Mercedes C 230 2001 2.3L Workshop Manual

mercedesbenz :: Mercedes Benz C 230K (202.024)
L4-2.3L SC (111.975) (2001)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Description and Operation

Parking Assist Control Module: Description and Operation

- Power supply to the sensors and warning displays

- Processing of ambient signals (trailer/reverse gear recognition, light, vehicle speed signal and Parktronic system switch)

- Actuation of the sensors

- Evaluation of echo journey times

- Generation of data telegrams for the warning displays

- Parktronic system (PTS) self-test

- Storing of system faults in the fault memory

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Diagrams > Driver-Side Fuse and Relay Module (K40/2) PE54.20-U-2100B

Relay Module: DiagramsDriver-Side Fuse and Relay Module (K40/2) PE54.20-U-2100B

Driver-side Fuse And Relay Module (K40/2) PE54.20-U-2100B

Wiring Diagram, Part 1

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Diagrams > Driver-Side Fuse and Relay

Module (K40/2) PE54.20-U-2100B > Page 11

C 230K (202.024) L4-2.3L SC (111.975) (2001)

Wiring Diagram, Part 2

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Diagrams > Driver-Side Fuse and Relay

Module (K40/2) PE54.20-U-2100B > Page 12

C 230K (202.024) L4-2.3L SC (111.975) (2001)

Wiring Diagram, Part 3

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Diagrams > Driver-Side Fuse and Relay

Module (K40/2) PE54.20-U-2100B > Page 13

C 230K (202.024) L4-2.3L SC (111.975) (2001)

Wiring Diagram, Part 4

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Diagrams > Driver-Side Fuse and Relay

Module (K40/2) PE54.20-U-2100B > Page 14

C 230K (202.024) L4-2.3L SC (111.975) (2001)

Component Description/Coordinates, K40/2 To Z3/27

Component Location photographs can be found via their component names at the vehicle level. Component Locations:

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Diagrams > Driver-Side Fuse and Relay Module (K40/2) PE54.20-U-2100B > Page 15

Relay Module: DiagramsFront Passenger-Side Fuse and Relay Module (K40/4) PE54.20-U-2200C

Front Passenger-side Fuse And Relay Module (K40/4) PE54.20-U-2200C

Wiring Diagram, Part 1

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Diagrams > Driver-Side Fuse and Relay

Module (K40/2) PE54.20-U-2100B > Page 16

C 230K (202.024) L4-2.3L SC (111.975) (2001)

Wiring Diagram, Part 2

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Diagrams > Driver-Side Fuse and Relay

Module (K40/2) PE54.20-U-2100B > Page 17

C 230K (202.024) L4-2.3L SC (111.975) (2001)

Wiring Diagram, Part 3

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Diagrams > Driver-Side Fuse and Relay

Module (K40/2) PE54.20-U-2100B > Page 18

C 230K (202.024) L4-2.3L SC (111.975) (2001)

Wiring Diagram, Part 4

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Diagrams > Driver-Side Fuse and Relay

Module (K40/2) PE54.20-U-2100B > Page 19

C 230K (202.024) L4-2.3L SC (111.975) (2001)

Component Description/Coordinates, G1 To W16/4

Component Description/Coordinates, W16/6 To Z38

Component Location photographs can be found via their component names at the vehicle level. Component Locations:

> Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Service and Repair > AR72.29-P-1000E Remove/Install Front Door Control Module

Door Module: Service and RepairAR72.29-P-1000E Remove/Install Front Door Control Module

AR72.29-P-1000E Removing And Installing Front Door Control Module

> Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Service and Repair > AR72.29-P-1000E Remove/Install Front

Door Control Module > Page 25

C 230K (202.024) L4-2.3L SC (111.975) (2001)

ERROR: stackunderflow
OFFENDING COMMAND: ~

STACK:

> Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Service and Repair > AR72.29-P-1000E Remove/Install Front Door Control Module > Page 26

Door Module: Service and RepairAR72.29-P-1100F Remove/Install Rear Door Control Module

AR72.29-P-1100F Removing And Installing Rear Door Control Module

Component Identification

Steps 1 - 3

> Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > AR91.30-P-0001F Remove and Installing Control Module and Switches For Left

and Right Front Heated Seats

Seat Heater Control Module: Service and RepairAR91.30-P-0001F Remove and Installing Control Module and Switches For Left and Right FrontHeated Seats

AR91.30-P-0001F Removing And Installing Control Module And Switches For Left And Right Front Heated Seats

- with CODE (873) Left and right front heated seats

Component Identification

Steps 1 - 7

> Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > AR91.30-P-0001F Remove and Installing Control Module and Switches For Left

and Right Front Heated Seats > Page 31

Seat Heater Control Module: Service and RepairAR91.30-P-0001F Remove/Install Control Module and Switches For Left and Right Front HeatedSeats

AR91.30-P-0001F Removing And Installing Control Module And Switches For Left And Right Front Heated Seats

- with CODE (873) left and right front heated seats

Component Identification

Steps 1 - 7

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module:

> P-42_45-105 > Mar > 09 > ABS/TCS - ESP Lamp ON/Codes C1401 Or C1405

Electronic Brake Control Module: Customer InterestABS/TCS - ESP Lamp ON/Codes C1401 Or C1405

Date: March 2, 2009
Order No.: P-B-42.45/105
Supersedes:
Group: 42

SUBJECT:All Model 202, 208, 210 Equipped with Code 472a (Electronic Stability Program)
ESP Indicator Lamp Illuminated / Fault Code C1401 or C1405

If you receive customer reports in the above model vehicles that the ESP indicator lamp is illuminated and fault code C1401 or C1405 is stored, performthe following to resolve.

