DIAGNOSTIC MANUAL - mahindra-direct.co.nz · ... Mahindra Ltd. © 2007 Mahindra & Mahindra Ltd...

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SCORPIO Vlx

DIAGNOSTIC MANUAL - ABS

Revision 1 MAN-00030

922BRKR011107EN-DM

RELEASED BY : TECHNICAL PUBLICATION CELL MAHINDRA & MAHINDRA LTD Rev 1 – 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. INDEX OF COMMONLY USED TERMS 3 2. INDEX OF DTC CODES 5 3. WIRING DIAGRAM 7 4. DTC BASED DIAGNOSTICS 8

MAN-00030922BRKR011107EN-DM

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Mahindra & Mahindra Ltd Scorpio Diagnostic Guide - ABS Confidential- For Internal Circulation Only Ver 1 Nov 07 Page 3 of 62

Index of Common Terms Used

DTC: Diagnostic Troubleshooting Codes ABS Lamp: Yellow lamp in cluster with the ABS written (photo to be inserted) Parking Brake Lamp: The parking brake lamp & the FLWI lamp is a combined red lamp. (Sketch required). The ABS errors will also be shown through this red lamp. DRP: Dynamic Rear Proportioning Note: DRP is equivalent to electronic LSPV. It is active only when the rear wheels are tending to lock. ABS : Anti Lock Braking System Note: ABS is active only in the extreme condition when the front wheel lock is taking place. In normal operation the braking does not activate the ABS functionality. Also the brake pedal pulsation when the ABS is active is normal Note: When the lock takes place normally the rear tend to lock first hence initially the DRP kicks in. Then the second stage if the front is locking then the ABS also becomes active. Under severe panic braking the front wheels can lock first or all the four wheels will tend to lock. Under this condition the ABS will come into operation immediately. WSS: Wheel Speed Sensor Front Toner Wheel: Is mounted inside the disc for front wheel spped signal to ABS ECU & serviced with disc & toner assembly & not serviced individually Rear Toner Wheel: Is mounted on to differential case assembly & serviced with differential case & not serviced individually for rear wheel speed signal to ABS ECU EOL: End of the Line (Only in the assembly line) Note: Clear all the DTC codes before giving the vehicle back to the customer. Any unhealed code should be attended and then only the vehicle to be released. It is recommended that when ever the vehicle reports to the workshop, the DTC codes should be checked & using print command in software save the image of error codes to maintain vehicle history. The status of the code (healed or not present) when it came to the workshop as well as before leaving the workshop, should be printed. (Use the print command in


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the diagnostic, converts to a PDF file, later the PDF file to be printed. This record should be kept in the vehicle history and can be useful later.) After clearing all the ABS related errors drive the vehicle and do at least 5 ABS braking application and check if any errors are recorded. Suggestion is that the vehicle speed should not exceed 50 Km/hr when doing the panic braking to check ABS performance. ISO : Isolation valve DUMP : Dump valve


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Index of DTC Codes

Code Description Page # 1800 WSS Open – Front Left 8-9 1801 WSS Open – Front Right 8-9 1802 WSS Open – Rear 8-9 1803 WSS Short – Front Left 10-11 1804 WSS Short – Front Right 10-11 1805 WSS Short – Rear 10-11 1806 WSS Missing – Front Left 12-13 1807 WSS Missing – Front Right 12-13 1808 WSS Missing – Rear 12-13

1809 WSS Erratic – Front Left 14-15 180A WSS Erratic – Front Right 14-15 180B WSS Erratic – Rear 14-15 180C WSS Drop Out – Front Left 16-17 180D WSS Drop Out –Front Right 16-17 180E WSS Drop Out – Rear 16-17 180F Mismatch Tyre 18-19 1810 Solenoid Open–ISO Front Left 20-21 1811 Solenoid Open–ISO Front Right 20-21 1812 Solenoid Open – ISO Rear 20-21 1813 Solenoid Open–Dump Front Left 20-21 1814 Solenoid Open–Dump Front Right 20-21 1815 Solenoid Open – Dump Rear 20-21 1816 ISO Front Left Solenoid -Driver Shorted 20-21 1817 ISO Front Right Solenoid -Driver Shorted 20-21 1818 ISO Rear Solenoid -Driver Shorted 20-21

