A B S Bosch 5 3 PDF

N.T.
3041A
B54X
A.B.S. BOSCH 5.3
CANCELS AND REPLACES TECHNICAL NOTE 2742A
For the sections not described in this note, refer to M.R. 302.
77 11 200 833 JUNE 1998 Edition Anglaise
"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 38-2
Without speedometer signal function

The 31 track connector 38-3
With speedometer signal function

The 31 track connector 38-4
Diagnostic socket 38-5
Without speedometer signal function

Wiring diagram 38-6
Wiring diagram key 38-7
With speedometer signal function

Wiring diagram 38-8
Wiring diagram key 38-9
Tyre circumference 38-10

Interchangeability between computer and
complete hydraulic assembly 38-10
Removal/refitting of the hydraulic
assembly/computer 38-11
Special notes for the removal/refitting of the
hydraulic assembly/computer on Safrane vehicles
equipped with the N7U engine 38-12
Bleeding 38-13
Hydraulic braking check 38-13
Checking the wheel speed sensors 38-14
Fault finding - Introduction 38-15
Fault finding - XR25 fiche 38-16
Fault finding - Interpretation of XR25 bargraphs 38-18
Fault finding - Checking conformity 38-34
Fault finding - Aid 38-35
Fault finding - Customer complaints 38-36
Fault finding - Fault charts 38-37
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
BOSCH ABS 38
The new BOSCH 5.3 ABS computers fitted to SAFRANE vehicles supply a vehicle speed signal (this signal
replaces that supplied by the speed sensor located on the gearbox), this function is known as the
"speedometer signal function".
OPERATING PRINCIPLE
The ABS computer calculates vehicle speed using the wheel speed and tyre circumference information stored
in the computer (see page 38-10).
NOTE CONCERNING THE BRAKING COMPENSATOR
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
ABS speed sensors
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
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
Allocation of connector tracks
Track Allocation Track Allocation
1 Rear right hand sensor earth 15 + after ignition computer feed

2 Rear right hand sensor information 16 Pump motor earth
3 Front right hand sensor earth 17 + before ignition feed (solenoid
4 Not connected valves and pump motor)
5 Front right hand sensor information 18 + before ignition feed (solenoid
6 Front left hand sensor earth valves and pump motor)
7 Front left hand sensor information 19 Electronic earth
8 Rear left hand sensor earth 20 ABS fault warning light
9 Rear left hand sensor information 21 NIVOCODE (REF) fault warning light
10 Not connected 22 Not connected
11 Fault finding line K 25 Not connected
12 Fault finding line L 26 Front right hand wheel speed output
13 Not connected 27 Not connected
14 Stop lights switch information 31 Not connected
38-3
ABS BOSCH 5.3
with
speedometer
signal function
BOSCH ABS 38
THE 31 TRACK CONNECTOR
PRN3813
Allocation of connector tracks
Track Allocation Track Allocation
1 Rear right hand sensor earth 15 + after ignition computer feed

2 Rear right hand sensor information 16 Pump motor earth
3 Front right hand sensor earth 17 + before ignition feed (solenoid
4 Not connected valves and pump motor)
5 Front right hand sensor information 18 + before ignition feed (solenoid
6 Front left hand sensor earth valves and pump motor)
7 Front left hand sensor information 19 Electronic earth
8 Rear left hand sensor earth 20 ABS fault warning light
9 Rear left hand sensor information 21 NIVOCODE (REF) fault warning light
10 Not connected 22 Vehicle speed output (speedometer
11 Fault finding line K signal function)
12 Fault finding line L 25 Not connected
13 Not connected 26 Front right hand wheel speed output
14 Stop lights switch information 27 Not connected
31 Not connected
38-4
BOSCH ABS 38
DIAGNOSTIC SOCKET
PRN3807
4 Chassis earth
5 Electronic earth
7 Fault finding line K
15 Fault finding line L
16 + battery
38-5
ABS BOSCH 5.3
without
speedometer
signal function
BOSCH ABS 38
WIRING DIAGRAM
PRN3811
38-6
ABS BOSCH 5.3
without
speedometer
signal function
BOSCH ABS 38
WIRING DIAGRAM KEY
118 ABS computer
119 Automatic transmission computer
150 Rear right hand wheel sensor
151 Rear left hand wheel sensor
152 Front right hand wheel sensor
153 Front left hand wheel sensor
160 Stop switch
207 Brake fluid minimum level
225 Diagnostic socket
247 Instrument panel
260 Fuse box
301 ABS electric pump assembly relay
363 Voice synthesiser unit
428 Main ABS relay
435 ABS solenoid valve unit
466 Shunt unit
R150 Passenger compartment / front left hand

