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SCORPIO Vlx

DIAGNOSTIC MANUAL - ABS

Revision 1
MAN-00030
922BRKR011107EN-DM

CONFIDENTIAL
• ONLY FOR INTERNAL CIRCULATION WITHIN RELEASED BY :
M&M AUTHORISED DEALERS & SERVICE CENTRES
• PASSING ON TO THRID PARTY IS NOT PERMITTED
• ALWAYS CHECK FOR THE LATEST VERSION
TECHNICAL PUBLICATION CELL
MAHINDRA & MAHINDRA LTD
Rev 1 – NOVEMBER 2007

The reproduction, translation, transmission, in part of whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. © 2007 Mahindra & Mahindra Ltd
MAN-00030
922BRKR011107EN-DM

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-00030
922BRKR011107EN-DM

Automotive Sector
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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MAN-00030
922BRKR011107EN-DM

Automotive Sector

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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MAN-00030
922BRKR011107EN-DM

Automotive Sector
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
Dump valve Front Left Solenoid -Driver
1819 20-21
Shorted
Dump valve Front Right Solenoid -Driver
181A 20-21
Shorted
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
Valve Solenoid-ISO Front Left- Over
1822 24-25
temperature
Valve Solenoid-ISO Front Right- Over
1823 26-27
temperature
1824 Valve Solenoid-ISO Rear- Over temperature 26-27
1825 Valve Solenoid - Dump Front Left - Over 26-27
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MAN-00030
922BRKR011107EN-DM

Automotive Sector
Temperature
Code Description Page #
Valve Solenoid - Dump Front Right - Over
1826 26-27
Temperature
Valve Solenoid - Dump Rear - Over
1827 26-27
Temperature
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
Base brake fluid sensor – open
1832 38-39
Base brake failure
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
Microprocessor HET Periodic Interrupt
1839 46-47
Failure.
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
Communication Missing Transfer Case
1842 58-59
Status
1843 Communication General K-Line Fault 60-61

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MAN-00030
922BRKR011107EN-DM

Automotive Sector

Circuit Diagram –

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MAN-00030 1800
922BRKR011107EN-DM
1801
Automotive Sector
1802
ABS Trouble Shooting

Description –

DTC Error Effect of DTC


Description

1800 WSS Open – Front Left ABS Lamp : ON


Parking Brake Lamp : OFF
1801 WSS Open – Front Right
ABS Status : Partially Active
DRP Status : Fully Active
1802 WSS Open – ABS Lamp : ON
Rear Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive

Performance Condition Possible Causes

Proper Performance:
• Defective wheel speed sensor
Under normal condition the Wheel • Defective wiring harness to wheel speed
speed signal are proportional and sensor
can be used for the ABS & DRP • Defective Microprocessor or Printed
functionality Circuit Board in the ECU.
• Electrical Pins bent of ECU or WSS

Malfunction:

WSS output signals out-of-range

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MAN-00030 1800
922BRKR011107EN-DM
1801
Automotive Sector
1802
Trouble Shooting –
Switch Off the Ignition

Remove EHCU connector (H-3) & sensor connector


(FL: H-5; FR: H-6; RR: H-7).

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 Change the wiring harness.


either in ECU or WSS. (Wiring Harness Part # -
Refer Table A)

Change the respective WSS as


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

Connect the wiring harness to


Sensors & EHCU.
Switch on the ignition &
check if the error is healed.

If Yes If No

The The problem is with ECU. Switch ignition


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

After replacement of the required component, connect the wiring harness to Sensor
& EHCU.
Switch on the Ignition & confirm if the error is healed.
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Page 9 of 62
MAN-00030 1803
922BRKR011107EN-DM
1804
Automotive Sector
1805
ABS Trouble shooting

Description –

DTC Error Effect of DTC


Description

1803 WSS Short – Front Left ABS Lamp : ON


Parking Brake Lamp : OFF
1804 WSS Short – Front
Right ABS Status : Partially Active
DRP Status : Fully Active

1805 WSS Short – ABS Lamp : ON


Rear Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive

Performance Condition Possible Causes

Proper Performance:
• Defective wheel speed sensor
Under normal condition the Wheel • Defective wiring harness to wheel speed
speed signal are proportional and sensor
can be used for the ABS & DRP • Defective Microprocessor or Printed
functionality Circuit Board in the ECU.
• Electrical Pins bent of ECU or WSS
Malfunction:

WSS output signals out-of-range

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MAN-00030 1803
922BRKR011107EN-DM
1804
Automotive Sector
1805

Trouble Shooting –
Switch Off the Ignition

Remove EHCU connector (H-3) & sensor connector


(FL: H-5; FR: H-6; RR: H-7).

