Ducato Relay Boxer Airbag Control Module failure.

[Brian Kirby]

This issue has been discussed several times on here, but I thought it might be helpful to post some general guidance on what to look for, what it means, and what to do about it.

First, the symptoms.

If the module develops a fault, you are likely to experience all or some of the following, as soon as the ignition is turned on, or later while driving.

1  Repeated alarm "bleeps", accompanied by a dashboard message "airbag - read manual".  This may persist for a while when driving but should cease after a few miles.  (Reading the manual is unlikely to be of much help, as the guidance is directed towards turning off, or on, the passenger airbag in the event you have fitted a rear facing child seat on the front passenger seat.)

2  A red warning light with a https://i0.wp.com/dashboardsymbols.com///wp-content/uploads/2010/11/SRS_air_bag_indicator.gif?resize=65%2C46&ssl=1 symbol on the dashboard.

3  An amber warning light with a https://i0.wp.com/dashboardsymbols.com/wp-content/uploads/2021/07/Air-bag.gif?resize=65%2C45&ssl=1 symbol on the left-hand end of the row of switches/lights either side of the hazard warning lights switch, just below the heater controls.

4  The mileometer readout flashing on and off. 

At the time the fault first arises these failure signs may spontaneously disappear, but will later reappear, possibly spontaneously, possibly when the engine is next re-started.

What the above are signalling is a failure in the airbag control module.  There are two possible remedies.  Both require connection of diagnostic equipment to confirm that a failed module is the cause.

First, if you have your own diagnostics, and know how to use them, you will get the diagnosis without further expense. You will then need to remove the module and send it for repair.  This should be the cheapest route.  "Crash Data" is one firm that can do this on a fast turnaround and have been very well reviewed.

Second, if you do not have your own diagnostic equipment, or do not feel competent to disconnect and remove the control module, you will need to get the van to a garage with suitable diagnostic equipment.  They may then be able to a) have your module repaired, or b) obtain a replacement module.

Third, and in some respects the cherry on the cake; take the van to a Fiat/Citroen/Peugeot authorised workshop, who will have the appropriate diagnostic equipment and access to replacement control modules.  Why the cherry on the cake?  Well, if, when you get the garage diagnosis confirming that the control module has failed, you contact the Fiat/Citroen/Peugeot customer service number, explaining that your van has a confirmed failed airbag control module, you should find that they will offer a replacement module free of charge, delivered to the garage and, depending on the age of the van, may also agree to contribute to the labour costs for diagnosis and repair.

There are numerous reports of this component failing, and also of the base vehicle manufacturer providing replacement modules free of charge, and in some cases contributing to the labour costs.

This is the limit of my current experience, as I do not yet have the final picture due to an outstanding query on UK stock of the modules.

The replacement module was volunteered FoC, but the matter of labour charges has not yet arisen.  As our van is a LHD direct import from Germany, so had the "Eurostandard" two-year warranty, and is now almost five years old, I'm thinking myself lucky to get the free module, so any contribution to the labour costs would be the real cherry on the cake!  Still, fingers crossed!

[rayc]

When my air bag module failed I received great service from Northern Auto Services https://northernautotech.co.uk/airbag-ecu-repair/

[TeamRienza]

Useful post Brian, mine failed in 2017 (2016 Fiat Ducato) and was out of warranty. Without much hassle Fiat sent a replacement unit (foc) to my dealer (Hymer and Fiat professional agents) who fitted it free of charge.

Definitely worth pursuing Fiat.

 

Davy

[Zydeco Joe]

Brians post is spot on I know as ours went this June while in Europe. When or if it happens to anyone like Brian said is get it checked out by a FIAP professional dealer but and I mean BUT DO Not Pay for it to be fixed till you (or the FIAT Dealer) get a message from FIAT telling you they will pay for the new unit. IF you do pay FIAT will NOT give you the free part that cost about £250. Be warned.

[Steve928]

 

On 11/18/2022 at 6:54 PM, Brian Kirby said:

..Well, if, when you get the garage diagnosis confirming that the control module has failed, you contact the Fiat/Citroen/Peugeot customer service number, explaining that your van has a confirmed failed airbag control module, you should find that they will offer a replacement module free of charge, delivered to the garage and, depending on the age of the van, may also agree to contribute to the labour costs for diagnosis and repair.

