ABS Fault - 2003 Passat TDI

[bobmac892]

Hi folks, I really hope someone can help solving this fault as it's driving me nuts now. A couple of weeks ago I had the "Check Brake Pads" light come on and off intermittently so I changed the front pads and discs as they were due for it. When I put it all back together I wound up with the ESP and ABS amber warning Lights lighting up constantly then as I'd drive off the red handbrake warning light came on and stayed on.

I had followed the Haynes manual to do the brakes except I missed the step where it suggests opening the bleed nipple when pressing the caliper pistons back into the caliper so I thought that maybe I had knackered the Pressure switch.

I have since bought a second hand ABS pump and control unit. I swapped the ABS controllers, re-coded it no problem but... no change.

Checked all of the fuses in the car and under the steering wheel area under the dash panel, no problems.

Then I have carried out a full bleed of the brakes, no change.

Then I have swapped the hydraulic unit (which had my cars original control unit fitted to it), re-coded the control unit again no problems but... no change.

VAG COM has consisently given and still gives the
Address 03: ABS Brakes
1 Fault Found:
01200 - ABS Valves Supply Voltage
35-00 - -

fault message and I am at the end of my tether as to what to do next.

Any suggestions welcomed.

Full VAG COM Print in the next post.

[bobmac892]

As I mentioned here's the full VAG COM autscan log:

VCDS Version: Release 11.11.4
Data version: 20120807
Wednesday,05,September,2012,19:56:07:22761
Chassis Type: 3B - VW Passat B5
Scan: 01 02 03 08 15 16 17 19 35 36 37 46 47 55 56 57 58 75 76 77


VIN: WVWZZZ3BZ3E315444 Mileage: 191000km/118681miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: 038-906-019-AVF.lbl
Part No: 038 906 019 GQ
Component: 1,9l R4 EDC 0000SG 1582
Coding: 00002
Shop #: WSC 05314
VCID: 6CD93CCA1CD31E78EDD
WVWZZZ3BZ3E315444 VWZ7Z0B6639948
No fault code found.
Readiness: 0 0 X X X
-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 4B0-614-517.lbl
Part No: 4B0 614 517 G
Component: ABS/ESP front 1728
Coding: 04255
Shop #: WSC 12345
VCID: 254F09EEBFB9EF30723
1 Fault Found:
01200 - ABS Valves Supply Voltage
35-00 - -
-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 3Bx-907-044.lbl
Part No: 3B1 907 044 J
Component: CLIMATRONIC B5GP 0006
Coding: 17000
Shop #: WSC 05311
VCID: 285100DAC8ABF258495
No fault code found.
-------------------------------------------------------------------------------
Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 1C0 909 605 C
Component: 08 AIRBAG VW61 04 0001
Coding: 12344
Shop #: WSC 05311
VCID: 244914EAB483163865D
No fault code found.
-------------------------------------------------------------------------------
Address 17: Instruments Labels: 3B0-920-xx5-17.lbl
Part No: 3B0 920 927 A
Component: KOMBI+WEGFAHRSP VDO V08
Coding: 05415
Shop #: WSC 00535
VCID: 234B17F6B18D11001C7
WVWZZZ3BZ3E315444 VWZ7Z0B6639948
No fault code found.
-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 05311
VCID: F0E1A8BAB0FB7A98515
No fault code found.
-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 1C0-959-799.lbl
Part No: 1C0 959 799 B
Component: 8Q Komfortgerát HLO 0003
Coding: 00258
Shop #: WSC 05311
VCID: 366DDEA2121F94A8CB9
Subsystem 1 - Part No: 1C2959802
Component: 8Q Tõrsteuer.FS KLO 0009
Subsystem 2 - Part No: 1C2959801
Component: 8Q Tõrsteuer.BF KLO 0009
Subsystem 3 - Part No: 1C0959811
Component: 8Q Tõrsteuer.HL KLO 0009
Subsystem 4 - Part No: 1C0959812
Component: 8Q Tõrsteuer.HR KLO 0009
2 Faults Found:
01135 - Interior Monitoring Sensors
36-10 - Open Circuit - Intermittent
00944 - Heated Exterior Mirror; Passenger Side (Z5)
35-00 - -
End ---------------------------------------------------------------------

[martin1810]

Check for 12V at the fat red/white wires on the abs unit. Check the fuses again. What warning lights are currently on.

[bobmac892]

I'll get that voltage checked shortly but as for the warning lights, I have;
ESP - constant amber
ABS - constant amber
then when you drive forward over 6mph the Handbrake light starts flashing red.

Usually the check pads comes on constant amber but since working on the car today that seems to be staying off.

[martin1810]

Check the master cylinder brake fluid level for the flashing handbrake warning.

[chipped3]

How old is your battery?

If your battery voltage drops below a certain voltage you will get both the ESP and ABS warnings on your display readout between the Dials. Mine is a 2002 Passat 130 TDI Sport, done 162k and it has happened to me twice......both times replacing the Battery has cured the problem. How did I find out? Because My dealer in Shrewsbury who was doing my servicing during its first three years told me my original battery was below par and needed replacement and would throw up the faults. Replaced with an identical Varta with 5 year Warranty and exactly the same message came up in June 2011 and new Varta fitted again and faults deleted. No issues since. Believe 12.4 volts is a minimum reading.

Tip; You can selectively peel off part of the sticker on top or the Varta battery so that you can check battery acid levels an you always could! I buy my Varta from Tayna in North Wales who do EVERY size of battery mail order next day.

[bobmac892]

Checked the voltage at the large red and white cable, over 12v with the engine running. Checking across the battery terminals 12.2v.

Bought a new battery from Halfords. Right type according to their guides, wrong physical size. Tried it anyway but it made no difference to the lights. Gonna bench charge the old battery over night and hope that gives a positive result.

If not any other ideas?

[bobmac892]

Mind you I still have to check the fuses. Apart from the normal fuse panel on the end of the dash, the fuses under steering wheel and those in the engine compartment (to the outside of the battery) are there any others I need to locate?

[chipped3]

When I replaced my battery in 2006 following the second ABS/ESP fault code displays, replacing the battery cured the problem but still needed to have the fault code display readings deleted. My VCDS was with my son 200 miles away so I had to have them deleted by a local garage costing £30 instead of a VW dealer wanting £70+ just to plug me in to VAGCOM. Had to pay up and have now bought an Autel hand held reader to be able to read/delete fault codes so that I don't need to fork out £30 again. If the fault code doesn't return, the problem is solved. Your reading of 12.2v is a partially charged battery You need 12.4v minimum preferably higher.

Re Halfords. I was given the wrong battery by Halfords Aberystwyth although their reference said it was correct. That is why I bought Mail Order from TAYNA in North Wales. Good service.

[bobmac892]

Chipped3

Nahdah. Tried the old battery having charged it overnight. I Vagcom deleted the error codes but turning the car on again and up came my the two li'l amber nemesis, ABS and ESP lights.

Took the old battery out, popped the new (but wrong sized one) back in and again Vagcom deleted the codes. Same B|@@&Y lights again. AAAAAAAARGH.

The worst thing is your solution makes sense though, the old battery is a minimum of 5 years old, probably more, maybe even original as it is a VAG Battery. Now wondering if the New batery is just WRONG!!! no thanks to Halfudds.

At least the "Check Brake Pads" warning beep has stopped and the check pads light isn't coming on any more. One down 2 and a flasher to go.