BODY CONTROL UNIT
DESCRIPTION AND OPERATION 86-3-27
If a direction indicator bulb failure or a trailer presence is detected, the following outputs can be generated depending
on the BCU logic states:
lTrailer detected.
lBulb failure detected.
lDirection indicator short circuit.
lDirection indicator relay stuck.
The BCU can be configured whether or not to provide bulb failure warnings.
When the direction indicators are operating, instrument pack direction indicators flash in sequence with the exterior
direction indicators. If a failure of an indicator bulb occurs, the corresponding instrument pack indication lamp will flash
quickly to warn of the problem.
The IDM monitors the current drawn through the circuit to detect for the occurrence of a lamp failure. If an indicator
lamp fails, the IDM detects the drop in current drawn through the resistor and operates the indicator relay at a faster
speed. The fast flash is demonstrated on the instrument pack direction indicator warning lamps to bring attention to
the driver that a direction indicator bulb failure has occurred. The current sense for the related indicator lamps (RH or
LH) are checked when a direction indicator request has been made that lasts for at least 160 ms. The current level
sensed is relative to the number of working bulbs and determines the request generated by the BCU.
The output is signalled to the instrument pack using the serial communications link. If the hazard warning lamps are
operating, both sets of direction indicators are checked using the current sensing functions to check the number of
bulbs on each side of the vehicle.
If the BCU detects that a direction indicator request has not been made, but one or other of the current sense inputs
indicate that current is flowing, a 'Relay stuck' output is generated.
Hazard lamps
The BCU controls the operation of the hazard warning lamps via the IDM and dedicated relays. The hazard warning
lamps are activated under the following conditions:
lThe vehicle is locked and the security system is set (the hazard warning lamps flash three times if the
superlocking feature is used, once if not).
lThe vehicle is unlocked (the hazard warning lamps flash once for a duration of two seconds).
lThe anti-theft alarm system is triggered (the hazard warning lamps flash in phase with and for the duration of the
audible warning).
lThe hazard warning switch is pressed (the hazard warning lamps flash until the hazard warning switch is pressed
for a second time).
lThe inertia switch is triggered (the hazard warning lamps flash until the inertia switch has been reset).
The hazard warning lamp operation may differ dependent on market and customer configuration options.
The hazard warning lamps are operated from a latching pushbutton switch located on the fascia. When the switch is
pressed, both left and right indicator lamps in the instrument pack flash to show that the hazard warning lamps are
operating and all hazard warning lamps flash simultaneously. If a trailer is fitted, the ICM detects this and a trailer
symbol in the instrument pack also flashes to show correct operation of the trailer direction indicators and hazard
warning lamps.
The BCU supplies a reference voltage to the hazard warning switch. When the hazard warning switch is operated an
earth path is completed which signals the BCU that a request for hazard lamp operation has been made. The BCU
then sends a signal to the IDM via the serial data bus to communicate the request. The IDM supplies an earth path
for both direction indicator relay coils simultaneously so that the hazard warning lamps are turned on concurrently.
The IDM controls the timing of the flash operations by continually removing and restoring the earth path to both
direction indicator relay coils simultaneously.
Number of working bulbs Request generated
3 Trailer detected
2 None (bulbs okay)
1 Bulb failure detected
0 Direction indicator short circuit detected
BODY CONTROL UNIT
86-3-30 DESCRIPTION AND OPERATION
Interior courtesy lamps
To determine when to provide an interior courtesy lamps enable output, the BCU checks the following input
conditions:
lIgnition state.
lTransit mode.
lDriver's door open.
lPassenger or rear door open.
The courtesy lamps operate at full brightness when they are first switched on. The BCU then gradually dims the lamps
(fade-out) before completely switching them off. Fade-out occurs over a period of two seconds following the logical
control signal to turn off the lights. When a door is opened, the BCU provides earth paths from the interior lamps, the
load space lamp and the ignition switch illumination. The following table lists the courtesy lamps operation and
duration for holding the lamps on that occurs after the BCU has detected a condition that signals the courtesy lamps
should be switched on:
Instrument pack
The BCU communicates with the instrument pack to provide a range of functions.
Odometer update
The BCU can be programmed for one of two options:
lOption 1 – no odometer error warning.
lOption 2 – odometer error warning.
In order to provide an LCD flash request to the instrument pack via the communications link, the following inputs are
checked:
lIgnition state.
lInstrument pack odometer value (via the communications link).
lBCU odometer value.