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 Change the wiring harness.


either in ECU or WSS. (Wiring Harness Part # - Refer
Table A)

Change the respective WSS as per


the DTC codes.
(Front WSS Part # - Refer Table A
Rear WSS Part # - Refer Table A)

Connect the wheel wiring


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

If Yes If No

The The problem is with ECU. Switch Off


problem is ignition; Detach EHCU connector;
Replace the ECU Assembly.
with WSS.
(ECU assembly 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.
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MAN-00030
922BRKR011107EN-DM 1806

Automotive Sector 1807

1808

ABS Trouble shooting

Description –

DTC Error Effect of DTC


Description

1806 WSS Missing – Front ABS Lamp : ON


Left Parking Brake Lamp : OFF
1807
WSS Missing – Front ABS Status : Partially Active
Right DRP Status : Fully Active

1808 WSS Missing – 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 • Wheel speed sensor not mounted
speed signal are proportional and correctly.
can be used for the ABS & DRP • Wheel speed sensor to toner-wheel gap
functionality out of tolerance.
• Excessive run-out at vehicle level on
Malfunction: toner ring teeth

WSS output signals out-of-range

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Page 12 of 62
MAN-00030
922BRKR011107EN-DM
1806

Automotive Sector 1807

1808
Trouble Shooting –

Switch Off the Ignition

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.

If Yes Any damage/ visual defect If No

Replace the affected Remove the wheel


Components assembly. Check the
bearing & races.

Reassemble.

Switch on the ignition,


clear all errors.
Switch on the
ignition, clear all
errors.

If complaint re-occurs then


only replace the affected
toner wheel assembly.

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MAN-00030 1809
922BRKR011107EN-DM
180A
Automotive Sector
180B

ABS Trouble shooting

Description –

DTC Error Effect of DTC


Description

1809 WSS Erratic – Front ABS Lamp : ON


Left Parking Brake Lamp : OFF
WSS Erratic – Front ABS Status : Partially Active
180A Right DRP Status : Fully Active

180B WSS Erratic – 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 • Wheel speed sensor not mounted
speed signal are proportional and correctly.
can be used for the ABS & DRP • Missing Tooth or Teeth on the wheel
functionality speed sensor tone – wheel.
• Excessive run-out at vehicle level on
Malfunction: toner ring teeth

WSS output signals out-of-range

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Page 14 of 62
MAN-00030 1809
922BRKR011107EN-DM
180A
Automotive Sector
180B

Trouble Shooting –

Switch Off the Ignition

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.

If Yes Any damage/ visual defect If No

Replace the affected Remove the wheel


Components assembly. Check the
bearing & races.

Reassemble.

Switch on the ignition,


clear all errors.
Switch on the
ignition, clear all
errors.

If complaint re-occurs then


only replace the affected
toner wheel assembly.

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Page 15 of 62
MAN-00030 180C
922BRKR011107EN-DM
180D
Automotive Sector
180E

ABS Trouble shooting

Description –

DTC Error Effect of DTC


Description

180C WSS Drop Out – Front ABS Lamp : ON


Left Parking Brake Lamp : OFF
180D
WSS Drop Out –Front ABS Status : Partially Active
Right DRP Status : Fully Active

180E WSS Drop Out – 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 • Defective wheel speed sensor


speed signal are proportional and • Defective harness to wheel speed sensor
can be used for the ABS & DRP • Defective terminals of WSS or wiring
functionality harness
• Wheel speed sensor not mounted
correctly.
Malfunction:

WSS output signals out-of-range

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MAN-00030 180C
922BRKR011107EN-DM
180D
Automotive Sector
180E

Trouble Shooting –

Switch Off the Ignition

Replace Wheel speed sensor & Check If suspect

Replace the WSS


If found OK wiring harness
suitably.