wing
R179 ABS / front left wing
38-7
ABS BOSCH 5.3
with
speedometer
signal function
BOSCH ABS 38
WIRING DIAGRAM
PRJ15083
38-8
ABS BOSCH 5.3
with
speedometer
signal function
BOSCH ABS 38
WIRING DIAGRAM KEY
118 ABS computer
119 Automatic transmission computer
150 Rear right hand wheel sensor
151 Rear left hand wheel sensor
152 Front right hand wheel sensor
153 Front left hand wheel sensor
160 Stop switch
207 Brake fluid minimum level
225 Diagnostic socket
247 Instrument panel
260 Fuse box
301 ABS electric pump assembly relay
363 Voice synthesiser unit
428 Main ABS relay
435 ABS solenoid valve unit
R149 Engine / front left wing
R150 Passenger compartment/ front left wing
R179 ABS / front left wing
38-9
ABS BOSCH 5.3
with
speedometer
signal function
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*.
SUFFIX "X" VALUES TO

TYRES
BE ENTERED
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.
Use # 30 to check that the suffix has been correctly entered.
INTERCHANGEABILITY BETWEEN THE COMPUTER AND THE COMPLETE HYDRAULIC ASSEMBLY
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
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)
Wheel bolts (5 bolts) 10 * A pipe wrench must be used.

Pipe bolts 1.2 to 1.6
REMOVAL
Disconnect the battery.
Fit a pedal press (to limit the amount of brake

fluid which runs out).
Remove:
- the front left hand wheel,
- the engine undertray,
- the wheel arch protector,
- the side mud guard.
11532S
Separate the wiring trough from the hydraulic as-

sembly/computer
Remove the power assisted steering pipe moun-

ting nut.
NOTE: before completely removing the hydraulic

assembly / computer, ensure that it is supported.
11531S
Disconnect the computer connector.
38-11
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.
In this case, it is necessary to remove the lower air

REFITTING filter unit mounting.
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
Refitting is the reverse of removal. Observe the

notes given earlier.
38-12
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.
2) Bleed the ABS hydraulic circuit.
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.
a.1 Open the brake bleed screw.

a.2 Pump the brake pedal (approximately 10 times).
a.3 Start the bleed command using the XR25.
a.4 Pump the brake pedal during the bleed fault finding phase.
a.5 At the end of the bleed cycle, continue to pump the brake pedal and close the brake bleed
screw.
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.
HYDRAULIC BRAKING CHECK
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:
- Cycle on the wheel to be tested:

• a fall in pressure of 200 ms with the pump starting simultaneously,
• an increase in pressure of 300 ms with the pump starting simultaneously.
Ten cycles are performed for the wheel in question.
- an increase in pressure to the master cylinder pressure in the four wheels,

- hydraulic pump motor stopped,
- the operator releases the brake pedal.
The hydraulic test of the wheel in question is now finished.
38-13
BOSCH ABS 38
CHECKING THE WHEEL SPEED SENSORS
The checking procedure to be carried out is:
1) A resistance check of the wiring to the sensor connectors:

from the computer connector to the 2 track speed sensor connector.
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).
3) A check of the gap using a set of calibrated shims:

- front: 1.38 mm maximum
- rear: 1.60 mm maximum.
4) A check of the sensor mounting.
38-14
BOSCH ABS 38
FAULT FINDING - INTRODUCTION
Conditions for applying the checks defined in this fault finding
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 .
Special tooling required for working on the ABS system
- XR25 test kit.
- XR25 cassette n° 18.
- 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
BOSCH ABS 38
FAULT FINDING - XR25 FICHE
FI21853
B54532.0
38-16
BOSCH ABS 38
FAULT FINDING - XR25 FICHE
MEANING OF BARGRAPHS
- Faults (always on coloured background):
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.
- Status (always on white background):
Bargraph always located at the top right.

