WIRING MANUAL

Vlx

MAN-00094
Supersedes MAN-00042

RELEASED BY -

TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.
www.teknetmahindra.com Rev2 – AUGUST 2010
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.

© 2010 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 Bolero Vlx 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 covers both BS III as well as BS IV variants

In spite of our best efforts to make the manual error-free, a few errors could have inadvertently crept in. If
you identify errors, functional or typographical, please inform your TEKline or pillay.ajay@mahindra.com.
Suggestions to improve the manual and make it more user-friendly are also welcome.

© 2010 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.
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

© 2010 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.
 TABLE OF CONTENTS

1. CONTROLLERS/FUSES/RELAYS – LOCATIONS 2

MAIN FUSE /RELAY BOX – MF 3

AUXILLARY/CRDe FUSE/RELAY BOX – AF 4
ENGINE COMPARTMENT FUSE/RELAY BOX – EF 5

2. WIRING HARNESS LAYOUT 6

3. INTERCONNECTORS – LOCATION/PINS/VIEWS 7
4. GROUND/EARTHING POINTS – LOCATIONS 9

5. INDIVIDUAL CIRCUITS

ENGINE MANAGEMENT SYSTEM (A-CONNECTOR) 10

ENGINE MANAGEMENT SYSTEM (K-CONNECTOR) - BSIII 11
ENGINE MANAGEMENT SYSTEM (K-CONNECTOR) - BSIV 12
STARTING CIRCUIT 13
CHARGING CIRCUIT 14
AC & HEATER CIRCUIT 15
INSTRUMENT CLUSTER CIRCUIT (BSIII) 16
INSTRUMENT CLUSTER CIRCUIT (BSIV) 18
POWER WINDOW CIRCUIT 20
REMOTE LOCKING SYSTEM 21
VOICE MESSAGING SYSTEM CIRCUIT 22
AUDIO CIRCUIT 23
CIGAR LIGHTER/12 V POINT CIRCUIT 24
HORN CIRCUIT 25
WIPER & WASHER – FRONT 26
HEADLAMP CIRCUIT 27
HEADLAMP LEVELLING CIRCUIT 28
INTERIOR LAMPS CIRCUIT 29
PARKING/REGISTRATION PLATE CIRCUIT 30
REVERSE LAMP CIRCUIT 31
STOP LAMP/CLUTCH PEDAL CIRCUIT 32
TURN AND HAZARD CIRCUIT 33

6. APPENDIX

Symbols and nomenclature 34

Wire Colour coding chart 38
 LOCATIONS – FUSEBOX/RELAYS/CONTROLLERS

CONTROLLERS / FUSE / RELAY BOX LOCATIONS - BOLERO Vlx

FUSES & RELAY BOXES ECUs & CONTROLLERS RELAYS/OTHERS
1 ENGINE COMPARTMENT FUSE BOX - EF 4 4WD CONTROLLER 8 STARTER RELAY
2 MAIN FUSE/RELAY BOX - MF 5 VMS CONTROLLER 9 SEAT BELT CHIME
3 AUX FUSE/RELAY BOX - AF 6 ENGINE CONTROLLER
7 REMOTE LOCKING CONTROLLER

MF

5 7

8 A
F
EF
6 9

2
 MAIN FUSE/RELAY BOX

LOCATION – ON RHS “A” PILLAR MF

MAIN FUSE/RELAY - RATINGS/CIRCUITS

FUSE FUSE FUSE FUSE
COLOUR CIRCUIT COLOUR CIRCUIT
No RATING No RATING
1 15A BLUE HEADLAMP LOW BEAM 11 15A BLUE HEADLAMP LOW BEAM
2 10A RED AUDIO/ACC 12 10A RED PARK LAMP
3 10A RED TURN & REVERSE 13 15A BLUE HORN/HAZARD
4 10A RED WIPER/WASHER 14 10A RED ROOF LAMP