1819 Dump valve Front Left Solenoid -Driver Shorted 20-21

181A Dump valve Front Right Solenoid -Driver Shorted 20-21

181B Dump valve Rear Solenoid -Driver Shorted 20-21 181C Valve solenoid ISO valve Front Left 22-23 181D Valve solenoid ISO valve Front Right 22-23 181E Valve solenoid ISO valve -Rear 22-23 181F Valve Solenoid Dump–Front Left-Shorted 22-23 1820 Valve Solenoid Dump–Front Right-Shorted 22-23 1821 Valve Solenoid –Rear Dump-Short 22-23

1822 Valve Solenoid-ISO Front Left- Over temperature 24-25

1823 Valve Solenoid-ISO Front Right- Over temperature 26-27

1824 Valve Solenoid-ISO Rear- Over temperature 26-27 1825 Valve Solenoid - Dump Front Left - Over 26-27


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Temperature Code Description Page #

1826 Valve Solenoid - Dump Front Right - Over Temperature 26-27

1827 Valve Solenoid - Dump Rear - Over Temperature 26-27

1829 Power Switch - Shorted 28-29 182A ABS Motor - Open 30-31 182B ABS Motor - Locked 32-33 182C ABS Motor – Open Fuse 34-35 182D Microprocessor ROM Failure 36-37 182E Microprocessor RAM Failure 36-37 182F Microprocessor Stack Failure 36-37 1830 Microprocessor Schedule Overrun Failure 36-37 1831 Microprocessor External watchdog Failure 36-37

1832 Base brake fluid sensor – open Base brake failure 38-39

1833 Ignition Voltage Supply low 40-41 1834 Ignition Voltage Supply High 42-43 1835 Ignition Voltage Supply – Excessive High 44-45 1836 Microprocessor Unimplemented Interrupt. 46-47 1837 Microprocessor Unexpected Exception. 46-47 1838 Microprocessor Solenoid Timeout Failure 46-47

1839 Microprocessor HET Periodic Interrupt Failure. 46-47

183A Microprocessor SPI Failure. 46-47 183B Microprocessor SPI Queue Overflow 46-47 183C Brake Pedal Switch Failed – Never Active 48-49 183D Brake Pedal Switch Failed–Always Active 48-49 183E Tooth count Failure (Out of Range) 50-51 183F Tyre Size Failure ( Mismatch/ out of range) 52-53 1840 Emission Rollers Mode Active 54-55 1841 Invalid Drive-train configuration 56-57

1842 Communication Missing Transfer Case Status 58-59

1843 Communication General K-Line Fault 60-61


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Circuit Diagram –


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ABS Trouble Shooting

Description –

DTC Error Description

Effect of DTC

1800

1801

WSS Open – Front Left

WSS Open – Front Right

ABS Lamp : ON

Parking Brake Lamp : OFF

ABS Status : Partially Active

DRP Status : Fully Active

1802 WSS Open – Rear

ABS Lamp : ON

Parking Brake Lamp : ON

ABS Status : Inactive

DRP Status : Inactive

Performance Condition Possible Causes Proper Performance: Under normal condition the Wheel speed signal are proportional and can be used for the ABS & DRP functionality Malfunction: WSS output signals out-of-range

• Defective wheel speed sensor • Defective wiring harness to wheel speed

sensor • Defective Microprocessor or Printed

Circuit Board in the ECU. • Electrical Pins bent of ECU or WSS

1800

1801

1802


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Trouble Shooting –

1800

1801

1802

After replacement of the required component, connect the wiring harness to Sensor & EHCU. Switch on the Ignition & confirm if the error is healed.