If illuminated, indicates dialogue has been established with the product computer.
If it remains extinguished
- The code does not exist.
- There is a tool, computer or XR25 / computer fault.
The representation of the following bargraphs indicates their initial status:

Initial status (ignition on, engine stopped, no operator action).
or
Indefinite
is illuminated when the function or condition specified on the
fiche is being met.
Extinguished
Illuminated extinguishes when the function or condition specified on the

fiche is no longer being met.
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
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.
Check that the diagnostic socket is correctly fed:

- + before ignition feed on track 16,
- earth on track 5.
Check the continuity and insulation of the diagnostic socket / ABS computer connection lines:
- between track 12 of the computer connector and track 15 of the diagnostic socket,
- between track 11 of the computer connector and track 7 of the diagnostic socket.
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
BOSCH ABS 38
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 connections on the 31 track ABS computer connector.
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
BOSCH ABS 38
2-3-4-5 Fiche n° 53
Bargraph 2, 3, 4 or 5 RH side or LH side flashing
Solenoid valve circuit
Even if present at time of testing, these faults will always be declared by a

flashing bargraph.
To confirm their presence and the need to apply the fault finding below, enter
NOTES command G20*. The fault is present if the bargraph reappears illuminated at the
end of the command.
If bargraph 11 LH side is also illuminated, deal with bargraph 11 LH side first.
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.
AFTER Erase the computer memory (GO**).

Carry out a road test followed by a check using the XR25.
REPAIR
B54532.0
38-20
BOSCH ABS 38
Fiche n° 53
6
Front left hand wheel sensor circuit
NOTES None.
Check the connection and condition of the sensor connections.
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:
- track 1 of the sensor / track 7 of the computer connector,
- track 2 of the sensor / track 6 of the computer connector.
Also check the insulation between these connections.
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.
AFTER Erase the computer memory (G0**).

REPAIR
B54532.0
38-21
BOSCH ABS 38
Fiche n° 53
6
Bargraph 6 RH side illuminated
Front right hand wheel sensor circuit
NOTES None.
connector.
memory.

REPAIR
B54532.0
38-22
BOSCH ABS 38
Fiche n° 53
7
Rear left hand wheel sensor circuit
NOTES None.
connector.
memory.

REPAIR
B54532.0
38-23
BOSCH ABS 38
Fiche n° 53
7
Bargraph 7 RH side illuminated
Rear right hand wheel sensor circuit
NOTES None.
connector.
memory.

REPAIR
B54532.0
38-24
BOSCH ABS 38
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).

connector.
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.
If the hydraulic assembly is not faulty, replace the computer.

REPAIR
B54532.0
38-25
BOSCH ABS 38
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).

connector.
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.
If the hydraulic assembly is not faulty, replace the computer.

REPAIR
B54532.0
38-26
BOSCH ABS 38
Bargraph 10 RH side illuminated or flashing Fiche n° 53

10
Pump motor circuit
XR25 aid: * 30 1.dEF : Permanent feed (relay sticks) or CO motor earth.
2.dEF : Engine does not turn.
3.dEF : Cumulative 1.dEF and 2.dEF
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.
Check the locking of the 2 track pump motor 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.
Replace the computer if the fault reappears.
2.dEF NOTES None.
Replace the hydraulic assembly (mechanical blocking of the pump).

REPAIR
B54532.0
38-27
BOSCH ABS 38
Fiche n° 53
11
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):
- Check the tightness and condition of the battery terminals.
- Check the 60A fuse on the engine connection unit.
- 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.
Erase the computer memory (G0**).

AFTER
If the computer is replaced, carry out another XR25 check.
REPAIR
B54532.0
38-28
BOSCH ABS 38
Bargraph 11 RH side illuminated Fiche n° 53

11
Feed
XR25 aid: * 12 1.dEF : Low voltage.
2.dEF : Excess voltage.
NOTES None.
Carry out the operations necessary to obtain the correct computer feed voltage: 9.5 volts < correct
voltage < 17.5 volts):
- Check the battery charge.
- Check the charging circuit.
- Check the ABS earths (tightness of the two earth bolts at the front of the front left hand wheel arch).