5 Not Used 15 20A YELLOW CENTRAL DOOR LOCKING/VMS

6 15A BLUE FOG LAMP/HEATER 16 5A BROWN ECU Diagnostic

7 Not Used 17 10A RED AUDIO MEMORY
8 10A RED CLUSTER/CHIME 18 30A PINK BLOWER
9 20A YELLOW ECU K28 19 10A YELLOW AC COMPRERSSOR
10 40A YELLOW POWER WINDOW 20 20A YELLOW CONDENSOR FAN

HEADLAMP
1 2 3 4 6 8 9
AC THERMO HIGH
15A 10A 10A 10A 15A 10A 20A
AMPLIFIER 20A
10
PULLER 40A
AC HEADLAMP
HEATER
FLASHER COMPRESSOR 11 12 13 14 15 16 17 18 19 20 LOW
RELAY
40A 15A 10A 15A 10A 20A 5A 10A 30A 10A 20A 20A

CONDENSOR BLOWER
WIPER
FAN RELAY RELAY
CONTROLLER
40A 40A

3
AUX. FUSE/RELAY BOX

LOCATION – BEHIND GLOVE BOX AF

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

MAIN FUSE
RELAY FUSE RATING COLOUR CIRCUIT
CRDe No
30 A 1 10A RED A/C REQUEST
2 10A RED HFM SENSOR SUPPLY
3 15A BLUE EGR/VGT/ BRAKE/CLUTCH
10A 4 15A BLUE CRDe ECU SUPPLY - K05
1
5 15A BLUE CLUSTER LAMPS

10A 6 10A RED CRDe ECU SUPPLY - K01

2

15A
3

15A
4

15A
5

10A
6

4
ENGINE COMPARTMENT FUSE BOX

LOCATION – LEFT FENDER

EF

100A 60A 60A 30A

6 5 4 1

ENGINE COMPARTMENT FUSE/RELAY BOX - FUSES/CIRCUITS/RATINGS

FUSE No FUSE RATING COLOUR CIRCUIT
1 30A PINK CRDe ECU
2
3
4 60A YELLOW MAXI FUSE 2
5 60A YELLOW MAXI FUSE 1
6 100A BLUE CHARGING SYSTEM

5
 WIRING HARNESS LAYOUT
HARNESS
DESCRIPTION
No
1 INSTRUMENT PANEL (IP)

2 ENGINE

3 CHASIS

4 ROOF LAMP

5 Door - Left Front

6 Door - Left Rear

7 Door - Right Front

8 Door - Right Rear

9 High Mounted Stop Lamp

9
1

2 4

8
7

5
6

6
 Inter - Connectors - Locations/Pins/Views
Description Location IC No Pins M/F Connector View

I/C IP to Engine WH A Pillar Left 1 21 M

I/C IP to Engine WH A Pillar Left 2 20 M

I/C IP to Engine WH A Pillar Left 3 7 M

I/C IP to ChassisWH A Pillar Left 4 10 F

I/C IP to Door WH Rear left A Pillar Left 5 6 F

I/C IP to Door WH Front left A Pillar Left 6 4 M

I/C IP to Roof Lamp A Pillar Left 7 2 F

I/C IP to Audio Behind IP Switch Plate 10 3 F

I/C IP to Door WH Rear Right A Pillar Right 11 8 M

I/C IP to Door WH Front Right A Pillar Right 12 6 F

I/C Audio to Front Speaker Behind IP Switch Plate 15 4 F

7
I/C Audio to Rear Speaker Behind IP Switch Plate 16 4 M

I/C Chassis to Back Door Back Door 18 2 M

I/C AC Potentiometer Behind IP Switch Plate 19 4 M

I/C IP to Diode Connector (Door) Behind IP Switch Plate 20 2 M

I/C IP to Diode Connector (Hand

Behind IP Switch Plate 21 3 M
Brake)

