W203 C240 ESP/ABS/BAS Problem!

skymastor · 05-08-2009, 08:31 PM

Hi Guys,

I've had a check through the forums and cannot seem to pull up anything relating to an issue I now have with my C240. So, I thought I would throw it to the floor for comments and suggestions before I start to shell out more money!

Well, it all started 2 weekends ago when I fitted new front wheel bearings to my yr 2k W203 C240. I replaced all bearings, races and rubber seals. All went in fine without any hassle. When I came to drive the car, a funny noise came from somewhere which I could not identify (which I thought was the gearbox), the car would not go above 10kmph as it landed in limp mode! I was then stuck with a car making a funny unidentified noise, 10kph speed in limp mode and ABS/ESP/BAS faults flashing all over the place in the dash! I re-checked the work and all was in order. I was totally stumped!

In the end I was left with no other choice but to take it to a stealer. The guys there checked it out and found that the rubber seals in the bearing kits were the wrong type because they did not have a magnetic strip in them for the wheel sensors and this placed the car into limp mode because no motion was sensed in the front wheels. They replaced the seals and the car drives again.

However, after they had replaced the seals, they also found that the front two wheel sensors needed changing too. They did this and the faults with the ABS/ESP/BAS still persisted. The DAS system then told them that the ESP box on the ABS pump that housed the ESP, BAS and ABS control modules needed replacement too because the DAS/STAR told them! MB Part number for this that they gave is A203 545 17 32, with the original on my car being A203 545 16 32. The price for this was 950 euro!!! As it is now, the car runs, but when the brake is applied that funny noise that I could not identify actually comes from the ABS pump that holds the control unit that MB says replacement. The noise is the same noise that is made as if the ABS system is in normal operation if you brake on a loose surface and the ABS takes over! Then after 50kph, the ABS warning light comes on, ESP/BAS/ABS faults are shown in the display, the systems are then turned off, allowing me to drive without problem, but without ESP/BAS and ABS!!

After a 500 euro bill for what they had done, I took my car with all the remaining faults in the hope to buy this unit from a scrapers so that I could cure my problems. I bought a unit with the exact same part number as my original one fitted to the car (A203 545 16 32) and also from a newer build year, but low and behold, the same problems are there with the same funny noise and the ESP/BAS/ABS turing off after 50kmph!

I ran carsoft on my car and it tells me that the the problem with the Traction/ESP is only that the front right hand sensor (which is actually the front left as you sit in the car because carsoft locations are given from the front of the car looking at it!) is open circuit and the resistance is wrong and needs checking. Bearing in mind that both front left and right have been replaced! I run live data on the ABS/ESP and I get signals from the sensors which relate to the speed that I drive at and from this I assume that the sensors are giving the correct readings to the control unit and works fine if live data says so? I'm confused!

However, I cannot get a response from the ABS and BAS units when I run carsoft though!

So fella's, the story is, after putting a new ESP control unit on (second hand thou) as recommended by MB, I still have the same problems with the noise from the ABS pump and the ABS/ESP/BAS turning off after 50kph, so I would assume that the ESP control units are OK? Right? Also, I get no response from the ABS and BAS modules in carsoft so I dont know if this is normal or they are blown? Or if that are actually contained in the ESP control unit?

Does anyone have any ideas on what the problem is please? Any info is appreciated..

Oh, so you all know, I have run this through the suppliers of the parts and I am waiting if they will take responsibility on what happened to these electronic parts after fitting the wrong supplied wheel bearing seals.

Thanks in advance...

BlackC55 · 05-08-2009, 09:41 PM

I will have a think about this one.

its a bit tricky....

Diesel Benz · 06-08-2009, 06:15 AM

While experts are thinking, can you clarify did you change the ESP control unit only, not the whole ESP unit with the hydraulic part and specifically the electric motor? Motors wear out, mainly brushes, could the noise be from the motor.