Note:

This condition is only valid for ESP control units 0255456132, 0255456232, 0255456332, and 0255450832 with software 43/97 and 52/97.

1. Using STAR Diagnosis process fault codes C1401 and or C1405 via the guided tests.

2. If the guided tests provide no results, then replace the ESP control unit with a revised part. Refer to EPCnet for applicable part numbers.

Refer to WIS document AD42.45-P-1000AZ for model 210 with engines 112/113 and 606. Refer to WIS document AD42.45-P-1001AZ for model 210with engine 119.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module:

> P-42_31-91 > Jan > 08 > ABS - Engine No Start/Limp Home/Multiple Codes Set

Electronic Brake Control Module: Customer InterestABS - Engine No Start/Limp Home/Multiple Codes Set

Date: January 10, 2008
Order No.: P-B-42.31/91
Supersedes:
Group: 42

SUBJECT: All Model 140, 170, 202, 208 and 210 Vehicles
Equipped with Brake Assist (BAS)
Engine Does Not Start and Tip Start Nonfunctional

If you receive customer reports in the above model vehicles of intermittent inability to start the engine and or tip start malfunction, perform thebelow steps to resolve.

Note:

The engine may be in limp home mode. This may be caused by the presence of moisture / corrosion at the CAN/voltage supply connector orthe Brake Assist (BAS) control unit. The following CAN fault codes may be stored individually or in combination.

1. Check the CAN/voltage supply (connector 3) at the BAS control unit for moisture or corrosion.

2. Eliminate the moisture/corrosion if it is present.

3.
If the condition persists, replace the Brake Assist (BAS) control unit (refer to WIS document AR42.31-P-6001A). Refer to EPC for the latestBAS/ESP control unit part numbers.

Note:

The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generatedon January 10, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.

Note:

This document is not an exension of warranty coverage. Please check warranty coverage prior to claim submission.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Electronic Brake Control Module: > P-42_31-91 > Jan > 08 > ABS - Engine No Start/Limp Home/Multiple Codes Set > Page 45

C 230K (202.024) L4-2.3L SC (111.975) (2001)

In Case of Warranty, use the table.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module:

> P-42_45-77 > Jul > 07 > ABS/TCS - ESP Lamp ON/Code C1142 Set

Electronic Brake Control Module: Customer InterestABS/TCS - ESP Lamp ON/Code C1142 Set

Date: July 17, 2007
Order No.: P-B-42.45/77
Supercedes:
Group: 42

SUBJECT:All Model 129, 140, 202, 208 an 210 Vehicles
Equipped with Electronic Stability Program (ESP) (CODE 472a)
ESP Indicator Lamp Illuminated / Fault code C1142

If you receive customer reports in the above model vehicles that the ESP indicator lamp is illuminated with fault code C1142 (lateral accelerationsensor) and that this condition followed any of the below

reported driving conditions, the fault code can be erased / ignored.

Note:

Do not submit warranty claims as there is not a manufacturing defect / failure.
^ Driving on high-bank curves.
^ Rear end collision.
^ Vehicle spins on a slippery road.
If none of the preceding situations occurred, process the fault code by following the diagnostic procedure contained within Star Diagnosis.
^ Model 129 with Engine 104, 113, 119, 120 - Refer to WIS document AD42.45-P-1001AZ
^ Model 140 - Refer to WIS document AD42.45-P-1001AZ
^ Model 210 with Engine 119 - Refer to WIS document AD42.45-P-1001AZ
^ Model 202 and 208 - Refer to WIS document AD42.45-P-1000AZ
^ Model 210 with Engine 112, 113, 606 - Refer to WIS document AD42.45-P-1000AZ

Note:

The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generatedon July 17, 2007. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Customer Interest for Electronic Brake Control Module: > P-42_45-77 > Jul > 07 > ABS/TCS - ESP Lamp ON/Code C1142 Set > Page 50

C 230K (202.024) L4-2.3L SC (111.975) (2001)

In Case of Warranty, use the table.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake

Control Module: > P-42_45-105 > Mar > 09 > ABS/TCS - ESP Lamp ON/Codes C1401 Or C1405

Electronic Brake Control Module: All Technical Service BulletinsABS/TCS - ESP Lamp ON/Codes C1401 Or C1405

Date: March 2, 2009
Order No.: P-B-42.45/105
Supersedes:
Group: 42

SUBJECT:All Model 202, 208, 210 Equipped with Code 472a (Electronic Stability Program)
ESP Indicator Lamp Illuminated / Fault Code C1401 or C1405

If you receive customer reports in the above model vehicles that the ESP indicator lamp is illuminated and fault code C1401 or C1405 is stored, performthe following to resolve.

