRIPTION LOCATION IC No PINS M/F CONNECTOR VIEWINTER-CONNECTORS - LOCATIONS/PINS/VIEWS

FLOOR to CHASIS Near FUEL TANK 21 2 F

FLOOR to REAR DOOR B-PILLAR LEFT 22 6 M

ROOF to HM STOP LAMP REAR ROOF PANEL 23 2 F

IP to ENGINE ROOM (Only in export models)

A-PILLAR RIGHT 24 3 M

M - MALE CONNECTOR WITH PINSF - FEMALE CONNECTOR

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

IC - 10 , 11 ,18

IC- 6IC- 16

IC- 17

IC- 21

IC- 15

IC- 22

IC- 23

IC- 19, 20

IC- 12

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GROUND No CIRCUITS CONTROLLED LOCATION

E0CRDe ECU (K02, K04, K06), TEMPERATURE GAUGE, FUEL GAUGE, STARTER RELAY, VEHICLE SPEED SENSOR, WATER IN FUEL SENSOR, HEADLAMP RELAY

ON BATTERY NEGATIVE POST

E1 BATTERY NEGATIVE TERMINAL TO BODY FRONT WHEEL HOUSE PANEL - LEFTE2 UNUSED FRONT WHEEL HOUSE PANEL - LEFT

E3TURN LEFT, SIDE MARKER LEFT , HEADLAMP/LEVELLING MOTOR - LEFT, FRONT WASHER MOTOR, HORN, CONDENSOR FAN, A/C PRESURE SWITCH, SIREN

FRONT WHEEL HOUSE PANEL - LEFT

E4FRONT FOG LAMP, PARK LEFT/RIGHT, TURN RIGHT, SIDE MARKER RIGHT , HEADLAMP/LEVELLING MOTOR - RIGHT, FRONT WIPER MOTOR, TAIL LAMP- LEFT, FLWI

FRONT WHEEL HOUSE PANEL - RIGHT

E5CIGAR LIGHTER, DEMISTER RELAY, DLC, FOG LAMP RELAY,BLOWER RELAY, CONDENSOR FAN RELAY,INETRIOR LAMP- FRONT/REAR, ILLUMINATION, HAZARD CONTROLLER, HAZARD SWITCH, COMBINATION SWITCH, VMS RESET SWITCH, HEAD LAMP LEVELLING SWITCH,

A-PILLAR RIGHT

E6 AUDIO A-PILLAR RIGHTE7 HVAC A-PILLAR LEFTE8 UNUSED A-PILLAR LEFT

E9CLUTCH SWITCH (4WD), DRIVER DOOR LOCK, FOLLOW ME HOME CONTROLLER,POWER WINDOW, SECURITY SYSTEM, CENTRAL DOOR LOCKING, SEAT BELT SWITCH, VMS UNIT, TANK UNIT

BELOW CETRE CONSOLE

E10 UNUSED

E11DEMISTER, REAR FOG LAMP, REGISTRATION PLATE, TAIL LAMP RIGHT, CHSML, STOP LAMPS, REAR WIPER, REAR WASHER, REVERSE LAMP, TURN REAR - LEFT/RIGHT