Change the wiring harness. (Wiring Harness Part # - Refer Table A)

Check continuity in wiring harness - between sensors’s mating connector to EHCU mating connector (Low to Low & High to High).

If Yes If No

The problem exists either in ECU or WSS.

Change the respective WSS as per the DTC codes. (Front WSS Part # - Refer Table A Rear WSS Part # - Refer Table A).

If Yes If No

The problem is with WSS.

The problem is with ECU. Switch ignition Off; Detach EHCU connector; Replace the ECU Assembly. (ECU assembly Part # - Refer Table A)

Connect the wiring harness to Sensors & EHCU. Switch on the ignition & check if the error is healed.

Remove EHCU connector (H-3) & sensor connector (FL: H-5; FR: H-6; RR: H-7).

Switch Off the Ignition


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ABS Trouble shooting

Description –


Effect of DTC

1803

1804

WSS Short – Front Left

WSS Short – Front Right

ABS Lamp : ON




1805 WSS Short – Rear

ABS Lamp : ON





• Defective wheel speed sensor • Defective wiring harness to wheel speed

sensor • Defective Microprocessor or Printed

Circuit Board in the ECU. • Electrical Pins bent of ECU or WSS

1803

1804

1805


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1803

1804

1805

Change the wiring harness. (Wiring Harness Part # - Refer Table A)

After replacement of the required component, connect the wheel harness to Sensor & EHCU. Switch on the Ignition & confirm if the error is healed.

Check continuity in wiring harness - between sensors’s mating connector to EHCU mating connector (Low to Low & High to High).

If Yes If No

The problem exists either in ECU or WSS.

Change the respective WSS as per the DTC codes. (Front WSS Part # - Refer Table A Rear WSS Part # - Refer Table A)

If Yes If No

The problem is with WSS.

The problem is with ECU. Switch Off ignition; Detach EHCU connector; Replace the ECU Assembly. (ECU assembly Part # - Refer Table A)

Connect the wheel wiring harness to Sensors & EHCU. Switch on the ignition & check if the error is healed.

Remove EHCU connector (H-3) & sensor connector (FL: H-5; FR: H-6; RR: H-7).



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ABS Trouble shooting Description –


Effect of DTC

1806

1807

WSS Missing – Front Left

WSS Missing – Front Right

ABS Lamp : ON




1808 WSS Missing – Rear ABS Lamp : ON





• Wheel speed sensor not mounted

correctly. • Wheel speed sensor to toner-wheel gap

out of tolerance. • Excessive run-out at vehicle level on

toner ring teeth

1806

1807

1808


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1806

1807

1808

Check the WSS mounting. Retighten to the specified torque. ( 20 ± 3 Nm ).

If the toner wheel appears to have come out of the disc or there is more run out of the disc. Check Toner wheel visually for any damage.


Any damage/ visual defect

Replace the affected Components

Remove the wheel assembly. Check the bearing & races. Reassemble.

Switch on the ignition, clear all errors.

If complaint re-occurs then only replace the affected toner wheel assembly.


If Yes If No


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Effect of DTC

1809

180A

WSS Erratic – Front Left

WSS Erratic – Front Right

ABS Lamp : ON




180B WSS Erratic – Rear ABS Lamp : ON





• Wheel speed sensor not mounted

correctly. • Missing Tooth or Teeth on the wheel

speed sensor tone – wheel. • Excessive run-out at vehicle level on

toner ring teeth

1809

180A

180B


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1809

180A

180B

Check the WSS mounting. Retighten to the specified torque. ( 20 ± 3 Nm ).

I. If the toner wheel appears to have come out of the disc or there is more run out of the disc.

II. Check Toner wheel visually for any

damage.


Any damage/ visual defect

Replace the affected Components

Remove the wheel assembly. Check the bearing & races. Reassemble.