(Wiring harness Part


Check WSS mounting.
# - Refer Table A)
Tighten to the specified
torque (20 ± 3 Nm).

Check Toner wheel Visually for


Damaged/Missing tooth (No. of
Teeth=60)

If found faulty

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.

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Page 17 of 62
MAN-00030 180F
922BRKR011107EN-DM

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Effect of DTC


Description

180F Mismatch Tyre ABS Lamp : ON


Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive

Performance Condition Possible Causes

Proper Performance:

Under normal condition the Wheel • Anything that generates consistent


speed signal are proportional and differences in apparent wheel
can be used for the ABS & DRP rotational speed.
functionality • Significantly different size tyres
installed on the vehicle.
• Rear toner wheel come out of the
diff case or free to rotate on diff case
Malfunction: assembly.

High variation in wheel speed

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Page 18 of 62
MAN-00030 180F
922BRKR011107EN-DM

Automotive Sector

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.

Switch Off the Ignition

Check toner wheel visually for damaged / missing


tooth / teeth. (No. of teeth 60)

If found faulty If found OK

Replace the disc & toner wheel Check if only


assembly on the front and toner wheel recommended tyres
on the rear. are installed on the
(Disc & toner wheel assembly Part # - vehicle.
Refer Table A
Differential Case & Rear Toner wheel
Assembly Part # - Refer Table A )
If No

Replace with the


recommended size tyres.

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

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Page 19 of 62
MAN-00030 1810
922BRKR011107EN-DM
1811
1812
Automotive Sector
1813
1814
1815
ABS Trouble shooting
1816
Description – 1817
1818
DTC Error Description Effect of DTC
1819
1810 Solenoid Open–ISO Front ABS Lamp : ON 181A
Left Parking Brake Lamp : OFF 181B
1811 Solenoid Open–ISO Front ABS Status : Partially Active
Right
DRP Status : Fully Active

1812 Solenoid Open – ISO Rear ABS Lamp : ON;


Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive
1813 Solenoid Open–Dump Front ABS Lamp : ON
Left Parking Brake Lamp : OFF
1814 Solenoid Open–Dump Front ABS Status : Partially Active
Right
DRP Status : Fully Active

1815 Solenoid Open – Dump ABS Lamp : ON


Rear Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive
1816 ISO Front Left Solenoid - ABS Lamp : ON
Driver Shorted Parking Brake Lamp : ON
1817 ISO Front Right Solenoid - ABS Status : Inactive
Driver Shorted
DRP Status : Inactive
ISO Rear Solenoid -Driver
1818
Shorted
Dump valve Front Left
1819 Solenoid -Driver Shorted
181A Dump valve Front Right
Solenoid -Driver Shorted

181B Dump valve Rear Solenoid


-Driver Shorted
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MAN-00030 1810
922BRKR011107EN-DM
1811
1812
Automotive Sector
1813
Performance Condition Possible Causes 1814
1815
Proper Performance:
1816
Under normal condition the Wheel • Defective Solenoid 1817
speed signal are proportional and • Defective Solenoid Driver FET 1818
can be used for the ABS & DRP • Defective Microprocessor or Printed
functionality 1819
circuit Board in the ECU.
• Anything that keeps solenoid 181A
feedback voltage low when the 181B
solenoid is not energized.
Malfunction:

HCU or ECU malfunction.

Trouble Shooting –

Switch Off the Ignition

Wait for 60 seconds.