Carry out another XR25 check.
REPAIR
B54532.0
38-29
BOSCH ABS 38
Fiche n° 53
12
Bargraph 12 LH side illuminated or flashing
Stop circuit
NOTES None.
Press the brake pedal, monitoring bargraphs 13 RH side and LH side.
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".

AFTER
If the computer is replaced, carry out another XR25 check.
REPAIR
B54532.0
38-30
BOSCH ABS 38
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).
Check the conformity of the targets: condition, number of teeth = 30.

REPAIR
B54532.0
38-31
BOSCH ABS 38
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.
Bargraph 13 LH side extinguished, brake pedal pressed down
BG13 RH side remains permanently illuminated.
If the brake lights operate:

- Ensure the continuity between the shunt unit on brake information and track 14 of the ABS computer
connector.
Intermediate front left wing / ABS R179 (track A2) + passenger compartment / front left wing 150
(track B1) connectors.
If the brake lights do not operate:

- Check the condition and adjustment of the stop switch and the 10A brake lights fuse (on the passenger
compartment connection unit). Replace it if necessary.
- Disconnect the stop switch then check / ensure the presence of +after ignition feed on track 1 of the
connector.
- Check the operation of the stop switch (closed contact between tracks 1 and 3).
- Check and ensure the continuity between track 3 of the stop switch connector and the shunt unit on
the stop information line.
Bargraph 13 illuminated permanently on the LH side
- 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
REPAIR
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BOSCH ABS 38
Fiche n° 53
14
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*.
Value of suffix "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.

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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)
Without speedometer signal

function
2 Computer conformity #12

With speedometer signal
function
Illumination of warning light for

ABS warning light 3 seconds when the ignition is
Ignition
3 operation - check switched on (consult fault
switched on
computer initialisation finding if it remains illuminated
or does not illuminate).
Recognition of brake 13
4 pedal not applied
13
Recognition of brake Press on
5
pedal applied brake pedal
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BOSCH ABS 38
FAULT FINDING - AID
Using the command modes:
Controlling the solenoid valves for hydraulic check: G03* to G06*
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.
Controlling the pump motor: G08*
Hold the brake pedal pressed down and enter G08* Motor operation should be noted
for 2 seconds.
Control of the pump motor and solenoid valves: G20*
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.
Replacing the computer:
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*.
Value of suffix "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.
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BOSCH ABS 38
FAULT FINDING - CUSTOMER COMPLAINTS
NOTES Only consult this customer complaint after a complete check using the XR25.
WARNING LIGHTS OPERATING FAULTS
The ABS warning light does not illuminate for 3 seconds when the ignition is
switched on. Chart 1
Permanent illumination of the ABS warning light, ignition on. Chart 2
Re-illumination of the ABS warning light after starting the engine. Chart 3
Intermittent illumination of the ABS warning light while driving.
FAULTS WHICH OCCUR WHEN BRAKING WITH ABS REGULATION
Locking of one or more wheels. Chart 4
Pulling. Chart 5
Unstable-Drifting. Chart 6
Unexpected ABS operation at low speed and with slight pedal pressure. Chart 7
Unexpected ABS operation on a poor road. Chart 8
Unexpected ABS operation with use of special equipment

Chart 9
(carphone, CB...).
Extension of brake pedal travel following a regulation phase

Chart 10
(with spongy pedal when entering regulation)
Spongy pedal. Chart 11
Brake pedal vibration. Chart 12
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
No communication with the ABS computer Chart 15
No vehicle speed information on the instrument panel Chart 16

(ABS computer with speedometer signal function)
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BOSCH ABS 38
FAULT FINDING - FAULT CHARTS
THE ABS WARNING LIGHT DOES NOT ILLUMINATE FOR 3

Chart 1
SECONDS WHEN THE IGNITION IS SWITCHED ON
Check the 10A instrument panel fuse on the

passenger compartment connection unit
(if the problem is common to all instrument
panel functions).
Switch off the ignition. Check the connections on the 31 track

