P38 EAS suspension problems

Hi
I am new to the forum so I would like to say Hello and thank you in advance for any answers or help anyone can give for our EAS problems.
We have had our P38 2.5 TD diesel (2001) for 6 years and it has done 101000 miles. It is a very good vehicle and we are very pleased with it.
It has always been very slow to pump up (arent they all ? !!) and there has always been a small leak somewhere which we could never find.
The 4 airbags were replaced about 12 months ago.
Suddenly last week it couldnt pump up, all 4 lights came on and the 35mph max sign. I took it to our normal local garage. He found a rear height sensor fault logged and he replaced it. It seemed to be better but very slow to pump up. We took it away but a fault immediately returned - either all lights on or no lights and the 35 max warning.
I rang the garage and I thought he was less than helpful. I dont think he really knows the system weel enough. I decided to investigate for myself. By using the advice on this forum (thank you !!) I immediately found that the pump was shot so I replaced that. It then pumped up to what seemed like the correct height but all 4 lights were lit up or when I started it again no lights. The warning light on the dash (arrow under car) was still on.
Decided to read the error faults for myself so I got the correct lead and a copy of RSW Solutions software (thanks again to RSW). At this point I had to get my son to help me and he found about 20 faults logged (I remember that a number were something to do with "valve" this or that). Unfortunately (I realise now that this was a BIG mistake) he did not write down the faults or give me enough time to do so !!! He also cleared the faults and unlocked the system.
However after this the 4 lights on the dash are still all lit up (indicating a fault) and although the car seems to be at the correct height (and doesnt lose air overnight) the system (going up or down etc) wont work.
I have gone through the EAS unlock programme 2 or 3 times again (having started the car at least 1 or 2 times inbetween) but there are no faults logged now at all. The car still seems to be pumped up ok but the EAS sytem will not work. Sometimes when I start it up all 4 lights (or even 3) are lit up with the warning light (arrow under a car) and sometimes no lights at or the car/arrow light on the dash.
Can anyone help me please ??? My suspicions centre on the valve block which has never been replaced or rebuilt but I dont really want to do this without having error codes to indicate what faults there are.
Although the car has been started up many times by me since trying diagnose the fault with the RSW software I realise that I have not driven it on the road - would this be the reason why no faults are now shown ???
Sorry for the length of this but I hope all the information is relevant !
Many thanks in anticipation.

Remove the kick panel from the L/H side of the passenger footwell and check the white connector plugs and sockets for damp and corrosion. Clean as required.

I assume you are getting the green "Good Idle" button on the RSW software? If not you have not cleared the faults.
The height sensor was probably not faulty as the pump was not making enough pressure when a lift was required.
As well as what Wammers has sugested, part and re-make the connectors in the EAS box a few times and check the two earth connections on the inner wing between the EAS box and the Airfilter box.
Let us know how you get on.
:welcome:

Hi
Wammers and Datatek VERY many thanks for your interest and advice. I will go out now and go through those things. I had checked the main EAS Ecu plug for damp etc but there did not really seem to be anything obvious. However I will check again.
Yes I did get the Green "Good Idle" message each time which is what has mystified me about there being no faults.
I presume that there is no way I have access to any history of faults with the RSW software ?
Very many thanks again. Will let you know how I get on.

confusedp38 said:

Hi
Wammers and Datatek VERY many thanks for your interest and advice. I will go out now and go through those things. I had checked the main EAS Ecu plug for damp etc but there did not really seem to be anything obvious. However I will check again.
Yes I did get the Green "Good Idle" message each time which is what has mystified me about there being no faults.
I presume that there is no way I have access to any history of faults with the RSW software ?
Very many thanks again. Will let you know how I get on.

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There is no fault history if you have deleted the faults.
It is not likely that the connector at the ECU will be the problem.

When you got the myriad of faults it is likely you did not have good communications with the ECU. A long list of conflicting faults, like the same valve stuck open and closed at the same time, are indicative of this. If you have good idle and there are no faults believe that scenario. The white plugs behind the kick panel are the interface to the ECU from the height selector switch on the dash. If they are corroded and damp you get interaction sending spurious signals to the ECU. That could certainly cause your problem. Eliminate that and see what you have then.