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

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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Page 21 of 62
MAN-00030
922BRKR011107EN-DM
181C

Automotive Sector 181D

181E
ABS Trouble shooting 181F

1820
Description –
1821

DTC Error Description Effect of DTC

181C Valve solenoid ISO valve ABS Lamp : ON


Front Left Parking Brake Lamp : OFF
Valve solenoid ISO valve ABS Status : Partially Active
181D Front Right DRP Status : Fully Active

181E Valve solenoid ISO valve - ABS Lamp : ON


Rear Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive
181F Valve Solenoid Dump–Front ABS Lamp : ON
Left-Shorted Parking Brake Lamp : OFF
Valve Solenoid Dump–Front ABS Status : Partially Active
1820 Right-Shorted DRP Status : Fully Active
1821 Valve Solenoid –Rear Dump- ABS Lamp : ON
Short Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive

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MAN-00030
922BRKR011107EN-DM

181C
Automotive Sector
181D

181E
Performance Condition Possible Causes
181F
Proper Performance:
1820
Under normal condition the Wheel • Solenoid shorted
speed signal are proportional and can 1821
• Defective Solenoid Driver FET
be used for the ABS & DRP • Defective Microprocessor or
functionality Printed circuit Board in the ECU.
• Anything that keeps the solenoid
voltage high when the solenoid is
supposed to be energized.
Malfunction:

HCU or ECU malfunction.

Trouble Shooting –

Switch Off the Ignition

Wait for 60 seconds.

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

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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Page 23 of 62
MAN-00030
922BRKR011107EN-DM
1822
Automotive Sector
1823

1824

1825
ABS Trouble shooting
1826

Description – 1827

DTC Error Description Effect of DTC

1822 Valve Solenoid-ISO Front ABS Lamp : ON


Left- Over temperature Parking Brake Lamp : OFF
ABS Status : Partially Active
1823 Valve Solenoid-ISO Front
Right- Over temperature DRP Status : Fully Active

1824 Valve Solenoid-ISO Rear- ABS Lamp : ON


Over temperature Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive

1825 Valve Solenoid - Dump Front ABS Lamp : ON


Left - Over Temperature Parking Brake Lamp : OFF
ABS Status : Partially Active
1826 Valve Solenoid - Dump Front
Right - Over Temperature DRP Status : Fully Active

1827 Valve Solenoid - Dump Rear - ABS Lamp : ON


Over Temperature Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status : Inactive

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Page 24 of 62
MAN-00030 1822
922BRKR011107EN-DM
1823
Automotive Sector
1824
Performance Condition Possible Causes 1825

Proper Performance: 1826

Under normal condition the Wheel • Anything that causes the solenoid 1827
speed signal are proportional and can to be active for a long period of
be used for the ABS & DRP time.
functionality

Malfunction:

HCU malfunction.

Trouble Shooting –

Switch Off the Ignition

Allow enough time interval for


solenoid to get cooled. (Approx. 10
Min.)

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

If not healed then replace the HCU.


(HCU Assembly Part # - Refer Table A)

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Page 25 of 62
MAN-00030 1828
922BRKR011107EN-DM

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC

1828 Power Switch - Open ABS Lamp : ON; Parking Brake Lamp :
ON
ABS Status : Inactive
DRP Status : Inactive

Performance Condition Possible Causes

Proper Performance:

Under normal condition the Wheel • Defective Power Switch.


speed signal are proportional and • Defective Microprocessor port
can be used for the ABS & DRP or printed circuit board in the
functionality ECU.

Malfunction:

ECU malfunction

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Page 26 of 62
MAN-00030
922BRKR011107EN-DM 1828

Automotive Sector

Trouble Shooting –

Switch Off the Ignition

Wait for 60 seconds.

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

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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Page 27 of 62
MAN-00030 1829
922BRKR011107EN-DM

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC

1829 Power Switch - Shorted ABS Lamp : ON


Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active

Performance Condition Possible Causes

Proper Performance:

Under normal condition the Wheel • Defective Power Switch.


speed signal are proportional and • Defective Microprocessor port
can be used for the ABS & DRP or printed circuit board in the
functionality ECU.

Malfunction:

ECU malfunction

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Page 28 of 62
MAN-00030 1829
922BRKR011107EN-DM

Automotive Sector

Trouble Shooting –

Switch Off the Ignition

Wait for 60 seconds.

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

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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Page 29 of 62
MAN-00030 182A
922BRKR011107EN-DM

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC

182A ABS Motor - Open ABS Lamp : ON


Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active

Performance Condition Possible Causes

Proper Performance:

Under normal condition the Wheel • Defective Motor (Open motor


speed signal are proportional and winding).
can be used for the ABS & DRP • Defective Motor Driver
functionality. (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.
Malfunction:

Motor malfunction

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Page 30 of 62
MAN-00030
922BRKR011107EN-DM 182A

Automotive Sector

Trouble Shooting –
Switch Off the Ignition

Remove wiring harness.