Note:

This condition is only valid for ESP control units 0255456132, 0255456232, 0255456332, and 0255450832 with software 43/97 and 52/97.

1. Using STAR Diagnosis process fault codes C1401 and or C1405 via the guided tests.

2. If the guided tests provide no results, then replace the ESP control unit with a revised part. Refer to EPCnet for applicable part numbers.

Refer to WIS document AD42.45-P-1000AZ for model 210 with engines 112/113 and 606. Refer to WIS document AD42.45-P-1001AZ for model 210with engine 119.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake

Control Module: > P-42_31-91 > Jan > 08 > ABS - Engine No Start/Limp Home/Multiple Codes Set

Electronic Brake Control Module: All Technical Service BulletinsABS - Engine No Start/Limp Home/Multiple Codes Set

Date: January 10, 2008
Order No.: P-B-42.31/91
Supersedes:
Group: 42

SUBJECT: All Model 140, 170, 202, 208 and 210 Vehicles
Equipped with Brake Assist (BAS)
Engine Does Not Start and Tip Start Nonfunctional

If you receive customer reports in the above model vehicles of intermittent inability to start the engine and or tip start malfunction, perform thebelow steps to resolve.

Note:

The engine may be in limp home mode. This may be caused by the presence of moisture / corrosion at the CAN/voltage supply connector orthe Brake Assist (BAS) control unit. The following CAN fault codes may be stored individually or in combination.

1. Check the CAN/voltage supply (connector 3) at the BAS control unit for moisture or corrosion.

2. Eliminate the moisture/corrosion if it is present.

3.
If the condition persists, replace the Brake Assist (BAS) control unit (refer to WIS document AR42.31-P-6001A). Refer to EPC for the latestBAS/ESP control unit part numbers.

Note:

The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generatedon January 10, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.

Note:

This document is not an exension of warranty coverage. Please check warranty coverage prior to claim submission.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Electronic Brake Control Module: > P-42_31-91 > Jan > 08 > ABS - Engine No Start/Limp Home/Multiple Codes Set > Page 60

C 230K (202.024) L4-2.3L SC (111.975) (2001)

In Case of Warranty, use the table.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake

Control Module: > P-42_45-77 > Jul > 07 > ABS/TCS - ESP Lamp ON/Code C1142 Set

Electronic Brake Control Module: All Technical Service BulletinsABS/TCS - ESP Lamp ON/Code C1142 Set

Date: July 17, 2007
Order No.: P-B-42.45/77
Supercedes:
Group: 42

SUBJECT:All Model 129, 140, 202, 208 an 210 Vehicles
Equipped with Electronic Stability Program (ESP) (CODE 472a)
ESP Indicator Lamp Illuminated / Fault code C1142

If you receive customer reports in the above model vehicles that the ESP indicator lamp is illuminated with fault code C1142 (lateral accelerationsensor) and that this condition followed any of the below

reported driving conditions, the fault code can be erased / ignored.

Note:

Do not submit warranty claims as there is not a manufacturing defect / failure.
^ Driving on high-bank curves.
^ Rear end collision.
^ Vehicle spins on a slippery road.
If none of the preceding situations occurred, process the fault code by following the diagnostic procedure contained within Star Diagnosis.
^ Model 129 with Engine 104, 113, 119, 120 - Refer to WIS document AD42.45-P-1001AZ
^ Model 140 - Refer to WIS document AD42.45-P-1001AZ
^ Model 210 with Engine 119 - Refer to WIS document AD42.45-P-1001AZ
^ Model 202 and 208 - Refer to WIS document AD42.45-P-1000AZ
^ Model 210 with Engine 112, 113, 606 - Refer to WIS document AD42.45-P-1000AZ

Note:

The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generatedon July 17, 2007. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Electronic Brake Control Module: > P-42_45-77 > Jul > 07 > ABS/TCS - ESP Lamp ON/Code C1142 Set > Page 65

C 230K (202.024) L4-2.3L SC (111.975) (2001)

In Case of Warranty, use the table.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > GF42.31-P-0001-01A Brake Assist (BAS): Driver

Information

Electronic Brake Control Module: Description and OperationGF42.31-P-0001-01A Brake Assist (BAS): Driver Information

GF42.31-P-0001-01A Brake Assist (BAS): Driver Information

Component Identification

A system indicator lamp is provided for the BAS in the instrument cluster. In the case of vehicles with ETS, ASC, or ESP, the BAS indicator lamp iscombined with the indicator lamp for the respective traction system.

Turning on ignition and starting engine

When the ignition is switched on (ignition/starter switch position "2"), the indicator lamp in the instrument cluster lights up (bulb check) and goes outwhen the engine is running.