The function is only active when the ignition state is on. The maximum allowed value is 999,999 miles (1,608,999
km).If the instrument pack odometer value is greater than the maximum allowed value, the maximum value is
assumed. The BCU odometer value is stored in EEPROM. If 16 identical values of the instrument pack odometer
reading is received consecutively, the instrument pack odometer value is compared with the BCU odometer value. If
the consecutive readings from the instrument pack differ, the BCU odometer value is incremented accordingly. If the
BCU odometer value is less than the instrument pack odometer value by up to 10 km, the BCU odometer value is set
equal to the instrument pack odometer value.
If the odometer warning option is enabled, and the contents of the instrument pack odometer value buffer is identical
to, or greater than BCU odometer value ± 10 km, the BCU sends an LED flash request to the instrument pack.
In the event of a communications link failure, this function will be unable to operate.
Control signal Additional conditions Duration
Door open - 10 minutes
Unlock signal from remote transmitter All doors closed and ignition switch not in
position III1 minute
Unlock signal from the driver's door lock All doors closed and ignition switch not in
position III1 minute
Ignition switch turned from position II or III to
position 0All doors closed 1 minute
Door changed from open to closed All other doors closed and ignition switch not
in position III15 seconds
Ignition switch in position III - Timer cancelled
BCU receives a lock command - Timer cancelled
Vehicle has transit mode enabled - 15 seconds on all occasions
BODY CONTROL UNIT
DESCRIPTION AND OPERATION 86-3-31
Gear position indicator illumination
On automatic gearbox models, two variations of illumination for the gear position indicators on the selector lever can
be programmed into the BCU. In option 1, illumination is provided when the ignition is on. In option 2, illumination is
enabled when the ignition is on and the side lamps are off.
Starter relay
The BCU checks the status of the following inputs and internal BCU conditions to determine whether or not to provide
an output to enable the starter relay:
lAutostart inhibit (vehicles with automatic gearbox only).
lSecurity start inhibit (immobilisation check).
lEngine running (link to instrument pack).
lEEPROM locked (internal check).
lIDM and BCU matched.
When the BCU receives a crank signal from the ignition switch, an earth path is completed to the starter relay coil,
provided that the security system has been de-activated. If the ECM has not received a valid unlock/ remobilise signal,
the starter relay will be disengaged and the engine stopped. The BCU also receives an engine running signal from
the instrument pack, so that if the ignition key is turned to the crank position while the engine is running, the starter
motor relay will not be engaged.
If the logic conditions are correct to allow starter operation, the completion of the earth path from the starter relay coil
to the BCU energises the coil and the relay contacts close to supply battery power to the starter motor.
When the ignition switch is released from the crank position, the power supply feed from the ignition switch to the
starter relay coil is interrupted and the relay contacts open to prevent further battery feed to the starter motor.
If a communications link failure is experienced, the BCU will be prevented from detecting the 'engine running'
condition and the BCU will default to assume that the engine is not running.
Cruise control
The Neutral/ Reverse/ Park/ Brake selected output is used by the cruise control system. The BCU checks for the
following inputs:
lIgnition on.
lGearbox state.
lBrake switch activated.
For vehicles with manual transmission, Neutral/ Reverse/ Park/ Brake selected output is on if the ignition is on and
brake switch activated is on. Otherwise, the Neutral/ Reverse/ Park/ Brake selected output is off.
For vehicles with automatic transmission, the Neutral/ Reverse/ Park/ Brake selected output is on if the ignition is on
and brake switch activated is on, or if the ignition is on and 'gearbox state' is in Neutral, Park or Reverse. Otherwise
Neutral/ Reverse/ Park/ Brake selected output is off.
Shift interlock (where fitted)
On automatic gearbox models, the BCU and IDM combine to operate a shift interlock solenoid, so that the gear
selector lever can only be moved when certain logical conditions have been satisfied. Operation of the interlock may
be affected, if the battery becomes discharged.
+ AUTOMATIC GEARBOX - ZF4HP22 - 24, DESCRIPTION AND OPERATION, Description.
When the gear selector lever is in the Park position and the ignition is off, an interlock solenoid is de-energised, locking
the gear selector lever in the Park position.
The gear selector lever can only be moved from the Park position when the ignition is switched on and the brake pedal
is depressed. When these conditions are satisfied, the brake pedal switch signal is received by the BCU which then
signals the IDM to energise the interlock relay. When the interlock relay is energised, the interlock solenoid is
operated, unlocking the gear selector lever.
