Documente Academic
Documente Profesional
Documente Cultură
3041A
B54X
For the sections not described in this note, refer to M.R. 302.
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the reference numbering system is forbidden without the prior written authority of
manufacturer in the production of the various component units and accessories Renault.
from which his vehicles are constructed."
C Renault 1998
Contents
Page
38 ELECTRONICALLY CONTROLLED
HYDRAULIC SYSTEM
OPERATING PRINCIPLE
The ABS computer calculates vehicle speed using the wheel speed and tyre circumference information stored
in the computer (see page 38-10).
On SAFRANE vehicles, the braking compensator is not fitted and its role is ensured by a programme stored in
the ABS assembly computer and is known as REF (Electronic Braking Distributor).
IMPORTANT: if the fuse is removed, do not brake sharply during a road test as the REF function is no longer
activated (identical front and rear pressure), there is therefore a risk that the vehicle will spin. (Rear wheel
lock-up).
IMPORTANT NOTE
As a result of the standardisation of the ABS sensors on the SAFRANE: modification to the sensor due to
development of the ABS (BOSCH 4.2 → BOSCH 5.3), the following procedure will have to be observed:
the depth of the sensor mounting hole in the stub-axle carried has been increased. However, to be able to fit
the new sensor in the old stub-axle carrier, the new bolt 77 03 006 227 must be shortened by 2 mm.
This operation may be carried out on vehicles manufactured before December on which the ABS sensor or its
mounting bolt need to be replaced.
38-2
ABS BOSCH 5.3
without
speedometer
signal function
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
THE 31 TRACK CONNECTOR
PRN3813
A Micro-spring connecting pins 20 and 21 (ABS and NIVOCODE warning lights) to earth (terminal 19) in the
event of the connector becoming disconnected
38-3
ABS BOSCH 5.3
with
speedometer
signal function
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
THE 31 TRACK CONNECTOR
PRN3813
38-4
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
DIAGNOSTIC SOCKET
PRN3807
4 Chassis earth
5 Electronic earth
16 + battery
38-5
ABS BOSCH 5.3
without
speedometer
signal function
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
WIRING DIAGRAM
PRN3811
38-6
ABS BOSCH 5.3
without
speedometer
signal function
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
WIRING DIAGRAM KEY
38-7
ABS BOSCH 5.3
with
speedometer
signal function
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
WIRING DIAGRAM
PRJ15083
38-8
ABS BOSCH 5.3
with
speedometer
signal function
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
WIRING DIAGRAM KEY
38-9
ABS BOSCH 5.3
with
speedometer
signal function
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
The tyre circumference is to be programmed into the memory of the new computer. This consists of entering
a suffix "X" using the XR25 and command G30*X*.
195/60R 15
195/65R 15 154
205/55R 16
Once the suffix is entered using command G30*X*, erase the computer memory, then switch off the ignition.
Due to the complete mechanical, hydraulic and electrical compatibility between the computers and the ABS
Bosch 5.3 hydraulic assemblies with and without the speedometer signal function, the component part num-
bers have been standardised.
In replacement and repair operations only computers with speedometer signal function will be fitted, even
on vehicles equipped with 1st generation computers (without the speedometer signal function).
When a computer is replaced and the ignition is switched on, the ABS warning light flashes rapidly indicating
that the tyre circumferences have not been programmed into the computer which allow the vehicle speed to
be calculated (even if the computer’s speedometer signal function is not used on the vehicle).
The flashing of the ABS warning light can be stopped by entering suffix 154 using command G30*154* on the
XR25.
ABS computers with the speedometer signal function are identified by code
on the XR25 display.
38-10
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
REMOVAL - REFITTING OF THE HYDRAULIC Release:
ASSEMBLY / COMPUTER - the six pipe unions* on the hydraulic assembly,
- the three hydraulic assembly/computer moun-
ting bolts.
TIGHTENING TORQUES (in daN.m)
REMOVAL
Remove:
- the front left hand wheel,
- the engine undertray,
- the wheel arch protector,
- the side mud guard.
