Chassis

GENERAL

FRONT AXLE

REAR AXLE

WHEELS AND TYRES

STEERING

MECHANICAL ELEMENT CONTROLS

ELECTRONICALLY CONTROLLED SYSTEMS

77 11 190 850
"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

NOVEMBER 1996
All copyrights reserved by Renault.

Edition Anglaise

Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.

Renault 1996

EXPLODED VIEW

PRG30.1

Chassis
Contents
Page Page

30 GENERAL
General braking system circuit diagram Tightening torques (in daN.m) Measuring points Underbody heights Parts that must be systematically replaced Brake fluid Front anti-roll bar specifications Rear anti-roll bar specifications Rear suspension bar specifications Rear torsion bar identification marks Brake unions and pipes The effect of geometry angles Principles of checking geometry Checking and adjusting front axle geometry Front axle fault finding Braking system fault finding Bleeding the braking system 30-1 30-2 30-6 30-8 30-9 30-9 30-10 30-11 30-11 30-12 30-13 30-13 30-14 30-15 30-16 30-17 30-20

33 REAR AXLE
Rear axle Brake drums Wheel cylinders Brake calipers Mechanical brake caliper control Brake shoes (drum) Brake pads (disc) Brake discs Hub bearings Shock absorbers Anti-roll bars on tubular rear axle Half suspension arms on tubular rear axle Bearings on tubular rear axle Suspension bars tubular rear axle Underbody height tubular rear axle Torsion bars four bar rear axle Underbody height four bar rear axle Four bar type rear axle Suspension arm bearings 33-1 33-2 33-4 33-5 33-7 33-9 33-23 33-25 33-26 33-30 33-31 33-32 33-33 33-27 33-39 33-40 33-42 33-43 33-46

31 FRONT AXLE
Subframe Lower suspension arms Lower suspension arm rubber bushes Lower suspension arm ball joint Brake pads Brake calipers Brake disc Stub axle carrier bearings Stub axle carrier Combined spring shock absorber assembly Spring and shock absorber assembly Anti-roll bar 31-1 31-4 31-5 31-6 31-7 31-12 31-14 31-16 31-19 31-20 31-21 31-27

35 WHEELS AND TYRES

Specifications Wheel balancing 35-1 35-3

Contents
Page

36 STEERING
Axial ball joints Manual steering box Anti-rattle bearing on manual steering box Power assisted steering box Steering box plunger Steering column Retractable steering column shaft 36-1 36-3 36-5 36-11 36-12 36-19

38 ELECTRONICALLY CONTROLLED
HYDRAULIC SYSTEMS
BENDIX ABS system

37 MECHANICAL ELEMENT CONTROLS

Master cylinder Brake servo Brake servo air filter Non-return valve Pedal assembly Handbrake lever Handbrake control Brake hoses Brake compensator Testing - Adjustment Clutch cable Clutch automatic wear take-up system External gear control Gear selection controls 37-1 37-2 37-4 37-5 37-6 37-7 37-10 37-11 37-13 37-15 37-16 37-19 37-25

Location and composition Electronic computer Speed sensors and targets Control relay of ABS device Operation Regulation in defect mode Pressure accumulator Removal-refitting of components Fault finding with XR25 Checking level - Bleeding Fault chart
BOSCH ABS system

38-1 38-6 38-6 38-7 38-10 38-13 38-14 38-16 38-32 38-65 38-70

Identification of the system Location and composition Operating principle Summary of regulation principle Self-testing Fault finding with XR25 Checking the wiring Wiring diagram Connectors Removal and refitting of components Bleeding Additional tests Brake compensator adjustment check Replacement of compensator Fault chart

38-87 38-88 38-96 38-104 38-106 38-111 38-125 38-126 38-128 38-130 38-135 38-137 38-143 38-144 38-145

GENERAL General braking system circuit diagram

30

NOTE: The following diagrams are general circuit diagrams and under no circumstances are they to be used for determining the positions of connections or identifying the type of circuit used on a given vehicle. When replacing any of the braking system component parts, always mark the pipes before disconnecting them so that they can be reconnected in their original positions. This is essential.

"X" TYPE BRAKING SYSTEM

"X" TYPE BRAKING SYSTEM

with load sensitive compensator

with fixed compensator which is integral with the wheel cylinder

91563S

91563-3S

30-1

GENERAL Tightening torques (in daN.m)

30

DIMENSIONS

TIGHTENING TORQUE

Bleed screws

0.6 to 0.8

Hoses on front wheel cylinders

M 10 x 100

1.3

Hoses on rear suspension arms

M 10 x 100 M 10 x 100 or M 12 x 100 M 10 x 100 or M12 x 100 M 10 x 100 or M12 x 100 M 10 x 100 or M12 x 100

1.3

Supply to rear wheel cylinders

1.3

Master cylinder outlets

1.3

Compensator inlet

1.3

Compensator outlet

1.3

30-2

FRONT AXLE

GENERAL Tightening torques (in daN.m)

30

All types except B - C - L 539 B - C - D - L 53 D

DI3030

30-3

FRONT AXLE

GENERAL Tightening torques (in daN.m)

30

B - C - L 539 B - C - D - L 53 D

DI3031

30-4

TUBULAR TYPE REAR AXLE

GENERAL Tightening torques (in daN.m)

30

DI3032

30-5

FOUR BAR TYPE REAR AXLE

GENERAL Tightening torques (in daN.m)

30

DI3033

30-6

FOUR BAR TYPE REAR AXLE

GENERAL Tightening torques (in daN.m)

30

91849R

30-7

GENERAL Underbody heights

The underbody heights are measured with the vehicle unladen, on a flat horizontal surface (preferably a lift): - fuel tank full, - tyre pressures correct. H1 and H4 is the dimension between the centre of the wheels and the ground. H2 is the dimension between the front side member and the ground in line with the wheel centres. H5 is the dimension between the centre of the suspension arm and the ground. Value in the section "Values and settings".

30

91936G1

92118

Measure dimensions : H1 and H2 at the front, H4 and H5 at the rear, and find the difference.

30-8

GENERAL Parts to be systematically replaced

Axial ball joint locking washer. Wheel balancing weight hooks. Hub bearings. Drive shaft bearing gaiter. Girling caliper guide mounting bolts. Stub axle lock nut. Mounting bolts : of the steering box, of the front axle sub-frame, rear axle.

30

Brake fluid

BRAKE FLUID CHANGE PERIODS

The design of our braking systems, in particular our disc brake units (hollow pistons that transmit very little heat, a small amount of fluid in the caliper cylinder, sliding calipers to avoid the necessity for a reserve of fluid in the hottest part of the wheel) avoids, as far as possible, risks of vapour lock, even when the brakes are intensively used (under mountain driving conditions). The brake fluids now used are subject to a slight deterioration, during their first few months of use, in that they absorb a small amount of water (see warranty booklet - maintenance of the vehicle, for changing fluid). Topping up the fluid level The wear on the brake pads and linings causes the level of the brake fluid in the reservoir gradually to fall. It is not necessary to top up this fall because the correct level is re-established when the pads are replaced. Obviously, however, the level must not be allowed to fall below the minimum mark. Officially approved brake fluids If two non-compatible brake fluids are mixed together in the same system, there could be a serious risk of leakage caused, in particular, by the deterioration of the seals and cup washers. To avoid such a risk, it is essential to use only brake fluids that have been tested and officially approved by our laboratories and which conform to Standard SAE J 1703 dot 3 or dot 4.

30-9

GENERAL Front anti-roll bar specifications

30
except

VEHICLE TYPE

B - C - L - S 530 531 532 53 W 53 H

B - C - D - L - S 53 ALL TYPES

B - C - L - S 530 531 532 53 W 53 H 23

DIAMETER

30-10

GENERAL Rear anti-roll bar specifications

30
4 BAR REAR AXLE

TUBULAR REAR AXLE

VEHICLE TYPE

B- C - L - S 530 - 531 - 532 53 H - 53 W

B- C - L - S 534, 536, 537, 53 A 53 B, 53 B, 53 G, 53 J,53 R,53 S

All types with ABS option and

B, C, D, L, S

X 53
SPORTS VERSION

533, 538, 53C, 53F 53K, 53T, 53V, 53Y 53Z, 535 353 A, F, H, C, D 453 A, F, C, D 553 A, F, H, C, D 853 A, 853 F 15 mm 17 mm 23.15 mm 31 24.75 mm 31

DIAMETER NUMBER OF SPLINES AT BEARING END NUMBER OF SPLINES AT DOUBLE SHACKLE END

30

30

Rear suspension bar specifications

TUBULAR REAR AXLE

4 BAR REAR AXLE

VEHICLE TYPE

B- C - L - S 530, 531, 532, 534, 536, 537 53 A, 53 B, 53 G, 53 H, 53 J, 53 R 53 S, 53 U, 53 W

All types with ABS option and

B, C, D, L, S

X 53
SPORTS VERSION

533, 535, 538, 53C, 53F, 53K, 53T, 53V, 53Y 53Z, 533 A, F, H, C, D 453 A, F, C, D 553 A, F, H, C, D 853 A, 853 F 21.7 mm 27 23 mm 27

DIAMETER NUMBER OF SPLINES AT BEARING END NUMBER OF SPLINES AT DOUBLE SHACKLE or ARM

19.8 mm 25

24

26

26

END

30-11

GENERAL Rear torsion bar identification marks

30

As the direction of the torsion in the bars is different, when loaded, the RH and LH bars are identified by : marks on their ends or letters stamped on their ends

LEFT HAND BAR

RIGHT HAND BAR

74384R

74385R

2 marks

3 marks

74384R1

74384R2

Letter G

Letter D

NOTE : the bars also have a drill end mark "1" which is used to position them in their bearings.

30-12

GENERAL Brake unions and pipes

30

The pipes between the master cylinder, the front calipers, the pressure limiting valve and the rear wheel cylinders are connected by unions that have
METRIC THREADS.

Consequently, it is important only to use the parts shown in the Parts catalogue for this vehicle. Parts identification : THE SHAPE of the ends of the steel or copper
PIPES (A),

THE SHAPE of the THREADED LOCATIONS in

the wheel cylinders (B), the fact that the pipe UNIONS are GREEN or BLACK in colour with an 11 mm or 12 mm external hexagon (C).

78491R

The effect of the geometry angles

The effect of the different geometry angles on the steering of the vehicle and on its tyre wear.
CAMBER

Differences in the variation of the parallelism between the right and left hand wheels cause (without any change in the position of the steering wheel): a pull to one side during acceleration, a pull to the other side during deceleration, changes in course holding when the vehicle is driven over bumpy roads.

It is the comparison between the left hand and right hand angles which is important. A difference of more than one degree from one side to the other causes the vehicle to pull to one side. This has to be corrected at the steering wheel and the result is abnormal tyre wear.
CASTOR

PARALLELISM

Once again it is the comparison between the left hand and right hand angles which is important. A difference of more than one degree causes the vehicle to pull to one side. This has to be corrected at the steering wheel and the result is abnormal tyre wear. Itcan be identified by a pull, at constant speed towards the side on which the angle is smallest.
STEERING BOX HEIGHT

The steering must be in the straight ahead position when this adjustment is carried out if a detrimental effect on the road holding is to be avoided. It is to be noted : that too much toe-out causes symmetrical excessive wear on the inside edge of both tyres, that too much toe-in causes symmetrical excessive wear on the outside edge of both tyres.

This height affects the variation in the parallelism that occurs as the suspension moves.

30-13

GENERAL Principles of checking the geometry

PRELIMINARY CHECKS

30

Before checking the axle geometry, check the following points and, if necessary, rectify them : - That the tyres on any given axle are the same from the point of view of : sizes, pressures, wear. - At the hinge and pivot points : the condition of the rubber bushes, the play in the ball joints, the bearing play. - The wheel run-out: this should not exceed 1.2 mm (it will be compensated for by the checking equipment). - That the underbody heights are the same on both sides of the vehicle (the condition of the suspension).

82699R

In this position, fit the checking equipment, and check the geometry. When adjusting the parallelism, ensure that both lengths x on the track rod end casings are the same.

DETERMINING THE STEERING CENTRE POINT

Before checking and adjusting the front axle geometry, the steering must be centralised to avoid the vehicle pulling to one side. Turn the steering to full lock in one direction. Make a mark (A) at the top of the steering wheel rim. Move the steering to full lock in the other direction whilst counting the number of turns and fractions of a turn. Return to half the number of turns (and fractions of a turn) noted. The steering is then in the "centre position".

83098R

30-14

GENERAL Checking and adjusting the front axle geometry

CHRONOLOGICAL ORDER OF OPERATIONS

30

Because of the design of the front axle, a change in one of its angles (castor, camber, kingpin, parallelism and variation) has repercussions, to a greater or lesser extent, on the other angles. (The castor angle is the one that has the most effect). It is therefore essential to carry out the operations in the following order - mount the equipment on the vehicle by following its manufacturers instructions, - find the steering centre point (see previous section) and lock the steering wheel, - lift the vehicle, taking the weight under the body, - eliminate the wheel run-out, - lower the vehicle on to the floating plates, - fit the pedal press to the brake pedal, - bounce the suspension to bring it to its nominal height, - check that the lengths X on the track rod end casings are the same, -

81940R

If both lengths X are the same : dimension A should be the same on both sides.

2 -

If the lengths X are not the same : note dimensions A on the right and left hand sides, subtract one from the other and equally distribute, on each side, half of the result.

Example : Reading on right hand side : 16 Reading on left hand side : 10 16 - 10 = 6 6 : 2 = 3 Turn the track rods to even-out the dimensions A on both sides : A = 13 note the readings A on the scales. zero the floating plates in this position, check, in the following order : the castor, the kingpin, the camber, the parallelism.