 

I'm not aware of any Peugeot owner receiving a replacement module free of charge, despite many trying and mentioning the support given by Fiat regarding the identical module. Are you that this applies to Peugeot & Citroen too, Brian?

[paulmold]

I've seen these modules for sale on ebay (used ones ) for £25-  £40, can these be any good, presumably they don't need to be programmed to van if Crashdata can supply new ones or do they ?

[Derek Uzzell]

If a new (or used) airbag control module is fitted, it must be programmed to match the vehicle it is installed in. Reprogramming is a task that will normally need to be carried out by a main agent for the make of vehicle involved.

(My understanding was that CrashData only offered a repair/reset service of the airbag module that was already on a vehicle.)

[rayc]

55 minutes ago, Derek Uzzell said:

(My understanding was that CrashData only offered a repair/reset service of the airbag module that was already on a vehicle.)

They also sell new modules in the event that the original cannot be repaired. If possible they can clone the data  from the original otherwise it needs 'programming' to the vehicle. An example below:

https://www.crashdata.co.uk/fiat-1393755080-new-airbag-module-p/6001.htm

[witzend]

Heres a short cut if Your MOT is due and You need a quick fix

 https://tinyurl.com/5e6skymn

[rayc]

35 minutes ago, witzend said:

Heres a short cut if Your MOT is due and You need a quick fix

 https://tinyurl.com/5e6skymn

I wonder if it the warning lamp still comes on when ignition is switched on before going out after 20 seconds or so? My display also had a scrolling warning message of airbag failure, would that continue?

[Brian Kirby]

16 hours ago, Steve928 said:

 

I'm not aware of any Peugeot owner receiving a replacement module free of charge, despite many trying and mentioning the support given by Fiat regarding the identical module. Are you that this applies to Peugeot & Citroen too, Brian?

That may be my error Steve, in which case my apologies to anyone whose hopes were erroneously raised.

I'm afraid had assumed, based on the numerous reports of constructive customer support for Ducatos that, as the vehicles were/are so closely related, and since the merger Fiat/Chrysler and Peugeot in to form Stellantis in 2021, there would be harmonisation on out of warranty responses on acknowledged defects.  But, from what you say, possibly not.

There seems little doubt that this defect is broadly acknowledged within the group, and I gathered a general recall had been considered within the group - but has seemingly not been imposed because the defect does not of itself present a general risk to road safety.  The technician at the garage our van is now at for repair said he deals with this defect more than once a month - and that is just one garage.

Maybe PSA based van owners should be speaking to DVSA?  It seems this defect has at least the potential (per DVSA leaflet ref: VOSA/SUP/2581A/APRIL 14 on safety recalls), "to put you, your passengers or other road users in danger if not acted upon".

[Grumpyman]

I had a Air bag module failure and contacted Fiat in Italy who sent me a letter of Intent for the sum of £200 to present to a fiat dealer.

[Steve928]

These are the instructions from Peugeot, taken from a service bulletin, on how to add an external earth cable to the airbag ECU, a modification that they now carry out when replacing a failed ECU. The elements of the airbag system use a common earth on the ECU's pin #1 - perhaps an earth problem is part of the reason why spurious voltages are detected in the ECU. I'll certainly be adding this when I get the chance.

 

[silverback]

Cheers Steve 928 will do this sometime

Jonathan

[the1andonly]

A new module can be added to a Ducato using a "proxi alignment" (writing ID to CANBUS control) with the  software Multiecuscan . Alfaobd may also (not checked or used) be able to do this and is applicable to Fiat, Citroen, Peugeot.

[Steve928]

It's 3 years since I had a Boxer but at that time AlfaOBD would only communicate with modules that shared the same ISO code with the Ducato i.e. it seemed that the developer had added Peugeot/Citroen to the menus and nothing more. So, for example, communicating with the TPMS module worked fine but trying to connect with an engine ECU failed - unsurprisingly it couldn't find a Bosch or Marelli 2.3 ECUs on the vehicle..

AlfaOBD may have improved, although I don't recall many updates and the listed ECUs remain the same, so personally I'd be very wary of initiating a proxi-alignment on a Peugeot/Citroen/Vauxhall (I guess we can't say PSA anymore?) vehicle with it. Communication with individual ECUs, if they connect, would seem to be fine.