If complaint re-occurs then only replace the affected toner wheel assembly.


If Yes If No


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Effect of DTC

180C

180D

WSS Drop Out – Front Left

WSS Drop Out –Front Right

ABS Lamp : ON




180E WSS Drop Out – Rear ABS Lamp : ON





• Defective wheel speed sensor • Defective harness to wheel speed sensor • Defective terminals of WSS or wiring

harness • Wheel speed sensor not mounted

correctly.

180C

180D

180E


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180C

180D

180E

Replace Wheel speed sensor & Check

Replace the disc & toner wheel assembly in the front and the toner wheel in the rear. (Disc & Toner wheel Part # - Refer Table A Rear Toner wheel assembly Part # - Refer Table A)

Switch on the Ignition & check if the error is healed.


If suspect

Replace the WSS wiring harness suitably. (Wiring harness Part # - Refer Table A)

If found OK

Check WSS mounting. Tighten to the specified torque (20 ± 3 Nm).

If found faulty

Check Toner wheel Visually for Damaged/Missing tooth (No. of Teeth=60)


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Description –


Effect of DTC

180F

Mismatch Tyre

ABS Lamp : ON




Performance Condition Possible Causes Proper Performance: Under normal condition the Wheel speed signal are proportional and can be used for the ABS & DRP functionality Malfunction: High variation in wheel speed

• Anything that generates consistent differences in apparent wheel rotational speed.

• Significantly different size tyres installed on the vehicle.

• Rear toner wheel come out of the diff case or free to rotate on diff case assembly.

180F MAN-00030922BRKR011107EN-DM

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Trouble Shooting – To get an indication go to the live data screen in the Diagnostic tool. Drive the vehicle and check the wheel speed (individual) and the see the difference.

Check toner wheel visually for damaged / missing tooth / teeth. (No. of teeth 60)

Replace the disc & toner wheel assembly on the front and toner wheel on the rear. (Disc & toner wheel assembly Part # - Refer Table A Differential Case & Rear Toner wheel Assembly Part # - Refer Table A )

Check if only recommended tyres are installed on the vehicle.

If found faulty If found OK

If No

Replace with the recommended size tyres.



180F MAN-00030922BRKR011107EN-DM

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DTC Error Description Effect of DTC

1810

1811

Solenoid Open–ISO Front Left

Solenoid Open–ISO Front Right

ABS Lamp : ON




1812 Solenoid Open – ISO Rear ABS Lamp : ON;




1813

1814

Solenoid Open–Dump Front Left

Solenoid Open–Dump Front Right

ABS Lamp : ON




1815

Solenoid Open – Dump Rear

ABS Lamp : ON




1816

1817

1818

1819

181A

181B

ISO Front Left Solenoid -Driver Shorted

ISO Front Right Solenoid -Driver Shorted

ISO Rear Solenoid -Driver Shorted

Dump valve Front Left Solenoid -Driver Shorted

Dump valve Front Right Solenoid -Driver Shorted

Dump valve Rear Solenoid -Driver Shorted

ABS Lamp : ON




1810

1811

1812

1813

1814

1815

1816

1817

1818

1819

181A

181B


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Performance Condition Possible Causes

Proper Performance: Under normal condition the Wheel speed signal are proportional and can be used for the ABS & DRP functionality Malfunction: HCU or ECU malfunction.

• Defective Solenoid • Defective Solenoid Driver FET • Defective Microprocessor or Printed

circuit Board in the ECU. • Anything that keeps solenoid

feedback voltage low when the solenoid is not energized.


1810

1811

1812

1813

1814

1815

1816

1817

1818

1819

181A

181B

Wait for 60 seconds.


If No

Replace The ECU Assembly. (ECU Assembly Part # - Refer Table A)

Connect the wheel harness. Switch on the Ignition & check if the error is healed.