83098R

30-15

GENERAL Checking and adjusting the front axle geometry

ADJUSTING PARALLELISM

30

One of several cases may arise : Parallelism 1

CORRECT

Distribution
INCORRECT

Correction to be carried out Turn the adjusting sleeves (or end fittings) by the same number of turns in opposite directions on the left hand and right hand sides, to obtain the same reading for dimension A on both sides. Adjust the parallelism by the same amount on the right and left hand sides whilst ensuring that dimensions A remain identical on both sides.

INCORRECT

CORRECT

INCORRECT

INCORRECT

First adjust dimensions A to make them the same on both sides and then adjust the parallelism by the method described in 2

Front axle fault finding

DEFECT

POSSIBLE CAUSE

Castor incorrect

Suspension arm bent Side member bent

Camber + kingpin correct but, Camber incorrect Kingpin incorrect Camber correct but Kingpin incorrect Kingpin correct but Camber incorrect

Suspension arm bent Side member bent

Stub axle carrier bent

Stub axle carrier bent

Suspension arm bent Parallelism variation incorrect See castor Side member bent Parallelism incorrect by more than 6 mm. RH or LH stub axle carrier bent.

30-16

GENERAL Braking system fault finding

This fault finding sequence is applicable to all the braking systems and braking components used on our current range of vehicles. During fault finding notice is only to be taken of those items that are relevant to the vehicle described in this Workshop Repair Manual. The fault finding sequence can be broken down into two distinct sections that make finding the fault easier: I II I The effect as noted on the pedal The effect on the vehicle behaviour.

30

THE EFFECT AS NOTED ON THE PEDAL

FAULT

POSSIBLE CAUSE

Stiff pedal : Heavy pressure required to obtain poor deceleration

- Assistance fault - Pads or shoes that are : - greasy, - glazed or of the incorrect type, - overheating owing to constant pressure on the brake pedal (descending an incline), incorrect type. - Pistons sticking, - A crushed or kinked pipe, - Worn pads or linings: almost no friction material left, commencement of metal to metal contact (loud noise).

Spongy pedal: Note : as the servo effect on present day vehicles is very high, one frequently gets the impression that the pedal is spongy. To determine whether the brakes are effective or not, one of two tests can be carried out. 1. With the vehicle moving A subjective test: the ratio between the pedal travel and braking effect. With the vehicle stationary and the engine switched off Carry out an additional test on the pedal travel: depress the brake pedal 5 times to empty the brake servo before taking the results of the test as valid.

- Air in the system : incorrectly bled. - Internal leakage within the braking circuit. - Insufficient fluid in the reservoir (braking system external leakage).

2.

30-17

GENERAL Braking system fault finding

Pedal travel excessive This test is to be carried out with the vehicle stationary and the engine switched off. Note : one must depress the brake pedal 5 times, to empty the brake servo, before the results of this test can be considered as valid. - Brake shoes incorrectly adjusted Drum brakes

30

- Manual adjustment : shoes too far from the drums. Disc and drum brakes - Automatic adjustment : handbrake cable too tight. Note : if the handbrake cable is not too tight when in the released position, the wear will automatically be taken up when the brake pedal is depressed. - Excessive and uneven wear on the pads or shoes (pads tapered or hollow). - Too much free travel at the master cylinder. - Brake fluid boiling or overheated.

Pedal going right down to the floor Test to be carried out with the vehicle stationary and the engine switched off. Note : one must depress the brake pedal 5 times, to empty the brake servo, before the results of this test can be considered as valid. II
EFFECT ON VEHICLE BEHAVIOUR

- Brake fluid leakage (check the system for leaks) - Defective cup washer between the two master cylinder circuits. - Brake fluid boiling.

FAULT

POSSIBLE CAUSE

Brakes "self-applying"

- Insufficient lead on the linings - Linings slightly greasy - Return springs require replacing

Brakes judder

- Oval drums - Excessive disc run-out - Discs of uneven thickness - Abnormal deposits on the discs (corrosion between the pads and the discs).

30-18

GENERAL Braking system fault finding

Vehicle pulling to one side (at the front) - Check front suspension and steering. - Caliper piston sticking*. - Tyres (wear - inflation pressure). - Crushed or kinked brake pipe*.

30

*WARNING : on vehicles with negative offset

front axle geometry, pulling to one side is the result of a fault on the circuit on the opposite side.

Vehicle pulling on one side (at the rear)

- Compensator or brake pressure limiting valve (adjustment - operation) - Piston sticking. - Shoes incorrectly adjusted. manual adjustment : shoes too far from the surfaces of the drums. Automatic adjustment : handbrake cable too tight.
NOTE : If the handbrake cable is not too tight,

when in the released position, the wear will be automatically taken up when the brake pedal is depressed. - Return springs. Brakes overheating - Master cylinder clearance insufficient and preventing the master cylinder returning to the released position. - Piston sticking or not returning correctly. - Crushed or kinked pipe. - Handbrake control sticking. - Handbrake control incorrectly adjusted.

30-19

GENERAL Bleeding the braking system

30

SPECIAL TOOLING REQUIRED

M.S. 815

Brake bleeding equipment

For vehicles equipped with a brake servo, it is important that, no matter what the method of bleeding used, the servo system should not be operating during the bleed operation. The system is bled using equipment M.S. 815 on a four post lift with the wheels on the ground. Connect the pipes of the M.S. 815 to the bleed screws on the: master cylinder wheel cylinder - compensator or pressure limiting valve. Connect the equipment to a source of compressed air (minimum pressure 5 bars). Connect the filling system to the brake fluid reservoir. Open the fluid supply and wait until the reservoir is full (both sections). Open the compressed air valve.

As these vehicles are equipped with an "X" type circuit, proceed as follows: Open: - the bleed screw on the rear right hand wheel and allow the fluid to run out for approximately 20 seconds, the bleed screw on the front left hand wheel and allow the fluid to run out for approximately 20 seconds

Take no notice of air bubbles in the bleed equipment pipes.

Proceed in the same way on the rear left hand wheel and the front right hand wheel. Check that the brake pedal is firm when pressed (press it down several times). Repeat the bleed operation if necessary. Top up the brake fluid level in the reservoir after disconnecting the equipment.

30-20

GENERAL Bleeding the braking system

30

86037R

30-21

FRONT AXLE Sub-frame

31

SPECIAL TOOLS REQUIRED

Mot. 1152

Set of tools for removing and refitting connection stud

TIGHTENING TORQUES (in daN.m)

Composition of the tool Mot. 1152 : 8.5 a threaded rod with two nuts. an extractor tube (A) with a washer (B), a support ring (C) with shoulder. a simple support ring (D).

Rear sub-frame mounting bolt

Removing the connection stud on the vehicle. Use a four post lift, taking the weight under the body. Raise the front of the vehicle. Remove the rear bolt from the sub-frame where the connection stud is located. Slacken the second rear bolt, but do not remove it.

92774R

92708S

31-1

FRONT AXLE Sub-frame

Wedge a nut between the stud and the body, and screw the threaded rod into it.

31

Check that the sub-frame support ring, with shoulder, has not moved during removal of the connection stud. Dimension A = 3.5 mm or B = 17 mm. If this ring has moved, reposition it and apply 2 welding beads at (S).

92708-1S

Fit the extractor tube (A) and washer (B).

92710R

Remove the connection stud by means of the second nut.

Connection stud removed.

92708-2R

92708-3S

31-2

FRONT AXLE Sub-frame

REFITTING

31

Remove the sub-frame bolt and rings (C) and (D). Tighten the sub-frame bolts to a torque of 8.5 daN.mm, with the connection stud pressed on.

Refitting the connection stud on the vehicle. Insert the two rings between the sub-frame and the body. Centre the ring (C) using its shoulder, followed by ring (D). Coat the connection stud with soapy water, and press it on using the sub-frame bolt.

92708-6S

92708-4R

When the stud has been pressed halfway home, insert washer (B).

92708-5R

31-3

FRONT AXLE Lower suspension arms

31

TIGHTENING TORQUES (in daN.m)

Nut securing lower arm to sub-frame Nuts on stub axle carrier keys Anti-roll bar bearing nut Lower ball joint joint Wheel bolts

9 5.5 3.5 7.5 9

REMOVAL

With the vehicle resting on its wheels, remove the anti-roll bar bearings (1) from the lower suspension arms.

90130R

the two bolts (3) that secure the suspension arm to the sub-frame.

85886R

Pull the anti-roll bar downwards. With the vehicle on axle stands, remove: the nut and the key (2),
85875R

the suspension arm.

31-4

FRONT AXLE Lower suspension arms

REFITTING

31

Note: ensure that the plastic protective washer A is in position on the lower ball joint shaft. Fit : - the suspension arm, - the two bolts (3), without tightening them, - the ball joint shaft into the stub axle carrier and tighten the nut (2) on the key to the specified torque. With the vehicle resting on its wheels : Refit the anti-roll bar without tightening its bearings. "Bounce" the suspension and tighten the suspension arm mounting nuts and the anti-roll bar bearing mounting nuts to the specified torques (tightening position: vehicle unladen).

Lower suspension arm rubber bushes

REPLACING

To ensure that the rubber bushes remain central with reference to the suspension arm centreline, they are to be replaced one at a time. Push out one of the worn bushes on the press using a tube with an outside diameter of 44 mm. Fit a new bush to obtain : dimension A = 147 0.5 mm. Push the second bush out on the press and fit the second new bush as described above to obtain : dimension A = 147 0.5 mm.

90404R1

31-5

FRONT AXLE Lower suspension arm ball joints

31

REMOVAL

If the gaiter is damaged, the complete ball joint must be replaced. Carry out the same operations as for removing the lower suspension arm. Loosen, without removing, the two bolts (3) mounting the suspension arm to the sub-frame.

85875R1

Remove : the two ball joint mounting bolts (4) , the ball joint.

REFITTING

Note: ensure that the plastic protective washer A is in position on the lower ball joint shaft. Fit the ball joint and tighten its bolts to the specified torque. Then complete the operation in the same way as for refitting the lower suspension arm.

31-6

GIRLING

FRONT AXLE Brake pads

31

SPECIAL TOOLING REQUIRED

Fre. 823

Piston return tool

TIGHTENING TORQUES (in daN.m)

REFITTING

Wheel bolts Brake caliper guide bolts

REMOVal

9 3.5

Push in the caliper piston using tool Fre. 823.

Disconnect the wear warning light wire. Push in the piston by pulling the caliper outwards, by hand.

82160R

Fit the new pads, together with their springs, ensuring that they are the correct way round.

81 589

90130-2R

Remove the guide bolts (7) using two spanners. Do not clean these bolts. Take out : - the sliding caliper, - the pads. Checking Check : - the fitting and condition of the piston dust cover and its retaining ring, - the condition of the dust covers (8) on the guides.

90130-1G

31-7

GIRLING

FRONT AXLE Brake pads

The pad with the wear warning light wire on it is fitted to the inside. Fit the caliper and its lower guide bolt (7) coated with Loctite FRENBLOC. Press down the caliper and fit the upper guide bolt also coated with Loctite FRENBLOC. Tighten the guide bolts to the specified torque starting with the lower one. Reconnect the warning light wire. Press the brake pedal a number of times to bring the piston into contact with the pads.

31

We would remind you that when replacing pads or carrying out work on this type of caliper, the guide bolts* must be automatically replaced and tightened to a torque of 3.4 to 3.8 daN.m , starting with the lower bolt.

90130-3R

* bolts supplied in the spares kit.

31-8

BENDIX

Series IV

FRONT AXLE Brake pads

31

SPECIAL TOOLING REQUIRED

Fre. 823

Piston return tool

TIGHTENING TORQUES (in daN.m)

Wheel bolts
REMOVAL

Disconnect the wear warning light wire. Push in the piston by pulling the caliper outwards by hand. Remove : - the clip (1), - the key (2), - the pads.

83491R

REFITTING

Push in the caliper piston using tool Fre. 823.

90148R

Check the condition of the dust cover (5) and the gaiters (6) that protect the caliper slides and replace them if necessary. If they are replaced, grease the end of the piston and both slides after first cleaning them with methylated spirits.
90147R

31-9

BENDIX

Series IV

FRONT AXLE Brake pads

correct direction of fitting :

31

Fit the two anti-rattle clips (3) to the new pads.

- on the outside, the pad and the groove (B) are offset towards the front of the vehicle, - on the inside, the pad and the groove (B) are offset towards the rear of the vehicle, - the wear warning light wires are to be on the same side as the bleed screw (V).

88244-1R

NOTE : these vehicles are equipped with offset brake pads.

88 074

Special features of offset brake pads :

88219R

88220G

the offset pad only has one shoulder on it (A) instead of the two on the symmetrical pad, the groove (B) is offset when compared with that of the symmetrical pad,

31-10

BENDIX

Series IV

FRONT AXLE Brake pads

Place the pads in the caliper and engage the key (2). Fit the clip (1) (there is only one clip per caliper). NOTE : the clip is at the inside end of the caliper (D), near the caliper bracket mounting bolt (C).

31

82762R

Reconnect the wear warning light wire. Press the brake pedal a number of times to bring the piston into contact with the pads.

31-11

FRONT AXLE Brake calipers

Blow out the piston, with compressed air, after first placing a wooden block between the caliper and the piston to avoid the piston being damaged. Any impact mark on its skirt would render it unusable.

31

85972S

Using a thin blade with rounded edges (for example a feeler gauge) take out the square section seal from its groove in the caliper.