If the BAS indicator lamp lights up while the engine is running, there is a fault in the BAS. The system is no longer functional, but the full brakingeffect with ABS is retained. In the case of the combined indicator lamp (BAS/ETS, BAS/ASC, BAS/ESP), the fault may be located in the BAS and/orthe traction system. If the fault is located in the BAS, the ETS, ASC or ESP system remains functional. If the fault is located in the traction system, theBAS remains functional.
In the case of vehicles with BAS integrated in the ESP, the ESP no longer functions if there is a fault in the BAS.

When driving

System faults which occur while the vehicle is being driven also cause the BAS indicator lamp to light up permanently.
The BAS indicator lamp may light up when the vehicle is being driven and then go out again after a while. This is caused by battery under voltage.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > GF42.31-P-0001-01A Brake Assist (BAS): Driver

Information > Page 68

Electronic Brake Control Module: Description and OperationGF42.30-P-4500-01A Function Description of ABS Control Module

GF42.30-P-4500-01A Function Description Of ABS Control Module

- with CODE (470a) Anti-lock braking system (ABS)

The ABS control module is divided up into the following functions:

- Signal conditioning

- Logic section

- Safety circuit

Signal conditioning

The following input signals are conditioned for the logic section:

-

- Stop lamp switch (4-pin) (S9/1)

Logic section

The conditioned signals are processed in the logic section and converted into output signals.

Speed signals:The conditioned speed signals are continuously compared with each other and then with the preset slip thresholds (differential speeds between the frontand rear wheels, depending on vehicle speed). The following variables are determined by way of this comparison

- Brake slip

- Wheel acceleration

- Front wheel driving speed

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation >

GF42.31-P-0001-01A Brake Assist (BAS): Driver Information > Page 69

C 230K (202.024) L4-2.3L SC (111.975) (2001)

3 speed sensors (models 170, 202, 208)4 speed sensors (model 168)

- Curve recognition

An ABS control mode is initiated if the variables determined exceed the preset slip thresholds.

Stop lamp switch signal:A signal is transmitted to the logic section when the brake is operated. The control module recognizes the braking process.

Safety circuit

The task of the safety circuit is to recognize defective signals in the control module and faults in the electric cable system. The actuation of the solenoidvalves and the return pump is monitored during the control process. If a fault is recognized, the system is switched off and this is displayed to the driverby the ABS malfunction indicator lamp (A1e17) coming on. A fault code is also stored in the control module.

In addition the safety circuit continuously monitors battery voltage. If the voltage falls below 10 V or exceeds 18-20 V, the system is also switched offagain until the voltage is in the specified range again.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > GF42.31-P-0001-01A Brake Assist (BAS): Driver

Information > Page 70

Electronic Brake Control Module: Description and OperationGF42.30-P-4500-02A Design of ABS Control Module

GF42.30-P-4500-02A Design Of ABS Control Module

- with CODE (470a) Anti-lock braking system (ABS)

There are several versions of the ABS control module, recognized by the shape of the housing (e.g. LK55):

­Shape of LK55 housingModel 202 up to 08/95

-

Shape of LK55/1 housingModel 202 as of 09/95Models 168, 170, 208 as of start of production

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > GF42.31-P-0001-01A Brake Assist (BAS): Driver

Information > Page 71

Electronic Brake Control Module: Description and OperationGF42.30-P-4500A Location/Task/Design/Function of ABS Control Module

GF42.30-P-4500A Location/Task/Design/Function Of ABS Control Module

- with CODE (470a) Anti-lock braking system (ABS)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation >

GF42.31-P-0001-01A Brake Assist (BAS): Driver Information > Page 72

C 230K (202.024) L4-2.3L SC (111.975) (2001)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > GF42.31-P-0001-01A Brake Assist (BAS): Driver

Information > Page 73

Electronic Brake Control Module: Description and Operation

GF42.31-P-0001-01A Brake Assist (BAS): Driver Information

GF42.31-P-0001-01A Brake Assist (BAS): Driver Information

Component Identification

A system indicator lamp is provided for the BAS in the instrument cluster. In the case of vehicles with ETS, ASC, or ESP, the BAS indicator lamp iscombined with the indicator lamp for the respective traction system.

Turning on ignition and starting engine

When the ignition is switched on (ignition/starter switch position "2"), the indicator lamp in the instrument cluster lights up (bulb check) and goes outwhen the engine is running.

If the BAS indicator lamp lights up while the engine is running, there is a fault in the BAS. The system is no longer functional, but the full brakingeffect with ABS is retained. In the case of the combined indicator lamp (BAS/ETS, BAS/ASC, BAS/ESP), the fault may be located in the BAS and/orthe traction system. If the fault is located in the BAS, the ETS, ASC or ESP system remains functional. If the fault is located in the traction system, theBAS remains functional.
In the case of vehicles with BAS integrated in the ESP, the ESP no longer functions if there is a fault in the BAS.

When driving

System faults which occur while the vehicle is being driven also cause the BAS indicator lamp to light up permanently.
The BAS indicator lamp may light up when the vehicle is being driven and then go out again after a while. This is caused by battery under voltage.