11532S
11531S
38-11
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
Completely remove the mounting bolts and the SPECIAL NOTES FOR REMOVAL / REFITTING OF
six pipe unions. THE HYDRAULIC ASSEMBLY / COMPUTER ON
SAFRANE VEHICLES EQUIPPED WITH THE N7U
REPLACING THE COMPUTER ENGINE
The computer may be replaced. In this case, it will Due to the location of components in the engine
be necessary to carry out the procedure indicated compartment, the removal-refitting of the hy-
on page 38-9. draulic assembly / computer is different in some
ways.
Refitting is the reverse of removal. It is necessary to remove the battery and its tray to
access the bolt (1).
Bleed the hydraulic circuit, observing the correct
order for the operations (see page 38-13).
11703R
REFITTING
38-12
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
BLEEDING
Bleeding procedure after replacement of the hydraulic assembly, master cylinder, pipes between the assem-
bly and the master cylinder.
1) Bleed the braking circuit in the conventional way by foot or use a tool which supplies a pressure of 1 bar
maximum.
If pedal travel is not correct after a road test with ABS regulation, bleed the ABS hydraulic circuit as indi-
cated below.
NOTE: bleed the system beginning with the rear right hand brake, then the rear left, front left then front
right.
a) Bleed the rear right hand brake by bleeding the secondary circuit of the hydraulic assembly using the
XR25.
b) Carry out the procedure described in a.1 to a.5 for the rear left, front left and front right brakes.
IMPORTANT: ensure that there is always enough brake fluid in the reservoir.
With the vehicle on a lift, the wheel to be tested is raised. One of the operators should be in the driver’s seat
with an XR25 test kit. Switch on the ignition, with the vehicle in neutral and in fault finding mode and press
the brake pedal. The second operator should apply a torque to the wheel so as to try and rotate it.
The operator generates a suitable command on the XR25 test kit which performs the cycle ten times: alter-
nate fall then rise in pressure on the wheel being checked. At the wheel, these actions on the ABS result in
the wheel alternately locking up and releasing ten times. The vibrating movements on the wheel, recorded
qualitatively by the operator show that the hydraulic circuit of this wheel is correctly connected.
The programme installed on the XR25 to perform this sequence is the following:
38-13
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
CHECKING THE WHEEL SPEED SENSORS
2) When possible, a visual check of the target teeth. Otherwise, start the procedure for checking if teeth are
missing (carried out by a computer programme).
38-14
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTRODUCTION
The checks defined in this fault finding are only to be applied to a vehicle if the description of the fault being
dealt with corresponds exactly with the display on the XR25 .
If a fault is dealt with due to a bargraph flashing, the conditions for confirming the actual presence of the
fault (and the need to apply fault finding) are given in the "Notes" box or at the start of the bargraph
interpretation procedure.
A bargraph should only be interpreted when it is permanently illuminated. Applying the tests recommended
in the fault finding when the bargraph is flashing will not allow the fault memorised to be located. In this
case, only the wiring of the faulty component should be checked (the fault is simply memorised since it was
not present at the time of the test).
NOTE: the ignition must have been switched off before use of the XR25 .
- Multimeter
Reminders: When memorising an intermittent fault, the ABS warning light will illuminate the next time the
vehicle is used until the speed equals 7.5 mph (12 km/h). When the fault is memorised, a counter
associated with the fault is set to 40. The value will be reduced each time the ignition is switched
on if the fault is not present when the vehicle speed exceeds 7.5 mph (12 km/h).
When the counter value equals 1, it is no longer reduced and the fault is erased.
B54532.0
38-15
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - XR25 FICHE
FI21853
B54532.0
38-16
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - XR25 FICHE
MEANING OF BARGRAPHS
If illuminated, indicates a fault on the product tested. The associated text defines the
fault.
The bargraph can be:
- Illuminated : fault present.
- Flashing : fault memorised.
- Extinguished : fault absent or not detected.
If it remains extinguished
- The code does not exist.
- There is a tool, computer or XR25 / computer fault.
or
Indefinite
is illuminated when the function or condition specified on the
fiche is being met.
Extinguished
Additional details:
Some bargraphs have a *. The command *.., when the bargraph is illuminated, which is used to display
additional information about the type of fault or status present.
B54532.0
38-17
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
Fiche n° 53
1
Bargraph 1 RH side extinguished
Code present
NOTES None.
