Lastlittleissuewithmy1998BMWE36

TouringABSPump
ByRayDavies

1comment

DIYABSHyraulicUnitRepairBMWM3Forum.com(E30M3|E36
M3|E46M3|E92M3|F80/X):

'viaBlogthis'

IneededsomewheelsafewmonthsagosoItookachanceona1998
BMWE36(3series)Estate.Iboughtthecarfor500sodidexpecta
fewissues.Hereiswhathasbeenreplacedsofar:

1.Brakepads
2.Brakepadsensors
3.Backshocksand1collapsedcoil
4.Backwiperunitandcontrolunit(stillnotworking:()
5.ABSsensors,frontandback

TheABSlightisstillonandItookittoa"guy"toresetthediagnostic
codeafterthesensorswerereplaced.Unfortunatelyitseemstobethe
ABSPumpatfault.

ItseemsthisisaknownissuesoIwillfixitmyselfwhentherainand
sleetstopsintheUK.

HerearethreearticlesIfound.

http://www.m3forum.net/m3forum/showthread.php?t=145202

1.RemovetheABSpump(hydrounit)
Disconnectthenegativebatteryterminal.Sukcoutasmuchofthe
brakefluidasyoucanfromthefluidresevoir(aturkeybaster
worksnicely).Thepumpislocatedbeneaththemastercyclinder.
You'llhavetoremoveyourMAFfromthethrottlebody.ItisNOT
necessarytoremovethebrakeresevoirormastercylinder.Itisa
goodideatolabelallthelinessoyouknowwhereeverthinggoes
whenyoureassemble.
Youmayrunintoproblemsremovingthehoseclampsfromthe
connectionstothefluidresevoir.Thisisactuallythehardestpart
ofthewholeDIY.BMWusesthoselovelysingleusesacrificial
crimpclamps.YouwillhavetocutthemoffwithyourDremel.DO
THISVERYSLOWLYANDCAREFULLY,oryouwillbebuyinganew
fluidresevoir.Alsobesureyouhavesomereplacementscrewtype
hoseclampsreadyforwhenyoureassemble(unlessyouare
masochisticandwanttointallnewBMWcrimpclamps).

2.Removepump(continued)
Thepumpisheldinplacebyasingleboltedrubberstopperinthe
frontoftheunit.Therearetwomorestoppersintheaftofthe
pumpwhichfitintotworetainingcups.Loosenthefrontnutandtilt
thefrontupwards,andpullthewholethingout.
Warning:Bepreparedforfluidspillage.

3.Removebottomplate
Marvelatyoursolenoids.

4.Testelectricalconnections
Refertowiringdiagrambelow.Thediagramontheright(fromBentley)
isonlyfor199596withoutAST.TheTableontheleftiscompiledfrom
theTevesMkIVmanual.

FromtheTevesMkIVmanualthatyoudownloaded,youcandetermine
theexpectedresistancesacrossthevariousvalves.Allthetestingwill
bedoneatthe12pinconnectoronthepump.Youshouldbeableto
verifythefaultyvalvefromyourdiagnosticsheet.

_________________
5.Removefilamentwire
Unsolderthefilamentwire.THISTHINFILAMENTistheculprit.
Withageitsometimescracksortearsorcorrodes.Don'tbother
tryingtofindthebreakinthecircuit,itisvirtuallyimpossibleto
see.Justremovethewholething.

6.Gasketseal
Beforereattachingtheharnesstothehydro,putabeadofgasket
sealantontheedgewheretheharnessmateswiththepumpbody.

7.Rewirethevalves
Hereisthepathformyparticularunit.Thisisn'tanexacttracing
ofthefilament.Ihadtogothelongwayforsomewires(for
example,TtoAtoDtoEtoB).

Rewiringinprogress
Commentary:Afterdoingthislittleexercise,IrealizewhyBMWwentwithfilamentwire
insteadoffullongaugedwires:filamentiseasiertoinstall.Theentirecircuitispreprinted&mass
producedontheconductorfilmalltheassemblerhastodoissauderallthepinsinorder,much
fasteronanassemblyline.Noneedtorouteindividualwires.Thedrawbackisthatthefilament
eventuallycorrodesordisintegrates,causingafault.

8.Verifyyourwiring
Onceyouaredonewiring,retesttheresistancesatthepinsusing
thetableinstep4above.Ifyoudideverythingright,thereadings
shouldnowbewithinspec.

http://www.staffordnet.net/repairs/bmw/abs_pump_rewire.htm

ABSPumpRewire

ThisishowIrewiredmyABSpumpinmy
1996BMW328i
Removethepumpbytakingoffthe5or6fluidlines,disconnectingthe
electricalconnector,andremovingthatonenutatthefrontendofthe
pumpassembly.Takesabout10minutestoremove.Itmightbeeasier
ifyouremoveanylittlebitsthatarehoveringabovethepump
assembly.ItookofftheMAFandairtubeandmovedsomeotherstuff
aroundtomakeiteasier.

Onceitisoff,takeittoyourbenchandCAREFULLYclampitinaviseor
otherwisepositionitinastablemannersothatyoucanremovethe
plateonthebottom.Thereare6torxheadedboltsthatyouremoveto
gettothisareaofthepump.
Thisiswhatitlookslikeatfirst:

Noteallthecorrodedflexicable.

Hereiswhatitlookslikeafteryoucarefullydesolderandremoveallthe
flexicableandrewireit:

HereisawiringdiagramIdrewup.

Allthesolenoidsshareacommoncontact,andthesearealltiedbackto
pins2and7ontheconnector.Noticethatpins2and7onthe
connectorarealsocommon.Inumberedthesemyselfandthese
numbersmeannothinganddonotrelatetoanynumbersyoumayfind
ontheconnector.
Istartedattherightsideoftheconnectorfromtheperspectivethatmy
picturesweretakenandnumbereditfromrighttoleft.Ididthisalso
becausethewirescomeintothatconnectorfromtheright.
Ihavenoideawhatgaugeofwiretouse.Iamobsessive,soIwent
biggerthanIamsureyoureallyneedto.Todoitoveragain,Iwould
buyagoodgradesiliconeinsulatedwiresothatyouwouldn'thaveso
muchtroublemeltingtheinsulationduringthesolderingjob.Weused
16gauge,butIbet18gaugewouldbeeasiertoworkwithandstillmeet
operatingexpectationsaswell.
Ibledthebrakesnormallystartingatthefarthestwheelandworkingmy
wayin.Thenormalway,havingsomeonepumpthenholdthebrakes
whileIcrackedthenipples.Iwentaheadandbledthemuntilthefluid
wasclearsoeffectivelychangingthefluid,butIdon'tthinkyouHAVEto
doitthatway.Lotsofpeopletalkaboutshortingtherelaytoactivate
thepumpduringbleeding,butIdidn'tdoit,andIhaveusedtheABS
severaltimesafterthisrepairanditisworkingfineandIstillhave
normalbrakepedalfeelandpressure.
MyABSlightwentrightoffafterweweredonebleedingthebrakesand
startedtheengine.
Hopethishelpsyouandgoodluckinyourrepair!

Paul
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