85971S

Clean the parts with methylated spirits. Replace any faulty parts with genuine replacement parts and refit the seal, the piston and the dust cover (fitting the retaining ring on the GIRLING assembly).

31-12

FRONT AXLE Brake calipers

TIGHTENING TORQUES (in daN.m)

31

Tighten the bleed screw.

BENDIX Series IV

Wheel bolts 9 Caliper mounting bolts (BENDIX Series IV) 10 Guide bolts (GIRLING) 3.5
REMOVAL

Place the caliper piston assembly on the stub axle carrier and tighten the two bolts (A) to the specified torque.

Loosen the brake hose at the wheel cylinder end. Remove the brake pads or linings (see corresponding section). Special features of the BENDIX Series IV Remove the two bolts (A) securing the assembly to the stub axle carrier.

94407-1S

Make sure that the locking plate is the correct way round, and that it is in the correct position (underneath head of bolts). All types Check the condition of the pads. If they are greasy, replace them. The system may be partially bled only if the brake fluid reservoir has not emptied during the operation. If it has, a complete bleed operation must be carried out. Press the brake pedal a number of times to bring the pistons into contact with the pads.
REPAIR

90149R

All types Unscrew the caliper piston from the hose (providing a container to catch the brake fluid). Check the condition of the hose and replace it if necessary (see the section on replacing a hose).
REFITTING

Any scoring of the caliper bore automatically involves the replacement of the entire caliper. Remove the brake caliper. Take off the dust cover (there is a retaining ring on the GIRLING assembly).

Screw the new caliper cylinder on to the hose. Loosen the bleed screw on the caliper cylinder and wait till brake fluid runs from it (ensure that there is enough fluid in the brake fluid reservoir).

31-13

FRONT AXLE Brake discs

The brake discs cannot be reground. A disc which is heavily worn or scored must be replaced by a new one.
TIGHTENING TORQUES (in daN.m) BENDIX Series IV

31

Wheel bolts Caliper mounting bolts Caliper bracket mounting bolts

BENDIX Series IV

9 10 6.5

REMOVAL

Remove : - the two bolts (A) that secure the brake assembly in place.
GIRLING
90149R

- the two disc mounting bolts (B) using Torx T40 type Allen key (e.g. Facom RX40 + adaptor or 89-40). - the disc.

91758R

88310-1R

REFITTING

Fit the disc to the hub and secure it in place with its two bolts (B). Refit the brake caliper, coat its bolts with Loctite FRENBLOC and tighten them to the specified torque. Press the brake pedal a number of times to bring the piston into contact with the pads.

31-14

FRONT AXLE Brake discs

REPLACING

31

Whenever a brake disc is replaced, it is essential also to replace the pads. To do this, first carry out the method described for removing the pads and then that described for replacing the caliper brackets (see the section entitled "Removing-Refitting"). Special features of the BENDIX Series IV To replace the disc, remove: - the pads, - the two bolts (C) from the caliper bracket.

90146R

31-15

FRONT AXLE Stub axle carrier bearings

SPECIAL TOOLING REQUIRED M.S.

31

Rou. Rou.
T.Av. T.Av. T.Av.

580 15 -01 604 -01 476 1050-02 1050-03

Inertia tool Shaft end protector Hub lock Ball joint extractor Hub extractor Adaptor

TIGHTENING TORQUES (in daN.m)

Shock absorber lower mounting bolt Nuts on lower ball joint key Track rod end nut Brake caliper mounting bolt Driveshaft nut Wheel bolts Checking the play

11 5.5 3.5 10 25 9

Mount a dial gauge on the hub and check that the play is between 0 and 0.05 mm.

REMOVAL

Remove : - the brake disc (see the corresponding section), - the driveshaft nut using tool Rou. 604-01.

91752R1

91751R

Extract the hub using tool T.Av. 1050-02 + 105003 + M.S. 580.

31-16

FRONT AXLE Stub axle carrier bearings

Remove the inner track ring from the hub using a jaw extractor type FACOM U53G +U53E and tool Rou. 15-01. Remove : - the mounting bolts (1), - the nut and the key (2),

31

91754R

83348G

the snap ring.

Disconnect the track rod using tool T.Av. 476.

Push out the outer track ring, on the press, using one of the inner track rings and leaving the ball cages and seals in position.

79057S

91753R

31-17

FRONT AXLE Stub axle carrier bearings

REFITTING

31

Remove the two plastic protectors (A) from the new bearing.

Fit the thrust washer (1) to the hub followed, on the press, by the bearing, using a tube, taking the weight on the inner track ring.

78624R

85902R

Fit the new bearing to the stub axle carrier, on the press, together with the plastic ring (B), using a tube. taking the weight on the outer track ring.

Refit the stub axle carrier to the vehicle. Coat the driveshaft stub axle with Loctite
SCELBLOC.

Do not take the load on the inner track ring. This could damage the bearing because the load required to insert it is very high.

91748S

79058-1S

From then on carry out the removal operations in reverse, tightening the nuts to the specified torques.

Remove the plastic ring (B). Fit the new circlip.

31-18

FRONT AXLE Stub axle carrier

31

The method of removing and refitting this component is identical to that for replacing the bearing.
NOTE: as a very high load is required to fit the

outer track ring (2) of the bearing into its bore, the bearing must be replaced by a new one every time this track ring is removed because the ball track is marked by the operation.

78626-4R

31-19

FRONT AXLE Combined spring - shock absorber assembly

31

TIGHTENING TORQUES (in daN.m)

Nuts on shock absorber rod Shock absorber lower mounting bolt Shock absorber cup mounting bolt Wheel bolts

6 11 3 9

REMOVAL

With the vehicle supported on axle stands, on the side concerned, remove : - the wheel, - the two shock absorber lower mounting bolts (1),
92114R1

- the shock absorber, whilst pressing down the lower suspension arm to avoid contact between the shock absorber and the driveshaft gaiter.
REFITTING

Refitting is the reverse of removal, taking care not to damage the driveshaft gaiter. Place the upper cup bolts in the appropriate holes. A manual steering B power steering

90130R1

the two upper mounting bolts (2),

92114-1R

Tighten, to torque : - the shock absorber lower mounting bolts (1), - the upper mounting bolts (2).

31-20

Tooling
SUS 1052

FRONT AXLE Spring and shock absorber assembly

31

Because of the high loads generated by the spring, it is essential to ensure that the tooling is in perfect condition.
SPECIAL TOOLING REQUIRED

Sus. 1052 Sus. 1052-02 Sus. 1052-03

Tooling for working on front springs and shock absorbers R19 retaining shell; R21 retaining shell

Use components (A) and (B) of tool Sus. 1052.

90102S

90100R

Upper and lower compression plates assembly. A B Thrust cup Retaining shell marked R19

Fit : - the spring-shock absorber assembly positioning the 2 half cups (A) and the two 1/2 shells (B),

For B, C, D, L 539 and 53 D B Retaining shell marked R 21.

DISMANTLING THE SPRING - SHOCK ABSORBER ASSEMBLY

Grip the lower part of tool Sus. 1052 in a vice.

92127R

31-21

Tooling
SUS 1052

FRONT AXLE Spring and shock absorber assembly

31

the upper plate, the two bolts that retain the upper shock absorber cup in the specified holes (the vehicle references are engraved on the upper plate),

Compress the spring by approximately 10 mm. Remove the nut from the shock absorber rod.

90104-2S 90104R1

the three compression bolts, injecting copious quantities of oil into the reservoirs provided.

Gradually and evenly release the spring pressure. Remove parts (1) to (6) in that order.

NOTE : as the threaded rods on the tool are subjected to very heavy loads, it is essential that they should be thoroughly oiled.

90104-1R

DI3102

Parts (4) and (5) form the front suspension pivot point.

31-22

Tooling
SUS 1052

FRONT AXLE Spring and shock absorber assembly

Assembly of Tool for B, C, D, L 539 AND 53 D The upper plate (1) of these shock absorber assemblies is offset.

31

93255S

For this type of shock absorber it will be necessary to use upper thrust cup Sus. 1052-03.

93254R

NOTE : depending on whether it is on the right or

left hand side, thrust cup Sus. 1052-003 has 2 drilled holes to enable the shock absorber pin to be centred.

31-23

Tooling
SUS 1052

FRONT AXLE Spring and shock absorber assembly

31

REASSEMBLING THE SPRING - SHOCK ABSORBER ASSEMBLY

Place the following in position : - the shock absorber (6), - the bearing (5), - the lower spring thrust cup (4), - the spring on the lower cup, placing it against its stop, - the upper plate assembly with the upper spring cup (1) in line with the correct reference marks. Ensure that the spring is correctly positioned against the upper stop.

90104-2S

Gradually and evenly release the spring pressure. Remove : - the upper plate from the tool, - the spring - shock absorber assembly from the compression tool.

92128S

Compress the assembly and pass the shock absorber rod through its hole. Fit the nut and tighten it to the specified torque.

31-24

With spring compressor

FRONT AXLE Spring and shock absorber assembly

31

Because of the high loads generated by the spring, it is essential to ensure that the tooling is in perfect condition.
EQUIPMENT REQUIRED

Make MG ZI

Type M90
ZKL 2013 ZKL 0055

Description Spring compressor Spring compressor Vice Tool for removing the shock absorber nut

Cup M3 NO2

FACOM

D83
RENA

TIGHTENING TORQUES (in daN.m)

Shock absorber upper mounting nut

REMOVAL

Fit the cups on the compression tool and place the assembly in position on the spring.

96049S

Gradually and evenly reduce the spring pressure. Remove parts (1) to (5) in the same order as for removing with the tool Sus. 1052.

95436S

Compress the spring until it slackens on the cup supports. Using tool FACOM D83 RENA remove the shock absorber rod nut.

31-25

With spring compressor

FRONT AXLE Spring and shock absorber assembly

31

REFITTING

Precautions to be taken before assembly The shock absorbers must be stored horizontally in the spares warehouse. Under these conditions, shock absorbers designed to operate vertically may deprime. Consequently it is sufficient to pump them manually several times in the vertical position before installing them on the vehicle. If a spring requires replacing, and in order to facilitate refitting, make sure that the spring and cups of the tool are in the correct position.

DI 3102

Tighten the nut (new) to the specified torque using tool FACOM D83 RENA.

95435S

Make sure that the components are fitted the right way round and in the correct order.

96049-1S

Release the spring pressure and remove the tool.

31-26

FRONT AXLE Anti-roll bar

31

TIGHTENING TORQUES (in daN.m)

Bearing mounting nuts To carry out this operation first remove : the exhaust downpipe, the gear control (manual gearbox).

3.5

REMOVAL

Remove items (1) to (3) on each side. Check the condition of the bearing assemblies and their bushes and replace them if necessary.

85890R

1 Bearing on sub-frame 2 Bearing on suspension arm 3 Anti-roll bar

31-27

FRONT AXLE Anti-roll bar

When carrying out any work on the anti-roll bar of these vehicles, only the bearings on arms (1) need be coated with Molykote 33 Medium grease.

31

85886R

Greasing of the bearings on sub-frame (2) is not permitted (risk of the bar moving and noise)

90110R

REFITTING

Refit parts (3) to (1). The bearings are to be tightened with the vehicle: unladen.

31-28

REAR AXLE Rear axle

33

TIGHTENING TORQUES (in daN.m)

Bearing mounting nut Wheel bolts Shock absorber lower mounting bolt
REMOVAL

8 8 6

With the vehicle on a two post lift, remove : - the two shock absorber lower mounting bolts, - the brake hoses, - the handbrake secondary cables, disconnecting them from the central control under the vehicle.
REFITTING

92214R

Support the rear axle and remove : - the four nuts that mount the bearings (A),

Refitting is the reverse of removal. Bleed the braking system. Adjust the handbrake control (see section 37).

92212R

the rear axle assembly.

NOTE : if one of the rear axle bearing mounting bolts is damaged, it can be replaced by removing the interior trim around the rear door or quarter panel to gain access to the bolt backing plate.

33-1

BENDIX

180 X 40

REAR AXLE Brake drums

33

The two brake drums must be of the same diameter and therefore regrinding one of the drums automatically involves regrinding the other. The maximum amount of metal that may be removed is 1 mm on diameter.
SPECIAL TOOLING REQUIRED

Emb. 880 Rou. 943

Inertia extractor Hub plug extractor

TIGHTENING TORQUES (in daN.m)

Wheel bolts Hub nut

REMOVAL

8 16

Remove the hub plug: tools Rou. 943 + Emb. 880.

92115R

Release the handbrake and slacken the handbrake secondary cables to allow the lever to move back. Pass a screwdriver through one of the wheel mounting bolt holes on the drum and push the handbrake lever to free the stud from the brake shoe (E). Help to release the lever by pushing it backwards.

90220G1

85 906

Remove : - the nut and washer from the stub axle, - the drum. Remove all dust from the drum and shoes.

33-2

REAR AXLE Brake drum

REFITTING

33

Fit : - the drum, - the washer and the nut, tightening it to torque, - the hub plug. Adjust : - the positions of the shoes by repeatedly pressing down the brake pedal, - the handbrake (see section 37 "Controls").

33-3

REAR AXLE Wheel cylinders

33

These vehicles are equipped with a fixed brake compensator that is integral with the wheel cylinder. If either the wheel cylinder or compensator is faulty, replace the entire assembly. Any attempt at repair is forbidden.

TIGHTENING TORQUES (in daN.m)

REFITTING

Wheel bolts Hub nut Bleed bolt Pipe union bolt

REMOVAL

8 16 0 .8 1 .3

Remove all dust from the drums and the shoes. Refitting is the reverse of removal (see section "Brake shoes"). Bleed the braking system. Check the cut off pressure.