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Description –


181C

181D

Valve solenoid ISO valve Front Left

Valve solenoid ISO valve Front Right

ABS Lamp : ON




181E

Valve solenoid ISO valve -Rear

ABS Lamp : ON




181F

1820

Valve Solenoid Dump–Front Left-Shorted

Valve Solenoid Dump–Front Right-Shorted

ABS Lamp : ON




1821

Valve Solenoid –Rear Dump-Short

ABS Lamp : ON




181C

181D

181E

181F

1820

1821


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Performance Condition Possible Causes Proper Performance: Under normal condition the Wheel speed signal are proportional and can be used for the ABS & DRP functionality Malfunction: HCU or ECU malfunction.

• Solenoid shorted • Defective Solenoid Driver FET • Defective Microprocessor or

Printed circuit Board in the ECU. • Anything that keeps the solenoid

voltage high when the solenoid is supposed to be energized.


181C

181D

181E

181F

1820

1821



If No





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Description –


1822 Valve Solenoid-ISO Front Left- Over temperature

1823 Valve Solenoid-ISO Front Right- Over temperature

ABS Lamp : ON




1824

Valve Solenoid-ISO Rear- Over temperature

ABS Lamp : ON




1825 Valve Solenoid - Dump Front Left - Over Temperature

1826 Valve Solenoid - Dump Front Right - Over Temperature

ABS Lamp : ON




1827

Valve Solenoid - Dump Rear - Over Temperature

ABS Lamp : ON




1822

1823

1824

1825

1826

1827


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Proper Performance: Under normal condition the Wheel speed signal are proportional and can be used for the ABS & DRP functionality Malfunction: HCU malfunction.

• Anything that causes the solenoid

to be active for a long period of time.


1822

1823

1824

1825

1826

1827

Allow enough time interval for solenoid to get cooled. (Approx. 10 Min.)



If not healed then replace the HCU. (HCU Assembly Part # - Refer Table A)


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Description –


1828

Power Switch - Open

ABS Lamp : ON; Parking Brake Lamp : ON



Performance Condition Possible Causes Proper Performance: Under normal condition the Wheel speed signal are proportional and can be used for the ABS & DRP functionality Malfunction: ECU malfunction

• Defective Power Switch. • Defective Microprocessor port

or printed circuit board in the ECU.

1828 MAN-00030922BRKR011107EN-DM

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1828



If No





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Description –


1829

Power Switch - Shorted

ABS Lamp : ON




Performance Condition Possible Causes Proper Performance: Under normal condition the Wheel speed signal are proportional and can be used for the ABS & DRP functionality Malfunction: ECU malfunction

• Defective Power Switch. • Defective Microprocessor port

or printed circuit board in the ECU.

1829 MAN-00030922BRKR011107EN-DM

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1829



If No

Replace The ECU Assembly. (ECU Assembly Part # - Refer Table A )




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Description –


182A

ABS Motor - Open

ABS Lamp : ON




Performance Condition Possible Causes Proper Performance: Under normal condition the Wheel speed signal are proportional and can be used for the ABS & DRP functionality. Malfunction: Motor malfunction

• Defective Motor (Open motor winding).

• Defective Motor Driver (Always On ) • Defective printed circuit board

(feedback shorted high) • Anything that keeps motor

feedback voltage high when the motor has been commanded off & should be stationary.

182A MAN-00030922BRKR011107EN-DM

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182A

Remove wiring harness.

Check the battery + & ground connections to the ECU mating connector terminals (Pin No. 31 & 45)

If OK If Not OK

Check & Replace Wheel Harness. (Wiring Harness Part #-Refer Table A)

Connect the wiring harness.


If Not

Switch off the Ignition.

Remove wheel harness & ECU.

Replace HCU assembly. (HCU Assembly Part # - Refer Table A)

Assemble the ECU assembly back on to the new HCU assembly.


If the error is healed; switch off the ignition & replace the ECU assembly with old ECU.