When the brake pedal is released, the feed to the BCU is removed and the shift interlock solenoid is de-energised.
The locking mechanism controlled by the solenoid will lock the gear selector lever once it is returned to the Park
position.
BODY CONTROL UNIT
86-3-34 DESCRIPTION AND OPERATION
Key-in warning
The BCU can be programmed to one of two options:
lOption 1 – no timeout.
lOption 2 – no key-in warning.
The BCU issues an audible warning No. 2 request, depending on the status of the following inputs:
lIgnition state.
lIgnition key inserted.
lDriver's door open.
If the key-in warning is programmed into the BCU for operation, audible warning No.2 will be requested if the ignition
switch is off, the ignition key inserted signal is on and the driver's door open signal is ON.
In the event of a communications link failure occurring, the audible warning request is not sent to the instrument pack.
SLABS HDC warning
The BCU issues an audible warning No. 3 request, depending on the status of the following inputs:
lIgnition state.
lSLABS HDC warning.
The SLABS warning transmitted by the SLABS ECU is a 2 Hz signal, audible warning No. 3 is requested on every
falling edge of this signal. If the signal from the SLABS ECU stays low for more than 650 ms, audible warning No. 3
is requested every 2 seconds, for 30 seconds, while the signal stays low.
In the event of a communications link failure occurring, the audible warning request is not sent to the instrument pack.
Transfer box in neutral warning
If the transfer box is in the neutral position and the ignition switch is on, the BCU issues an audible warning No. 4
request. The BCU checks for the following inputs:
lTransfer box neutral selected.
lIgnition on.
The transfer box in neutral warning is activated by communicating with the instrument pack via the serial datalink. If
a communications link failure occurs while the transfer box in neutral warning is active, the audible warning will not
operate.
Lights on warning
If the ignition switch is off while the side lamps or headlamps on and the driver's door is opened, the BCU issues an
audible warning No. 5 request.
The BCU checks for the following inputs:
lDriver's door open.
lIgnition on.
lSide lamps.
lDipped beam state.
lMain beam state.
The lights on warning is activated by communicating with the instrument pack via the serial datalink. If a
communications link failure occurs while the lights on warning is active, the audible warning will not operate.
SLABS raise/lower
Before enabling a SLS vehicle raise/ lower request, the BCU checks the logical condition of the following inputs:
lIgnition state.
lSLABS raise request.
lSLABS lower request.
If the ignition switch is in position 0 or I, the vehicle raise/ lower request is off.
With the ignition switch in position II, and the 'SLABS raise' request and 'SLABS lower' request both off, the vehicle
raise/ lower request output is driven at 25 Hz with a 50% duty cycle and the vehicle height remains unchanged.
If the 'SLABS lower' request input is on, the vehicle raise/lower request output is driven at 25 Hz with a 25% duty cycle,
lowering the vehicle.
If the 'SLABS raise' request input is on, the vehicle raise/lower request output is driven at a 25 Hz with a 75% duty
cycle.
BODY CONTROL UNIT
REPAIRS 86-3-35
REPAIRS
Body control unit (BCU)
$% 86.55.75
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove 4 bolts securing glove box and remove
glove box. 4.Remove 4 fixings securing closing panel and
remove panel.
5.Disconnect 5 multiplugs from BCU.
6.Remove nut and bolt securing BCU to bracket
and remove BCU.
BODY CONTROL UNIT
86-3-36 REPAIRS
7.Remove rubber ring from locating peg.
Refit
1.Fit rubber ring to new BCU.
2.Fit BCU to bracket and secure with nut and bolt.
3.Connect multiplugs to BCU.
4.Fit closing panel and secure with fixings.
5.Fit glove box and secure with bolts.
6.Connect battery earth lead.
7.Fit battery cover and secure with fixings.
8.Programme and calibrate new BCU using
TestBook.
ALARM SYSTEM AND HORN
DESCRIPTION AND OPERATION 86-4-17
Operation
Standard system functions
All vehicles have the following functions as standard.
lLocking.
lUnlocking.
lFuel cut off switch unlocking.
lInternal locking.
lElectric fuel flap release.
Locking
The doors are locked by pressing the lock button on the handset or by locking the vehicle from the driver's door with
the key.
In order to lock the vehicle, the following conditions must be met:
lThe driver's door is closed.
lThe ignition is off.
lThe fuel cut off switch is not tripped.
lThe bonnet is closed.
lThe vehicle is not super locked.