I/C 20 I/C 11,12

I/C 21
I/C 18

I/C 10,15,16
I/C 19,20,21

I/C 1,2 3
I/C 4,5,6,7

8
 Ground Location Chart
Ground No Circuits Controlled Location
CRDe ECU, Starter Relay, Vehicle Speed sensor, Water in Fuel,Horn, head Lamp LH , Turn
0 Signal LH , HLLD Motor LH,Park LH
On Battery negative pole
1 Battery Negative terminal to Body. On LH Fendor
2 Body to Engine On Front Panel (Below battery Tray)
3 Battery Negative terminal to Engine Engine Block
4 Wiper control, CDL, Power window,Seat Belt, VMS unit & Reset Sw A Pillar Left
Blower,Thermo amplifier, Heater,Cluster lamps,Interier Lamps, Passenger comp. Panel
5 Cigarate lighter,Hazard sw, Combination Sw, HLLD Sw,Audio,Head Lamp Relay, ( Behind Cluster)
6 Park RH,Condensor fan,Front Wash Motor,Turn Signal RH,HLLD LH,Head Lamp RH On RH Fendor ( On Aircleaner Bolt)
7 Park,Stop,Reverse, Tank Unit,Registration Lamp Rear Body LH
8 CRDe ECU On ECU Bracket

E7
E6

E5

E2
E3 E8

E4
E0
E1

9
13
14
15
 INSTRUMENT CLUSTER – BOLERO Vlx (BS-III)

1. FUEL GAUGE 13. HIGH BEAM

2. BATTERY CHARGING 14. TURN INDICATOR - RIGHT
3. LOW OIL PRESSURE 15. TACHO METER
4. DOOR AJAR 16. SEAT BELT WARNING
5. PARK BRAKE LOW BRAKE FLUID 17. FRONT FOG
6. WATR IN FUEL 18. GLOW PLUG
7. ODO METER 19. HIGH TEMPERATURE WARNING
8. TRIP A/TRIP B 20. ENGINE CHECK LAMP
9. SPEEDO METER 21. 4WD LOW
10. MODE/SET KNOB 22. OBD LAMP/MIL
11. TURN INDICATOR – LEFT 23. 4WD HIGH
12. SECURITY SYSTEM 24. TEMPERATURE GAUGE
16
17
 INSTRUMENT CLUSTER – BOLERO Vlx (BS-IV)

1. FUEL GAUGE 13. HIGH BEAM

2. BATTERY CHARGING 14. TURN INDICATOR - RIGHT
3. LOW OIL PRESSURE 15. TACHO METER
4. DOOR AJAR 16. SEAT BELT WARNING
5. PARK BRAKE LOW BRAKE FLUID 17. FRONT FOG
6. WATR IN FUEL 18. GLOW PLUG
7. ODO METER 19. HIGH TEMPERATURE WARNING
8. TRIP A/TRIP B 20. ENGINE CHECK LAMP
9. SPEEDO METER 21. 4WD LOW
10. MODE/SET KNOB 22. OBD LAMP/MIL
11. TURN INDICATOR – LEFT 23. 4WD HIGH
12. SECURITY SYSTEM 24. TEMPERATURE GAUGE

18
19
21
23
24
25
26
27
28
29
30
31
32
33
 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

34
 ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM

SYMBOL EXPLANATION

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

MOTOR
35
 ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM
SYMBOL EXPLANATION

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

DIODE

85 86

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

85 86

36
 ELECTRICAL SYMBOLS USED IN WIRING DIAGRAM
SYMBOL EXPLANATION

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

85 86

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

SOLENOID

37
 WIRE COLOUR CODES
WIRE CODE WIRE COLOUR
B BLACK
BL/L BLUE
G GREEN
Gr GRAY
O ORANGE
P PINK
R RED
Sb/S SKY BLUE
V VIOLET
W WHITE
Y YELLOW
Br BROWN

DECODING WIRE COLOUR

Y-R

BASE COLOUR – Y – YELLOW

TRACER COLOUR – R - RED

38