Remove : - the drum (see the corresponding section), - the brake shoe (see the section entitled "Brake shoes"). Slacken : - the rigid pipe union on the wheel cylinder, using a pipe spanner, - the two bolts that secure the cylinder to the brake backing plate and remove the cylinder. Check the condition of the shoes. If, in particular, they are greasy, replace them.

92116R

33-4

REAR AXLE Brake caliper

33

TIGHTENING TORQUES (in daN.m)

REFITTING

Wheel bolts Brake caliper mounting bolt

REMOVAL

9 10

Retighten the rigid pipe union, without locking it. Fit the caliper, coat the bolts with Loctite FRENBLOC and tighten them to torque. Lock the rigid pipe union.

Remove the brake shoes (see corresponding section). Release the rigid brake pipe on the cylinder side. Disconnect the handbrake cable.

Slacken the cylinder bleed screw and wait for the brake fluid to run out (check that the compensation reservoir level is sufficient). Retighten the bleed screw. Check the condition of the shoes, and refit them. Carry out partial bleeding of the system only if the compensation reservoir has not emptied completely during the operation. Otherwise bleed the system completely. Press down the brake pedal several times to bring the piston in contact with the shoes.

REPAIR

Remove the brake caliper. The slightest scratch on the caliper bore automatically means replacement of the complete caliper.
88993R

It is not permitted to remove the inside of the piston (P).

Remove the two mounting bolts (A) on the stub axle carrier. Slacken the pipe union (allow for the escape of brake fluid).

74194-1R

Place the caliper in a vice fitted with jaws. Remove the rubber dust cover.

33-5

REAR AXLE Brake caliper

Remove the piston by unscrewing it with a square section screwdriver.

33

Remove the sealing piston from its groove with a steel blade with rounded edges. Clean the parts with methylated spirits and refit them. Lubricate the seal and piston with brake fluid. Progressively press the piston by hand to avoid damaging the seal. Press the piston home by screwing it with a screwdriver until the piston rotates, but will advance no further. Position the piston so that the line (R) marked on its support face is located on the bleed screw (P) side, to allow correct bleeding of the caliper and normal fitting of the shoes in the central groove of the piston.

88306S

When the piston rotates, progressively apply compressed air in the cylinder, taking care not to remove the piston by force; insert a wooden block between the caliper and piston to avoid damaging the piston. Any impact mark or scratch will render the piston unusable.

88311R

Coat the piston plunger with grease. Fit the new protective cover.
88398S

33-6

REAR AXLE Mechanical brake caliper control

33

SPECIAL TOOLS REQUIRED

B. Vi.28-01 Fre. 1047

Claw extractor Key for removing the handbrake control on the rear caliper

REMOVAL

Place the caliper and its cap in a vice with jaws. Remove : the sealing cover (1), the piston (2) by unscrewing it, the clip (3).

Turn the dust cap (4) over (this cap is shrunk on to the pin (7)). Remove the circlip (5).

88393R

Compress the spring washers (6), tools Fre. 1047 + B. Vi. 28-01. Remove : the pin (7) fitted with the dust cap (4) by pulling the lever, the thrust pin (8). the spring (9), the adjusting screw (10), the washer (11), the spring washers(6), the ring (12) using a pin punch, the O-ring (13).
74439-2R

Clean all the parts with methylated spirits.

33-7

REAR AXLE Mechanical brake caliper control

REFITTING

33

Fit : - the O-ring (13), - the ring (12) until it is flush with face (A) using a tube of suitable diameter.

74486-1R

Check the positioning of the spring washers, which must be fitted as shown in the diagram to enable the handbrake lever to move to the "rest" position. Refitting is then the reverse of removal. Position the piston so that the line (R) on its support face is facing the bleed screw (P).

88311R

33-8

BENDIX

180 X 40

REAR AXLE Brake shoes (drum brakes)

33

SPECIAL TOOLING REQUIRED

Emb. 880 Rou. 943

Inertia extractor Hub plug extractor

TIGHTENING TORQUES (in daN.m)

REMOVAL

Wheel bolts Hub nut Composition of the Bendix 180x40 RAI brake (Automatic Wear Take-up System).

9 16

All the shoes or linings on a given axle must be replaced at the same time. Never fit linings of different makes or grades. Remove the lower spring (2) using brake shoe pliers.

90217-1R

Fit a clip to the wheel cylinder piston.

90223R

A B C P F 1 2 3 4

Leading shoe Trailing shoe Fixed point Brake shoe end RAI Upper return spring Lower (end) return spring Side retaining spring Handbrake lever return spring

33-9

BENDIX

180 X 40

REAR AXLE Brake shoes (drum brakes)

33

Using a set of combination grips, remove the shoe side retaining springs (R) whilst holding the connecting rod (T) against the brake backing plate.

On the work bench, remove the RAI and shoe assembly. Release the handbrake lever.

86560-1

93725S

Unhook clip (E) with a small screwdriver.

90218-1G1

Slide each shoe end (P) alternately above the fixed point (C). Lock the shoe ends one against the other to remove the ends from the wheel cylinder. Separate the assembly (RAI and shoes) from the brake backing plate, then remove it after having unclipped the handbrake cable.

93723R

33-10

BENDIX

180 X 40

REAR AXLE Brake shoes (drum brakes)

33

Rotate the leading shoe (A), in the direction of the arrow, so that the bolt head is released from the RAI. This enables the upper spring (1) to be removed without force.

Marking and refitting the RAI component parts

Left toothed nut and bolt

93717-1R

The bolt has a left-hand thread, the toothed nut has a slot (G) and the clip is not painted.
93724R

To remove the RAI assembly pull it in the direction of the arrow (1), then rotat in the direction of arrow (2). Remove the spring (4) and the handbrake lever.

Right toothed nut and bolt

93717S

The bolt has a right-hand thread, the toothed nut has no slot, and the clip shows traces of paint.
93722R

33-11

BENDIX

180 X 40

REAR AXLE Brake shoes (drum brakes)

Left-hand RAI assembly

33

Refitting of the RAI (automatic wear take-up system) Make sure that the ratchet is in the correct position. 1st fitting

93716R

Note the G (left-hand) in the casting and the position of the bracket.
90222S

Right-hand RAI assembly

2nd fitting

93715R

93714-1S

Note the D (right-hand) in the casting and the position of the bracket. In both cases the clip attachment must not be wedged between the bolt head and the toothed nut. Leave a slight lateral clearance (J).

Refit the bracket, the solid section of which must be positioned between the blade and the lever.

33-12

BENDIX

180 X 40

REAR AXLE Brake shoes (drum brakes)

33

93714S

Then assemble the levers with their respective nuts and bolts, screw, pin and right-hand nut in the right-hand lever, passing through the hole in the bracket and the same for the left-hand RAI.

93720R

On the bench, refit the RAI assembly and shoes Refit the handbrake lever on the trailing shoe with a new clip, then disarm the lever. Position the spring (4) in the notch on the shoe, paying attention to the direction of fitting, then secure the shortest hook to the shoe.

Place the upper spring (1) in the notches on the two shoes, then pull in the direction of the arrows. The bolt locator must be positioned in that of the leading shoe (A).

93719R

93721R

Hook the RAI assembly on to the spring (4), then pull in the direction of the arrows. The RAI assembly automatically comes to rest in its operating position.

33-13

BENDIX

180 X 40

REAR AXLE Brake shoes (drum brakes)

33

Attach clip (E) and re-arm the handbrake lever.

90217-1R1

ADJUSTMENT
93718R

REFITTING

Using a screwdriver adjust the diameter across the shoes by turning the toothed wheel (F) to obtain a diameter (X) of between : 179.2 mm and 179.5 mm.

Present the assembly on the vehicle. Attach the handbrake cable to the lever. Tighten the shoe ends and position the other ends on the wheel cylinder pistons, taking care not to damage the caps. Position the shoes on the fixed point (C). Fit the side retaining springs (3). Remove the clips from the wheel cylinder pistons, then refit the lower spring (2).

90223R1

Carry out the same adjustment on the other backing plate assembly. Refit the drums without tightening the nuts.

33-14

BENDIX

180 X 40

REAR AXLE Brake shoes (drum brakes)

Adjust the positions of the shoes by repeatedly pressing the brake pedal (approximately 20 times). Make sure that the automatic wear take-up system is operating correctly (characteristic "click" at the drums). Remove the drums. Make sure: - that the cables are sliding correctly, - that the handbrake levers (L) are correctly supported on the shoes. BENDIX

33

90223G

Progressively tension the cables at the central adjuster so that the levers (L) start to move between the 1st and 2nd notch of the travel of the control lever and remain applied from the 2nd notch. Lock the central adjustment lock nut. Refit: - the drums and tighten the nuts to a torque of 16 daN.m, - the plugs.

33-15

BENDIX

203 X 38

REAR AXLE Brake shoes (drum brakes)

33

SPECIAL TOOLING REQUIRED

Emb. 880 Rou. 943

Inertia extractor Hub plug extractor

TIGHTENING TORQUES (in daN.m)

REMOVING

Wheel bolts Hub nut Composition of the BENDIX 203 x 38 RAI (automatic wear take-up system).

9 1 7.5

All the shoes or linings on a given axle must be replaced at the same time. Never fit linings of different makes or grades. Remove: - the brake drum (see corresponding section), - the lower spring (2) with brake shoe pliers.

98992R

A B C P F 1 2 3 4

Leading shoe Trailing shoe Fixed point Brake shoe end RAI Upper return spring Lower (end) return spring Side retaining spring Handbrake lever return spring

98993R

Fit a clip to the wheel cylinder pistons.

33-16

BENDIX

203 X 38

REAR AXLE Brake shoes (drum brakes)

33

Using a set of combination grips, remove the shoe side retaining springs (R) whilst holding the connecting rod (T) against the brake backing plate (E).

On the work bench, remove the RAI and shoe assembly. Release the handbrake lever.

86560-1

99022S

Unhook clip (E) with a screwdriver.

98994G

Slide each shoe end (P) alternately above the fixed point (C). Lock the shoe ends one against the other to remove the ends from the wheel cylinder. Separate the assembly (RAI and shoes) from the brake backing plate, then remove it after having unclipped the handbrake cable.

98995R

33-17

BENDIX

203 X 38

REAR AXLE Brake shoes (drum brakes)

33

Rotate the leading shoe (A), in the direction of the arrow, so that the bolt head is released from the RAI. This enables the upper spring (1) to be removed without force.

Marking and refitting of the component parts of the RAI (automatic wear take-up system) Left-hand toothed nut and bolt

98997R

The bolt has a left-hand thread, the toothed nut has two slots (G).
98996R

To remove the RAI assembly it pull it in the direction of the arrow (1), then rotate in the direction of arrow (2). Remove the spring (4) and the handbrake lever.

Right-hand toothed nut and bolt

98997-1R

The bolt has a right-hand thread, the toothed nut has one slot.
98991-1R

NOTE : Remove all dust from the components

with a brake cleaning agent.

33-18

BENDIX

203 X 38

REAR AXLE Brake shoes (drum brakes)

Left-hand RAI assembly Refitting the RAI Make sure that the ratchet is in the correct position.

33

98998R

98999S

Right-hand RAI assembly The body and bracket are reversed, but blade (5) must be located on top. In both cases the clip attachment must not be wedged between the bolt head and the toothed nut. Leave a slight clearance (J).

Refit the bracket, the solid section of which must be located between the blade and lever.

33-19

BENDIX

203 X 38

REAR AXLE Brake shoes (drum brakes)

33

99000S

Then assemble the levers with their respective bolts and nuts, screws, pin and right-hand nut in the right-hand lever, passing through the hole in the corner plate. The same applies to the righthand RAI. On the bench, refit the RAI assembly and shoes Refit the handbrake lever on the trailing shoe with a new clip, then disarm the lever. Position the spring (4) on the notch on the shoe, paying attention to the direction of fitting, and fit the shortest hook on the shoe.

99002R

Place the upper spring (1) in the notches on the two shoes, then pull in the direction of the arrows. The bolt locator must be positioned in that of the trailing shoe (A).

98996-1R

99001R

Hook the RAI assembly on the spring (4), then pull in the direction of the arrows. The RAI assembly automatically comes to rest in its operating position.

33-20

BENDIX

203 X 38

REAR AXLE Brake shoes (drum brakes)

33

Attach the clip (E) and re-arm the handbrake lever.

98993-1R

ADJUSTING
99003R

REFITTING

Using a screwdriver, adjust the diameter across the shoes by turning the toothed wheel (F) to obtain a diameter (X) of between 202.5 mm and 202.7 mm.

Present the assembly on the vehicle. Attach the handbrake cable to the lever. Tighten the shoe ends and place the other ends on the wheel cylinder pistons, taking care not to damage the caps. Place the shoes on the fixed point (C) Fit the side retaining springs (3). Remove the clips from the wheel cylinder pistons, then refit the lower spring (2).

98992-1R

Carry out the same adjustment on the other backing plate assembly. Refit the drums without tightening the nuts.

33-21

BENDIX

203 X 38

REAR AXLE Brake shoes (drum brakes)

Adjust the positions of the shoes by repeatedly pressing the brake pedal (approximately 20 times). Make sure that the RAI is operating correctly (characteristic "click" at the drums). Remove the drums. Make sure that: - the cables are sliding correctly, - the handbrake levers (L) are correctly supported on the shoes.

33

98992-1R1

Progressively tension the cables at the central adjuster so that the levers (L) start to move between the 1st and 2nd notch of the travel of the control lever and remain applied from the 2nd notch. Tighten the central adjusting lock nut. Refit: - the drums and tighten the nuts to a torque of 17.5 daN.m, - the plugs.

