Sticking gears & limp mode!

Help please

Hello again guys and gals, I am at my wits and pockets end! I did previously post and
took your advice to get codes read S320 CDi 2001. Jobs done and parts replaced since
first codes read etc.
New mass sensor, air filter, oil seperator (not seperating), No1 injector, gearbox oil and
filter renewed (at merc garage/indi), all gaskets from turbo to inlet (rubber rings & board)
replaced, removed intercooler and cleaned (not too dirty), EGR removed and cleaned
(water side not too bad 4 months old (prior to my purchase), inlet side absolutely caked in
carbon and oil), Fingers up inlet manifold and a hand full came out, manifold off, if I
condensed the amount of crud it would fill 4 mugs (amazed it was running at all), clip
union (from stepper motor) to secondary flap openings was disconnected with flaps closed
and siezed, steam cleaned EGR and inlet manifold, new gaskets/rings for heat exchanger
and EGR. refitted all in anticipation of a new car like feel, started car and left on tickover
to warm up, fair amount of smoke/fumes two bad black patches on the grass (doh) from
exhausts, out for a run (15 miles) felt as if it were breathing better then, LIMP MODE
(aargh).
I had previously removed the gear selector module, opened the black box and cleaned the
led sensors for selector position and repaired a broken case fixing which worked fine for
three weeks, then back to sticking in any gear it fancied, job done again and fine for one
week. Sorry about the length of this post, but I thought it best to give all info. So I think
try a main dealer diagnostic they might be better (against my better judgement). After
their first test they said they could not tell me for sure if it were the selector module at
fault as the report was inconclusive and could I return the vehicle once it had played up
again. So back I went the following day with both problems, onto their machine it went,
initial and final tests after clearing codes, and you guessed it, can we keep the car for two
days to run as many tests and work we deem required to fix your bank balance, sorry
problem. Below are all the relavant codes, I have ommited dodgy seat and comand,
mirrors etc for obvious reasons. A couple of small points that may help are, the vacuum
pipe from pump to brake cylinder does not appear to seal very well, it can slide off without
using the retaining clip tabs (tried a bit of PTFE as a short term bodge) to help the suck.
Seems to stick in the particular gear it was in when braking to a stop, ie third to stop, pull
away in third etc, although not always. If I accelerate around a bend in limp mode on
occasion it seems to be able to rev (higher than the usual 2K) some times up to 3.5K
(Strange). I have checked as best I can the vacuum units for the EGR and the turbo and
pipes, if anyone knows a difinitive way it would be appreciated.The BAS and ESP warnings
come on at random and apparently have done for years with no major side effects
(mmm)!
ecas = event current and stored cas = current and stored es = event stored s = stored
First diagnostic from Merc indi,
04.08.09
ETC Event p2311,p2314,p2316,p2312,p2315,p2404,p240c all es
ESM Code p1856,p1911 both s
CDI 2 Code p1470-016 s,p0100-001 ecas,p0100-128 ecas, event p0703-128 es
ESP Code c1022-025,c1200-008,c1204-003,c1201-003,c1024-004 all s
Airmatic Code c1026-002,c1026-004,c1026-016,c1027-001 all s
05.08.09 follow up merc indi
ETC Event p2311 ecas,p2314,p2316,p2312,p2315,p2404,p240c all es
ESM Code p1856 cas
CDI 2 Code p1470-016 s
ESP Code c1022-025,c1200-008,c1204-003,c1201-003,c1024-004 all s

