Error code 96: Connection with EGS failed (an update ASC light on)

roadvoyager1

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We have been doing some work on the brakes of my Z3 (1999 2.8 with M52TU and manual transmission). Codes were read using a Snap-on Ethos reader and after reset, error code 96 remained. Checking on various forums it seems that EGS is the Electronic Gearbox System and refers to the controller for the automatic gearbox.

The actual readout was:
Error code 96: CAN Connection with EGS failed

Can anybody confirm that EGS is unique to the auto box and cars fitted with manual transmission do not have an EGS. If this is correct, my logic is that connection failed because there is nothing to connect to i.e. there is not a fault. Do any other members have access to an Ethos reader and has something like this been seen before?

Thank you for any help you can offer.
 
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GazHyde

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I've not heard of that particular code reader before. I've had a quick Google but can't find much on the subject, but the error you put in the thread title and in the thread are different. Which is correct?
 

roadvoyager1

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Garry,

Thanks for picking up on the discrepancy. Realised after posting I had missed the "CAN" from the error message in the title.

To clarify,the actual readout was:

96: CAN Connection with EGS failed
(I add "Error code")

CAN is the Controller Area Network (sorry if you already know this). EGS seems to be Electronic Gearbox System.

The reader is a professional unit supplied by Snap on Tools.which has a list price of £3K with BMW key software installed. We selected BMW Z3 1999 2.8ltr and S1 option.

Hopefully all is clear now.
 

roadvoyager1

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Thanks for spending time looking this up Garry. I spent a couple of hours last night before posting the question and came up with little more than I have included above.
 

roadvoyager1

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Apologies in advance this is going to be a bit of a long post.

Had the codes checked using another generic code reader by a friend of a friend who runs a small independent garage. He generally works on VW/Audi but had the reader key for BMW which was used. Didn't get the model of the code reader but it was a full pro garage type from a German Manufacturer. We still picked up the same error code 96: CAN Connection with EGS failed. Unfortunately that is where the trail ended we could not trace any further into the software. We used the 20 pin connector under the bonnet.

Now a bit of background and my request for guidance from other forum members. The initial concern had been present since I bought the car. Very occasionally the ABS and ASC lights would come on and stay on. Sometimes I could relate this to particularly hard acceleration, others a small bump in the road would induce them to show. When the car was serviced codes were read using a puka BMW machine and the "ABS pump" code came up (think it was code 113 or maybe 133). I was quoted £500 to fit a refurbished ABS pump. Some thought was therefore required!! After researching I found that there is a bit of a history of dry solder joints on these units.

I could get my existing pump refurbished (by ECU testing) for around £250 inc postage or obtain a good replacement for somewhat less. I eventually tracked down a replacement with matching part numbers from a 1998 2.8 (M52TU) build date 21.10.98. So exactly the same part numbers on the pump and control module and from a car that left the factory 4 months before mine.

As we would be changing the ABS pump we decided to do a check and refurb of the whole braking system. Rigid pipes had been replaced with copper a few years back and this is that we did:-

- replaced all flexibles, which were becoming hard, with Goodridge Stainless steels.
- replaced bleed nipples with HEL stainless steel.
- cleaned and checked over front and rear calipers plus handbrake shoes (fronts replaced last year, everything else in good condition).
- replaced rusty bolts and clips as required.
- changed out the ABS pump with module.
- bleed the brakes and purged each line with around 250ml fresh brake fluid.

To get easy access the ABS pump the air intake boots were removed. We found the second boot with the take off to the idle control valve had a small split and both boots were replaced to prevent future problems. Also changed the front drop links as those fitted were looking rather tired.

When completed the brake a very positive and firm, however, the ACS light is now on (ABS light is off - hooray!).

So this is where we connected up to the second code reader. Apart from the "96" nothing else showed up. The reader could certainly see the ABS module, returning the BMW part number 1164896, hardware number 05 and software number 43 along with various index numbers.