Depending on system configuration a mislock occurs if these conditions are not met. The doors may lock (depending
on condition not met) and the system may not fully arm, depending on configuration of the system. If a mislock occurs
an audible warning is emitted and the vehicle becomes partially armed.
Unlocking
The doors are unlocked by pressing the unlock button on the handset or by unlocking the vehicle from the driver's
door with the key. This may unlock only the driver's door or it may unlock all doors depending on system configuration.
Fuel cut off switch unlocking
In the event that the vehicle experiences a force strong enough to actuate the switch, all the doors on the vehicle
immediately unlock. The following conditions must be met for this to occur:
lThe security system is not armed.
lThe ignition is on.
This same action causes the fuel pump to shut off and disables the Engine Control Module (ECM). In some markets,
this action may also cause the direction indicators lights to flash.
ALARM SYSTEM AND HORN
86-4-22 DESCRIPTION AND OPERATION
The code is recorded on the security information card and is entered as follows:
1Using the key, turn the driver's door lock to the UNLOCK position and hold in this position for at least 5 seconds.
An audible warning is then emitted to indicate that the body control unit is ready to accept the code. Return the
key to the centre position. It is now possible to use the key to enter the separate numerical values of the four
digits that make up the EKA code.
2Enter the first digit of the code. If the first digit is 4, turn the key to the UNLOCK position 4 times. Ensure the
key is fully returned to the centre position after each turn of the key.
3Enter the second digit of the code. If the second digit is 3, turn the key to the LOCK position 3 times. Ensure
the key is fully returned to the centre position after each turn of the key.
4Enter the third digit of the code. If the third digit is 2, turn the key to the UNLOCK position twice. Ensure the key
is fully returned to the centre position after each turn of the key.
5Enter the fourth digit of the code. If the fourth digit is 1, turn the key to the LOCK position once. Ensure the key
is fully returned to the centre position after each turn of the key.
6Finally, turn the key to the UNLOCK position and back to the centre position, a double bleep will indicate that
the code has been entered correctly. A single bleep indicates that the code has been entered incorrectly.
Then, before opening the door, wait 5 minutes for the alarm and immobiliser to be de-activated. During the 5
minute wait for the alarm and immobiliser to be de-activated, the alarm indicator LED in the instrument pack
continues to flash (one flash every 2 seconds). DO NOT OPEN THE DOOR OR ATTEMPT TO ENTER THE
CAR until the full delay period has elapsed.
When the 5 minute wait has elapsed, the alarm indicator LED stops flashing. Immediately open the door, insert
the key in the ignition switch and turn the switch to position II. If the ignition switch is not turned to position II
within 30 seconds of the end of the 5 minute wait, the engine is automatically immobilised again.
The EKA code will not be recognised if there is an interval of 10 seconds or more between key turns or if the key is
held turned for 5 seconds or more during the procedure.
In some system configurations a successful EKA code entry is indicated by the audible warning device pulsing twice
for a period of 50 ms on, 200 ms off. The theft deterrent LED is switched on for 1 second, all doors unlock, the alarm
disarms and the vehicle is remobilised allowing the engine to start.
If an incorrect code is entered, an audible warning is emitted and the procedure must be repeated. Up to a maximum
of 10 attempts to enter the code is possible. After 10 attempts, the BCU will not allow any further codes to be entered
for a period of 10 minutes.
Single point entry
Single point entry (SPE) allows the driver to unlock the driver's door while leaving all other doors locked.
There are two configurations for single point entry:
lSPE not active.
lSPE active.
To use SPE, press the unlock button on the handset once. Depressing the unlock button a second time in the space
of one minute unlocks the remaining doors. SPE is also possible by turning the key in the driver's door lock to the
unlock position once. Turning the key to the unlock position again within one minute unlocks the remaining doors.
In order for SPE to operate, the following conditions must be met:
lThe ignition is off.
lAll doors are locked.
Speed related locking
For added protection the vehicle doors can automatically lock when the vehicle exceeds a specific road speed.
There are two configurations for speed related locking:
lSpeed related locking not active.
lSpeed related locking active.
Speed related locking causes the doors to automatically lock when the vehicle exceeds a speed of 4 mph (7 km/h).
When the ignition is switched off, the doors are automatically unlocked. Depressing the instrument panel mounted
central door unlocking switch disables the speed related locking for the duration of the journey.
Speed related locking only activates once per ignition cycle. If speed related locking activates and a door is then
unlocked, the door does not automatically re-lock.