GF42.30-P-4500-01A Function Description of ABS Control Module

GF42.30-P-4500-01A Function Description Of ABS Control Module

- with CODE (470a) Anti-lock braking system (ABS)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation >

GF42.31-P-0001-01A Brake Assist (BAS): Driver Information > Page 74

C 230K (202.024) L4-2.3L SC (111.975) (2001)

The ABS control module is divided up into the following functions:

- Signal conditioning

- Logic section

- Safety circuit

Signal conditioning

The following input signals are conditioned for the logic section:

­3 speed sensors (models 170, 202, 208)4 speed sensors (model 168)

- Stop lamp switch (4-pin) (S9/1)

Logic section

The conditioned signals are processed in the logic section and converted into output signals.

Speed signals:The conditioned speed signals are continuously compared with each other and then with the preset slip thresholds (differential speeds between the frontand rear wheels, depending on vehicle speed). The following variables are determined by way of this comparison

- Brake slip

- Wheel acceleration

- Front wheel driving speed

- Curve recognition

An ABS control mode is initiated if the variables determined exceed the preset slip thresholds.

Stop lamp switch signal:A signal is transmitted to the logic section when the brake is operated. The control module recognizes the braking process.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation >

GF42.31-P-0001-01A Brake Assist (BAS): Driver Information > Page 75

C 230K (202.024) L4-2.3L SC (111.975) (2001)

Safety circuit

The task of the safety circuit is to recognize defective signals in the control module and faults in the electric cable system. The actuation of the solenoidvalves and the return pump is monitored during the control process. If a fault is recognized, the system is switched off and this is displayed to the driverby the ABS malfunction indicator lamp (A1e17) coming on. A fault code is also stored in the control module.

In addition the safety circuit continuously monitors battery voltage. If the voltage falls below 10 V or exceeds 18-20 V, the system is also switched offagain until the voltage is in the specified range again.

GF42.30-P-4500-02A Design of ABS Control Module

GF42.30-P-4500-02A Design Of ABS Control Module

- with CODE (470a) Anti-lock braking system (ABS)

There are several versions of the ABS control module, recognized by the shape of the housing (e.g. LK55):

-

-

Shape of LK55/1 housingModel 202 as of 09/95Models 168, 170, 208 as of start of production

GF42.30-P-4500A Location/Task/Design/Function of ABS Control Module

GF42.30-P-4500A Location/Task/Design/Function Of ABS Control Module

- with CODE (470a) Anti-lock braking system (ABS)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation >

GF42.31-P-0001-01A Brake Assist (BAS): Driver Information > Page 76

C 230K (202.024) L4-2.3L SC (111.975) (2001)

Shape of LK55 housingModel 202 up to 08/95

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation >

GF42.31-P-0001-01A Brake Assist (BAS): Driver Information > Page 77

C 230K (202.024) L4-2.3L SC (111.975) (2001)

GF42.31-P-4500-01A BAS Control Unit, Function

GF42.31-P-4500-01A BAS control unit, function

In all vehicles with engines 112, 113, 605, 606, 611, 612, 613 and ESP
the BAS function is integrated in the ESP control unit (N47-5).
With models 163, 168, 203, 209, 215, 220
the BAS function is integrated in the ESP control unit (N47-5).

The BAS control unit (N48) is divided up functionally as follows:^

Signal conditioning

^ Logic section
^ Safety circuit

Signal conditioning

The following input signals are conditioned for the logic section:^

2 rpm sensors at front (via CAN from traction system control unit: ABS, ETS, ASR or ESP)

^ Stop lamp switch (via CAN from traction system control unit: ABS, ETS, ASR or ESP)
^ Vehicle identification (vehicle model and engine type via CAN from corresponding engine control unit)
^ BAS diaphragm travel sensor
^ BAS release switch

Logic section

After the ignition is switched on, system initialization and safety checking is started. The system is enabled following a satisfactory check sequence.

The conditioned input signals are processed in the logic section and the following values are calculated^

Vehicle speed from the front wheel speed signals.

^ Vehicle acceleration from several successive wheel speed measurements.
^

The control unit checks the voltage signal from the diaphragm travel sensor every 3 ms. The pedal speed is calculated from the voltage differencebetween two successive measurements.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation >

GF42.31-P-0001-01A Brake Assist (BAS): Driver Information > Page 78

C 230K (202.024) L4-2.3L SC (111.975) (2001)

^ Learning algorithm: calculation of vehicle deceleration for adaptation of triggering threshold to different braking system conditions.
^

Threshold: this is calculated from the basic threshold (vehicle identification values), vehicle speed, brake pedal speed and the values from thelearning algorithm.

If the calculated values exceed the specified threshold, BAS activation is initiated.
BAS activation is interrupted immediately following a signal from the BAS release switch.

Safety circuit

The task of the safety circuit is to detect faulty signals in the control unit and faults in the electrical cabling system.
The following components are monitored continuously:

^ BAS solenoid valve (A7/7y1)
^ BAS diaphragm travel sensor (A7/7b1)
^ BAS release switch (A7/7s1) and
^ stop lamp switch (S9/1).