A bit more head scratching and internet searching and we have a short list of possible causes/remedies:

1. ABS module software levels different causing error 96 (could it have changed during the 4 months between manufacture?). How easy/expensive would it be to get this recoded?
2. Front left ABS sensor plug disturbed when brake wear sensor changed. They share a housing in the wheel arch. (would error code be showing if this was the cause?).
3. Hand brake binding on one side causing a slight difference in wheel speed and ACS error (having driven 100 miles in 2 hours on Sunday without any sign of excess heat in the rear hubs this seems most unlikely to me).
4. ACS throttle control unit or connections disturbed when air intake boots replaced (not found much information on exactly how this can be checked - any ideas ??).
5. Would disconnecting the battery for 20 minutes force a reset (bit of a long shot, but seems to work sometimes with PCs!!).

Other than getting the codes read on a dedicated BMW reader at a dealer has anybody got suggestions for where we might look next?

Thanks for reading.
 

Brian H

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First of all, well done in clearing the ABS light. Now to the ACS light, I would revisit the front left sensor if you think you disturbed the connector. You can test the sensors with a multimeter if you have one by disconnecting them, spinning the wheel and reading the sensor with your meter.

You could try the battery discussion trick, it would no do any harm, sometimes these systems need a few runs without any errors to extinguish the light.
 
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zedonist

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The new abs module needs to be coded in the ECU, the light you are getting is because of a module number mismatch in the DME control unit. If you access to INPA and DIS you can recode yourself in 10 minutes. If not I think their should be good Indy or engine specialists that can do it.

I am sure there are some members on here with the capability
 

Brian H

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If the unit needs to be coded Rich would you not expect to also see the ABS light?
 

oldcarman

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I agree with Rich, the ABS is not being recognized by your ECU through your DME UNIT. There is nothing I can find In my manual that explains how to recode. Good news if it can be said is that the brake system continues to work normally just the ABS is disconnected electronically as the module does a self diagnostic when you start your car which shows as a light on your dash. Sorry can't give you more, maybe @t-tony could elaborate. JIM
 
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zedonist

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If the unit needs to be coded Rich would you not expect to also see the ABS light?
From what I have read Brian yes the code mismatch will throw the light on the dash, it seems to be quite common on replacement units, and perhaps repair of the original unit is way to go.
 

roadvoyager1

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Thank you for quick feedback. Will try the easy fixes first; battery disconnect, ssensor check then scratch head and get more splinters.

Any more ideas or comments? Please feel free to comment. Thank you.
 

roadvoyager1

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Two down and light still on. Tried disconnecting the battery which failed to have the desired effect. Also visually checked the sensor connection and no damage or signs of it having moved. Will check the sensor function with a multimeter later.

If the unit needs to be coded Rich would you not expect to also see the ABS light?
My thought are the same as @Brian H regarding the ABS module needing to be recoded. If this were the problem I would expect to see both the ABS and ASC lights on. I only have the ACS light. Perhaps others, with a better understanding of the system than could throw some light on this.
 

Brian H

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Do you have INPA? This will allow you to see the status of all the components in the ACS system.
 

roadvoyager1

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@ Brian H Unfortunately not and there do not seem to be any other forum members near me that do (looking on the other Z forum). Just looked at BCables web site and the price of their set-up (excluding PC obviously) is about the same as a local indy has quoted to just plug his BMW reader in and tell me what it sees!!
 

Brian H

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It is a worth while bit of kit, especially if you are keeping hold of your zed for a while, I have used mine an numerous occasions and probably saved a small fortune. If you do opt for the BCables kit make sure you opt for the 20pin connector if this is an option.
 

Zed Carer

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My thought are the same as @Brian H regarding the ABS module needing to be recoded. If this were the problem I would expect to see both the ABS and ASC lights on. I only have the ACS light. Perhaps others, with a better understanding of the system than could throw some light on this.
The ABS is not coded - the system just does a system check and if everything is OK the light goes out, I had this when I fitted a replacement pump/control unit. The ASC function IS CODED to the individual vehicle and it just needs re-coding, IIRC I paid £48.
 
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Haschish

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roadvoyager1, I would love to know if recoding your module worked for you.

My ASC light has been on since I bought my '99 Z3 roadster ~ 3 years ago. I have code: 96 Connection of EGS to CAN bus
when I connect to the port under my hood/bonnet. My module was repaired by modulemaster but this didn't change the continuous ASC light on the dash. I'm thinking perhaps a previous owner changed the module but failed to have it recoded.

Your thoughts are welcome!
 
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