WIRING MANUAL

SCORPIO
MAN-00130

RELEASED BY –

TECHNICAL PUBLICATION
CELL
MAHINDRA & MAHINDRA LTD.
Rev1 – MAY 2011
www.teknetmahindra.com
ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP-TO-DATE AT THE TIME OF PUBLICATION.
HOWEVER, SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE. THIS
MANUAL IS STRICTLY MEANT FOR RESTRICTED INTERNAL CIRCULATION WITHIN M&M AUTHORIZED
DEALER SERVICE CENTERS.

© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without
the written permission of Mahindra & Mahindra Ltd.
 ABOUT THE WIRING MANUAL

The wiring manual outlines complete electrical network plan of the Mahindra Scorpio mDi CR vehicle.

Wiring diagrams are technical drawings representing the electrical /electronic structure of the vehicle. Understanding
this manual is the quickest way to identify and repair a trouble, first time right. The manual defines as to how the
various systems are integrated and works, functions and operates. All the electrical components are shown, including
their locations, colors of connecting wires and connectors.

The manual is structured as below –

Component locations – Indicates schematically the location of the crucial components like fuses, relays and
controllers (ECUs)

Circuit Plans – Specifies the circuit diagram of Individual circuits, function wise.

Harness Layout – Indicates the physical layout of the wiring harness across the topography of the vehicle. It also
indicates the connectors and their codes/locations.

Inter-harness Connectors – Specifies the code, locations and pin-out view of the connectors in between
separate wiring harnesses.

Terminal Connectors –Specifies the code, locations and pin-out view of the major connectors which terminate at
controllers (ECUs)

Ground Points – Specifies the locations of the various grounding points across the vehicle body/chasis.

© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without the
written permission of Mahindra & Mahindra Ltd.

2
Good electrical/electronic troubleshooting process

When troubleshooting any problem related to electrical/electronic system, follow the 5-step process –

STEP 1 – Verify the customer complaint

• Turn on all the component/functions in the problem circuit to check accuracy of the customer
complaint.
• Replicate the customer complaint
• Note down the symptoms
• Do not begin disassembly or testing unless you have narrowed down the probable causes.

STEP 2 – Read and analyze the wiring diagrams

• Locate the specific circuit diagram of the problem circuit

• Understand how the circuit is supposed to work by tracing the circuit from power source through
components on to ground.
• Check other circuits which share components/fuse/ground/switch with this circuit.
• Isolate the circuit/component with problem.

STEP 3 -Inspect circuit/component with problem isolated

• Make a circuit test to check the diagnosis

• Narrow down the probable causes using troubleshooting charts/diagnosis charts

STEP 4 – Repair the problem

• Make necessary repairs as authorized

STEP 5 – Re-check the circuit

• Repeat the system check to ensure that the problem is eliminated

• Check related circuits
• Ensure that the customer symptom is eliminated

© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without
3 the
written permission of Mahindra & Mahindra Ltd.
 TABLE OF CONTENTS

1. CONTROLLERS/FUSES/RELAYS – LOCATIONS
ENGINE COMPARTMENT FUSE/RELAY BOX - EF 6
MAIN FUSE /RELAY BOX – MF 7
AUXILIARY FUSE 1 - AF1 8
AUXILIARY FUSE 2 - AF2 8
2. INDIVIDUAL CIRCUITS
EMS ECU SCORPIO M2Di CR Ex 9
INJECTORS 10
START-STOP CIRCUIT 11
IMMOBILIZER 12
STARTING CIRCUIT 13
CHARGING CIRCUIT 14
HVAC CIRCUIT 15
INSTRUMENT CLUSTER CIRCUIT - 2WD 16
CIGAR LIGHTER/12 V POINT CIRCUIT 17
FUEL LID OPENER 18
HORN CIRCUIT 19
HEADLAMP CIRCUIT 20
HEADLAMP LEVELLING CIRCUIT 21
STOP LAMP CIRCUIT 22
REVERSE LAMP CIRCUIT 23
PARKING/REGISTRATION PLATE CIRCUIT 24
INTERIOR LAMPS CIRCUIT 25
TURN AND HAZARD CIRCUIT 26
3. WIRING HARNESS LAYOUT
4. INTERCONNECTORS – LOCATION/PINS/VIEWS
5. TERMINAL CONNECTORS
6. GROUND/EARTHING POINTS – LOCATIONS
7. APPENDIX
Symbols and nomenclature
Wire Color coding chart 3
 CONTROLLERS/ FUSE/ RELAYBOX LOCATIONS-SCORPIO M2Di CR
FUSES & RELAY BOXES ECUs ECUs & CONTROLLERS
1 ENGINE COMPARTMENT FUSE BOX 5 ENGINE CONTROLLER 6 STARTER RELAY
2 MAIN FUSE/RELAY BOX 7 IMMOBILISER CONTROL UNIT
3 AUX FUSE/RELAY BOX (AF1)
4 AUX FUSE/RELAY BOX (AF2)