Ensure that the XR25 is not the cause of the fault by trying to communicate with a computer on another
vehicle. If the XR25 is not at fault and dialogue is not established with any other computer on the same
vehicle, it may be that a faulty computer is disrupting fault finding lines K and L. Disconnect each
computer in turn to locate the faulty one reentering DII each time.
Check that the ISO selector is in position S8, that you are using XR25 cassette 18 and the correct access
code.
Check the battery voltage and carry out the necessary operations to obtain the correct voltage (9.5 volts
< U battery < 17.5 volts).
Check for the presence and condition of the ABS fuse on the passenger compartment connection unit
(10A).
Check the connection of the computer connector and the condition of its connections.
Check the connection and the condition of the connections for the front left wing / ABS (R179) +
passenger compartment / front left wing (R150) connectors.
Check the ABS earths (tightening of the two earth bolts in front of the front left hand wheel arch).
Check that the computer is correctly fed:
- earth on track 19 of the 31 track connector,
- + after ignition feed on track 15 of the 31 track connector.
If dialogue is still not established after these various checks, replace the ABS computer.
AFTER When communication has been established, deal with any illuminated fault
bargraphs.
REPAIR
B54532.0
38-18
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
Fiche n° 53
1
Bargraph 1 LH side illuminated
Feed / Computer
NOTES None.
Check the condition and position of the 60A ABS fuse on the engine connection unit.
Ensure the continuity between the fuse and tracks 17 and 18 of the computer connector (presence of
+before ignition feed on both tracks). Check the tightness and condition of the battery terminals.
Check the ABS earths (at the front of the front left hand wheel arch) and visually check all the ABS wiring.
Erase the computer memory, exit fault finding mode (G13*) and switch off the ignition.
Carry out another check using the XR25. If the "feed / computer" fault persists, replace the ABS
computer.
AFTER
After replacing the computer, carry out another check using the XR25.
REPAIR
B54532.0
38-19
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
2-3-4-5 Fiche n° 53
Bargraph 2, 3, 4 or 5 RH side or LH side flashing
Solenoid valve circuit
Check the ABS earths (tightness of the two bolts at the front of the front left hand wheel arch).
Check the condition and position of the 60A ABS on the engine connection unit.
Check the connection and condition of the connections on the 31 track computer connector (solenoid
valve earth on track 16).
Erase the computer memory, exit fault finding mode (G13*) and switch off the ignition.
Switch on the ignition and carry out another check using the XR25 and command G20*.
If the "solenoid valve circuit" fault reappears, replace the ABS computer.
B54532.0
38-20
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
Fiche n° 53
6
Bargraph 6 LH side illuminated
Front left hand wheel sensor circuit
NOTES None.
If the connector is correct, check the resistance of the sensor at its connector. Replace the sensor if its
resistance is not approximately 1.6 Kohms.
If the resistance is correct, check and ensure the continuity of the connections between the sensor
connector and the computer connector:
Visually check the sensor wiring and check the quality of the connections on the 31 track computer
connector.
If all the checks are correct, reconnect the computer and the wheel speed sensor then erase the computer
memory.
Exit fault finding mode (G13*) and switch off the ignition.
Switch on the ignition again and replace the sensor if the fault reappears.
If the fault reappears after the sensor is replaced, replace the computer.
B54532.0
38-21
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
Fiche n° 53
6
Bargraph 6 RH side illuminated
Front right hand wheel sensor circuit
NOTES None.
If the connector is correct, check the resistance of the sensor at its connector. Replace the sensor if its
resistance is not approximately 1.6 Kohms.
If the resistance is correct, check and ensure the continuity of the connections between the sensor
connector and the computer connector:
Visually check the sensor wiring and check the quality of the connections on the 31 track computer
connector.
If all the checks are correct, reconnect the computer and the wheel speed sensor then erase the computer
memory.
Exit fault finding mode (G13*) and switch off the ignition.
Switch on the ignition again and replace the sensor if the fault reappears.
If the fault reappears after the sensor is replaced, replace the computer.
B54532.0
38-22
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
Fiche n° 53
7
Bargraph 7 LH side illuminated
Rear left hand wheel sensor circuit
NOTES None.
