Traction Control/ABS - Codes C1140/C1145 Set
Date: August 19, 2004Order No.: P-B-42.45/23f
Supersedes: P-B-42.45/23e dated March 25, 2003
Group: 42
Revision:
Required Warranty Parts Information for Returned ESP Control Modules
SUBJECT:
Model 203, from Model Year 2002 to January 3, 2003 Production
Model 209, from Model Year 2003 to January 3, 2003 Production
Electronic Stability Program (ESP) with Failure Codes C1140 and/or C1145
If you encounter instances in the above models of failure codes C1140 and/or C1145 in the Electronic Stability Program (ESP), this may be the result of a layer of oxidation on contact pins 18, 19 and 20 in the connector at the ESP electronic control module. This results in an increased contact resistance and Star Diagnosis System (SDS) interprets this as a brake pressure sensor failure. Changing the ESP electronic control unit will not result in a long lasting solution. If no other reason for this failure code can be found, perform the following repair.
Note:
All replaced ESP control modules must be returned to the Quality Evaluation Center (QEC) indicated by NetStar parts disposition. Each returned ESP control unit must include a printout of the STAR Diagnosis fault codes. In order to obtain a printout navigate through the following STAR Diagnosis menus: [Control Units --> Chassis --> ESP --> Electronic Stability Program --> Fault Codes]. Warranty claims filed for ESP control modules after August 19, 2004, without including the STAR Diagnosis printout will be debited and the corresponding parts will be sent back to the dealer.
1. Disconnect negative battery cable from battery.
2. Remove connector from ESP control module. Remove ground wire at ground point W9 on vehicles built as of January 2002.
3. Push tabs (Figure 1 callout 1) lightly outward with a small screwdriver while lifting up on cover (Figure 1 callout A).
4. Remove spacer (Figure 2 callout B) from the ESP connector by using a small screwdriver and pressing upwards.
5. Remove cable tie from ESP connector and expose approximately 30 cm of the wiring.
6. Locate and prepare to remove pins 18, 19 and 20 from the plug housing. These are located in 2nd, 3rd and 4th position from the top. See Figure 3.
7. Insert special tool W220 589 01 99 60 (insert MQS) carefully from the front side into the opening next to the contact pin. Lightly press the plastic locking tab outward and simultaneously gently pull the corresponding wire out of the connector. See Figure 4. Note which wire comes out of which connector cavity for Step 10.
8. Separate the 3 wires corresponding to the wire lengths in the repair harness. Keep in mind that an additional 7 cm in wire length will be needed. The 3 butt splices should each be separated by 5 cm and not overlap. See Figure 5 - callout a.
9. Connect each cut end of the ESP harness wires with the corresponding wire from the repair kit paying particular attention to the wire colors. Insert both ends into the solder splice connector and twist the connector to insure the wire ends are fully inserted, please refer to WIS document no. AH00.19-P-1000-04A. Using the Steinel hot air gun, heat the connector to at least 400 degrees Celsius starting at the conical end. The dial setting on the gun should be set to approximately 13 to 14, please refer to SI 58.20/118 dated November 2001 for more specific information. Heat until the solder ring disappears and the shield lies tightly against the wires.
10. After connecting the repair kit, reinstall the pins in the connector housing. Pay close attention that the pins audibly latch in place. Confirm this by gently tugging on the wire.
11. Remove the connector at the brake pressure sensor (Figure 6). Check the overall resistance for each of the 3 wires from the ESP connector to the brake pressure sensor connector with both connectors disconnected. The resistance must be less than 0.5 ohms. Be sure to compensate for the resistance of the test leads. Reinstall the brake pressure sensor connector (Figure 6).
12. Reinstall the electrical connector at the ESP electronic control module and spacer (Figure 2 - callout B) in the connector housing. Starting at the ESP connector housing, wrap the wires with the cloth tape insuring that the solder splice connectors do not come in contact with each other and the ends point towards the bulkhead.
13. Take one of the two cleaning tools from the kit and apply 4 drops of lighter fluid to the tip. See figures 7 and 8. Carefully use the moist cleaning tool to clean pins 18, 19 and 20 (these are the 2nd, 3rd and 4th pins from the top in the center row) for the ESP electronic control unit. Perform this in a well ventilated area. See Figure 9. Rub each pin four times with the cleaning tool. Be careful not to bend the pins. Wait one minute.
14. Take the second cleaning tool from the kit. Using this tool dry, clean pins 18, 19 and 20 (these are the 2nd, 3rd and 4th pins from the top in the center row) for the ESP electronic control unit. Rub each pin four times with the cleaning tool. Be careful not to bend the pins.
15. Reinstall the ESP connector cover (Figure 1 - callout a).
16. Fasten harness to connector with cable tie.
17. Reinstall ESP electronic control unit and reinstall connector on control unit. Reattach ground wire at ground point W9 on cars built as of January 2002. Tightening torque is 10 Nm.
18. Reconnect battery ground cable.
19. Clear failure codes and restore programming for windows, sliding roof and radio preset stations.
Parts Information