Disconnect the computer then switch on the yes connector.
ignition again. Replace the computer if the fault persists.
Does the warning light illuminate?
no
Check the condition of the ABS warning

light bulb and its feed.
Ensure the continuity of the connection
between track 20 of the computer
connector and the warning light (track 27 of
the blue instrument panel connector).
If the fault persists, check the operation of

the instrument panel.
AFTER
Carry out a road test then check using the XR25.
REPAIR
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BOSCH ABS 38
PERMANENT ILLUMINATION OF THE ABS WARNING LIGHT,

Chart 2
IGNITION ON (no fault declared by the XR25)
Disconnect the computer and check the

position of the shunt in the 31 track
connector (between track 19 and tracks 20
and 21).
On the computer side, ensure the presence
of the shunt opening pin between tracks 19
and 20/21 of the computer connector.
Reconnect the computer.

Check whether there is continuity between Look for a fault at the shunt or a short
track B2 of the R150 connector, engine yes circuit to earth of the connection between
compartment side (black module) and track 20 of the computer connector and
earth. R150 on track B2 (black module).
Is continuity ensured?
no
Look for a short circuit to earth of the

connection between track B2 of the R150
connector and the ABS warning light (track
27 of the blue instrument panel connector).
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REPAIR
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BOSCH ABS 38
RE-ILLUMINATION OF THE ABS WARNING LIGHT AFTER STARTING THE ENGINE
Chart 3
INTERMITTENT ILLUMINATION OF THE ABS WARNING LIGHT WHEN DRIVING
Check the voltage of the computer supply: 9.5 volts < correct voltage < 17.5 volts.
If necessary, carry out the following operations:
- Check the battery charge (check the charging circuit if necessary).
- 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.
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BOSCH ABS 38
Chart 4 LOCKING OF ONE OR MORE WHEELS
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:
- A possible inversion of the speed sensor connections.
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.
- A possible inversion of the hydraulic assembly pipes.
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
REPAIR
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BOSCH ABS 38
Chart 5 PULLING
Disconnect one wheel speed sensor.

Start the engine and ensure that only the
ABS fault warning light is illuminated. If the
brake fault warning light is also illuminated, If the brake pedal travel is relatively long,
do not drive the vehicle as the "braking bleed the brake circuit.
compensator" function if no longer yes
ensured. If travel is normal, check the tyre pressures,
Carry out a road test without ABS. the front axle, or for any leaks in the circuit.
Does the fault persist under these

conditions?
no
Raise the vehicle so that the wheels can be

rotated and check:
- a possible inversion in the connection of
the speed sensors,
- a possible inversion of the hydraulic
assembly pipes).
For these two tests, consult and apply the
methods defined in Chart 4.
Check the condition of the ABS targets and
that they are correct to specification.
Also check the sensor/ target air gap over
one wheel revolution.
If the fault persists, replace the hydraulic
assembly.
Erase the computer fault memory.

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BOSCH ABS 38
Chart 6 UNSTABLE - DRIFTING
Disconnect one wheel speed sensor.

Start the engine and ensure that only the
ABS fault warning light is illuminated. If the
brake fault warning light is also illuminated,
do not drive the vehicle as the "braking Road handling fault not connected with the
compensator" function is no longer ABS system.
yes
ensured. Check the condition of the brake linings and
Carry out a road test without ABS. that they are to specification and check the
tyre pressures, the front axle...
Does the fault persist under these
conditions?
no
Normal behaviour linked to the operation

of the system during the regulation phase in
particular on surfaces with uneven grip or
which are poorly coated.
Erase the computer fault memory.