If the connector is correct, check the resistance of the sensor at its connector. Replace the sensor if its
resistance is not approximately 1.6 Kohms.
If the resistance is correct, check and ensure the continuity of the connections between the sensor
connector and the computer connector:
Visually check the sensor wiring and check the quality of the connections on the 31 track computer
connector.
If all the checks are correct, reconnect the computer and the wheel speed sensor then erase the computer
memory.
Exit fault finding mode (G13*) and switch off the ignition.
Switch on the ignition again and replace the sensor if the fault reappears.
If the fault reappears after the sensor is replaced, replace the computer.
B54532.0
38-23
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
Fiche n° 53
7
Bargraph 7 RH side illuminated
Rear right hand wheel sensor circuit
NOTES None.
If the connector is correct, check the resistance of the sensor at its connector. Replace the sensor if its
resistance is not approximately 1.6 Kohms.
If the resistance is correct, check and ensure the continuity of the connections between the sensor
connector and the computer connector:
Visually check the sensor wiring and check the quality of the connections on the 31 track computer
connector.
If all the checks are correct, reconnect the computer and the wheel speed sensor then erase the computer
memory.
Exit fault finding mode (G13*) and switch off the ignition.
Switch on the ignition again and replace the sensor if the fault reappears.
If the fault reappears after the sensor is replaced, replace the computer.
B54532.0
38-24
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
8 Fiche n° 53
Bargraph 8 RH side or LH side flashing
Front right hand or front left hand wheel sensor signal
Even if present at the time of testing, these faults will always be declared by BG8
LH side or RH side flashing.
To confirm their presence and therefore the need to apply the fault finding be-
low, carry out a road test. The fault is present if the bargraph illuminates during
NOTES the test.
If bargraphs 6 and 8 LH side are both illuminated, deal with bargraph 6 first.
If bargraphs 6 and 8 RH side are both illuminated, deal with bargraph 6 first.
Check the quality of the wheel speed sensor mounting (position and that it is tightened to the correct
torque).
Check the sensor / target air gap over one wheel revolution: 0.3 < air gap < 1.4.
Check the conformity of the target (condition, number of teeth = 30).
Visually check the sensor wiring and check the quality of the connections on the 31 track computer
connector.
If all the checks are correct, reconnect the computer and the wheel speed sensor then erase the computer
memory.
Exit fault finding mode (G13*) and carry out a road test. Replace the sensor if the fault reappears.
If the fault reappears after the sensor is replaced, it may be caused by a solenoid valve operating fault. It is
therefore necessary to carry out a hydraulic check of the solenoid valves using the XR25 and command
G03* or G04* (consult the "aid" section).
If ten locking/releasing cycles are not performed on one of the wheels, replace the hydraulic assembly.
B54532.0
38-25
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
9 Fiche n° 53
Bargraph 9 RH side or LH side flashing
Rear right hand or rear left hand side wheel sensor signal
Even if present at the time of testing, these faults will always be declared by BG9
LH side or RH side flashing.
To confirm their presence and therefore the need to apply the fault finding be-
low, carry out a road test. The fault is present if the bargraph illuminates during
NOTES the test.
If bargraphs 7 and 9 LH side are both illuminated, deal with bargraph 7 first.
If bargraphs 7 and 9 RH side are both illuminated, deal with bargraph 7 first.
Check the quality of the wheel speed sensor mounting (position and that it is tightened to the correct
torque).
Check the sensor / target air gap over one wheel revolution: 0.6 < air gap < 1.6.
Check the conformity of the target (condition, number of teeth = 30).
Visually check the sensor wiring and check the quality of the connections on the 31 track computer
connector.
If all the checks are correct, reconnect the computer and the wheel speed sensor then erase the computer
memory.
Exit fault finding mode (G13*) and carry out a road test. Replace the sensor if the fault reappears.
If the fault reappears after the sensor is replaced, it may be caused by a solenoid valve operating fault. It is
therefore necessary to carry out a hydraulic check of the solenoid valves using the XR25 and command
G05* or G06* (consult the "aid" section).
If ten locking/releasing cycles are not performed on one of the wheels, replace the hydraulic assembly.
B54532.0
38-26
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
If bargraph 10 RH side is flashing, confirm the presence of the fault and therefore
the need to apply the fault finding below by entering command G20* on the
XR25 .