33-22

REAR AXLE Brake pads (disc brakes)

33
9

TIGHTENING TORQUES (in daN.m)

Wheel bolts

REMOVAL

REFITTING

Remove: - the clip (1) - the key (2), - the pads.

Push in the caliper piston and tighten it using a square section screwdriver until it rotates but goes in no further.

88992R

88311R

Check the condition of the dust cover (5) and the gaiters (6) that protect the caliper slides and replace them if necessary. If they are replaced, grease the end of the piston and both slides after first cleaning them with methylated spirits.

Position the piston so that the line (R) on its support surface faces the bleed screw (P).

88394R

33-23

REAR AXLE Brake pads (disc brakes)

33

Fit the anti-rattle clips (3) to the new pads.

88244R

Place the pads in the caliper, making sure that they are the right way round. Engage the key (2) and refit the clip (1) (there is only one clip per caliper).
NOTE: the clip (1) is at the inside end of the caliper

near bolt (4).

82762R

Press the brake pedal a number of times to bring the piston into contact with the pads.

33-24

REAR AXLE Disk brakes

33

SPECIAL TOOLING REQUIRED

Emb. 880 Rou. 943

Inertia extractor Hub plug extractor

TIGHTENING TORQUES (in daN.m)

Wheel bolts Hub nut Caliper bracket

9 16 10

This vehicle is equipped with a hub/brake disc assembly which cannot be reground. If heavily worn or scored it must be replaced by a new assembly.

REMOVAL

Remove : - the brake pads (see corresponding section), - the two caliper bracket securing bolts (A).
88310-2R

NOTE : If a hub/disc assembly is to be replaced, re-

fer to the "Bearing" section.

REFITTING

Fit the hub/disc/bearing assembly on the stub axle previously coated with oil SAE 80 W. Refit: - the stub axle nut and tighten it to torque, - the hub plug, - the brake caliper bracket, coat the bolts with Loctite FRENBLOC and tighten them to torque, - the brake pads (see corresponding section).
88992R1

- the hub plug, tool Rou. 943+ Emb. 880, - the stub axle nut (3), - the hub/disc/bearing assembly.

Press the brake pedal a number of times to bring the piston into contact with the pads.

33-25

REAR AXLE Hub bearings

33

SPECIAL TOOLING REQUIRED

Emb. 880 Rou. 943 Tav.1050-02

Inertia extractor Hub plug extractor Hub extractor

TIGHTENING TORQUES (in daN.m)

REMOVAL

Hub nut Wheel bolts

16 9

Remove : - the hub plug using tools Rou. 943 + Emb. 880,

CHECKING

Check the end play in the bearing with a dial gauge mounted on the drum. It should be : 0 to 0.03 mm max.

92115R

the drum (see the corresponding section).

Extract from the drum : - the bearing retaining circlip, - the bearing, using a tube (1).

DI3305

85907R

33-26

REAR AXLE Hub bearings

REFITTING

33

Using a tube (2) and a press, fit the bearing until it is against its shoulder. Fit: - a new circlip, - the drum to the stub axle which has previously been oiled with oil grade SAE 80W , - the new lock nut, tightening it to torque, - the hub plug. Adjust: - the positions of the brake shoes by repeatedly pressing the brake pedal, - the handbrake (see section 37 ~Controls").

33-27

REAR AXLE Hub bearings

33

SPECIAL TOOLING REQUIRED

Emb. Rou.
T.Av.

880 943 1050

Inertia extractor Hub plug extractor Hub extractor

TIGHTENING TORQUES (in daN.m)

Wheel bolts Hub nut Brake caliper bracket

CHECKING

9 16 10

Check the end play in the bearing with a dial gauge mounted on the drum. It should be : 0 to 0.03 mm max.

88992R1

the nut and the stub axle washer, the hub/disc/bearing assembly.

Extract from the hub/disc: : - the bearing retaining circlip, - the bearing, using a tube (1).

DI3306

REMOVAL

Remove: - the brake pads (see corresponding section), - the caliper bracket (two bolts (A)), - the hub plug: tools Rou. 943 + Emb. 880.

85907R

33-28

REAR AXLE Hub bearings

VEHICLES EQUIPPED WITH DISCS REFITTING

33

Using a tube (2) and a press, fit the bearing until it is against its shoulder. Fit: - a new circlip, the disc to the stub axle which has previously been oiled with oil grade SAE 80W , the new lock nut, tightening it to torque, the hub plug, the caliper bracket, coat the two mounting bolts with Loctite FRENBLOC and tighten to torque, the brake pads (see corresponding section).

Press down the brake pedal a number of times to bring the piston into contact with the pads.

33-29

REAR AXLE Shock absorbers

TIGHTENING TORQUES (in daN.m)

33

2 6

the shock absorber.

Upper securing nut Lower securing bolt

REMOVAL

With the vehicle resting on its wheels, remove : - the upper mounting (1) from inside the vehicle,

DI3307

PRECAUTIONS TO BE TAKEN BEFORE FITTING

Shock absorbers are stored horizontally in the parts stores. Under these conditions, it is possible for a shock absorber that is designed to work vertically to become deprimed.
85919R

the lower mounting (2).

Consequently, before fitting it to the vehicle, it should be held vertically and pumped several times by hand.

REFITTING

Fit : - the shock absorber, - the nuts and mounting bolts (after first greasing them with MOLYKOTE BR2 grease). Tighten the nuts and bolts to torque. Refit the rubber caps.

92117R

33-30

REAR AXLE Anti-roll bar on tubular type rear axle

33

TIGHTENING TORQUES (in daN.m)

Bar mounting bolt

4.5

REMOVAL

92211R

1 2

Mounting bolts Handbrake cable retaining clips

Raise the vehicle on a lift with its wheels hanging free. Remove the bolts (1) and the clips (2) from either side and retrieve the captive nuts. Remove the bar.

REFITTING

Fit, on either side - the clips (2), - the bolts (1) with their captive nuts. Tighten the bolts to torque.

33-31

REAR AXLE Half suspension arms on tubular type rear axle

TIGHTENING TORQUES (in daN.m) REFITTING

33

Bearing mounting nut Anti-roll bar mounting securing bolt Wheel bolts Shock absorber lower mounting bolt

8 4.5 9 6

Check that the bearing tracks or the needle races are in perfect condition. If not, replace them (see section entitled "Rear axle bearings - tubular type rear axle". As the needle races are greased for life, it is not necessary to regrease them.
NOTE: new suspension arms as supplied by the

REMOVAL

With the vehicle supported on a two post lift, remove : - the anti-roll bar, - the shock absorber lower mounting bolt, - the handbrake secondary cable, disconnecting it from the central control under the vehicle, - the brake hose, - the two nuts that securing the bearing (A).

Parts Department are fitted with bearing tracks or needle races (depending on the size). Insert the two half suspension arm assemblies one into the other until the correct dimension (B) is obtained.
NOTE: dimension (B) corresponds to the distance

between the same anti-roll bar securing points on the suspension arms. It is therefore possible to obtain this dimension by placing the anti-roll bar in its location and checking its securing bolts enter correctly. Ensure that it is fitted the correct way round.

92211R1

Slacken the two nuts (A) on the bearing on the other side to be able to free the half suspension arm and remove its anchor points. Remove the half suspension arm by separating it from the other.
86320R

Refitting is then the reverse of removal.

NOTE: If one halff suspension arm assembly is

replaced, bond the brake backing plate mounting bolts with Loctite FRENBLOC. Bleed the braking system. Adjust the handbrake control (see section 37).

33-32

REAR AXLE Bearings on tubular type rear axle

This operation is carried out after first removing the entire rear axle assembly and separating the two suspension arms.
SPECIAL TOOLING REQUIRED

33

T. Ar. 960 T. Ar. 960-02

Bearing extractor Bearing extractor + spacer

REMOVAL

Remove from the female arm (left hand): the outer bush (6), using tool T.Ar. 960, the inner bush (7) using the small end of tool T.Ar. 960.

Grind almost through the bearing tracks on the male arm (right hand), with a straight grinder, taking care not to mark the tube.

90864S

Split the bearing tracks with a cold chisel and remove them.
86182R

86180R

33-33

REAR AXLE Bearings on tubular type rear axle

Cut and remove the seal (5). Fit : the small needle race to mandrel (A),

33

mandrel (A) into the tube using mandrel (B) as a guide.

90863R

REFITTING

Tool T.Ar. 960-05. is required to fit needle races and their tracks.

90866R

Push them in on the press until mandrel (A) is flush with face (2) on mandrel (B)

90874R

90868R

33-34

REAR AXLE Bearings on tubular type rear axles

33

Fit : - the large needle race to mandrel (B),

Push down, with the press until mandrel (B) makes contact with the tube.

90865R

90868-2R

Remove mandrels (B) and (A). Fit a new seal (5) to the male tube. mandrel (B) into the tube using mandrel (A) as a guide. The bearing tracks have a lead chamfer at one end. It is essential to ensure that they are the correct way round with chamfer (4) positioned as shown in the drawing to ensure that that there is sufficient bearing area to fit the track.

90868-1R

90941R

33-35

REAR AXLE Bearings on tubular type rear axles

Fit : the large bearing track into the sleeve (D), the assembly of sleeve (D) and (C) over the tube.

33

90867-3R

Push down on the press until sleeve (C) is flush with edge (3) of the tube.

90867-5R

Push down the assembly (D) and (C) until sleeve (C) is flush with edge (3) of the tube.

90867-4R

Remove sleeves (C) and (D).

IMPORTANT

When pushing in the bearings, if the load is being taken on the axle mounting bearing assemblies, it is essential to ensure that the suspension bars are correctly located in their anchor points (there is a risk of them coming out). Recentralise them if necessary.
90867-2R

Assemble the two half suspension arm assemblies. NOTE : It is not necessary to grease the needle races. They are supplied ready greased. Then reconnect and refit the rear axle to the vehicle (see corresponding section).

Fit : - the small bearing track in the sleeve (C), - the sleeve (C) over the tube with sleeve (D) acting as a guide.

33-36

REAR AXLE Suspension bars - tubular type rear axle

33

SPECIAL TOOLING REQUIRED

Emb. 880

Inertia extractor

TIGHTENING TORQUES (in daN.m)

Shock absorber upper mountings Shock absorber lower mountings

REMOVAL

2 6

A B C D E F

Nut 14 mm diameter Nut 12 mm diameter 12 mm diameter threaded rod 660 mm long Washers inside diameter 12 mm Spacer inside diameter 12.5 mm outside diameter 20 mm, 60 mm long Weld

With the vehicle wheels hanging free, remove the shock absorber on the side concerned. Extract the bar, from one side, using tool Emb. 880.

75505R

Pre-adjust the tool to obtain dimension "X". See the section "Value and settings" for dimension X, depending on the type of vehicle.

92213R

REFITTING

To place the suspension arm in the correct position for fitting the bar, a special tool must be made up locally.

75329R

33-37

REAR AXLE Suspension bars - tubular type rear axle

Fit the tool in place of the shock absorber.

33

75 422-2

92119G

Coat the splines on the suspension bar with grease MOLYKOTE BR2, insert it into the bearing and into the suspension arm determining, by turning the bar, the position in which it will enter freely into the splines on both the arm and the bearing. Remove the tool and refit the shock absorber. Lower the vehicle on to its wheels and measure the underbody heights (see section entitled "Underbody height - Tubular type rear axle"). Check and, if necessary, adjust the headlights.

33-38

REAR AXLE Underbody height - tubular type rear axle

CHECKING

33

Remove the bar. As 3 mm is the minimum adjustment that can be obtained by moving one differential spline, it is only possible to adjust the height of the vehicle in multiples of 3 mm. Lower the suspension arm to offset the bar by the number of splines that represents the height to be taken up: Example : 10 mm = 3 splines Refit the bar so that it engages, freely, into the splines on both the arm and the bearing. Check and, if necessary, adjust the headlights.

Park the vehicle, unladen but with its fuel tank full, on a flat horizontal surface.

92118G1

GOOD ROAD VERSIONS

See section entitled "value and settings" for value H4-H5, depending on the type of vehicle.
ADJUSTING

Only the underbody height is adjustable by turning the torsion bars. Determine the dimension "X", on the vehicle, by adjusting the bracket (D) on the locally manufactured tool until the bar can be slid, by hand, into its anchor points.

33-39

REAR AXLE Torsion bars on four bar type rear axles

33

DI3308

This type of rear axle consists of : two suspension arms connected by an "L" section beam. This assembly (1) cannot be dismantled. If any part is distorted, the entire assembly must be replaced. two bars known as anti-roll bars (3). two bars known as suspension bars (4). a double shackle (2) that connects the bars.

This assembly is secured to the body by two pivot bearings mounted on rubber bushes. NOTE: It is forbidden to use the "L" section beam (1) as a jacking point to lift the vehicle.

33-40

REAR AXLE Torsion bars on four bar type rear axles

EXTRACTION OF THE BARS FROM THEIR SPLINES

33

Remove the wheels.

SPECIAL TOOLING REQUIRED

Emb. 880

Inertia extractor

SUSPENSION BARS

ANTI-ROLL BARS

Release the suspension bars from their splines using inertia extractor tool Emb. 880.

Release the anti-roll bars using inertia extractor tool Emb. 880.

92120-1R

92120R

33-41

REAR AXLE Underbody height - four bar type rear axle

CHECKING

33

Park the vehicle, unladen but with its fuel tank full, on a flat horizontal surface.

91936

92118G1

GOOD ROAD VERSIONS

See the section "value and settings" for value H4 - H5, depending on vehicle type.