Check the battery + & ground connections to the


ECU mating connector terminals (Pin No. 31 & 45)

If OK If Not OK

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

Connect the wiring harness.

Switch on the Ignition & check if


the error is healed.

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.

Switch on the Ignition &


check if the error is healed.

If the error is healed; switch


off the ignition
All copyrights reserved by & replace the Switch on the Ignition & check if the error is healed.
ECU assembly with old ECU.
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Page 31 of 62
MAN-00030
922BRKR011107EN-DM 182B

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC

182B ABS Motor - Locked ABS Lamp : ON


Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active

Performance Condition Possible Causes

Proper Performance:

Under normal condition the Wheel • Defective Motor (Locked/ seized)


speed signal are proportional and • Defective Motor Driver
can be used for the ABS & DRP (Always On )
functionality • 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
Malfunction: winding of the coasting motor.

Motor malfunction

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Page 32 of 62
MAN-00030
922BRKR011107EN-DM 182B

Automotive Sector

Trouble Shooting –

Switch Off the Ignition

Remove wiring harness.

Check the battery + ve & ground connections to the


ECU mating connector terminals (Pin No. 31 & 45)

If OK If Not OK

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

Connect the wiring harness.

Switch on the Ignition & check if


the error is healed.

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.

Switch on the Ignition &


check if the error is healed.

If the error is healed; switch


off the ignition & replace the
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Switch on the Ignition & check if the error is healed.
ECU &assembly
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Page 33 of 62
MAN-00030
922BRKR011107EN-DM 182C

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC

182C ABS Motor – Open Fuse ABS Lamp : ON


Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active

Performance Condition Possible Causes

Proper Performance:

Under normal condition the Wheel • Blown or Removed Motor Supply


speed signal are proportional and Fuse
can be used for the ABS & DRP • Faulty Wheel Harness
functionality

Malfunction:

Motor malfunction

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Page 34 of 62
MAN-00030 182C
922BRKR011107EN-DM

Automotive Sector

Trouble Shooting –

Switch Off the Ignition

Check Motor Supply Fuse

If Not OK

Replace Fuse

Switch on Ignition &


check if error is healed.

If Not

Switch off the Ignition.

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.

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Page 35 of 62
MAN-00030
922BRKR011107EN-DM
182D

Automotive Sector 182E

182F

1830
ABS Trouble shooting
1831

Description –

DTC Error Description Effect of DTC

182D Microprocessor ROM Failure ABS Lamp : ON


Parking Brake Lamp : ON
182E Microprocessor RAM Failure
ABS Status : Inactive
182F Microprocessor Stack Failure DRP Status : Inactive
1830 Microprocessor Schedule
Overrun Failure

Microprocessor External
1831 watchdog Failure

Performance Condition Possible Causes

Proper Performance:

Effective ABS / DRP operation. (No • Defective Microprocessor


wheel lock)

Malfunction:

Defective microprocessor

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Page 36 of 62
MAN-00030 182D
922BRKR011107EN-DM
182E
Automotive Sector
182F

1830
Trouble Shooting –
1831

Switch Off the Ignition

Wait for 60 seconds.

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

If No

Replace The ECU Assembly. (ECU Assembly


Part # - Refer Table A)

Connect the wiring harness. Switch on the Ignition &


check if the error is healed.

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Page 37 of 62
MAN-00030
922BRKR011107EN-DM 1832

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC

1832 Base brake fluid sensor – ABS Lamp : ON


open Parking Brake Lamp : ON
Base brake failure ABS Status : Partially active
DRP Status : Partially active

Performance Condition Possible Causes

Proper Performance:
• Parking Brake Failure
Enough fluid availability for • Low brake fluid level sensor
effective braking & ABS / DRP reading
functionality. • Disconnected sensor
• Faulty wiring harness
• Faulty sensor

Malfunction:

Brake fluid unavailable

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Page 38 of 62
MAN-00030
922BRKR011107EN-DM
1832
Automotive Sector

Trouble Shooting –

Switch Off the Ignition

Check if Hand brake is ON

If Yes If No

Release the Hand Brake. Check if the Brake Fluid


Level is above the
Minimum Level marked
in the reservoir.