If a fault is detected, the system switches off. This is indicated to the driver by switching on the indicator lamp:^

BAS, BAS/ETS, BAS/ASR or BAS/ESP indicator lamp (A1 e39, e49, e48 or e47).

^ In models 203, 209, 215, 220 via the multifunction display (A1p13).
In addition, a fault code is stored in the control unit.

The safety circuit also constantly monitors the battery voltage. If the voltage falls below 10 V or exceeds 16-18 V, the system is also switched off untilthe voltage returns to the specified range.

GF42.31-P-4500A BAS Control Unit, Location/Task/Function

GF42.31-P-4500A BAS control unit, location/task/function

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Page 79

Electronic Brake Control Module: Service and Repair

For model name/model number cross reference refer to Model Designation Table. See: Application and IDNOTE:
Removal
NOTE:

^

The Brake Assist System control module is contained within the ESP control module on vehicles with Electronic Stability Program (BAS) (ESP)

^ The sealing ring of the diaphragm travel sensor may be sucked into brake booster if vacuum is present
^ If this is the case, the brake booster must be replaced.

1. Operate the brake pedal several times until the vacuum in the brake booster is reduced2. Disconnect connector of control module (16a)3. Disconnect BAS release switch/solenoid valve connector (A7/7x2)4. Disconnect BAS diaphragm travel sensor connector (A7/7xl)5. Disconnect BAS control module (N48) from mounting.

Installation

6. Install in reverse order, noting the following:

- Ensure control module (N48) is properly located in mounting

- Control parameter setting of BAS control module is performed automatically by engine control module, after engine start.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: > P-42_45-105

> Mar > 09 > ABS/TCS - ESP Lamp ON/Codes C1401 Or C1405

Traction Control Module: Customer InterestABS/TCS - ESP Lamp ON/Codes C1401 Or C1405

Date: March 2, 2009
Order No.: P-B-42.45/105
Supersedes:
Group: 42

SUBJECT:All Model 202, 208, 210 Equipped with Code 472a (Electronic Stability Program)
ESP Indicator Lamp Illuminated / Fault Code C1401 or C1405

If you receive customer reports in the above model vehicles that the ESP indicator lamp is illuminated and fault code C1401 or C1405 is stored, performthe following to resolve.

Note:

This condition is only valid for ESP control units 0255456132, 0255456232, 0255456332, and 0255450832 with software 43/97 and 52/97.

1. Using STAR Diagnosis process fault codes C1401 and or C1405 via the guided tests.

2. If the guided tests provide no results, then replace the ESP control unit with a revised part. Refer to EPCnet for applicable part numbers.

Refer to WIS document AD42.45-P-1000AZ for model 210 with engines 112/113 and 606. Refer to WIS document AD42.45-P-1001AZ for model 210with engine 119.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer Interest for Traction Control Module: > P-42_45-77 >

Jul > 07 > ABS/TCS - ESP Lamp ON/Code C1142 Set

Traction Control Module: Customer InterestABS/TCS - ESP Lamp ON/Code C1142 Set

Date: July 17, 2007
Order No.: P-B-42.45/77
Supercedes:
Group: 42

SUBJECT:All Model 129, 140, 202, 208 an 210 Vehicles
Equipped with Electronic Stability Program (ESP) (CODE 472a)
ESP Indicator Lamp Illuminated / Fault code C1142

If you receive customer reports in the above model vehicles that the ESP indicator lamp is illuminated with fault code C1142 (lateral accelerationsensor) and that this condition followed any of the below

reported driving conditions, the fault code can be erased / ignored.

Note:

Do not submit warranty claims as there is not a manufacturing defect / failure.
^ Driving on high-bank curves.
^ Rear end collision.
^ Vehicle spins on a slippery road.
If none of the preceding situations occurred, process the fault code by following the diagnostic procedure contained within Star Diagnosis.
^ Model 129 with Engine 104, 113, 119, 120 - Refer to WIS document AD42.45-P-1001AZ
^ Model 140 - Refer to WIS document AD42.45-P-1001AZ
^ Model 210 with Engine 119 - Refer to WIS document AD42.45-P-1001AZ
^ Model 202 and 208 - Refer to WIS document AD42.45-P-1000AZ
^ Model 210 with Engine 112, 113, 606 - Refer to WIS document AD42.45-P-1000AZ

Note:

The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generatedon July 17, 2007. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Customer

Interest for Traction Control Module: > P-42_45-77 > Jul > 07 > ABS/TCS - ESP Lamp ON/Code C1142 Set > Page 92

C 230K (202.024) L4-2.3L SC (111.975) (2001)

In Case of Warranty, use the table.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control Module: > P

-42_45-105 > Mar > 09 > ABS/TCS - ESP Lamp ON/Codes C1401 Or C1405

Traction Control Module: All Technical Service BulletinsABS/TCS - ESP Lamp ON/Codes C1401 Or C1405

Date: March 2, 2009
Order No.: P-B-42.45/105
Supersedes:
Group: 42

SUBJECT:All Model 202, 208, 210 Equipped with Code 472a (Electronic Stability Program)
ESP Indicator Lamp Illuminated / Fault Code C1401 or C1405

If you receive customer reports in the above model vehicles that the ESP indicator lamp is illuminated and fault code C1401 or C1405 is stored, performthe following to resolve.