7
2

6
3
6 1 5

5
 ENGINE COMPARTMENT FUSE/RELAY BOX

LOCATION - FRONT LEFT FENDER EF

60A 60A 30A HEAD LAMP
1 2 3 4 HIGH BEAM HORN
RELAY RELAY
100A 20 A 20 A
12
HEAD LAMP WATER IN
LOW BEAM FUEL
15A 15A 15A RELAY RELAY
5 6 7 8 9 10 11 20 A
20 A

FUSE No FUSE RATING COLOUR CIRCUIT

1 60A YELLOW MAXI FUSE 1
2 60A YELLOW MAXI FUSE 2
3
4 30A PINK ECU SUPPLY
5
6
7
8 15A BLUE HEADLAMP - HIGH
9 15A BLUE HEADLAMP - LOW
10 15A BLUE HORN
11
12 100A BLUE CHARGING SYSTEM

6
 MAIN FUSE/RELAY BOX – SCORPIO M2Di CR
LOCATION – BELOW STEERING WHEEL

MAIN FUSE/RELAY BOX - FUSES/CIRCUITS/RATINGS

FUSE FUSE COLOUR CIRCUIT FUSE FUSE COLOUR CIRCUIT
No RATING No RATING
1 10A RED INTERIOR LAMP 12
2 5A ORANGE IMMOBILISER 13 10A RED AUDIO
3 10A RED FUEL LID 14 10A RED PARK
4 30A GREEN CONDENSER FAN 15
5 15A BLUE FRONT FOG LIGHT 16 15A BLUE TURN SIGNAL/STOP LAMP
6 15A BLUE IGNITION SUPPLY 17 10A RED T15 SUPPLY IMMOB
7 18 15A BLUE FRONT WIPER
8 19 15A BLUE CIGAR LIGHTER
9 20A YELLOW FUEL PUMP 20 15A BLUE AUX. A/C
10 5A ORANGE DIAGNOSTICS SUPPLY 21
11

7
 AUX. FUSE / RELAY BOX
LOCATION – BEHIND GLOVE BOX/BLOWER MOTOR
AF-1
WIPER RELAY ACCESSORIES AUX. FUSE/RELAY BOX - FUSES/CIRCUITS/RATINGS
10 A CUTOFF RELAY
FUSE No FUSE RATING COLOUR CIRCUIT
40 A/30A
1 15A BLUE EGR/IMV
2 10A RED ECU SUPPLY
CONDENSOR 3 10A BLUE BRAKE SW/FUEL PUMP
BLOWER FAN CLUSTER LAMP
RELAY
4 15A RED
RELAY
40 A 40 A 5
6 10A RED HFM SENSOR / AC

10A 10A 15A 10A 10A

1 2 3 4 5 6

7 8 9

AUX. FUSE/RELAY BOX – SCORPIO M2Di Ex

LOCATION – BELOW CENTRAL CONSOLE AF-2
FEEDPUMP
RELAY
20A

8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
 WIRING HARNESS LAYOUT- SCORPIO M2Di Ex
HARNESS No DESCRIPTION
1 INSTRUMENT PANEL (IP)
2 ENGINE ROOM
3 ENGINE
4 FLOOR
5 DOOR - BACK DOOR
6 ROOF
7 FEED PUMP PIGTAIL

