three bars of death??

[Chrisjcb]

Hello and thanks to all that will probably answer my questions soon as these are common failures on the cdi smart 451 2009 reg.

Hoping for the answer. i have the three bars after doing a service on my friends car, i have checked the wiring harness between the ecu under the carpet to the gearbox with a multi-meter and all seems fine also to the gearbox selector module.

First question is the clutch actuator supposed to engage when you turn on the ignition or only when in neutral with brake pressed?

Number two to reset the gearbox i have read that you hold the brake pedal down and turn on the ignition is this correct?  should the clutch actuator depress the clutch whilst doing this reset?

Number three--- should i just set fire to it... lol only kidding.

I look forward to hopefully some advice as my friend isn't very happy with me at the moment.

Thanks Chris.

 

 

[Huronlad]

Welcome to the club.

 

Specifically what servicing did you perform on the car?

 

A fault code would make troubleshooting easier and more accurate.

 

Have you tried disconnecting the battery for 10 - 15 minutes?

[jwight]

Unless the cdi transmission is different from the gasser (don't think it is), try doing the transmission relearn mentioned in the owners manual. 

 

Teaching-in the transmission system:
X Stop the vehicle in a safe location.
X Move the gear selector lever to park
position P.
X Turn off the engine.
X Wait at least 30 seconds before
restarting.
X Press the brake pedal.
X Restart the engine
Three bars instead of P appear in the
multifunction display.
X Wait at least 30 seconds.
The transmission is taught in.

When teaching-in was successful:
P appears in the multifunction display
again and normal transmission operating
is restored.

After an unsuccessful teaching-in:
Three bars instead of P appear in the
multifunction display.
X Do not continue to drive.
X Turn off the engine.

 

 

[Chrisjcb]

Thanks for your input guys. unfortunately i cant do the reteach as the engine wont even start all i have is the three bars.

When i connected my diagnostic (delphi) no fault codes were there. This is my puzzle.

The service was fuel filter, oil filter and oil and air filter. to remove the air filter i had to remove the intercooler pipe from the cooler and the egr.

When this happened i looked at many forums and it is a common fault that the intercooler rubs through the harness underneath that connects to the selector module(motors) hence why i dropped the engine down and checked the cables.

Thanks again Chris.

[jwight]

Just for the heck of it, try turning the key to position one (electrical power) and assuming you get all the normal lights on the instrument cluster, try moving the shift lever through all the gear positions a few times.  Doesn't cost anything and it might wake up the transmission.....

[Chrisjcb]

ok for an update.

I totally removed the gearbox harness and did a thorough test on the bench using a headlight bulb as my test light so as to put some current through the cables to make sure there was no issues.

I reconnected everything and the engine still didnt start , still three bars.

I then connected my Delphi diagnostics and omg!! codes lots of em!!!

here we go.

p0805 - clutch system fault

           - permanent

p1801 - Teach in of mechanism unsuccessful

           - permanent

p2802 - Incremental sensor "Transmission";signal fault

           - intermittent

p0707 - Control unit; internal error

           - intermittent

p0887 - Transmission relay, does not switch off

           - permanent

p1800 - teaching requirements 

           - permanent

p0805 -Clutch system fault

           - permanent

p1801 - Teach-in of mechanism unsuccessful

           - Permanent

Help.

i cleared all faults and got the engine to start once then all faults reappeared i was messing around for about 4 hours today and till cant get it working. 

i did a reset of the controll unit with my delphi and the clutch actuator made a noise but didnt move /press the clutch, sounded like crunching cogs?

first time i have heard this.

Please help any one.

 

[Huronlad]

Throwing all those codes after removing and reinstalling a harness would suggest to me a bad or several bad connections.  Spraying the connectors with contact cleaner would be a good first step.  

 

Are you disconnecting the battery when fiddling with the electrics?

 

Have you touched the clutch actuator or it's wiring harness at all?

[Willys]

Hmmm....sounds to me like he needs both his clutch and tranny taught back in.....after finding out why it went out in the first place. Perhaps check for a punched through clutch fork arm hole? Or siezed actuator ...that can be taught in by hand almost just to get it running but should be done right using a STAR, no?  I would look at all connections to the ECU,  SAM etc for green stuff, then carefully opening up all of these computers checking for cold solder joints and water damage. AS HURONLAD said  MAKE SURE BATTERY IS DISCONNECTED...!   Also, when cleaning pins etc, watch out for capacitor discharges across pins. I cooked my ECU by brushing the pins with sensor cleaner and a tooth brush...beware....these computers can be very expensive! They also say they need to be replaced as a set, but i think you could replace them one by one...but unsure of that. When i installed my 3 and retaught them in I did each one seperately which makes me think they could be replaced one by one also...?  But do not quote me on that!....Just beware of stored up energy within these computers....any capacitor has a small charge stored in it I think waiting to be released?

 

The tranny is a very simple one, very much like a motorcycle's. I'll bet the clutch actuator went out and messed the whole system up....?

 

[LooseLugNuts]

4 hours ago, Chrisjcb said:

clutch actuator made a noise but didnt move /press the clutch, sounded like crunching cogs

 

that doesnt sound good

 

looking inside the actuator is probably the easiest thing to do

 

i like to start with the easiest things

 

 

 

also sidenote to above...i find that removing battery from circuit and then touching car positive lead to negative will discharge all capacitors

[Chrisjcb]

13 hours ago, LooseLugNuts said:

 

that doesnt sound good

 

looking inside the actuator is probably the easiest thing to do

 

i like to start with the easiest things

 

 

 

also sidenote to above...i find that removing battery from circuit and then touching car positive lead to negative will discharge all capacitors

 

[Chrisjcb]

ok another update.

I did as  LooseLugNuts said and removed the actuator and found the worm drive had sheered off the motor  so im on a waiting game now for a new one to arrive. 

I will keep everyone informed when the new actuator arrives from Italy.

[Chrisjcb]

Ok Guys. Here's the update.

 Its working Yea. 

Thanks LooseLugNuts did as you said and after fitting the new actuator and re teaching the clutch and gearbox all is good. 

I really appreciate all of your help on this forum all of you have been very helpful.

I now know that if i get another one like this roughly where to start. 

Many thanks. This is solved.