The yaw rate and lateral acceleration sensor is calibrated to the ESP control unit. Now if you swapped unit but are using the old yaw sensor, your ESP cannot be working right (I would not expect fault codes though).

skymastor · 06-08-2009, 06:22 AM

I did exchange the ESP unit only, however, I did get the ABS block which it was attached to with the one from the scrappy but did not change this because MB said it was only the control unit and the block was fine. I did ask them and followed their advice. I will at the weekend change the block too.

Still does not explain why carsoft only says that one of the front sensors is open circuit but live data shows a speed pulse from all four and I get no response from the ABS and BAS modules!! Strange...

Thanks for the advice so far fellas.. Speak soon....

lynall · 06-08-2009, 07:30 AM

So its pointing to the control unit again, if you have a signal from all 4 yet the box cant see it, its got to be duff, be strange to have 2 duff ones though.

Seems even stranger that it was fine before wrong seals fitted. are you sure they havent damaged one of the sensors when fitting it?

What voltages are each sensor producing? when the wheel is spun at a steady speed.

Lynall

skymastor · 06-08-2009, 09:47 AM

I don't know what voltage the sensors are producing, but I do know that MB changed the fronts and replaced them with new ones. All through DAS/STAR... I know... Bizarre...

BlackC55 · 06-08-2009, 10:46 AM

I am sure there is another control unit for the esp.

skymastor · 06-08-2009, 11:38 AM

I would think so too, because the unit I replaced (A203 545 17 32) just says ESP on it, and I also get ABS, BAS as well as ESP faults showing in the display.

Does anyone actually know and can Identify where the ABS, BAS and ESP units are situated on my W203?

Thanks guys....

BlackC55 · 06-08-2009, 11:43 AM

Whats the first six numbers of your chassis?

skymastor · 06-08-2009, 12:03 PM

WDB2030612F

Cheers...

skymastor · 07-08-2009, 01:34 PM

Any other thoughts fella's

Diesel Benz · 07-08-2009, 02:55 PM

Quote:

Originally Posted by skymastor

Any other thoughts fella's

Did you sync your steering wheel angle sensor?

skymastor · 07-08-2009, 06:43 PM

If you mean full lock from side to side then yes I did..

BlackC55 · 07-08-2009, 08:29 PM

Give me a call tomorrow on 02392 570123 and I will have a look through Wis and try and guide you on the right path of what to do next.

skymastor · 08-08-2009, 03:10 AM

Hi BlackC55..

Thanks for your advice and help. I will call you tomorrow.

Kindest regards...

:-)