Replace the ECU assembly. (ECU assembly Part # - Refer Table A)



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Description –


182B

ABS Motor - Locked

ABS Lamp : ON




Performance Condition Possible Causes Proper Performance: Under normal condition the Wheel speed signal are proportional and can be used for the ABS & DRP functionality Malfunction: Motor malfunction

• Defective Motor (Locked/ seized) • Defective Motor Driver (Always On ) • Bad Motor connections • Defective Motor driver. • Defective Printed Circuit Board (

Feedback Line Open ) • Anything that keeps motor

feedback voltage low when it is expected to be driven high by back – EMF across the rotor winding of the coasting motor.

182B MAN-00030

922BRKR011107EN-DM

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182B

Remove wiring harness.

Check the battery + ve & ground connections to the ECU mating connector terminals (Pin No. 31 & 45)

If OK If Not OK

Check & Replace Wiring Harness. (Wiring Harness Part #- Refer Table A)

Connect the wiring harness.


If Not


Remove wheel harness & ECU.

Replace HCU assembly. (HCU Assembly Part # - Refer Table A)

Assemble the ECU assembly back on to the new HCU assembly.


If the error is healed; switch off the ignition & replace the ECU assembly with old ECU.


Replace the ECU assembly. (ECU assembly Part # - Refer Table A)



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Description –


182C

ABS Motor – Open Fuse

ABS Lamp : ON




Performance Condition Possible Causes Proper Performance: Under normal condition the Wheel speed signal are proportional and can be used for the ABS & DRP functionality Malfunction: Motor malfunction

• Blown or Removed Motor Supply

Fuse • Faulty Wheel Harness

182C MAN-00030

922BRKR011107EN-DM

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Check Motor Supply Fuse

If Not OK

Replace Fuse

Switch on Ignition & check if error is healed.

If Not


Remove the wheel Harness & check the battery + & ground connections to the ECU mating connector terminals (Pin No. 31 & 45)

If found faulty

Set right the connections or replace the ABS Chassis Wiring. (ABS Chassis Wiring Harness Part # - Refer Table A)

Switch on Ignition & check if error is healed.


182C MAN-00030922BRKR011107EN-DM

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Description –


182D

182E

182F

1830

1831

Microprocessor ROM Failure

Microprocessor RAM Failure

Microprocessor Stack Failure

Microprocessor Schedule Overrun Failure

Microprocessor External watchdog Failure

ABS Lamp : ON




Performance Condition Possible Causes Proper Performance: Effective ABS / DRP operation. (No wheel lock) Malfunction: Defective microprocessor

• Defective Microprocessor

182D

182E

182F

1830

1831


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182D

182E

182F

1830

1831



If No


Connect the wiring harness. Switch on the Ignition & check if the error is healed.



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Description –


1832

Base brake fluid sensor – open

Base brake failure

ABS Lamp : ON


ABS Status : Partially active

DRP Status : Partially active

Performance Condition Possible Causes Proper Performance: Enough fluid availability for effective braking & ABS / DRP functionality. Malfunction: Brake fluid unavailable

• Parking Brake Failure • Low brake fluid level sensor

reading • Disconnected sensor • Faulty wiring harness • Faulty sensor

1832 MAN-00030

922BRKR011107EN-DM

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1832

Check if Hand brake is ON

If Yes

Release the Hand Brake. Check if the Brake Fluid Level is above the Minimum Level marked in the reservoir.

If Yes

If No

If No

Top up the Brake Fluid.

Check the Fluid Level Switch.

If found faulty

Replace the switch. (FLWI Switch Part # - Refer Table A)



Find the reason for leak- correct if required.


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Description –


1833

Ignition Voltage Supply low ABS Lamp : ON


ABS Status : Fully Active


Performance Condition Possible Causes Proper Performance: Availability of sufficient ignition voltage for Effective ABS / DRP operation. Malfunction: This fault is set if the Ignition Voltage Supply is less than 10V for 100 msec.