Airmatic Code c1026-002,c1026-004,c1026-016,c1027-001 all s

14.09.09 main dealer initial test
ETC Event p2311,p2314,p2316,p2312,p2315,p2404,p240c,p2313 all es
ESM Code p1856,p1911 both s
CDI 2 Code p1470-016,p1403-032,p0110-002,p0105-001,p1664-008,p1192-004 all s,
Event p0703-128 es
ESP Code c1022-025,c1200-008,c1204-003,c1201-003,c1024-004 all s
Airmatic Code c1026-002,c1026-004,c1026-016,c1121-002,c1027-001,c1027-002,c1517002 all s
They failed to give me the final quick test
15.09.09 main dealer initial test
ETC Event p2311,p2314,p2316,p2312,p2315,p2404 ecas,p240c all es
ESM Code p1856 s
CDI 2 Event p0703-128 ecas
ESP Code c1022-025 cas,c1200-008 cas,c1204-003 s,c1201-003 s ,c1024-004 cas
Airmatic Code c1026-002,c1026-004,c1026-016,c1027-001 all s
15.09.09 main dealer final quick test
ETC Event p2311,p2314,p2316,p2312,p2315 all es
ESM tick
CDI 2 Event p0703-128 es
ESP Code c1022-025,c1200-008,c1204-004 all s
Airmatic Code c1026-002,c1026-004,c1026-016,c1027-001 all s
Congratulations if you have made it this far, apologies for the length again. If any of you
kind wizards can help solve my problems I will personally buy you a beer as I do travel the
country as a taxi driver, and hopefully in the S before too much longer, I have only had it a
short time but do now understand why you guys love em (when they work). Any queries
or questions and I will get back to you as soon as I can. Many thanks, Danny

22-09-2009, 07:02 PM
#2

Buggerlugs
Hardcore MB Enthusiast

Join Date: Sep 2008

Location: Barnsley, near Barbados.
Car: Triumph Sprint RS

Looks like
something
is dragging
down the
CAN bus.
The CAN is
the Control
Area
Network,
much like a
home PC
wired

network
where
information
is shared
between
individual
modules.

Posts: 142

It could be
one of the
onboard
modules or
it could be
a wiring
fault, it's
gonna
need some
time
spending
on it to pin
down.

Sponsored Links

22-09-2009, 08:22
#3
PM

alexander patie
Hardcore MB Enthusiast
Join Date: Aug 2009
Location: sunny suffolk
Posts: 606

here is this for your perusal...

STAR TekInfo=
all the cdi codes and test procedures.

22-09-2009, 08:27
#4
PM

alexander patie
Hardcore MB Enthusiast
Join Date: Aug 2009
Location: sunny suffolk
Posts: 606

and gearbox codes...

STAR TekInfo
i note you keep getting back brake pedal signal fault, better
change that too for good luck, could it be that simple? yes, it

could.

24-09-2009, 03:00
#5
PM

sclasscab
New Member

Threadstarter

Hi again, do any of you think I need to change the gear selector

module? I dont know where else to start, I know this would not
effect the limp mode but at least I could drive it to work out the
limp diagnosis, what do you guys recommend?

Join Date: Jul 2009

Location: Norwich
Car: S320 CDI
Posts: 12

24-09-2009, 11:54
#6
PM

alexander patie
Hardcore MB Enthusiast

why do you suspect the esm? it is not the hot favourite

regarding limp home, unless i missed something? did you cross
reference all those fault codes??

Join Date: Aug 2009

Location: sunny suffolk
Posts: 606

25-09-2009, 09:17
#7
AM

Buggerlugs
Hardcore MB Enthusiast

Join Date: Sep 2008

Location: Barnsley, near
Barbados.

The ESM is also on the CAN bus so could be a candidate. The

vehicle modules are connected in what is essentially a paralell
electrical circuit by 2 hardwired connections named CAN high
and CAN low. The implication is that any module on the circuit
by virtue of the way they are connected can (and often does)
"drag down" the whole bus when an internal module failure
occurs, this causes multiple CAN error messages in various
modules.
It looks at the moment that the raft of DTC's you have are resetting straight after they have been cleared, this ought to
simplify matters. You're gonna need a STAR or
similar.......Unplug say the ESM 1st, clear the codes and see

Car: Triumph Sprint RS

Posts: 142

what re-sets with the ESM unplugged, sure, you're gonna get an
ESM comms/CAN code from the TCM, but if the other modules
then come back online and you don't get the CAN codes for
ECM, instrument cluster etc. then there's your culprit, if not then
repeat the operation for the other modules, if none of that has
the desired effect then it looks like a wiring loom fault.
Just one more quick check.......Make sure you have a healthy
battery, if when cranking the battery voltage drops below about
10V this can cause heaps of trouble.
HTH.
__________________
Buggerlugs (Disturbing the peace since 1963)

25-09-2009, 11:21
#8
AM

sclasscab
New Member

Threadstarter
Join Date: Jul 2009
Location: Norwich
Car: S320 CDI
Posts: 12

Thank you for the help Buggerlugs, do you know if I can buy a
reader cheaply and if so where from, as I suspect my local indi
would not be happy with me tying up his machine for that length
of time. I can get a secondhand gear selector for 220, and with
the sticking in gears I am leaning towards it, any ideas. Thanks
again guys.