05-08-2009, 08:31 PM	#1
skymastor Hardcore MB Enthusiast Join Date: Dec 2006 Location: South Yorkshire & NRW Germany Car: C240 Avantgarde with AMG Styling Posts: 169	W203 C240 ESP/ABS/BAS Problem! Hi Guys, I've had a check through the forums and cannot seem to pull up anything relating to an issue I now have with my C240. So, I thought I would throw it to the floor for comments and suggestions before I start to shell out more money! Well, it all started 2 weekends ago when I fitted new front wheel bearings to my yr 2k W203 C240. I replaced all bearings, races and rubber seals. All went in fine without any hassle. When I came to drive the car, a funny noise came from somewhere which I could not identify (which I thought was the gearbox), the car would not go above 10kmph as it landed in limp mode! I was then stuck with a car making a funny unidentified noise, 10kph speed in limp mode and ABS/ESP/BAS faults flashing all over the place in the dash! I re-checked the work and all was in order. I was totally stumped! In the end I was left with no other choice but to take it to a stealer. The guys there checked it out and found that the rubber seals in the bearing kits were the wrong type because they did not have a magnetic strip in them for the wheel sensors and this placed the car into limp mode because no motion was sensed in the front wheels. They replaced the seals and the car drives again. However, after they had replaced the seals, they also found that the front two wheel sensors needed changing too. They did this and the faults with the ABS/ESP/BAS still persisted. The DAS system then told them that the ESP box on the ABS pump that housed the ESP, BAS and ABS control modules needed replacement too because the DAS/STAR told them! MB Part number for this that they gave is A203 545 17 32, with the original on my car being A203 545 16 32. The price for this was 950 euro!!! As it is now, the car runs, but when the brake is applied that funny noise that I could not identify actually comes from the ABS pump that holds the control unit that MB says replacement. The noise is the same noise that is made as if the ABS system is in normal operation if you brake on a loose surface and the ABS takes over! Then after 50kph, the ABS warning light comes on, ESP/BAS/ABS faults are shown in the display, the systems are then turned off, allowing me to drive without problem, but without ESP/BAS and ABS!! After a 500 euro bill for what they had done, I took my car with all the remaining faults in the hope to buy this unit from a scrapers so that I could cure my problems. I bought a unit with the exact same part number as my original one fitted to the car (A203 545 16 32) and also from a newer build year, but low and behold, the same problems are there with the same funny noise and the ESP/BAS/ABS turing off after 50kmph! I ran carsoft on my car and it tells me that the the problem with the Traction/ESP is only that the front right hand sensor (which is actually the front left as you sit in the car because carsoft locations are given from the front of the car looking at it!) is open circuit and the resistance is wrong and needs checking. Bearing in mind that both front left and right have been replaced! I run live data on the ABS/ESP and I get signals from the sensors which relate to the speed that I drive at and from this I assume that the sensors are giving the correct readings to the control unit and works fine if live data says so? I'm confused! However, I cannot get a response from the ABS and BAS units when I run carsoft though! So fella's, the story is, after putting a new ESP control unit on (second hand thou) as recommended by MB, I still have the same problems with the noise from the ABS pump and the ABS/ESP/BAS turning off after 50kph, so I would assume that the ESP control units are OK? Right? Also, I get no response from the ABS and BAS modules in carsoft so I dont know if this is normal or they are blown? Or if that are actually contained in the ESP control unit? Does anyone have any ideas on what the problem is please? Any info is appreciated.. Oh, so you all know, I have run this through the suppliers of the parts and I am waiting if they will take responsibility on what happened to these electronic parts after fitting the wrong supplied wheel bearing seals. Thanks in advance...

05-08-2009, 09:41 PM	#2
BlackC55 Hardcore MB Enthusiast Join Date: Feb 2007 Location: Horndean, Portsmouth, Hampshire, Southsea Car: C43 AMG with mods, ML270, Mk1 Golf cab. Mk1 Caddy fully restored 7.5T truck Rotax Max race Kart ETC Posts: 8,251	I will have a think about this one. its a bit tricky.... __________________ Prestige car Service: I am listed here on MBClub please click to see services and discounts available.

06-08-2009, 06:22 AM	#4
skymastor Hardcore MB Enthusiast Threadstarter Join Date: Dec 2006 Location: South Yorkshire & NRW Germany Car: C240 Avantgarde with AMG Styling Posts: 169	I did exchange the ESP unit only, however, I did get the ABS block which it was attached to with the one from the scrappy but did not change this because MB said it was only the control unit and the block was fine. I did ask them and followed their advice. I will at the weekend change the block too. Still does not explain why carsoft only says that one of the front sensors is open circuit but live data shows a speed pulse from all four and I get no response from the ABS and BAS modules!! Strange... Thanks for the advice so far fellas.. Speak soon.... Last edited by skymastor; 06-08-2009 at 06:24 AM.

06-08-2009, 07:30 AM	#5
lynall Hardcore MB Enthusiast Join Date: Jul 2008 Location: Kent Car: The silver one. Posts: 3,152	So its pointing to the control unit again, if you have a signal from all 4 yet the box cant see it, its got to be duff, be strange to have 2 duff ones though. Seems even stranger that it was fine before wrong seals fitted. are you sure they havent damaged one of the sensors when fitting it? What voltages are each sensor producing? when the wheel is spun at a steady speed. Lynall __________________ Mine 210.070 Wifes 203.064 Slow S2 1959

06-08-2009, 10:46 AM	#7
BlackC55 Hardcore MB Enthusiast Join Date: Feb 2007 Location: Horndean, Portsmouth, Hampshire, Southsea Car: C43 AMG with mods, ML270, Mk1 Golf cab. Mk1 Caddy fully restored 7.5T truck Rotax Max race Kart ETC Posts: 8,251	I am sure there is another control unit for the esp. __________________ Prestige car Service: I am listed here on MBClub please click to see services and discounts available.

