Sensitivity - Operational

Type Distributor presenter Date Factory Sharing

■ GSSC _Case study Case study South Africa

Sumeer Ka-
dathlal
28 Aug 2023 HMI Dist/Dealer

Title ● All warning lights On in the cluster.

Model VIN Mileage(km) Production date Solving date DTC code

Info C162308, C128504, B261700, C161688,
BI3 MALBG511VPM208458 190 km 2023-02-07 2023-08-25
C162887, C162800

Detail symptom  All warning lights On in the cluster.

Condition Happening condi-

 While driving. Cycle  While driving.
tion

Trouble cause  Terminal out position on joint connector. Result  Fitted terminal correctly.

Detailed inspection Inspection result

1.Phenomenon
- We one BI3 vehicle, customer complaint dash lights come on while driving.
2.Detail inspection Diagnosis to follow below.

• On inspection of the vehicle, while driving, found all the warning lights will come on
the cluster.
• Check the resistance of the CAN system, 60 ohms.
Detail
Info • Dealer swopped the ACU, ABS and MDPS modules, problem persists.
• Measured the CAN system again, shows 60 ohms.
• Inspected all connectors and joint connectors, found terminal out of position on
joint connector.
3. Remedy
• Fitted terminal properly in the connector.

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Video of symptom.

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Warning lights On in the cluster. Connected GDS, found the follow DTCs.

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Measure the resistance in CAN system, 60 ohms. Measure the voltage, both CAN H and CAN L show 2,4v.

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Swopped the ACU, ABS and MDPS module, still the same, inspected the wiring as per ETM on the common systems.

Swopped with
good units, still
the same.

Terminal out
of position.

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Found at JM02, terminal out of position.

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Conclusion

• Customer complaint, the dash lights come on while driving.

• On testing the vehicle, found the warning lights on the cluster come on, while driving.
• Connected the GDS, found DTCs – C162308, C128504, B261700, C161688, C162887, C162800.
• The common system is ABS, ACU, MDPS and CLU modules.
• Checked the resistance in the CAN system, found 60 ohms – okay.
• Swopped the ABS, ACU, MDPS and CLU modules with a good vehicle, problem still happens.
• Doubled checked the CAN system, found the JM02 connector, terminal out of position.
• Fitted the terminal correctly, tested the vehicle and problem is solved.

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