25-09-2009, 12:24
#9
PM

Buggerlugs
Hardcore MB Enthusiast

Quote:

Originally Posted by sclasscab

Thank you for the help Buggerlugs, do you know if I can buy a
reader cheaply and if so where from,

Join Date: Sep 2008

Location: Barnsley, near
Barbados.
Car: Triumph Sprint RS

Sorry m8, I don't. Problem is, the "cheap" readers won't be any
use anyway. TBH, if I were you I'd have the car into a
competent local MB specialist or Sparky and let them have a
couple of hours on it.

Posts: 142

25-09-2009, 05:35
#10
PM

sclasscab
New Member

Threadstarter
Join Date: Jul 2009
Location: Norwich
Car: S320 CDI
Posts: 12

Another reason I think it may be the selector module is, whilst

in my main dealers buying some bits the other day I asked the
price and availability of the gear selector module, it showed up
on his stock record that MB had issued 559 of them in the UK in
the last year. I asked him about recall but due to the
age/mileage of my car they would'nt touch me (doh)! Shall I
plump for the secondhand one 220 with 3 months guarantee,
or main dealer 370 +vat and an hour coding at 115 + 7-10
from Germany? I also have a wedding to do next weekend! Any
advice gratefully received.

25-09-2009, 06:49
#11
PM

Buggerlugs
Hardcore MB Enthusiast

The only further help I can offer right now is to tell you that I've
never had to code a new ESM. Perhaps that's something to
clarify with your dealer?

Join Date: Sep 2008

Location: Barnsley, near
Barbados.
Car: Triumph Sprint RS
Posts: 142

25-09-2009, 07:17
#12
PM

alexander patie

thanks, but i understand the technology buggerlugs, this is my

Hardcore MB Enthusiast
Join Date: Aug 2009
Location: sunny suffolk
Posts: 606

day job.

i suggest again that the o/p changes the brake pedal switch
first, as it is a recurring fault and known problem. also very
cheap and easy to do.
yes, it could be a module corrupting can comms, but why
suspect the esm? as buggerlugs says, disconnecting them one
at a time is a good way. i read this as an intermittent fault
however, and as such it is sadly not possible to go this way. the
esm can be swapped for a s/h one if the part numbers are the
same, but should need the coding setting for the specific car, eg
engine type. i do wonder how much oil has got into the etc
module though, could be worth a look...

26-09-2009, 03:32
#13
PM

sclasscab
New Member

Threadstarter
Join Date: Jul 2009
Location: Norwich
Car: S320 CDI
Posts: 12

Sorry guys I should have said before re the brake switch, I have
had three new ones altogether, including one the MB garage
tried whilst doing their diagnosis test. Also noticed a leak from
the banjo joint on the bulkhead end of the fuel rail, I have new
MB washers does anyone know the torque setting for the banjo
as I would hate to ring it off whilst tightening? Pretty please.
Thanks again for all your posts.

26-09-2009, 04:02
#14
PM

alexander patie
Hardcore MB Enthusiast
Join Date: Aug 2009
Location: sunny suffolk
Posts: 606

no idea of the torque, but it would be hard to get a wrench in

anyway. i should not worry too much, the rail is made of a hard
material and it would be very hard to overtighten (unless you
were actually trying to).
you are showing us four test results at the top of the page, are
we to understand that all module memories were erased after
each test? i can see some obviously were, but unless all were
each time we may get the wrong picture.
i work in stowmarket danny, if you wish us to have a look then
you can ring me at work on monday. i suggest you pm me for

details if interested...

27-09-2009, 04:01
#15
PM

sclasscab
New Member

Threadstarter
Join Date: Jul 2009
Location: Norwich
Car: S320 CDI
Posts: 12

I was told they tried to clear them after each test, however I
was told there were some they could not clear. Alexander I am
not allowed to pm until I have posted 30 times, is it possible for
you to mail me your number and a convenient time for me to
call you.