The fault that requires adjustment may take one of three forms: A B C correct height on one side, but excessive right/left hand difference, incorrect height and excessive right/left hand difference, incorrect height, but correct right/left hand difference.

33-42

REAR AXLE Four bar type rear axle

ADJUSTING

33

1. A

AFTER REPLACING A REAR AXLE

The height is correct on one side but the difference between the LH and RH sides is excessive

Any difference between the RH and LH sides must always be taken up by adjusting the anti-roll bar on the lowest side. NOTE: it is essential to adjust on the lowest side and bring it up to the same as the highest side.

In this new position, refit : - the anti-roll bar at the point where it will slide in freely and check the number of splines offset on the arm and double shackle, - the two suspension bars without offsetting the marks. Fit : - the shock absorbers, - the wheels. With the vehicle resting on its wheels, check and if necessary adjust the headlights.

B Mark the positions in the bearings and in the double shackle: - of the two suspension bars, - of the anti-roll bar on the lowest side. Fit the tools set to the dimension "X" that corresponds to the vehicle type. Remove: - the suspension bars, - the anti-roll bar which has been marked. Measure the dimension between the centre of the wheel and the ground (on the side without an anti-roll bar).

If the heights are incorrect and the difference between the RH and LH sides is excessive

The difference between the RH and LH sides must always be taken up by adjusting the anti-roll bar on the lowest side. NOTE: it is essential to adjust on the lowest side and bring it up to the same as the highest side. Mark the positions in the bearings and in the double shackle: - of the two suspension bars, - of the anti-roll bar on the lowest side. Fit the tools set to the dimension "X" that corresponds to the vehicle type. Remove: - the suspension bars, - the anti-roll bar which has been marked. Measure the dimension between the centre of the wheel and the ground (on the side without an anti-roll bar).

92118-1S

Reduce this dimension by the amount of difference between the RH and LH sides already measured by increasing dimension "X" on the tool. NOTE: do not alter the adjustment of the tool on the other side.

92118-1S

33-43

REAR AXLE Four bar type rear axle

Reduce this dimension by the amount of difference between the RH and LH sides already measured by increasing dimension "X" on the tool. NOTE: do not alter the adjustment of the tool on the other side. In this new position, refit the anti-roll bar at the point where it will slide in freely. Then, by adjusting both tools, reduce or increase the dimension between the centre of the wheel and the ground, simultaneously on both sides, by the height difference measured on the highest side when the vehicle was checked. In this position, refit the suspension bars at the point at which they will slide in freely. Fit : - the shock absorbers, - the wheels. With the vehicle resting on its wheels, check and if necessary adjust the headlights. C If the heights are incorrect but the difference between the RH and LH sides is correct

33

Refit the suspension bars at the point at which they will slide in freely. Fit : - the shock absorbers, - the wheels. With the vehicle resting on its wheels, check and if necessary adjust the headlights. 2.
READJUSTING THE SUSPENSION HEIGHT ON A VEHICLE

When adjusting the suspension height on a vehicle that has already seen service, it is essential to determine the point at which the bars enter freely. Remove the wheels and shock absorbers. Fit the special tools in place of the shock absorbers, setting them at a dimension "X" that corresponds to the free position of the suspension arms.

The underbody height is adjusted by turning the suspension bars. Mark the positions of the two suspension bars in their bearings and in the double shackle. Fit the tools set to the dimension "X" that corresponds to the vehicle type. Remove the suspension bars. Measure the dimension between the centre of the wheel and the ground (on both sides). By adjusting both tools, reduce or increase this dimension, simultaneously on both sides by the amount of height difference measured when the vehicle was checked.

92119G

33-44

REAR AXLE Four bar type rear axle

A If the difference between the RH and LH sides is excessive B

33

If the heights are incorrect but there is no difference between the RH and LH sides

Mark the positions, in the bearings and the double shackles : - of the two suspension bars, - of the anti-roll bar on the lowest side. Remove the three bars using tool Emb. 880.

Mark the positions of the two suspension bars in the bearings and in the double shackle. Remove the two bars using tool Emb.880.

92120-1R

92120R

Thoroughly clean and grease the anchor points and the bars. Find, by altering dimension "Y" on the side on which the anti-roll bar has been removed, the position at which the bar will slide in freely, that corresponds to the two position marks. From this position, adjust both tools simultaneously to determine the position at which the suspension bars will slide in freely , that corresponds to the position marks. Tighten the tools at the dimensions "Y" thus obtained. In this new position, carry out the normal adjustment procedure (see the section on "Adjustment after replacing the rear axle").

Thoroughly clean and grease the anchor points and the bars. Adjust both tools simultaneously to determine the points at which the bars slide in freely, that correspond to the position marks. Tighten the tools at the dimensions "Y" thus obtained. In this new position, carry out the normal adjustment (see the section on "Adjusting after replacing the rear axle" *). (*) WARNING : when re-adjusting, it is the dimension "Y" that is to be used as the starting point for this adjustment and not the dimension "X" stated in this manual.

33-45

TUBULAR REAR AXLE

REAR AXLE Suspension arm bearings

33

This operation is to be carried out after first removing the suspension arms and suspension bars from the vehicle.
REMOVAL

Saw through the inner bush taking care not to cut into the suspension arm tube.

Totally immerse the bearing in brake fluid to soften the rubber in the rubber bush.

75362S

REFITTING

DI3309

The new bearing is fitted to the suspension arm, on a press, ensuring that the bush is correctly positioned in the suspension arm at the correct spacing. Position Ensure that dimension "X" between the thrust face of the bearing and the stub axle centreline is correct. All types X = 15 mm

Using a two or three arm extractor, remove the outer part of the bearing by tearing the rubber.

85909S

85910R

33-46

TUBULAR REAR AXLE

REAR AXLE Suspension arm bearings

Spacing In this position, push the bearing into the arm until the bearing dimension between centres is : Y = 1268 1 mm

33

DI3304R

Fit the suspension arm to the vehicle.

33-47

FOUR BAR TYPE REAR AXLE

REAR AXLE Suspension arm bearings

33

This operation is carried out after first removing the rear axle and the suspension bars from the vehicle.
REMOVAL

Weld a spacer (e.g. a nut) to the centre tube of the bearing.

92220-1R

90 241

Spacing With the bearing in this position, push it in until the bearing dimension between centres is : Y = 1268 1 mm

92220G

Extract the bearing - bush assembly on the press.

REFITTING

The bearing is fitted to the suspension arm on the press ensuring that its position and spacing, with reference to the suspension arm, are correct. Position Ensure that dimension "X" between the thrust face of the bearing and the centre line of the stub axle is correct. All types X = 24 mm
92220R1

Fit the rear axle assembly to the vehicle and refit the suspension bars (see the corresponding section).

33-48

WHEELS AND TYRES Specifications

WHEELS

35

The identification marking on the wheels can take one of two forms : - an engraved mark in the case of pressed steel wheels, - a cast-in mark in the case of light alloy wheels. The identification mark provides the main dimensional specifications of the wheel. It may be in complete form : Example : 5 1/2 J 14 4 CH 36 or simplified form Example : 5 1/2 J 14

A WHEEL TYPE WIDTH (in inches)

C
NOMINAL

D Number of holes

E Tyre retaining profile

F Offset in mm

RIM
PROFILE

(in inches). At tyre bead

5 1/2 J 14 4 CH 36

5 1/2

14

CH

36

The wheel bolts are on a pitch circle diameter of : 100 mm. Maximum permissible run-out : 1.2 mm measured at the wheel rim (point G). Maximum eccentricity : 0.8 mm measured on the tyre bead locating surface.

DI3501

35-1

WHEELS AND TYRES Specifications

TYRES

35

The identification marking may take one of two forms, for any given type of tyre.

Example : or 175 1 175 1 / /

175/70 S R 13 175/70 R 13 80 S 70 2 70 2 S 3 R 4 R 4 13 5 13 5 80 6 S 3

85920R

175

Width of tyre :

Expressed in millimetres (or in inches) and measured at the widest point on the tyre. l = 175 mm h/l = 0.8 (normal) h/l = 0.7 (low) h/l = 06 (extra low) Up to 180 km/h Up to 190 km/h Up to 200 km/h Up to 210 km/h Up to 230 km/h More than 230 km/h Cross ply Radial Bias belted no inscription 70 60 S T U H V Z no inscription R B (Bias belted)

70

Series or h/l ratio :

Maximum speed :

Tyre structure :

13

Wheel diameter

Expressed in inches or in millimetres. C = 13 inches

80

Reference stating the load that can be carried by each tyre.

35-2

WHEELS AND TYRES Specifications

These tyres are of the tubeless type.

35

Their inflation pressures must be checked when they are cold. The rise in temperature that occurs whilst the vehicle is being driven causes the pressure to increase by 0.2 to 0.3 bars. If the pressures are ever checked when the tyres are warm, allow for this increase in pressure and never deflate them. These vehicles are equipped with four wheels to which chains cannot be fitted. If you want to use chains you must fit 5 j 14 wheels and 165/65 - 14 M + S tyres.

Wheel balancing

BALANCE WEIGHTS

Use only the balance weights supplied by the Parts Department : which are fixed by hooks to pressed steel wheels (the hook forms part of the weight), which are fixed by hooks (flat hooks) or which are self-adhesive for light alloy wheels.

A B

Pressed steel wheels Light alloy wheels

88659R

35-3

WHEELS AND TYRES Specifications

35
Tyres Inflation pressure (1)
FRONT REAR

Types

Wheels

Run-out (mm)

Tightening torque for wheel nuts (daN.m)

B 530 - C 53A - B 535 C 530 - L 53 A - C 535 L 530 - B 53 G - L 535 S 530 - L 53 G B 531 - B 53 W C 531 - C 53 W L 531 - L 53 W B 53 A - S 53 W B533 - B53F - 353D - B53Z C533 - C53F - 353F - C53Z L533 - L53F - 453A - L53Z B536 - B53V - 453C L536 - C53V - 453D B538 - B53Y - 453F C538 - D53V - 553A L538 - C53Y - 553C B53C - D53Y - 553D C53C - L53Y - 553F D53C - 353A - 853A L53C - 353C - 853F B534 - B53J - B53Z C534 - C53J - C53Z L534 - L53J - L53Z S534 - S53J B532 - S537 C532 - B53B L532 - C53B B537 - L53B C537 - B53H L537 - L53H B539 - C53D C539 - D53D L539 - L53D B53D B53K - B53T - 453H C53K - C53T - 553H
L53K - L53T S53K - S53T

5 x 13

1,2

145 R 13 S 165/70 R 13 T

2.0

2.2

5 1/2 x 13 5 1/2 x 14 1,2 8

175/70 175/70 175/65 175/65

R R R R

13 13 14 14

T H T H

2.0

2.2

5 x 13 5 1/2 x 13

1,2

165/70 R 13 T 175/70 R 13 T

2.2

2.2

5 x 13

1,2

155 R 13 T 165/70 R13T

2.0

2.2

6 1/2 x 15

1,2

195/50 R13V

2.2

2.2

5 1/2 x 13 5 1/2 x 14

1,2

165/70 R 13 T 175/70 R 13 T 175/65 R 14 T

2.2

2.2

For vehicles equipped with automatic transmission increase the pressure by 0.1 bar on the front wheels. (1) Fully laden and motorway use.

35-4

STEERING Axial ball joints

36

SPECIAL TOOLING REQUIRED

Dir.

812 -01 or 832 -01 476

Spanners for tightening axial ball joints

Dir.
T.Av.

Ball joint extractor

TIGHTENING TORQUES (in daN.m)

Ball joint nut Axial ball joint Axial ball joints with flat locking washers.

3.5 5

90145R 86111G

Disconnect the track rod end using tool T.Avv.476

86 114

86 112

REMOVING THE BALL JOINT : assembly (2) must be replaced by a new one. If the slots on the ball joint are not damaged, the ball joint can be reused.
REMOVAL

85965R

Loosen the lock nut (E) whilst holding the axial ball joint with an open ended spanner at (P).

Remove: - the ball joint casing, counting the number of threads engaged to be able to pre-adjust the parallelism when refitting. - the rack gaiter.

36-1

STEERING Axial ball joints

Loosen the axial ball joint using spanner Dir. 81201 or Dir. 832-01 whilst holding the stop washer (2) with a C spanner to prevent the rack rotating.
NOTE : before tightening the ball joint using

36

spanner Dir. 812-01 or Dir. 832-01, check that the tabs on the locking washer (2) are in line with the flats (B) on the rack. Refit the gaiter and its clip. Screw the ball joint into the sleeve by the same number of turns as was noted during removal. Reconnect the steering bar to the stub axle carrier. Check and, if necessary, adjust the parallelism then tighten the lock nut on the sleeve.

82367R1

REFITTING

Fit the following to the rack (4) : - the stop washer-locking washer assembly (2), - the axial ball joint (1) after coating its thread with LOCTITE "FRENBLOC" .

83510-1R2

36-2

STEERING Manual steering box

36

DI3602

SPECIAL TOOLING REQUIRED

T.Av. 476

Ball joint extractor

TIGHTENING TORQUES (in daN.m)

Cut the ring (2) that retains the rubber protector. 3.5 5 5

Track rod end nut Axial ball joint Steering box mounting bolt
REMOVAL

Disconnect the ball joints using tool T.Av. 476.

92215R1

85965R

36-3

STEERING Manual steering box

Push back the protective cover towards the bulkhead and remove : - the eccentric bolt (1) on the steering column universal joint,

36

To do this : - Loosen the lock nut (E) while holding the axial ball joint, using an open ended spanner at (P), - unscrew the ball joint casings, noting the number of turns of thread engaged.