If Yes If No

Check the Fluid Top up the


Level Switch. Brake Fluid.

If found faulty

Replace the switch.


(FLWI Switch Part # -
Refer Table A)

Find the reason


for leak- correct if
required.

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

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Page 39 of 62
MAN-00030
922BRKR011107EN-DM

Automotive Sector 1833

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC

1833 Ignition Voltage Supply low ABS Lamp : ON


Parking Brake Lamp : OFF
ABS Status : Fully Active
DRP Status : Fully Active

Performance Condition Possible Causes

Proper Performance:

Availability of sufficient ignition • Ignition Voltage supply is


voltage for Effective ABS / DRP providing low Ignition Voltage
operation. levels.
• Defective cables
• Defective Printed Circuit Board in
ECU.
Malfunction:

This fault is set if the Ignition


Voltage Supply is less than 10V for
100 msec.

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Page 40 of 62
MAN-00030
922BRKR011107EN-DM

Automotive Sector
1833

Trouble Shooting –

Switch Off the Ignition

Check Battery Voltage.

If required Charge
the Battery.

If Not

Switch on the Ignition & check if the error


is healed.

Remove wiring Harness & check for any


Short Circuit in the Harness.

If found Faulty.

Replace the wiring Harness. (Wiring


Harness Part # - Refer Table A)

Switch on the Ignition & check if the error


is healed.

If Not

Replace the ECU Assembly. (ECU Assembly


Part # - Refer Table A)

Connect the wiring harness. Switch on the


Ignition & check if the error is healed.

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Page 41 of 62
MAN-00030 1834
922BRKR011107EN-DM

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC

1834 Ignition Voltage Supply High ABS Lamp : ON


Parking Brake Lamp : OFF
ABS Status : Fully Active
DRP Status : Fully Active

Proper Performance :

Availability of correct ignition voltage for Effective ABS / DRP operation

Performance Condition Possible Causes

Proper Performance:

Availability of sufficient ignition • Ignition Voltage supply is


voltage for Effective ABS / DRP providing High Ignition Voltage
operation. levels.
• Defective Printed Circuit Board in
ECU.
Malfunction:

This fault is set if the Ignition


Voltage is greater than 16V for
100 msec.

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Page 42 of 62
MAN-00030
922BRKR011107EN-DM 1834

Automotive Sector

Trouble Shooting –

Switch Off the Ignition

Remove wiring Harness & check for any


Short Circuit in the Harness.

If found Faulty.

Replace the wiring Harness.


( Wiring Harness Part # Refer Table A)

Switch on the Ignition & check if the error


is healed.

If Not

Replace the ECU Assembly. (ECU Assembly


Part # - Refer Table A)

Connect the wiring harness. Switch on the


Ignition & check if the error is healed.

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Page 43 of 62
MAN-00030 1835
922BRKR011107EN-DM

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC

1835 Ignition Voltage Supply – ABS Lamp : ON


Excessive High Parking Brake Lamp : ON
ABS Status : Inactive
DRP Status: Inactive.

Performance Condition Possible Causes

Proper Performance:
• Ignition Voltage supply is
Availability of sufficient ignition providing excessively High Ignition
voltage for Effective ABS / DRP Voltage levels.
operation. • Defective Printed Circuit Board in
ECU.
Malfunction:

This fault is set if the Ignition


Voltage is greater than 19.5V for
15 msec.

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Page 44 of 62
MAN-00030
922BRKR011107EN-DM 1835

Automotive Sector

Trouble Shooting –

Switch Off the Ignition

Remove wheel Harness & check for any


Short Circuit in the Harness.

If found Faulty.

Replace the wiring Harness. (Wiring


Harness Part # - Refer Table A)

Switch on the Ignition & check if the error


is healed.

If Not

Replace the ECU Assembly. (ECU Assembly


Part # - Refer Table A)

Connect the wiring harness. Switch on the


Ignition & check if the error is healed.