• Ignition Voltage supply is

providing low Ignition Voltage levels.

• Defective cables • Defective Printed Circuit Board in

ECU.

1833


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1833

Check Battery Voltage.

If required Charge the Battery.


If Not

Remove wiring Harness & check for any Short Circuit in the Harness.

If found Faulty.

Replace the wiring Harness. (Wiring Harness Part # - Refer Table A)


If Not

Replace the ECU Assembly. (ECU Assembly Part # - Refer Table A)




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Description –


1834

Ignition Voltage Supply High ABS Lamp : ON




Proper Performance : Availability of correct ignition voltage for Effective ABS / DRP operation

Performance Condition Possible Causes Proper Performance: Availability of sufficient ignition voltage for Effective ABS / DRP operation. Malfunction: This fault is set if the Ignition Voltage is greater than 16V for 100 msec.

• Ignition Voltage supply is providing High Ignition Voltage levels.

• Defective Printed Circuit Board in ECU.

1834 MAN-00030922BRKR011107EN-DM

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1834

Remove wiring Harness & check for any Short Circuit in the Harness.

If found Faulty.

Replace the wiring Harness. ( Wiring Harness Part # Refer Table A)


If Not





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Description –


1835

Ignition Voltage Supply – Excessive High

ABS Lamp : ON



DRP Status: Inactive.

Performance Condition Possible Causes Proper Performance: Availability of sufficient ignition voltage for Effective ABS / DRP operation. Malfunction: This fault is set if the Ignition Voltage is greater than 19.5V for 15 msec.

• Ignition Voltage supply is providing excessively High Ignition Voltage levels.

• Defective Printed Circuit Board in ECU.

1835 MAN-00030922BRKR011107EN-DM

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1835

Remove wheel Harness & check for any Short Circuit in the Harness.

If found Faulty.



If Not





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Description –


1836

1837

1838

1839

Microprocessor Unimplemented Interrupt.

Microprocessor Unexpected Exception.

Microprocessor Solenoid Timeout Failure.

Microprocessor HET Periodic Interrupt Failure.

183A Microprocessor SPI Failure.

ABS Lamp : ON




183B

Microprocessor SPI Queue Overflow

ABS Lamp : ON




1836

1837

1838

1839

183A

183B


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Performance Condition Possible Causes Proper Performance: Effective ABS / DRP operation. (No wheel lock) Malfunction: Defective microprocessor

• Defective Microprocessor


1836

1837

1838

1839

183A

183B



If No





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Description –


183C

Brake Pedal Switch Failed – Never Active

183D Brake Pedal Switch Failed–Always Active

ABS Lamp : ON




Performance Condition Possible Causes Proper Performance: Brake switch produces output based on Pedal input Malfunction: Defective signal

• Defective Brake Switch • Defective wiring Harness • Defective Printed Circuit Board

or Microprocessor in ECU.

183C

183D


Automotive Sector




Check Brake Switch

If found Faulty

Replace Brake Switch. (Brake Switch Part # - Refer Table A)


If Not

Remove ECU mating connector & check Brake Switch input.

If found Faulty

Replace wiring harness. (Wiring Harness Part # - Refer Table A)


If Not

Replace ECU Assembly. (ECU Assembly Part # - Refer Table A)

Connect the wiring Harness Switch on the Ignition & check if the error is healed.


183C

183D


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Description –


183E

Tooth count Failure (Out of Range) ABS Lamp : ON




Performance Condition Possible Causes Proper Performance: Under normal condition the Wheel speed signal are proportional and can be used for the ABS & DRP functionality ( No wheel lock) Malfunction: Defective signal

• ECU NVRAM corruption • Incorrect Tooth Count • Tooth Count not programmed.

183E MAN-00030

922BRKR011107EN-DM

Automotive Sector




183E



If No

Use the Diagnostic tool & Re-flash the ABS EHCU using VIN no. of vehicle




If Not

Switch Off the Ignition.