Note:

This condition is only valid for ESP control units 0255456132, 0255456232, 0255456332, and 0255450832 with software 43/97 and 52/97.

1. Using STAR Diagnosis process fault codes C1401 and or C1405 via the guided tests.

2. If the guided tests provide no results, then replace the ESP control unit with a revised part. Refer to EPCnet for applicable part numbers.

Refer to WIS document AD42.45-P-1000AZ for model 210 with engines 112/113 and 606. Refer to WIS document AD42.45-P-1001AZ for model 210with engine 119.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Control Module: > P

-42_45-77 > Jul > 07 > ABS/TCS - ESP Lamp ON/Code C1142 Set

Traction Control Module: All Technical Service BulletinsABS/TCS - ESP Lamp ON/Code C1142 Set

Date: July 17, 2007
Order No.: P-B-42.45/77
Supercedes:
Group: 42

SUBJECT:All Model 129, 140, 202, 208 an 210 Vehicles
Equipped with Electronic Stability Program (ESP) (CODE 472a)
ESP Indicator Lamp Illuminated / Fault code C1142

If you receive customer reports in the above model vehicles that the ESP indicator lamp is illuminated with fault code C1142 (lateral accelerationsensor) and that this condition followed any of the below

reported driving conditions, the fault code can be erased / ignored.

Note:

Do not submit warranty claims as there is not a manufacturing defect / failure.
^ Driving on high-bank curves.
^ Rear end collision.
^ Vehicle spins on a slippery road.
If none of the preceding situations occurred, process the fault code by following the diagnostic procedure contained within Star Diagnosis.
^ Model 129 with Engine 104, 113, 119, 120 - Refer to WIS document AD42.45-P-1001AZ
^ Model 140 - Refer to WIS document AD42.45-P-1001AZ
^ Model 210 with Engine 119 - Refer to WIS document AD42.45-P-1001AZ
^ Model 202 and 208 - Refer to WIS document AD42.45-P-1000AZ
^ Model 210 with Engine 112, 113, 606 - Refer to WIS document AD42.45-P-1000AZ

Note:

The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generatedon July 17, 2007. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Traction Control Module: > P-42_45-77 > Jul > 07 > ABS/TCS - ESP Lamp ON/Code C1142 Set > Page 102

C 230K (202.024) L4-2.3L SC (111.975) (2001)

In Case of Warranty, use the table.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > Page 103

Traction Control Module: Locations

GF42.40-P-4500-03C ASR V Control Module Arrangement

- with CODE (212a) Electronic traction system (ETS)

- with CODE (471a) Acceleration slip regulation (ASR)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Description and Operation > GF42.35-P-4500-01A Function of ETS Control Module

Traction Control Module: Description and OperationGF42.35-P-4500-01A Function of ETS Control Module

GF42.35-P-4500-01A Function Of ETS Control Module

- with CODE (212a) Electronic traction system (ETS)

To adapt to the various engine variants, manual or automatic transmission and different versions of the rear axle brake calipers, control modules must becoded with the Hand-Held Tester after installation in the vehicle variant concerned.
The ETS/SPS control module is divided up functionally as follows:

- Signal conditioning

- Logic section

- Safety circuit

- Additional functions

-

Signal conditioningThe following input signals are conditioned for the logic section:-

4 speed sensors

- Stop lamp switch, 4-pin

- Terminal 61

­Logic sectionThe conditioned input signals are processed in the logic section and converted into output signals.

The logic section is divided up functionally as follows:-

ETS control mode

- Starting-off control logic (manual transmission)

- Temperature monitoring

ETS control mode

The control mode for brake intervention on one side is recognized from the vehicle speed and ETS slip recognition between the left and right drivewheel.
Switching on condition: Speed difference between the left and right rear wheel > 4 km/h

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Description and Operation > GF42.35-P-

4500-01A Function of ETS Control Module > Page 106

C 230K (202.024) L4-2.3L SC (111.975) (2001)

Switching off condition: Speed difference between the left and right rear wheel=2 km/h below the switching-on threshold.
Speed range: 0-40 km/h
If the switching on condition is maintained above 40 km/h during an acceleration process, the control mode is continued up to max. 80 km/h.
The control mode for brake intervention on both sides is recognized from the vehicle speed/cornering and ETS slip recognition.
Switching on condition: Both rear wheels at least 2.8 km/h faster than the vehicle speed

- Cornering recognition: Speed difference between the left and right front wheel > 1 km/h

- speed range=15-80 km/h On period: max. 2 seconds

Starting-off control logic (manual transmission)

A starting-off logic circuit is integrated into the ETS/SPS control module to prevent the engine "stalling" due to brake intervention when starting off.

Depending on the vehicle speed,a mean minimum rear axle speed (= theoretical minimum engine speed) is specified which depends on the current ETSbrake control pressure.