92216R

90145R

the two bolts (2),

REFITTING

Refitting is the reverse of removal. When fitting a new steering box, fit the ball joint casings in the positions noted during removal. Refit the steering box and steering bar assembly to the vehicle. Position the universal joint and tighten the eccentric bolt. Fit the rubber protector and secure it with a new PVC ring.
85879R

Check the parallelism.

the steering box.

Never unscrew the axial ball joints from the steering rack unless they are to be replaced. If the steering box is to be replaced, the ball joint casings at the stub axle carrier end are to be removed for fitting to the new one.

36-4

STEERING Anti-rattle bearing on manual steering boxes

SPECIAL TOOLING REQUIRED

36

Dir. Dir.
T.Av.

812 -01 or 832 -01 476

Spanners for tightening the axial ball joints Ball joint extractor

TIGHTENING TORQUES (in daN.m)

Wheel bolts Track rod end nut Axial ball joints

REMOVAL

8 3.5 5

Support the front of the vehicle on axle stands and remove the wheel on the opposite side to the steering column. Remove : - the rack gaiter, - the axial ball joint (see the corresponding section). Turn the steering to full lock until the rack is no longer projecting from its housing and thus releases the anti-rattle bearing.
16193

REFITTING

Carefully clean the rack and the anti-rattle bearing location. Coat them with MOLYKOTE BR2 grease. Fit the new anti-rattle bearing with the steering in the same position as during removal, taking care to insert its three lugs into the slots (A).

16193-1

Grind off the sharp end from a flat screwdriver and lever out the anti-rattle bearing.

16193-2

Move the rack back into the bearing. Refit the following to the rack : - the stop washer with a new locking washer, - the axial ball joint, - the ball joint casing at the stub axle carrier end. Check and, if necessary, adjust the parallelism.

36-5

ENGINE TYPE F

STEERING Power assisted steering box

36

DI3606

SPECIAL TOOLING REQUIRED

Mot. 453-01 T.Av. 476

Hose clamps Ball joint extractor

TIGHTENING TORQUES (in daN.m)

Remove the eccentric bolt (1) from the steering column universal joint. 3.5 5 5

Track rod end nut Axial ball joint Steering box mounting bolt
REMOVAL

Disconnect the ball joints using tool T.Av. 476.

92059R

85965R

36-6

ENGINE TYPE F

STEERING Power assisted steering box

-

36

Place a clamp Mot. 453-01 on each of the hoses leading from the oil reservoir.

the mounting for the bracket securing the low pressure pipe.

92123R1

92121R

Remove : - the air filter casing, - the mounting for the bracket securing the high pressure pipe.

the piece of connecting hose from the low pressure pipe,

92122R

92124R

36-7

ENGINE TYPE F

STEERING Power assisted steering box

36

the exhaust down pipe, disconnecting it from the manifold and its central connection under the vehicle.

Fully unscrew the pipes leading to the cylinder (have a container ready to catch the oil).

90200R

92125R

Under the vehicle, unscrew then remove the pipes leading to the cylinder (provide a container to catch the oil).

90201R

92126R

the pipes leading from the oil reservoir and the high pressure pump to the rotary valve.

NOTE : fit plugs to the take-offs on the steering

box to prevent dirt entering the unit.

Entirely remove the low pressure pipe.

36-8

ENGINE TYPE F

STEERING Power assisted steering box

36

Remove: - bolt (2) from the right hand steering box mounting, - the four bolts that secure the steering box to the sub-frame.

To do this : - loosen the lock nut (E) whilst holding the axial ball joint with an open ended spanner at (P), - unscrew the ball joint casings, noting the number of turns of thread engaged.

92123R

Lower the steering box and remove the right hand support. Take out the box through the left hand cowl side panel.
REFITTING

90145R

If a new steering box is to be fitted : fit the ball joint casings in the positions noted during removal, remove the right hand support from the steering box together with the pipes leading to the cylinder, plugging the take-offs to prevent dirt entering.

Place the steering box in position. Refit the right hand support and bolt (2). Fit: : - the pipes from the cylinder to the valve and to the steering box body, without tightening them, - the four steering box mountings, tightening them to the specified torque. Tighten the pipes leading to the cylinder and the bolt on the right hand support.

90060S

Never unscrew the axial ball joints from the rack assembly unless they are to be replaced. If the steering box is to be replaced, the ball joint casings at the stub axle carrier end will have to be removed for fitting to the new one.

36-9

ENGINE TYPE F

STEERING Power assisted steering box

Reconnect the pipes leading to the rotary valve, correctly positioning the low pressure pipe. Tighten the mountings on the pipe retaining brackets and the piece of connecting hose. Correctly position the universal joint and tighten the eccentric bolt. Refit: - the exhaust down pipe, - the ball joints on the stub axle carriers, - the air filter casing. Remove clamps Mot. 453-01. Fill the system with oil up to the marker on the filter in the reservoir. Turn the steering to the left and to the right (without the engine running) to fill the system with oil. Repeat this operation with the engine running then top up the level in the reservoir (see section 13 "Filling the system"). Check and, if necessary, adjust the parallelism.

36

36-10

STEERING Steering box plunger

ADJUSTING

36

If there has been a complaint of the steering box rattling, before considering replacing the steering box, ensure that its plunger is correctly adjusted.

The steering box must be removed before carrying out this operation. 1. Determining the source of the rattle

Grip the steering rack bar on the same side as the plunger and check the amount of axial play (by pulling it backwards and forwards). If there is play accompanied by a rattling noise, the plunger is responsible. 2. Adjusting

Loosen the adjusting nut (1) by lifting out the points where the flange on the nut is peaned into the housing (A). Tighten the adjusting nut by two notches, using a 10 mm allen key, and check whether the play has disappeared. Maximum permissible take-up : 3 notches. Relock the nut by peaning the flange on the nut into two diametrically opposed slots on the steering box housing.

83920R

36-11

STEERING Steering column

36

DI3607

TIGHTENING TORQUES (in daN.m)

REMOVAL (with Airbag option) 4 3 Removing the Airbag cushion (without removing the steering wheel)
WARNING : It is forbidden to handle pyrotechnic systems (airbag and pre-tensioners) near a source of heat or a flame; there is a risk of triggering them.

Steering wheel nut Eccentric bolt REMOVAL (without the Airbag option) Remove : - the lower cover under the steering wheel, - the steering column upper and lower half cowlings, - the steering wheel after first marking its position.

Remove the airbag by means of its two bolts located behind the steering wheel (tightening torque: 0.5 daN.m). Disconnect its connector and connect the dummy ignition module of XRBAG Ele. 1288 taking care to avoid discharging the battery as the warning light flashes. NOTE: If the steering wheel is to be removed, disconnect the batteries by means of the small black 4 track connector.
IMPORTANT : Never reconnect the airbag cushion and the battery on a steering wheel that has been removed as there is a risk of triggering.

36-12

STEERING Steering column

36

90285S

Remove : - the controls after first disconnecting them, - the two bolts (1) that secure the dashboard to the steering column,
96682R3

Loosen the screws on the steering column switch assembly, without actually removing the switch and push it down to release the retaining cone.

92209R

36-13

STEERING Steering column

the eccentric bolt (2) on the universal joint.

36

Remove : - the four steering column mounting bolts,

POWER STEERING

92059R

92210R1

MANUAL STEERING

Cut the ring that retains the rubber protector and push back the protector towards the bulkhead.

the lower left hand dashboard mounting (see section 57), the lower cover from the heater controls, the three dashboard mounting bolts (see section 57).

Slightly lift the dashboard to free the clip (3). Take out the steering column after first disconnecting the steering lock switch. Power steering Free the gaiter (E) from the bulkhead and remove it at the same time as the steering column.

92216R

36-14

STEERING Steering column

REFITTING

36

SPECIAL FEATURES FOR REFITTING THE STEERING WHEEL EQUIPPED WITH AN AIRBAG

Check the length of the retractable shaft (see the corresponding section). Fit the steering column. Lift the dashboard and insert the clip (3) in its location. Power steering Engage the gaiter (E) on the bulkhead.

It is essential to replace its nut (prebonded nut) and tighten it to the specified torque (4.5 daN.m). Reconnect the batteries

IMPORTANT : before reconnecting the drivers airbag cushion the following procedure must be carried out for checking operation of the system : Check that the warning light flashes when the battery box is connected to the computer.

Connect : - the dummy ignition module to the connector of the drivers airbag cushion and check that the warning light is extinguished, - the drivers airbag cushion in place of the dummy ignition module (tightly clamp connector (E), tight connection). Check that the warning light is extinguished and screw the cushion back on to the steering wheel. If the warning light does not operate as indicated above, consult the repair manual entitled "Airbag and belt pre-tensioners" (first generation) Part Number 77 11 176 120, and check the system with the XRBAG module (El. 1288). Tighten the two airbag cushion mounting bolts to a torque of 0.5 daN.m.
WARNING :

DI3608

Resecure : - the steering column, - the dashboard. Reconnect the steering lock switch. Fit : - the two bolts (3), - the control switches to the steering column and reconnect them, - the upper and lower steering column half cowlings, - the lower cover under the steering wheel, - the lower cover for the heater control assembly, - the steering wheel in the position marked during dismantling, - the eccentric bolt (1).

Failure to follow these instructions may prevent the systems from operating normally and even result in accidental triggering. It is not permitted to carry out work on the airbag cushion or pretensioners with an ohmmeter or other electrical measuring instrument as this may result in triggering of the system.

36-15

STEERING Steering column

Manual steering Refit the rubber protector and secure with a new PVC ring.

36

92215R

36-16

STEERING Steering column

ADJUSTING THE CLEARANCE UNDERNEATH THE STEERING WHEEL

36

In all cases, before tightening eccentric bolt (1)

When reconnecting the steering column/steering pinion the following points must be followed: 1 Insert block Dir. 1189 between the steering wheel and the half cowlings.

92216R3

The clevis must be bonded to the pinion to ensure that the centre of the clevis and centre of the pinion are in line when tightening.
93707R

For adjustable steering columns refitting must be carried out with the steering wheel in the low position.

36-17

STEERING Steering column

36

A locking lever under the steering column enables the driver to adjust the height of the steering wheel to suit his own convenience. In certain cases, the stiffness of this locking system may require adjusting.

ADJUSTING THE STIFFNESS OF THE LOCKING SYSTEM

Remove the lower cover under the steering wheel. Loosen the lever clamp nut (1). Bring the steering column shaft into the lower position.

87848-1R

Position the locking lever (3) at a distance X = 30 mm from the steering column support. Refit: - the nut (1), - the lower cover under the steering wheel. Check that the lever is readily accessible, if not increase or reduce the above dimension by 10 mm.

87848R

Lock the steering column by tightening the nut (2) with the locking lever (3).

36-18

STEERING Retractable steering column shaft

REMOVAL - REFITTING

36

These vehicles are equipped with an assembly consisting of a retractable shaft, a steering wheel shaft and a steering column shaft that cannot be dismantled. If it is found impossible to fit the eccentric bolt on the universal joint, check that the length of the shaft is correct. If it is not, replace the entire assembly (see the section on the steering column).

CHECKING

92218R

LEFT HAND DRIVE

RIGHT HAND DRIVE

Manual steering L = 408 1 mm Power steering L = 355.5 1 mm

Manual steering L = 406 1 mm Power steering L = 354.5 1 mm

36-19

MECHANICAL ELEMENT CONTROLS Master cylinder

37

TIGHTENING TORQUES (in daN.m)

M 10 x 100 M 12 x 100 Brake servo mounting bolt

REMOVAL

1.3 1.3 1.3

Empty and remove the brake fluid reservoir by pulling it upwards.

91101R

NOTE : these vehicles are equipped with master

cylinders that are an integral part of the brake servo. Whether the brake servo leaks or not depends directly on the master cylinder. When carrying out any work on these components, fit a new seal (A). Fit the master cylinder, aligning it with the brake servo, so that the thrust rod (P) correctly enters into its location on the master cylinder.

92219R

Remove: - the pipes, marking their positions, - the two nuts securing it to the brake servo.
REFITTING

Check the length of the thrust rod. All types, both LH and RH drive. Dimension X = 22.3 mm.
DI3710

This dimension is adjusted, depending on the model, at adjusting stud (P).

Reconnect : - the pipes in the positions marked before they were removed, - the brake fluid reservoir, pressing it down to clip it into the master cylinder. Bleed the braking system.

37-1

MECHANICAL ELEMENT CONTROLS Brake servo

REFITTING

37

Before refitting, check:

TIGHTENING TORQUES (in daN.m)

Master cylinder to brake servo Brake servo to bulkhead

1.3 2

The brake servo cannot be repaired. The only operations that can be carried out on it are replacing : - the air filter, - the non-return valve.
REMOVAL

All left hand drive types : - dimension L = 124.5 mm, adjustable on certain models by means of rod (C), - dimension X = 22.3 mm, adjustable on certain models by means of stud (P). All right hand drive types : - dimension L = 117.5 mm, adjustable on certain models by means of rod (C), - dimension X = 22.3 mm, adjustable on certain models by means of stud (P).

Disconnect the battery. Remove the master cylinder. Disconnect the vacuum hose from the brake servo. Remove the pin from the clevis that connects the brake pedal to the thrust rod. Slacken the nuts that secure the brake servo in place and remove the unit.

91101R1

Fit the master cylinder (see the instructions in the section concerned). Bleed the braking system.

90383R

37-2

MECHANICAL ELEMENT CONTROLS Brake servo

37

SPECIAL TOOLS REQUIRED

Mot

453 -01

Hose clamps

EQUIPMENT REQUIRED

NAUDER* vacuum pump

CHECKING THE UNIT FOR LEAKS

When checking the brake servo for leaks, ensure that there is an absolute seal between it and the master cylinder. If there is any leakage at this point, replace seal (A).