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Page 45 of 62
MAN-00030
922BRKR011107EN-DM

1836
Automotive Sector
1837

1838
ABS Trouble shooting 1839

183A
Description –
183B

DTC Error Description Effect of DTC


1836 Microprocessor Unimplemented ABS Lamp : ON
Interrupt. Parking Brake Lamp : ON
1837 Microprocessor Unexpected ABS Status : Inactive
Exception.
DRP Status : Inactive
Microprocessor Solenoid Timeout
1838 Failure.

1839 Microprocessor HET Periodic


Interrupt Failure.

183A Microprocessor SPI Failure.


183B Microprocessor SPI Queue ABS Lamp : ON
Overflow Parking Brake Lamp : OFF
ABS Status : Fully Active
DRP Status : Fully Active

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Page 46 of 62
MAN-00030
922BRKR011107EN-DM

Automotive Sector
Performance Condition Possible Causes
1836
Proper Performance:
1837
Effective ABS / DRP operation. (No wheel • Defective Microprocessor
lock) 1838

1839
Malfunction: 183A

Defective microprocessor 183B

Trouble Shooting –

Switch Off the Ignition

Wait for 60 seconds.

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

If No

Replace The ECU Assembly. (ECU


Assembly Part # - Refer Table A)

Connect the wiring harness. Switch on the Ignition &


check if the error is healed.

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Page 47 of 62
MAN-00030
922BRKR011107EN-DM
183C

Automotive Sector 183D

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC


183C Brake Pedal Switch Failed – Never ABS Lamp : ON
Active Parking Brake Lamp : OFF
ABS Status : Fully Active
183D Brake Pedal Switch Failed–Always DRP Status : Fully Active
Active

Performance Condition Possible Causes

Proper Performance:

Brake switch produces output based on • Defective Brake Switch


Pedal input • Defective wiring Harness
• Defective Printed Circuit Board
or Microprocessor in ECU.
Malfunction:

Defective signal

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Page 48 of 62
MAN-00030 183C
922BRKR011107EN-DM
183D
Automotive Sector

Trouble Shooting –

Switch Off the Ignition

Check Brake Switch

If found Faulty

Replace Brake Switch. (Brake


Switch Part # - Refer Table A)

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

If Not

Remove ECU mating connector & check Brake Switch


input.

If found Faulty

Replace wiring harness.


(Wiring Harness Part # - Refer
Table A)

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

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.

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Page 49 of 62
MAN-00030
922BRKR011107EN-DM 183E

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC


183E Tooth count Failure (Out of Range) ABS Lamp : ON
Parking Brake Lamp : OFF
ABS Status : Fully Active
DRP Status : Fully Active

Performance Condition Possible Causes

Proper Performance:

Under normal condition the Wheel speed • ECU NVRAM corruption


signal are proportional and can be used for • Incorrect Tooth Count
the ABS & DRP functionality ( No wheel • Tooth Count not programmed.
lock)

Malfunction:

Defective signal

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Page 50 of 62
MAN-00030
922BRKR011107EN-DM 183E

Automotive Sector

Trouble Shooting –

Switch off the Ignition.

Wait for 60 seconds.

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

If No

Use the Diagnostic tool &


Re-flash the ABS EHCU
using VIN no. of vehicle

Switch Off the Ignition.

Wait for 60 seconds.

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

If Not

Replace the ECU Assembly.


(ECU Assembly Part # - Refer Table A)

Connect the wiring harness. Switch on the Ignition &


check if the error is healed.

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Page 51 of 62
MAN-00030
922BRKR011107EN-DM 183F

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC


183F Tyre Size Failure ( Mismatch/ out of ABS Lamp : ON
range) Parking Brake Lamp : OFF
ABS Status : Fully Active
DRP Status : Fully Active

Performance Condition Possible Causes

Proper Performance:

Under normal condition the Wheel speed • NVRAM corruption


signal are proportional and can be used for • Incorrect Tyre Size
the ABS & DRP functionality ( No wheel • Tyre Size not programmed.
lock)

Malfunction:

Defective signal

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Page 52 of 62
MAN-00030
922BRKR011107EN-DM 183F

Automotive Sector

Trouble Shooting –

Switch off the Ignition.

Wait for 60 seconds.