27
 INTER-CONNECTORS - LOCATIONS/PINS/VIEWS - SCORPIO M2Di Ex

DESCRIPTION LOCATION IC NO PINS M/F CONNECTOR VIEW

ENGINE TO IP A - PILLAR LH 1 20 F

ENGINE TO IP A - PILLAR LH 2 20 M

IP TO ENGINE A - PILLAR LH 3 20 F

IP TO ENGINE A - PILLAR LH 4 20 M

IP TO ENGINE COMPTT A - PILLAR RH 5 18 M

IP TO ENGINE COMPTT A - PILLAR RH 6 5+2 M

28
IP TO FLOOR A - PILLAR RH 7 10 F

IP TO HVAC BEHIND CENTRE BEZEL 8 7 F

FLOOR TO FUEL FEEDPUMP NEAR FUEL TANK 9 2 F

FLOOR TO FUEL FEEDPUMP NEAR FUEL TANK 10 2 F

FLOOR TO BACK DOOR D - PILLAR RH 11 4 F

ROOF TO FLOOR A - PILLAR RH 12 4 M

29
ENGINE COMPTT TO IP A - PILLAR RH 13 18 F

ENGINE COMPTT TO IP A - PILLAR RH 14 5+2 F

BACKDOOR TO FLOOR D - PILLAR RH 15 4 M

IP TO FLOOR A - PILLAR RH 16 4 F

IP TO ENGINE COMPTT A - PILLAR RH 17 2 F

ENGINE COMPTT TO IP A - PILLAR RH 18 2 M

30
FLOOR TO IP A - PILLAR RH 19 10 M

FLOOR TO IP A - PILLAR RH 20 4 M

FLOOR TO ROOF A - PILLAR RH 21 4 F

IC- 5, 6,7, 12,13,14,

16,17,18,19,20,21 IC-
11,15

IC- 8

IC- 9,10

IC -1,2,3,4

31
 TERMINAL CONNECTOR

NO. DESCRIPTION LOCATION CONNECTOR VIEW

1 ECU TERMINAL ENGINE

CONNECTOR

32
 GROUND LOCATION CHART
GROUND
CIRCUITS CONTROLLED LOCATION
No

E0 BATTERY EARTH, ECU ON BATTERY NEGATIVE POST

FLWI SWITCH, WIPER MOTOR FRONT, FRONT

FOG LAMP, HEADLAMP/LEVELLING MOTOR -
E1 RIGHT, PARK LAMP RIGHT, TURN SIGNAL RIGHT,
FRONT WHEEL HOUSE PANEL - RIGHT
HEADLAMP RIGHT, CONDENSOR FAN

TURN SIGNAL LEFT, HEADLAMP LEFT.

PARKLAMP LEFT, WASHER FRONT MOTOR,
E2 HORN RH & LH, HEADLAMP LEVELLING MOTOR -
FRONT WHEEL HOUSE PANEL - LEFT
LEFT, RELAY LO & HIGH COIL

SIDE MARKERS LEFT & RIGHT, FUEL

E3 PUMP,INTERIORLAMPS
BELOW DRIVERS SEAT

TAIL LAMP LEFT & RIGHT, REGISTRATION

E4 PLATE NO., FUEL LID, IC BACK DOOR
D-PILLAR RIGHT

FRONT FOG RELAY, FUEL LID RELAY,BLOWER

MOTOR RELAY, FLASHER CONTROL,
COMBINATION SWITCH LIGHT, HEAD LAMP
LEVELLING SWITCH,CIGAR LIGHTER, FUEL LID
E5 SWITCH, HAZARD SWITCH,CONDENSOR FAN
A-PILLAR RIGHT
RELAY, MODE SELECTION SWITCH, BREAK
SWITCH, DIAGNOSTIC, IMMOBILIZER , CLUTCH
START RELAY

E7 HVAC A-PILLAR RIGHT

E8 AUDIO SYSTEM A-PILLAR RIGHT

E9 ECU EARTH

FLWI - BRAKE FLUID LEVEL WARNING INDICATOR

HMSL HIGH MOUNTING STOP LAMP

33
 E5,E7,E8

E4 E1 E4

E3

E13 E14

E0

E2

34
ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM
SYMBOL EXPLANATION
Y-R WIRE WITH COLOUR OF WIRE

Y- BASE COLOUR ; R - TRACER COLOUR

Y-R (Refer colour chart for colour codes)

WIRES - NOT JOINED

WIRES - JOINED

SHILEDED WIRE

TWISTED WIRE

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

EARTH / GROUND

GROUND ON COMPONENT

POWER SOURCE - BATTERY

POWER SOURCE - DC

POWER SOURCE - AC

10 A FUSE WITH RATING & DIRECTION OF FLOW

COIL / INDUCTOR

RESISTANCE/RESISTOR

VARIABLE RESISTOR/RHEOSTAT

POTENTIOMETER

SWITCH - PUSH TO MAKE

SWITCH - TOGGLE

SWITCH - PUSH TO BREAK

SWITCH - ON/OFF

CAPACITOR

VARIABLE CAPACITOR

35
ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM
SYMBOL EXPLANATION

LAMP

INDICATOR LAMP

MOTOR

DIODE

ZENNER DIODE

LIGHT EMITTING DIODE (LED)

TRANSISTOR (NPN)

TRANSISTOR (PNP)

30 87

4-POINT, NO (NORMALLY OPEN) RELAY

85 86

30 87

4-POINT, NC (NORMALLY CLOSED) RELAY

85 86

30 87

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

85 86 DIODE

30
87
4-POINT, NC (NORMALLY CLOSED) RELAY WITH DE-SPIKING
DIODE
85 86

87
30
87a
5 POINT RELAY (CHANGE OVER RELAY)
85 86

87
30
87a
5 POINT RELAY (CHANGE OVER RELAY) WITH DE-SPIKING
85 86 DIODE

SOLENOID

36
 WIRE COLOUR CODES
WIRE CODE WIRE COLOUR
B BLACK
L /Bl BLUE
G GREEN
Gr GRAY
O ORANGE
P PINK
R RED
Sb SKY BLUE
V VIOLET
W WHITE
Y YELLOW
Br BROWN

DECODING WIRE COLOUR

Y -R

BASE COLOUR – Y – YELLOW

TRACER COLOUR – R - RED

37