If the mean rear axle speed is less than the specified mean minimum rear axle speed, pressure is reduced in the brake caliper. This control characteristicis varied on vehicles with manual transmission depending on the brake control pressure, mean rear axle speed and vehicle speed between 4 and 28 km/h.

Temperature monitoring

In an exceptional case, there is the risk of the rear wheel brakes overheating due to the dual load of the brake and the ETS control. For this reason therear wheel brake lining temperature is calculated continuously in the control module and when a calculated lining temperature is reached at the respectivebrake, no further ETS control is permitted until the temperature has reduced again.

If ETS control is prevented by temperature monitoring, the ETS malfunction indicator lamp comes on and remains on as if the ETS control waseffective, but for at least 5 seconds. The exceeded temperature is also retained in the fault memory.

Temperature calculation

The brake lining temperature is calculated separately on the left and right. It is determined without a temperature sensor. The following inputs areevaluated to calculate brake lining temperature.

- Vehicle speed

- Brake operation

- Calculated brake pressure from the ETS control logic

After-running mode after "ignition OFF"

Safety circuit

The task of the safety circuit is to recognize defective components in the control module and faults in the electrical wiring system.. After "ignition ON"and when a speed of 7 km/h is exceeded for the first time, system tests are carried out, which recognize faults at the solenoid valves, thehigh-pressure/return pump and the speed sensors. Constant monitoring is also carried out even during ABS or ETS control. If a fault is recognized, thesystem is switched off and this is displayed to the driver by ETS or ABS malfunction indicator lamp (A1e35 or A1e17) coming on. A fault code is alsostored in the control module. The safety circuit also constantly monitors battery voltage. If a voltage of 10.5 V is not achieved the system is also switchedoff until the voltage is again in the specified range.

Additional functions

Partial function of speed-sensitive power steering (models 140, 210)

The control module calculates the specified current for actuating the SPS P-valve (Y10) from the vehicle speed which is available internally and thestatus signal.

Wheel speed and speed status signal outputs

The voltage supply to the ETS/SPS control module is ensured by this operating mode even after "ignition OFF". As a result the brake lining temperaturescontinue to be calculated and cannot be reset by "ignition OFF/ignition ON". After ignition is switched off, the temperature continues to be calculateduntil a calculated temperature of 30 degrees C is reached, but for a maximum of 30 minutes. The voltage supply to the ETS/SPS control module is thenswitched off.

- Wheel speed output: The ETS/SPS control module supplies the current wheel speed of each wheel for systems which need a wheel speed signal.

­Speed status signal output: The ETS/SPS control module supplies the speed status signal for systems which need information on the current drivecondition (vehicle stationary, vehicle driving, speed sensor defective).

Indicator lamp actuation

The signals from the brake pad wear contacts and the parking brake are recorded as of control module version LK55/1. They are transmitted to theinstrument cluster via a serial data bus together with the signals for the ABS and ETS malfunction indicator and warning lamps and on vehicles withCAN connection on the instrument cluster via a CAN data bus.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Description and Operation > GF42.35-P-4500-01A Function of ETS Control Module > Page

107

Traction Control Module: Description and OperationGF42.45-P-4500-04B ESP Control Module, Task

GF42.45-P-4500-04B ESP Control Module, Task

- with CODE (472) Electronic Stability Program (ESP)

­Perform all brake control functions for ABS, ASR, and ESP. With ASR and ESP the data is exchanged with the engine/ transmission control unitsvia the CAN engine compartment (CAN-C).

- Influence the engine/transmission management in the case of an ESP control

- Contains the complete Brake Assist (BAS) control unit function

- Supplies other systems with the vehicle speed signal and wheel rpm signal (direct or via CAN).

-

Via the engine compartment CAN (CAN-C) supplies the instrument cluster (A1) with the signals for the ABS indicator lamp (A1e17), ESPwarning lamp (A1e41) (on model 163 ETS warning light (A1e36)) and for the BAS/ESP indicator lamp (A1e47) (except models 203, 209) or themultifunction display (A1p13) (except models 129, 163, 170).

-

Via the engine compartment CAN (CAN-C) supplies the instrument cluster (A1) with the signal for the brake pad wear warning lamp (A1e6)(except model 209) and brake fluid and parking brake warning lamp (A1e7) (models 129, 168, 170, 202, 203, 208, 209, 210), brake fluid warninglamp, parking brake and brake power distribution (model 163).

­On vehicles with CODE (213a) speed-sensitive power steering (PML) the ESP, SPS and BAS [ESP, PML and BAS] control unit (N47-5) (models129, 210) also contains the electronics and control logic required for this.

­The ESP and BAS control unit (N47-5) (model 203) contains the software for CODE (477) tire pressure loss warning (RDW). It detects a pressureloss via a comparison of wheel speeds and displays it in the multifunction display (A1p13) (except models 129, 163, 170) an.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Description and Operation > GF42.35-P-4500-01A Function of ETS Control Module > Page

108

Traction Control Module: Description and OperationGF42.45-P-4500C Location / Task / Function of ESP Control Module

GF42.45-P-4500C Location / Task / Function Of ESP Control Module

- with CODE (472a) Electronic Stability Program (ESP)