94 E420 project, asr issue and dash brake lights

[DLL]

Hey Everyone
I recently bought a 2nd 94 E420, with ASR. It was local, cheap, and drove home - so couldn't say no. Body decent, interior fair, paint horrible. Previous owner really wanted dual exhaust, so deleted cats and did a muscle car look with small mufflers, it's a bit loud!
It drove fine at highway speed, but would sputter at 4K rpm, not rev higher, like hitting rev limiter.
Parking brake, wear sensor, ABS and ASR lights on full time.
The PO wasn't a car guy, at all. He said something about cutting brake sensor wires - IDK why.
I started at the bottom, some sensors were missing or in bad condition, I had some on hand, replaced the ugly ones. The pads look about 50%.
Under the hood: there was a blown fuse in the BM/GM module (replaced), MAF sensor was loose and flopping around (replaced boot), pcv hoses were broken (replaced), had platinum plugs in horrible condition (replaced with correct non resistor). Distributor caps were wet inside but decent, cleaned up.
Now: I took it for a short drive yesterday on side streets (unplated yet). It was raining. ASR and ABS lights are out. Car will now rev normally in motion. However, when I pulled back into my garage, the ASR light came back on, and it was having the ASR gas pedal response. I checked fuses in the module again all OK.
I disconnected the battery for a minute, on reconnecting ASR light went away.
Parking brake and brake wear lights still on full time.
Any suggestions?
Thanks

 

[gsxr]

ASR light / limp mode will normally reset after you turn the ignition off/on... should not need to disconnect the battery. Next step is pulling blink codes, in particular from pin 7 (E-GAS) for the ASR light mystery.

Brake pad wear light - you'll have to carefully trace all the wiring, but check the sensors & cables at all 4 wheels to start with.

"BRAKE" light... hmm... check fluid level, and level sensor?

 

[DLL]

Thanks
I did most of the above work yesterday.
I'm going to be away a few days, will look into it further late next week.

 

[DLL]

D'oh!
I just checked, brake fluid was low. I just never thought to check as brakes felt fine.
That took care of the parking brake light, sensor light still on, will dig further into that later
Thanks!!

 

[gerryvz]

D'oh!
I just checked, brake fluid was low. I just never thought to check as brakes felt fine.
That took care of the parking brake light, sensor light still on, will dig further into that later
Thanks!!

You should check the brake lines and calipers on all four corners, to ensure that there is no leakage of brake fluid at the wheels. Also of course check the master cylinder, ASR pump area (remove the plastic cover), and so forth. That missing brake fluid went somewhere, so you should do the diligence to see, if anywhere obvious, where it would have disappeared to.

 

[DLL]

You should check the brake lines and calipers on all four corners, to ensure that there is no leakage of brake fluid at the wheels. Also of course check the master cylinder, ASR pump area (remove the plastic cover), and so forth. That missing brake fluid went somewhere, so you should do the diligence to see, if anywhere obvious, where it would have disappeared to.

Funny you should mention that, I just noticed fluid on the floor, left side, under the master cylinder area.
I'll dig into that too later

 

[DLL]

Funny you should mention that, I just noticed fluid on the floor, left side, under the master cylinder area.
I'll dig into that too later

A quick look shows 2 brake lines running through the inner fender. I looked at a non asr E320 parts car (with fenders off), it doesn’t have those lines. So, I’m guessing it’s the brake lines that actually apply brakes, when ASR activated. Probably, one rusted / cracked / leaking or something. Hopefully I can figure an easy way to get to it.