[Robinhood]

I'm the latest to suffer this issue.

Funnily enough, I had a minor blip on the day Brian made his first post, but it cleared itself (and I used Multiecuscan to remove any residual effects).

All has been quiet since but, despite a couple of test starts before this morning's journey for a few days away, it then threw a fault as I drove off the drive.

Various symptoms as above, but it has settled down to the regular airbag ECU "internal corruption" code and the airbag light on.

I've decided to have the few days away and not have a crash 😉, and now need to decide the best way ahead.

Frankly, given I can determine codes and do a proxi-align if need be, for convenience I'm inclined to sort it myself, so I think an initial attempt at a reflash by a "specialist", and if that doesn't work/last, a (new) replacement from one of the resellers.

[Robinhood]

The error code is B0100-49 which appears to be one of those that can be remedied by various suppliers.

I removed the unit earlier today, and it's waiting to go off by post first thing Monday.

It was mildly fiddly, but largely only because working at floor-level in a Ducato is a job for a double-jointed dwarf, and I'm neither. The small piece of trim that has to come off to expose two of the retaining bolts was probably the most awkward.

I took all the necessary precautions to "quiesce" everything before removal, and also disconnected the solar panel and leisure batteries, just in case.

Fingers crossed 🤞. Whilst it's away I'll look at making up an additional earth lead, as per a post above.

[Brian Kirby]

You're a far braver man than me, Bob!  🙂  Hope it all turns out well.

[Robinhood]

3 hours ago, Brian Kirby said:

You're a far braver man than me, Bob!  🙂  

Possibly more foolhardy - we shall see!   👀💨

[rayc]

I had great service from the guy who runs this company. 

https://northernautotech.co.uk/airbag-ecu-repair/

 

[Robinhood]

On 12/6/2022 at 9:33 AM, Steve928 said:

These are the instructions from Peugeot, taken from a service bulletin, on how to add an external earth cable to the airbag ECU, a modification that they now carry out when replacing a failed ECU. The elements of the airbag system use a common earth on the ECU's pin #1 - perhaps an earth problem is part of the reason why spurious voltages are detected in the ECU. I'll certainly be adding this when I get the chance.

FWIW, scrutiny of my wiring now the unit is removed reveals that the loom from one of the connectors is earthed to a nearby stud.

Interestingly enough, I'm not convinced it is entirely as originally designed, as the lead is separate but attached to the main loom with yellow electricians tape, and it looks like a  fly-lead (much as in the Peugeot illustration) but disappearing into the connector instead.

I have no intention of dissembling that any further, but I have made up a separate lead which will be additionally attached as per the Peugeot picture. (6mm ring terminal and star washer each end for anyone who wants to make their own).

[Robinhood]

On 1/22/2023 at 9:43 AM, rayc said:

I had great service from the guy who runs this company. 

https://northernautotech.co.uk/airbag-ecu-repair/

 

Mine went off the there this morning.

I can't say I'm fully confident that 

i) it will be fixable (though the code captured is one that ostensibly should be clearable by them flashing it)

ii) even if it is fixed, that it wont then re-occur

...but, at £60 all-in (and some labour and sucking of teeth from me), I have to give it a go.

[Steve928]

20 hours ago, Robinhood said:

FWIW, scrutiny of my wiring now the unit is removed reveals that the loom from one of the connectors is earthed to a nearby stud.

Interestingly enough, I'm not convinced it is entirely as originally designed, as the lead is separate but attached to the main loom with yellow electricians tape, and it looks like a  fly-lead (much as in the Peugeot illustration) but disappearing into the connector instead.

I have no intention of dissembling that any further, but I have made up a separate lead which will be additionally attached as per the Peugeot picture. (6mm ring terminal and star washer each end for anyone who wants to make their own).

I recall reading somewhere recently of an airbag ECU replacement at a Peugeot dealer where the loom was opened up and the negative lead (pin 1 at the airbag ECU) was taken to a chassis stud just as you describe. This seemed like possibly a more effective solution than just earthing the ECU's casing but then as yours has failed even with this modification it would seem to indicate that everyone is still clutching at straws.

[Robinhood]

....unless it was done by Hymer, it would be original, not a subsequent replacement (but it certainly looks a bit "Heath Robinson").