Automotive Sector




Description –


183F

Tyre Size Failure ( Mismatch/ out of range)

ABS Lamp : ON




Performance Condition Possible Causes Proper Performance: Under normal condition the Wheel speed signal are proportional and can be used for the ABS & DRP functionality ( No wheel lock) Malfunction: Defective signal

• NVRAM corruption • Incorrect Tyre Size • Tyre Size not programmed.

183F MAN-00030

922BRKR011107EN-DM

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183F



If Not

Use the Diagnostic tool & enter Tyre Size (M1 / N1)





If Not


Replace the ECU Assembly. ( ECU Assembly Part # - Refer Table A)


Automotive Sector




Description –


1840

Emission Rollers Mode Active ABS Lamp : FLASH

Parking Brake Lamp : FLASH



Performance Condition Possible Causes Proper Performance: This Message appears when EOL (End of Line) test is running. Malfunction:

• Emission Rollers Test is Active • Incorrect communication bus

message

1840 MAN-00030922BRKR011107EN-DM

Automotive Sector



Trouble Shooting – This Message appears when EOL test is running.

1840 MAN-00030922BRKR011107EN-DM

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Description –


1841

Invalid Drive-train configuration

ABS Lamp : ON




Performance Condition Possible Causes Proper Performance: Proper input to ECU on Drive-train status / Drive mode configuration ensures effective ABS / DRP functionality ( No wheel lock) Malfunction: Defective signal

• NVRAM corruption • This fault will be set if the drive-

train configuration value stored in NVRAM is not valid, or if the Drive-train configuration in NVRAM is set to 2WD & the ECU receives a transfer case mode message via comms.

1841 MAN-00030922BRKR011107EN-DM

Automotive Sector




1841

Check whether correct flashing is done in ECU is installed in the vehicle. (2WD ECU for 2WD vehicle & 4WD ECU for 4WD vehicle )

If it is a 2 WD vehicle; check if DMD unit is assembled in the vehicle.

If Yes

Remove it.

If No


Replace the ECU Assembly. ( ECU Assembly Part # - Refer Table A)



Automotive Sector




Description –


1842

Communication Missing Transfer Case Status

ABS Lamp : ON;




Performance Condition Possible Causes Proper Performance: Proper input to ECU on Drive-train status / Drive mode configuration ensures effective ABS / DRP functionality ( No wheel lock) Malfunction: Defective signal

• NVRAM corruption • This fault will be set if the drive-

train configuration value stored in NVRAM is not valid, or if the Drive-train configuration in NVRAM is set to 2WD & the ECU receives a transfer case mode message via comms

1842 MAN-00030

922BRKR011107EN-DM

Automotive Sector




Malfunction; out-of-range This fault will be set if the drive train configuration in NVRAM is set to 4WD & ECU does not receive a Transfer Case Mode message via comms within five seconds of Ignition ON.

• Communication Bus failure • Drive Mode Data Unit failure


Check whether correct flashing is done in ABS EHCU

If Yes If No

Check if DMD connection is OK.


Try Re-flashing, if it does not work, Replace the ECU. (ECU Assembly Part # - Refer Table

Switch Off Ignition & Switch ON again. & see if error is healed.


1842 MAN-00030922BRKR011107EN-DM

Automotive Sector




Description –


1843

Communication General K-Line Fault

ABS Lamp : OFF




Performance Condition Possible Causes Proper Performance: Effective communication process in the K-Line bus ensures effective ABS & DRP functionality ( No wheel lock) Malfunction:

• This fault is set if the K – Line bus

experiences errors in processing of communications.

• Bad K – Line cable. • Bad K – Line peripheral on the

Microprocessor in the ECU

1843 MAN-00030922BRKR011107EN-DM

Automotive Sector




1843

If found Faulty




Check wiring harness.


If found OK


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