D-PILLAR RIGHT

E12 UNUSED D-PILLAR LEFTE13 UNUSEDE14 BATTERY NEGATIVE TERMINAL TO ENGINE ENGINE BLOCK - LEFTE15 CRDe ECU, A-PILLAR LEFT

FLWI - BRAKE FLUID LEVEL WARNING INDICATORCHMSL - CENTRAL HIGH MOUNTED STOP LAMP

GROUND LOCATION CHART

E4

E5, E6

E7, E8

E3

E2E10

E1

E9

E11

E12

E13 E14

E15

E4

E0

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INDIVIDUAL CIRCUITS

ENGINE MANAGEMENT SYSTEM (CRDe) STARTING CIRCUIT CHARGING CIRCUIT HVAC CIRCUIT INSTRUMENT CLUSTER CIRCUIT POWER WINDOW CIRCUIT REMOTE LOCKING SYSTEM CIGAR LIGHTER/12 V POINT CIRCUIT HORN CIRCUIT DEMISTER CIRCUIT WIPER & WASHER FRONT CIRCUIT WIPER & WASHER REAR CIRCUIT HEADLAMP CIRCUIT HEADLAMP LEVELLING CIRCUIT FOLLOW-ME-HOME CIRCUIT PARKING/REGISTRATION PLATE CIRCUIT INTERIOR LAMPS CIRCUIT STOP LAMP/CLUTCH PEDAL CIRCUIT TURN AND HAZARD CIRCUIT REVERSE LAMP CIRCUIT FOG LAMP CIRCUIT VOICE MESSAGING SYSTEM CIRCUIT AUDIO CIRCUIT FUEL LID OPENER 4WD CIRCUIT

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1. TACHOMETER 2. SPEEDOMETER 3. ODOMETER 4. TRIP A/TRIP B/CLOCK 5. MODE KNOB 6. SET KNOB 7. REAR FOG 8. ENGINE CHECK LAMP 9. ABS FAULT LAMP 10. GLOW PLUG 11. BATTERY CHARGING 12. SECURITY SYSTEM 13. HIGH BEAM 14. LOW OIL PRESSURE 15. LOW BRAKE FLUID/ HAND BRAKE 16. DOOR AJAR 17. TEMPERATURE GAUGE 18. WATER IN FUEL 19. DRIVER SEAT BELT 20. 4WD HIGH 21. 4WD LOW 22. OBD CHECK LAMP 23. FUEL GAUGE 24. DIRECTION INDICATOR 25. DIRECTION INDICATOR 26. HIGH TEMPERATURE LAMP UPTO VIN 72D75112

5

INSTRUMENT CLUSTER - SCORPIO (All New) CRDe

612 11 7 19 189 14

2

43 2015 21 17 26 16

1013 232425 1 22 8

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

FROM VIN 72D75113

INSTRUMENT CLUSTER - SCORPIO (All New) CRDe

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SYMBOL EXPLANATION

WIRE WITH COLOUR OF WIRE

Y-R Y- BASE COLOUR ; R - TRACER COLOUR (Refer colour chart for colour codes)

WIRES - NOT JOINED

WIRES - JOINED

SHILEDED WIRE

TWISTED WIRE

>> IC12/17CONNECTOR IC12 - CONNECTOR NO 17 - PIN NO IN CONNECTOR 12

EARTH / GROUND

GROUND ON COMPONENT

POWER SOURCE - BATTERY

POWER SOURCE - DC

POWER SOURCE - AC

FUSE WITH RATING & DIRECTION OF FLOW

ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM

Y-R

10 A

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SYMBOL EXPLANATION ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM

COIL / INDUCTOR

RESISTANCE/RESISTOR

VARIABLE RESISTOR/RHEOSTAT

POTENTIOMETER

SWITCH - PUSH TO MAKE

SWITCH - TOGGLE

SWITCH - PUSH TO BREAK

SWITCH - ON/OFF

CAPACITOR

VARIABLE CAPACITOR

LAMP

INDICATOR LAMP

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SYMBOL EXPLANATION ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM

MOTOR

DIODE

ZENNER DIODE

LIGHT EMITTING DIODE (LED)

TRANSISTOR (NPN)

TRANSISTOR (PNP)

4-POINT, NO (NORMALLY OPEN) RELAY

4-POINT, NC (NORMALLY CLOSED) RELAY

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

30

86

87

85

30

86

87

85

30

86

87

85

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SYMBOL EXPLANATION ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM

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

5 POINT RELAY (CHANGE OVER RELAY)

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

SOLENOID

30

86

87

85

30

86

87

85

87a

3087

85

87a

86

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Y-R

DECODING WIRE COLOUR

BASE COLOUR Y YELLOWTRACER COLOUR R - RED

WIRE CODEB BLACK

BL/L BLUEG GREENGr GRAYO ORANGEP PINKR RED

Sb/S SKY BLUEV VIOLETW WHITEY YELLOWBr BROWN

WIRE COLOUR CODESWIRE COLOUR

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