Hi
Thanks once again for your help. I took the car out for a short run. Still 4 lights on and the wading light on the right. Did a check through the RSW software again. It said "7:Vehicle has moved" and also under F9 "128 faults" -there were no details for this. cleared and reset. Started car. Then there were 4 lights (but wading light gone out) plus car/arrow light on dash. Checked all plugs, earth connections as suggested. Nothing obvious and all seemed in good condition - only the slightest bit of oil (not on the contacts) on the side (inside) of the Bosch Transmission Controller. After that started up and now only the 2 top lights lit up plus the car/arrow light on the dash. Did another RWS system check/unlock again. No faults. Did unlock again just to be on the safe side. Started up again. Still 4 lights all lit up with the car/arrow on the dash.
In case it helps, the car is sitting with the wheelarches 120mm above the top of the tyre which looks as if it may be on the wading height ?
Anyone got any ideas please ? Very grateful for any suggestions ?
Thanks very much again for help to date.

Thanks very much Wammers for your further reply. You will see in my post that I checked the white plug as you suggested but nothing obvious.
However I see that you say "white plugS". I could only see one in my car in that area. It was next door to what looked like a (tall) relay. Where else should I look ?
Many thanks again

confusedp38 said:

Thanks very much Wammers for your further reply. You will see in my post that I checked the white plug as you suggested but nothing obvious.
However I see that you say "white plugS". I could only see one in my car in that area. It was next door to what looked like a (tall) relay. Where else should I look ?
Many thanks again

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Don't know where you have looked but there is no tall relay. Remove the trim panel at the bottom of the N/S A post near the passengers left foot. Below and to the left of the glove box.

Thanks very much again Wammers.
I had checked under the left hand seat where I thought all the connectors were ! Your original post says quite clearly "kick panel" . Sorry !! My fault !! Will go out and check the kick panel. Thanks very much for the clarification. It seems clear that despite all the things I have done I haven't touched the problem yet which should tell me something.
Will let you know. Thanks again.

confusedp38 said:

Thanks very much again Wammers.
I had checked under the left hand seat where I thought all the connectors were ! Your original post says quite clearly "kick panel" . Sorry !! My fault !! Will go out and check the kick panel. Thanks very much for the clarification. It seems clear that despite all the things I have done I haven't touched the problem yet which should tell me something.
Will let you know. Thanks again.

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If a panel is down near the feet it is commonly known as a kick panel.

Thanks you very much Wammers. Finally found something obviously wrong !!
Got access to the 2 white multiplugs you mentioned behind kick plate. the inner one seems ok but the outer one, when taken apart shows clear signs of green/blue staining inside to a number of the pins. What is the best way of cleaning ? I know that it is difficult to get each pin out and back in without introducing a new fault. Can they be successfully cleaned with a spray of something like brake cleaner or Wurth/saBesto contact spray or do I need to do something more comprehensive ??
Many thanks again.

confusedp38 said:

Thanks you very much Wammers. Finally found something obviously wrong !!
Got access to the 2 white multiplugs you mentioned behind kick plate. the inner one seems ok but the outer one, when taken apart shows clear signs of green/blue staining inside to a number of the pins. What is the best way of cleaning ? I know that it is difficult to get each pin out and back in without introducing a new fault. Can they be successfully cleaned with a spray of something like brake cleaner or Wurth/saBesto contact spray or do I need to do something more comprehensive ??
Many thanks again.

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Contact cleaner such as Aeroclean 50. The best answer if you can solder is to cut the wires one at a time, solder and insulate with glue filled heatshrink sleeve.