NOTES
The fault is present if the bargraph illuminates at the end of the command.
1.dEF NOTES Replace the computer if the pump motor operates permanently.
3.dEF
Check the ABS earths (tightness of the two earth bolts at the front of the front left hand wheel arch).
Check / ensure the continuity between the ABS earth and track 16 of the computer connector.
If all the checks are correct, reconnect the computer then erase its memory using command G0**.
Exit fault finding mode (G13*) and carry out a road test.
B54532.0
38-27
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
Fiche n° 53
11
Bargraph 11 LH side illuminated
Solenoid valve feed fault
NOTES None.
Carry out the operations necessary to obtain the correct voltage between tracks 19 and 17/18 of the 31
track ABS computer connector (9.5 volts < correct voltage < 17.5 volts):
- Ensure the continuity between the 60A fuse and tracks 17 and 18 of the computer connector.
- Check the ABS earths (tightness of the two earth bolts at the front of the front left hand wheel arch).
- Check / ensure the continuity between the ABS earth and track 19 of the computer connector.
If all the checks are correct, reconnect the computer then erase the fault memory using command G0**.
Exit fault finding mode (G13*) and carry out a road test. Replace the computer if the fault reappears.
B54532.0
38-28
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
NOTES None.
Carry out the operations necessary to obtain the correct computer feed voltage: 9.5 volts < correct
voltage < 17.5 volts):
- Check the ABS earths (tightness of the two earth bolts at the front of the front left hand wheel arch).
B54532.0
38-29
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
Fiche n° 53
12
Bargraph 12 LH side illuminated or flashing
Stop circuit
NOTES None.
Are the "pedal released" and "pedal pressed down" positions recognised?
YES Check the two stop light bulbs and the rear lights unit earth (no earthing of
track 14 across the bulbs when the pedal is not pressed down).
NO Apply the fault finding described in the interpretation for bargraphs 13 LH side
and RH side for "bargraph 13 LH side extinguished, brake pedal pressed
down".
B54532.0
38-30
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
Fiche n° 53
12
Bargraph 12 RH side flashing
Target of one of the wheels
Even if present at the time of testing, this fault will always be declared by BG12
RH side flashing.
NOTES
To confirm its presence and therefore the need to apply the fault finding below,
carry out a road test. The fault is present if the bargraph illuminates during the
test.
Check the quality of the mounting for the wheel speed sensors (position and that it is tightened to the
correct torque).
B54532.0
38-31
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
13
Bargraphs 13 RH side and LH side
Brake pedal Illuminated on the LH side if the pedal is pressed
down.
Illuminated on the RH side if pedal not pressed down.
Apply the checks only if bargraph illumination is not consistent with pedal
NOTES position.
- Check the condition and the adjustment of the stop switch. Replace it if necessary.
- Check the operation of the stop switch (closed contact between tracks 1 and 3). Replace the stop switch
if there is permanent continuity between these two tracks.
- Check and ensure the insulation from 12 volts of the connection between track 3 of the stop switch
connector and track 14 of the ABS computer connector.
Intermediate front left wing/ ABS R179 (track A2) + passenger compartment / front left wing R150 (track
B1) connector.
AFTER
Carry out a road test followed by a check using the XR25.
REPAIR
B54532.0
38-32
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - INTERPRETATION OF XR25 BARGRAPHS
Fiche n° 53
14
Bargraph 14 LH side illuminated
Speedometer signal function programming
NOTES None.
The ABS Bosch 5.3 computer with "speedometer signal function" provides the vehicle speed signal to all
users of this information in the vehicle (instrument panel, engine control, variable power assisted stee-
ring, ...).
This vehicle speed signal replaces that which was delivered by the speed sensor located on the gearbox.
The ABS computer calculates vehicle speed based on wheel speed and tyre circumference.
The tyre circumference is to be programmed into the memory of the new computer. This involves ente-
ring a suffix "X" using the fault finding tool and command G30*X*.
205/55/R16
195/65/R15 X = 154
195/60/R15
After the suffix is entered using command G30*X*, erase the computer memory then switch off the igni-
tion.
Use #30, to check that the suffix has been correctly entered.