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

If Not

Use the Diagnostic tool &


enter Tyre Size (M1 / N1)

Switch off the Ignition.

Wait for 60 seconds.

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

If Not

Replace the ECU Assembly.


( ECU Assembly Part # - Refer Table A)

Connect the wiring harness. Switch on the Ignition &


check if the error is healed.

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Page 53 of 62
MAN-00030 1840
922BRKR011107EN-DM

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC


1840 Emission Rollers Mode Active ABS Lamp : FLASH
Parking Brake Lamp : FLASH
ABS Status : Inactive
DRP Status : Inactive

Performance Condition Possible Causes

Proper Performance:
• Emission Rollers Test is Active
This Message appears when EOL (End of • Incorrect communication bus
Line) test is running. message

Malfunction:

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Page 54 of 62
MAN-00030 1840
922BRKR011107EN-DM

Automotive Sector

Trouble Shooting –

This Message appears when EOL test is running.

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Page 55 of 62
MAN-00030 1841
922BRKR011107EN-DM

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC


1841 Invalid Drive-train ABS Lamp : ON
configuration Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active

Performance Condition Possible Causes

Proper Performance:

Proper input to ECU on Drive-train • NVRAM corruption


status / Drive mode configuration • This fault will be set if the drive-
ensures effective ABS / DRP train configuration value stored in
functionality ( No wheel lock) 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.
Malfunction:

Defective signal

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Page 56 of 62
MAN-00030
922BRKR011107EN-DM 1841

Automotive Sector

Trouble Shooting –

Switch off the Ignition.

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 No If Yes

Replace the ECU Assembly. Remove it.


( ECU Assembly Part # - Refer
Table A)

Connect the wiring harness. Switch on the Ignition &


check if the error is healed.

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Page 57 of 62
MAN-00030
922BRKR011107EN-DM 1842

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC


1842 Communication Missing ABS Lamp : ON;
Transfer Case Status Parking Brake Lamp : OFF
ABS Status : Partially Active
DRP Status : Fully Active

Performance Condition Possible Causes

Proper Performance:

Proper input to ECU on Drive-train • NVRAM corruption


status / Drive mode configuration • This fault will be set if the drive-
ensures effective ABS / DRP train configuration value stored in
functionality ( No wheel lock) 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
Malfunction:

Defective signal

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Page 58 of 62
MAN-00030 1842
922BRKR011107EN-DM

Automotive Sector
Performance Condition Possible Causes

Malfunction; out-of-range

This fault will be set if the drive • Communication Bus failure


train configuration in NVRAM is set • Drive Mode Data Unit failure
to 4WD & ECU does not receive a
Transfer Case Mode message via
comms within five seconds of
Ignition ON.

Trouble Shooting –

Switch off the Ignition.

Check whether correct flashing is done in


ABS EHCU

If No If Yes

Try Re-flashing, if it does not Check if DMD connection


work, Replace the ECU. (ECU is OK.
Assembly Part # - Refer Table

Connect the wiring harness. Switch Off Ignition & Switch ON


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

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Page 59 of 62
MAN-00030 1843
922BRKR011107EN-DM

Automotive Sector

ABS Trouble shooting

Description –

DTC Error Description Effect of DTC


1843 Communication General K- ABS Lamp : OFF
Line Fault Parking Brake Lamp : OFF
ABS Status : Fully Active
DRP Status : Fully Active

Performance Condition Possible Causes

Proper Performance:

Effective communication process in • This fault is set if the K – Line bus


the K-Line bus ensures effective ABS experiences errors in processing of
& DRP functionality ( No wheel lock) communications.
• Bad K – Line cable.
• Bad K – Line peripheral on the
Microprocessor in the ECU

Malfunction:

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Page 60 of 62
MAN-00030
922BRKR011107EN-DM 1843

Automotive Sector

Trouble Shooting –

Switch off the Ignition.

Check wiring harness.

If found OK If found Faulty

Replace the ECU Assembly. (ECU Replace the wiring Harness.


Assembly Part # - Refer Table A) (Wiring Harness Part # - Refer
Table A)

Connect the wiring harness. Switch on the Ignition &


check if the error is healed.

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Page 61 of 62