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REPAIR
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BOSCH ABS 38
Chart 7 UNEXPECTED ABS OPERATION AT LOW SPEED AND WITH

SLIGHT PEDAL PRESSURE
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
REPAIR
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BOSCH ABS 38
UNEXPECTED ABS OPERATION ON A POOR ROAD

Chart 8
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
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BOSCH ABS 38
Chart 9 UNEXPECTED ABS OPERATION WITH USE OF SPECIAL

EQUIPMENT (carphone, CB...)
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
REPAIR
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BOSCH ABS 38
EXTENSION OF BRAKE PEDAL TRAVEL FOLLOWING A

Chart 10 REGULATION PHASE (with spongy pedal when entering
regulation)
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.
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BOSCH ABS 38
Chart 11 SPONGY PEDAL
Presence of air in the brake circuits.
Bleed the circuits, beginning with the rear right hand, then rear left hand, front left hand then front right
hand brakes.
Repeat the operation if necessary.
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BOSCH ABS 38
Chart 12 BRAKE PEDAL VIBRATION
Normal reaction of the brake pedal during an ABS regulation phase or during limiting of the pressure on
the rear axle ("braking compensator" function).
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BOSCH ABS 38
NOISE FROM THE PUMP, THE PIPES OR THE HYDRAULIC

Chart 13 ASSEMBLY
- 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).
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BOSCH ABS 38
Chart 14 THE ABS WARNING LIGHT DOES NOT ILLUMINATE,

COMPUTER DISCONNECTED
Disconnect the ABS computer.

Check for the presence of the shunt between track 19 and tracks 20 and 21 of the computer connector.
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REPAIR
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BOSCH ABS 38
Chart 15 NO COMMUNICATION WITH THE ABS COMPUTER
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.
Check that the diagnostic socket is correctly fed:

- +before ignition feed on track 16,
- earth on track 5.
Check the continuity and insulation of the diagnostic socket / ABS computer connection lines:
- between track 12 of the computer connector and track 15 of the diagnostic socket,
- between track 11 of the computer connector and track 7 of the diagnostic socket.
If dialogue is still not established after these various checks, replace the ABS computer.
AFTER
REPAIR
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BOSCH ABS 38
NO VEHICLE SPEED INFORMATION ON THE INSTRUMENT

Chart 16 PANEL
(COMPUTER WITH SPEEDOMETER SIGNAL FUNCTION)
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
REPAIR
B54532.0
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A B S Bosch 5 3 PDF

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A.B.S. BOSCH 5.3

CANCELS AND REPLACES TECHNICAL NOTE 2742A

77 11 200 833 JUNE 1998 Edition Anglaise

Operating principle 38-2

Without speedometer signal function

With speedometer signal function

Diagnostic socket 38-5

Without speedometer signal function

With speedometer signal function

Tyre circumference 38-10

NOTE CONCERNING THE BRAKING COMPENSATOR

ABS speed sensors

Allocation of connector tracks

Track Allocation Track Allocation

1 Rear right hand sensor earth 15 + after ignition computer feed

Allocation of connector tracks

Track Allocation Track Allocation

1 Rear right hand sensor earth 15 + after ignition computer feed

7 Fault finding line K

15 Fault finding line L

118 ABS computer

119 Automatic transmission computer

150 Rear right hand wheel sensor

151 Rear left hand wheel sensor

152 Front right hand wheel sensor

153 Front left hand wheel sensor

160 Stop switch

207 Brake fluid minimum level

225 Diagnostic socket

247 Instrument panel

260 Fuse box

301 ABS electric pump assembly relay

363 Voice synthesiser unit

428 Main ABS relay

435 ABS solenoid valve unit

466 Shunt unit

R150 Passenger compartment / front left hand

R179 ABS / front left wing

118 ABS computer

119 Automatic transmission computer

150 Rear right hand wheel sensor

151 Rear left hand wheel sensor

152 Front right hand wheel sensor

153 Front left hand wheel sensor

160 Stop switch

207 Brake fluid minimum level

225 Diagnostic socket

247 Instrument panel

260 Fuse box

301 ABS electric pump assembly relay

363 Voice synthesiser unit

428 Main ABS relay

435 ABS solenoid valve unit

R149 Engine / front left wing

R150 Passenger compartment/ front left wing

R179 ABS / front left wing

SUFFIX "X" VALUES TO

Use # 30 to check that the suffix has been correctly entered.

INTERCHANGEABILITY BETWEEN THE COMPUTER AND THE COMPLETE HYDRAULIC ASSEMBLY

Wheel bolts (5 bolts) 10 * A pipe wrench must be used.

Disconnect the battery.

Fit a pedal press (to limit the amount of brake