B54532.0
38-33
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - CHECKING CONFORMITY
NOTES Only carry out this conformity check after a complete check using the XR25.
Order of
Function to be checked Action Bargraph Display and notes
operations
D11
1 XR25 dialogue (selector on
S8)
Recognition of brake 13
4 pedal not applied
13
Recognition of brake Press on
5
pedal applied brake pedal
B54532.0
38-34
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - AID
Raise the vehicle so that the wheels can be rotated and check that they rotate freely.
Hold the brake pedal down to prevent the wheel being tested from turning when it is moved by hand
(do not brake too hard so as to be at the releasing limit).
Enter G0X* The ten locking / unlocking cycles must be noted on the wheel concerned.
Hold the brake pedal pressed down and enter G08* Motor operation should be noted
for 2 seconds.
Hold the brake pedal pressed down and enter G20* The motor and solenoid valves
should operate briefly.
Bleed the hydraulic circuits: G15*3* front left / G15*4* front right / G15*5* rear left / G15*6* rear
right
Apply the procedure described in the section in the Technical Note on "Bleeding the circuits".
NOTE: The brake pedal should be pressed down when the bleed command is entered on the XR25.
The Bosch 5.3 ABS computer with "speedometer signal function" provides the vehicle speed signal to all
users of this information in the vehicle (instrument panel, engine control, variable power assisted stee-
ring, ...).
This vehicle speed signal replaces that which was delivered by the speed sensor located on the gearbox.
The ABS computer calculates vehicle speed based on wheel speed and tyre circumference.
The tyre circumference is to be programmed into the memory of the new computer. This involves ente-
ring a suffix "X" using the fault finding tool and command G30*X*.
205/55/R16
195/65/R15 X = 154
195/60/R15
After the suffix is entered using G30*X*, erase the computer memory then switch off the ignition.
Use #30 to check that the suffix has been correctly entered.
B54532.0
38-35
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - CUSTOMER COMPLAINTS
NOTES Only consult this customer complaint after a complete check using the XR25.
The ABS warning light does not illuminate for 3 seconds when the ignition is
switched on. Chart 1
Re-illumination of the ABS warning light after starting the engine. Chart 3
Intermittent illumination of the ABS warning light while driving.
Pulling. Chart 5
Unstable-Drifting. Chart 6
Unexpected ABS operation at low speed and with slight pedal pressure. Chart 7
Noise from the pump, the pipes or the hydraulic assembly. Chart 13
OTHER CASES
The ABS warning light does not illuminate, computer disconnected Chart 14
B54532.0
38-36
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
no
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-37
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
no
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-38
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
Chart 3
INTERMITTENT ILLUMINATION OF THE ABS WARNING LIGHT WHEN DRIVING
NOTES Only consult this customer complaint after a complete check using the XR25.
Check the voltage of the computer supply: 9.5 volts < correct voltage < 17.5 volts.
- Check the ABS earth (tightness of the two earth bolts at the front of the front left hand wheel arch).
Disconnect the computer and check the condition of the connections and the position of the shunt in the
31 track connector (between track 19 and tracks 20 and 21).
On the computer side, check the condition of the opening pin for this shunt.
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-39
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
Reminder: The locking of wheels on a vehicle equipped with ABS or tyre squeal, which feels like locking
to the customer, may be linked to normal operation of the system and should not always be
considered as faults:
- Locking authorised below 4 mph (6 km/h) (the system no longer regulates operation).
- Braking with ABS regulation on very poor roads (significant tyre squeal).
However, if the wheel(s) are actually locking, raise the vehicle so that the wheels can be rotated and check:
Use function #01, #02, #03 and #04 turning the associated wheels and ensure the consistency of the
results obtained.
If the value measured is zero, turn the other wheels to confirm an electrical inversion of the sensors and
repair the wiring.
Use functions G03*, G04*, G05* and G06* pressing the brake pedal and check that there are ten
unlocking / locking cycles on the wheel concerned (consult the "aid" section).
If the ten cycles are not carried out on the wheel tested (wheel remains locked), check whether they are
carried out on another wheel (confirmation of an inversion: repair).
If the ten cycles are not carried out on a wheel without inversion of the pipes, replace the hydraulic
assembly.