06-08-2009, 06:15 AM	#3
Diesel Benz Hardcore MB Enthusiast Join Date: Feb 2006 Location: Europe Car: 221.122 & 212.025 & 204.089 Posts: 2,900	While experts are thinking, can you clarify did you change the ESP control unit only, not the whole ESP unit with the hydraulic part and specifically the electric motor? Motors wear out, mainly brushes, could the noise be from the motor. The yaw rate and lateral acceleration sensor is calibrated to the ESP control unit. Now if you swapped unit but are using the old yaw sensor, your ESP cannot be working right (I would not expect fault codes though).

06-08-2009, 09:47 AM	#6
skymastor Hardcore MB Enthusiast Threadstarter Join Date: Dec 2006 Location: South Yorkshire & NRW Germany Car: C240 Avantgarde with AMG Styling Posts: 169	I don't know what voltage the sensors are producing, but I do know that MB changed the fronts and replaced them with new ones. All through DAS/STAR... I know... Bizarre...

06-08-2009, 11:38 AM	#8
skymastor Hardcore MB Enthusiast Threadstarter Join Date: Dec 2006 Location: South Yorkshire & NRW Germany Car: C240 Avantgarde with AMG Styling Posts: 169	I would think so too, because the unit I replaced (A203 545 17 32) just says ESP on it, and I also get ABS, BAS as well as ESP faults showing in the display. Does anyone actually know and can Identify where the ABS, BAS and ESP units are situated on my W203? Thanks guys....

06-08-2009, 11:43 AM	#9
BlackC55 Hardcore MB Enthusiast Join Date: Feb 2007 Location: Horndean, Portsmouth, Hampshire, Southsea Car: C43 AMG with mods, ML270, Mk1 Golf cab. Mk1 Caddy fully restored 7.5T truck Rotax Max race Kart ETC Posts: 8,251	Whats the first six numbers of your chassis? __________________ Prestige car Service: I am listed here on MBClub please click to see services and discounts available.

06-08-2009, 12:03 PM	#10
skymastor Hardcore MB Enthusiast Threadstarter Join Date: Dec 2006 Location: South Yorkshire & NRW Germany Car: C240 Avantgarde with AMG Styling Posts: 169	WDB2030612F Cheers...

07-08-2009, 01:34 PM	#11
skymastor Hardcore MB Enthusiast Threadstarter Join Date: Dec 2006 Location: South Yorkshire & NRW Germany Car: C240 Avantgarde with AMG Styling Posts: 169	Any other thoughts fella's

07-08-2009, 06:43 PM	#13
skymastor Hardcore MB Enthusiast Threadstarter Join Date: Dec 2006 Location: South Yorkshire & NRW Germany Car: C240 Avantgarde with AMG Styling Posts: 169	If you mean full lock from side to side then yes I did..

07-08-2009, 08:29 PM	#14
BlackC55 Hardcore MB Enthusiast Join Date: Feb 2007 Location: Horndean, Portsmouth, Hampshire, Southsea Car: C43 AMG with mods, ML270, Mk1 Golf cab. Mk1 Caddy fully restored 7.5T truck Rotax Max race Kart ETC Posts: 8,251	Give me a call tomorrow on 02392 570123 and I will have a look through Wis and try and guide you on the right path of what to do next. __________________ Prestige car Service: I am listed here on MBClub please click to see services and discounts available.

08-08-2009, 03:10 AM	#15
skymastor Hardcore MB Enthusiast Threadstarter Join Date: Dec 2006 Location: South Yorkshire & NRW Germany Car: C240 Avantgarde with AMG Styling Posts: 169	Hi BlackC55.. Thanks for your advice and help. I will call you tomorrow. Kindest regards... :-)

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