Thanks again Wammers and Datatek for your continued help. Have investigated the bad looking multiplug further. When I started cleaning the male pins very carefully with a tiny file one fell straight off ! Clearly it was only just hanging on. Cut the 2 ends off (it was the grey/red wire) soldered together and insulated. Cleaned all the other pins (male and female) very carefully and put the multiplug back together. Started up but the same problems (all 4 lights and car/arrow on dash lit up) Went through the RWS diagnosis again. No faults logged. Reset anyway. On start up same problems - all 4 lights lit up and car/arrow on dash but sometimes on startup no lights at all on EAS (or car/arrow).
In view of this and your last post Datatek would your advice be to eliminate the multiplug completely by soldering each wire to its twin ? The multiplug does not look very good inside and it is obviously difficult to be certain that everything is making a good contact.
Thanks again both for your time and interest in replying. Very much appreciated.

confusedp38 said:

Thanks again Wammers and Datatek for your continued help. Have investigated the bad looking multiplug further. When I started cleaning the male pins very carefully with a tiny file one fell straight off ! Clearly it was only just hanging on. Cut the 2 ends off (it was the grey/red wire) soldered together and insulated. Cleaned all the other pins (male and female) very carefully and put the multiplug back together. Started up but the same problems (all 4 lights and car/arrow on dash lit up) Went through the RWS diagnosis again. No faults logged. Reset anyway. On start up same problems - all 4 lights lit up and car/arrow on dash but sometimes on startup no lights at all on EAS (or car/arrow).
In view of this and your last post Datatek would your advice be to eliminate the multiplug completely by soldering each wire to its twin ? The multiplug does not look very good inside and it is obviously difficult to be certain that everything is making a good contact.
Thanks again both for your time and interest in replying. Very much appreciated.

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Maybe bad contacts, maybe interaction due to contamination. If you cut and properly reconnect that will eliminate that as a problem. If things continue take a look at the selector switch itself they do fail now and again.

wammers said:

Maybe bad contacts, maybe interaction due to contamination. If you cut and properly reconnect that will eliminate that as a problem. If things continue take a look at the selector switch itself they do fail now and again.

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As above^^^^^^^^^^^

Hi
Getting a bit desperate now ! Just spent 4 hours very carefully cutting the wires individually off the bad looking multiplug, soldering them together, shrink wrapping and spiral binding them. No difference ! I didn't do the same to the other multiplug as it all looked ok.
Then turned my attention to the height control switch. Took it off. Nothing obvious. Wiggled all the wires with ignition on . This didn't change the lights. Is there any way of checking its function ? Or just by substituting another one ?
With the engine running it seems that the car is at its max height. By pressing the switch the car goes down to what looks like its normal height but the 4 lights do not change.
On various startups it has the 4 lights plus the car/arrow light sometimes. Other times it has 3 lights and sometimes no lights.
I have done another RWS diagnostic test. No faults (it showed good idle first) shown.
Checked the fuse box and the 3 main fuse culprits. All ok and looked in good condition.
It still seems that I have not touched the problem even though I found the very bad multiplug.
Anyone with any more ideas please ? Very grateful for any help. Thank you.

confusedp38 said:

Hi
Getting a bit desperate now ! Just spent 4 hours very carefully cutting the wires individually off the bad looking multiplug, soldering them together, shrink wrapping and spiral binding them. No difference ! I didn't do the same to the other multiplug as it all looked ok.
Then turned my attention to the height control switch. Took it off. Nothing obvious. Wiggled all the wires with ignition on . This didn't change the lights. Is there any way of checking its function ? Or just by substituting another one ?
With the engine running it seems that the car is at its max height. By pressing the switch the car goes down to what looks like its normal height but the 4 lights do not change.
On various startups it has the 4 lights plus the car/arrow light sometimes. Other times it has 3 lights and sometimes no lights.
I have done another RWS diagnostic test. No faults (it showed good idle first) shown.
Checked the fuse box and the 3 main fuse culprits. All ok and looked in good condition.
It still seems that I have not touched the problem even though I found the very bad multiplug.
Anyone with any more ideas please ? Very grateful for any help. Thank you.

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The switch is not just a switch it contains electronics. It can fail. Only way to know is to fit another unfortunately.

wammers said:

The switch is not just a switch it contains electronics. It can fail. Only way to know is to fit another unfortunately.

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Electronics in the switch? Looks like 4 indicators, a lock switch and an up/down button

Datatek said:

Electronics in the switch? Looks like 4 indicators, a lock switch and an up/down button

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Ok carry on then i'll leave it to you. No electronics in the switch so why is AMR5823 £309.32 and the later YUF101930 £333.58? A lot for a basic item with a few lamps and rocker switch.