Check the condition of the ABS targets and that they are correct to specification.
Also check the sensor/target air gap over one revolution of each wheel:
Front 0.3 mm < air gap over one revolution < 1.4 mm.
Rear 0.6 mm < air gap over one revolution < 1.6 mm.
If the fault persists after these checks, replace the hydraulic assembly.
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-40
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
Chart 5 PULLING
NOTES Only consult this customer complaint after a complete check using the XR25.
no
B54532.0
38-41
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
no
B54532.0
38-42
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
Brake pedal vibrations may be felt which are connected to the reactions of the system in particular
situations:
- Crossing rumble strips.
- Tight cornering with lifting of the inside rear wheel.
This feeling may simply be connected with the operation of the "braking compensator" function when the
pressure on the rear axle is limited.
If the problem is different, check the speed sensor connectors (poor connections) and the air gaps.
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-43
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
On poor road surfaces it is normal to feel hesitation and vibrations of the pedal as well tyre squeal which is
more significant than on good surfaces.
The result is the impression of a variation in efficiency which should be considered normal.
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-44
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
Check that the equipment which is causing the problem when it is used is approved.
Check that the equipment has been correctly installed without modification to the original wiring, in
particular that of the ABS (connections to earth and +after ignition feed / before ignition feed for ABS
not authorised).
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-45
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
Passage of air from the hydraulic assembly regulation channels to the brake circuits.
Bleed the circuits in accordance with the procedure recommended in the Technical Note (use the XR25
command modes).
Following the operation, carry out a road test with ABS regulation.
If the fault persists, carry out the above operation again once or twice.
If the customer complaint is particularly pronounced and bleeding the circuit does not improve matters,
replace the hydraulic assembly.
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-46
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
Bleed the circuits, beginning with the rear right hand, then rear left hand, front left hand then front right
hand brakes.
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-47
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
Normal reaction of the brake pedal during an ABS regulation phase or during limiting of the pressure on
the rear axle ("braking compensator" function).
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-48
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
- Vibration of the assembly: check the presence and condition of the rubber mountings for insulating the
assembly mounts.
- Vibration of the pipes: check that all the pipes are correctly engaged in their mounting clips and that
there is no contact between the pipes or between the pipes and the bodywork.
To determine the source of the noise, functions G03*, G04*, G05* and G06* on the XR25 can be used
(consult the "aid" section).
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-49
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-50
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
Ensure that the XR25 is not the cause of the fault by trying to communicate with a computer on another
vehicle. If the XR25 is not faulty and dialogue cannot be established with another computer on the same
vehicle, it may be that a faulty computer is disrupting fault finding lines K and L. Disconnect each computer
in turn to locate the faulty one.
Check that the ISO selector is in position S8, that you are using XR25 cassette 18 and the correct access
code.
Check the battery voltage and carry out the necessary operations to obtain the correct voltage (9.5 volts <
U battery < 17.5 volts).
Check for the presence and condition of the ABS fuse on the passenger compartment connection unit
(10A).
Check the connection of the computer connector and the condition of its connections.
Check the connection and the condition of the connections for the front left wing/ABS (R179) + passenger
compartment / front left wing (R150) connectors.
Check the ABS earths (tightening of the two earth bolts at the front of the front left hand wheel arch).
Check that the computer is correctly fed:
- earth on track 19 of the 31 track connector,
- +after ignition feed on track 15 of the 31 track connector.
If dialogue is still not established after these various checks, replace the ABS computer.
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-51
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
NOTES Only consult this customer complaint after a complete check using the XR25.
Use the XR25 to check for the presence or absence of vehicle speed information on the other systems using
a signal sent by the ABS computer (engine control, VPAS, ...).
• If it appears that only the instrument panel is not receiving the signal, ensure the continuity of the
connection between track 22 of the ABS computer connector and the instrument panel connector.
• If no user is receiving the signal, look for a continuity or insulation fault of the connection between
track 22 of the ABS computer connector and the various users of the vehicle speed information or an
internal fault of one of the signal user systems (disconnect each in turn).
If the fault persists after these various checks, replace the ABS computer.
AFTER
Carry out a road test then check using the XR25.
REPAIR
B54532.0
38-52