DI3701

The brake servo is to be checked for leaks, on the vehicle, with the hydraulic system in operating condition. Connect the NAUDER* vacuum pump between the brake servo and a vacuum source (the inlet manifold) using a "T" union and a piece of pipe which is as short as possible. Run the engine at idling speed for one minute. Pinch flat the pipe (clamp Mot. 453-01) between the "T" union and the vacuum source. Stop the engine. *use as vacuum gauge.

If the vacuum falls by more than 33 mbars (25 mm/Hg) in 15 seconds, there is a leak which may be at either: the non-return valve (replace it by a new one), the thrust rod diaphragm (in this case replace the brake servo).

If the brake servo fails, the braking system will still operate but the pressure required at the pedal will be much higher to give the same amount of braking as would be obtained with servo assisted brakes.

37-3

MECHANICAL ELEMENT CONTROLS Brake servo air filter - Non-return valve

REPLACING THE NON-RETURN VALVE

37

REPLACING THE AIR FILTER

This operation can be carried out on the vehicle.

REMOVAL

Disconnect the vacuum inlet pipe from the brake servo. Pull and twist the non-return valve to free it from its rubber sealing washer.

83 212

75 564

91101G 74883S

It is not necessary to remove the brake servo to replace its air filter (F). Extract the old filter (F) from under the pedal assembly, using a screwdriver or metal hook. Cut the new filter at A (see illustration) and place it round the rod. Then push it into its location ensuring that it covers the entire bore to avoid the possibility of unfiltered air entering.

REFITTING

Check the condition of the sealing washer and the non-return valve. Replace any faulty parts. Refit the assembly.

37-4

MECHANICAL ELEMENT CONTROLS Pedal assembly

SPECIAL FEATURES

37

After removing the brake control it is essential to refit it with bolts that have an underhead length of 20 mm max (A).

DI3726

37-5

MECHANICAL ELEMENT CONTROLS Handbrake lever

REPLACING

37

Release the handbrake and remove nut (1) and its washer. Release the control linkage from the clip (2) and from the brake compensator.

92217R3

Remove : - the cover from the seat belt anchor points, - the two bolts from the seat belt anchor point. Make a slight cut in the carpeting (3).

PHOTO
NOTICE R9

Disconnect the handbrake switch wire. Unscrew the two bolts that secure the lever support to the floor. Remove the handbrake lever assembly. On refitting, adjust the handbrake lever travel.

37-6

MECHANICAL ELEMENT CONTROLS Handbrake control

Remove :
ADJUSTING

37

both rear wheels, both drums.

If the handbrake is incorrectly adjusted, with the cable too tight : the automatic brake shoe wear take-up system cannot operate, the brake pedal travel is too long.

Under no circumstances are the cables to be retensioned to remedy this fault. It will only reappear in a very short time. The handbrake is not a wear take-up system, it must only be adjusted when one of the following has been replaced: - the shoes or linings, - the cables, - the control lever. Any adjustment other than following these operations is forbidden. With the vehicle raised on a lift that locates under the body, slacken nut (1) to release the central brake compensator fully.

Check that the automatic wear take-up system is operating correctly by turning the toothed wheel (D) (ensure that it will rotate in both directions), then reduce the tension at the wheel by 5 to 6 teeth.

BENDIX

90 328

92217R2 90223G1

37-7

MECHANICAL ELEMENT CONTROLS Handbrake control

Ensure : - that the cables slide freely, - that the handbrake levers (B) locate correctly on the shoes.

37

BENDIX

90 328

90223G

Progressively tension the cables at the central adjuster so that the levers (L) start to move between the 1st and 2nd notch of the travel of the control lever and remain applied from the 2nd notch. Tighten the lock nut. Fit the drums. After lowering the vehicle to its wheels : Adjust the shoes by gradually but firmly depressing the brake pedal a number of times whilst listening for the automatic wear take-up system to operate.

37-8

MECHANICAL ELEMENT CONTROLS Handbrake control

DISC BRAKES

37

Ensure: - that the cables slide freely. - that the handbrake levers travel correctly and move them as far as they will go towards the rear of the vehicle.

88993R1

Gradually tension the cables at the central adjuster until the stop (A) comes into contact with the lever, without moving it. Complete the adjustment so that the levers start to move between the 1st and 2nd notch of the travel of the control lever and remain applied from the 2nd notch. Tighten lock nut (1).

92217R2

37-9

MECHANICAL ELEMENT CONTROLS Brake hoses

37

These vehicles are fitted with brake hoses that have no copper seals. The seal is obtained by contact between the taper on the hose shoulder (A) and the bottom of the tapping.
TIGHTENING TORQUES (in daN.m)

B = 1.3 C = 1.3

84619R

PRECAUTIONS TO BE TAKEN WHEN REMOVING - REFITTING A WHEEL CYLINDER OR A HOSE

For reasons of safety, to prevent the brake hose from twisting and avoid any risk of it making contact with a suspension component, the operations must be carried out in the following order:

REMOVAL

REFITTING

Unscrew the union (1) between the rigid pipe and the hose (2) to the point at which the spring (3) is released. This will free the hose from the splines (4).

Place the caliper in position on the brake assembly and screw the hose into it, tightening it to a torque of 1.3 daN.m. With the wheels hanging free and the steering in the "straight ahead" position, position the female end of the hose on the retaining (5) (the hose must not be twisted) and fit : - the spring (3), - the rigid pipe to the hose, taking care to prevent the hose from turning when the union is screwed in. Bleed the braking system.

85536R

Unscrew the hose from the caliper and, when applicable, remove the caliper.

37-10

MECHANICAL ELEMENT CONTROLS Brake compensator

TESTING PRINCIPLE

37

These vehicles are equipped with fixed brake compensators that are integral with the wheel cylinders. The pressure readings are taken in an X configuration, i.e. on opposite sides of the vehicle, by comparing the pressure at the rear wheels with a given pressure on the front wheels. It is essential to test both circuits. I II : front right / rear left hand circuit : front left / rear right hand circuit

The fixed compensator is integral with the wheel cylinder This type of compensator can only be tested ; if the pressure is incorrect, replace the complete compensator - wheel cylinder assembly.

TESTING PRINCIPLE

X53 with ABS option and X53 sports version. These vehicles are equipped with a load sensitive compensator. The pressure readings are taken in an X configuration, by comparing the pressure at the rear wheels with a given pressure at the front wheels. These dual compensators have two totally separate bodies which act in an X configuration on one front wheel and one rear wheel. It is essential to test both circuits. I : front right / rear left hand circuit II : front left / rear right hand circuit

Load sensitive compensator On load sensitive compensators the adjusting system enables the rear pressure to be adjusted according to the front pressure. The adjusting system acts simultaneously on both bodies. If the pressure is incorrect on only one of the two bodies, replace the compensator.

85925S

37-11

MECHANICAL ELEMENT CONTROLS Brake compensator

37

ESSENTIAL TOOLING REQUIRED

Fre. 244 -04 or Fre. 1085

Pressure gauge for testing the compensator pressure settings

TESTING

TEST PRESSURES

Connect two pressure gauges (A) Fre. 244-04 or Fre. 1085 : - one to the front right hand wheel, - the other to the rear left hand wheel. Bleed the pressure gauges : screw (P).

The compensators on these vehicles can only be tested. If the readings are incorrect, replace the entire wheel cylinder. See the section "Values and settings" for the compensator values, depending on vehicle type.

92129R

Gradually press down the brake pedal until the test pressure (see pressure chart) is obtained at the front wheels;. Then read the corresponding pressure at the rear wheels; correct if necessary. Carry out the same operations on the other circuit, i.e.: - one on the front left hand wheel, - the other on the rear right hand wheel. If there is a considerable difference (pressures outside the tolerances), replace the wheel cylinder. The assembly cannot be repaired.

37-12

MECHANICAL ELEMENT CONTROLS Testing - Adjusting

The brake compensator must be tested and adjusted with the vehicle on the ground, unladen, and with one person on board the vehicle.
SPECIAL TOOLING REQUIRED

37

Fre. 1085 Pressure gauge for testing the compensator pressure settings Since the compensator has two separate bodies, it is essential to test them one after the other.
ADJUSTING

TESTING

Connect two pressure gauges Fre. 1085 : - one on the front right hand wheel, - the other on the front left hand wheel. Bleed the braking system (the pressure gauge is bled using screw P).

90269G

78457S1

To adjust: release nut (A) and alter the position of rod (B) in sleeve (C).

Gradually press down the brake pedal until the test pressure (see pressure chart) is obtained at the front wheels. Then read the corresponding pressure at the rear wheels; correct it if necessary.

37-13

MECHANICAL ELEMENT CONTROLS Testing - Adjusting

37

See the section "Values and settings" for the compensator settings, depending on vehicle type. NOTE : it is not permitted to alter the position of nut (F).

90268R

37-14

MECHANICAL ELEMENT CONTROLS Clutch cable

REMOVAL REFITTING

37

Unhook the cable from the fork, in the engine compartment. Inside the vehicle, remove the transverse ventilation ducting. Press down the pedal to pull the cable. Lift out the cable end from its location on the wear take-up quadrant and the eye (A) on the toothed cam .

From inside the engine compartment, feed the cable through into the passenger compartment. Inside the vehicle, check that the rockers (1) and (2) can freely return to their released position.

DI3727

Pass the cable through the eye (A) on the toothed cam and place the cable end in its location on the toothed quadrant (S). Fit the cable to the clutch fork.

92191R

Pull out the cable sleeve stop from the support on the pedal assembly. Remove the complete cable via the engine compartment.

89204S

Check that the cable sleeve stop is correctly aligned on the bulkhead. Press down the brake pedal to pull the cable sleeve stop into the bulkhead. The system adjusts itself automatically.

37-15

MECHANICAL ELEMENT CONTROLS Clutch automatic wear take-up system

SECTION

37

85872-1S

EXPLODED VIEW

DI3728

37-16

MECHANICAL ELEMENT CONTROLS Clutch automatic wear take-up system

PRINCIPLE OF OPERATION WEAR TAKE-UP TESTING

37

Spring (R) applies a constant tension to the wear take-up quadrant (S). As the cable is permanently under tension, it pulls on the fork and keeps the thrust bearing in permanent contact with the diaphragm. The adjustment is automatic.
"DECLUTCHING" MOVEMENT

To ensure that the system operates correctly, check : 1 that the toothed cam (C) pivots round its pin, 2 that the rockers (1) and (2) return freely to the released position.

When the pedal is pressed down, its toothed cam (C) engages with the teeth on the wear take-up quadrant (S) to prevent it from pivoting and to allow it to pull the clutch cable.

DI3727

3.

Pull the cable at the clutch fork on the gearbox.

There should be at least 2 cm of "slack" in the cable.

85872-1R

89204S

These checks enable it to be verified that the toothed cam (C) and the toothed quadrant (S) are free in the "clutch engaged" position.

37-17

MECHANICAL ELEMENT CONTROLS Clutch automatic wear take-up system

4 Check the fork movement. It should be : X = 17 to 18 mm

37

91830R1

These tests must be carried out before any rectification work on the actual clutch unit.

37-18

MECHANICAL ELEMENT CONTROLS External gear control

The vehicles are equipped with a double locking external gear control that prevents any possibility of selecting reverse instead of first without the latch being lifted.
PRINCIPLE OF OPERATION

37

The upper latch (A) operates through a cable (C) on a second latch (D) at the bottom of the lever. The locking effect is therefore obtained by a synchronised upper stop (H) and lower stop (B). NOTE : this control system must be adjusted with first gear engaged.

DI3703

DI3707

37-19

MECHANICAL ELEMENT CONTROLS External gear control

EXPLODED VIEW AND TIGHTENING TORQUES

37

DI3729

1 2 3 4 5 6 7 8 9 10

Link Return spring on 3rd/4th line Casing Pad Lever and latch assembly Protective gaiter Gear lever knob Circlip Bush Sleeve

37-20

MECHANICAL ELEMENT CONTROLS External gear control

CONSUMABLES

37

SPECIAL TOOLING REQUIRED

Nuts mounting casing to body Bolt mounting link to clevis

REMOVAL

1.5 3

Grease grade 33 Medium : Shift lever pivot point REFITTING (Special operations) Coat the shift lever pivot points with grease grade 33 Medium. Bond the knob (7) to the lever. Adjust the gear control.

From inside the vehicle, release the gaiter (6) from the console. Under the vehicle, disconnect : - the flexible exhaust pipe mountings, - the return spring (2), - the link (1) from the lever clevis. Remove the nuts which secure the casing to the body and take out the lever - casing assembly whilst pulling the exhaust pipe to one side.

Tighten the nuts and bolts to the specified torques.

DI3730

Grip the gear lever clevis in a vice fitted with soft jaws and remove : - the knob (7), - the gaiter (6), - the circlip (8). Remove the lever and latch assembly from the casing. NOTE : the Parts Department supplies the lever and latches as a complete assembly.

37-21

MECHANICAL ELEMENT CONTROLS External gear control

37

SPECIAL TOOLING REQUIRED

B.Vi. 1133

Tool for locking the type JB gearbox input lever in 1st

TIGHTENING TORQUES (in daN.m)

Bolt securing link to clevis

ADJUSTING

Select 1st gear at the gearbox.

92079R

DI3702

37-22

MECHANICAL ELEMENT CONTROLS External gear control

Fit tool B.Vi. 1133 to take up the play.

37

Fit the link (1) to the lever clevis leaving a space of approximately 5 mm between the link and the clevis body. Bring the lower latch on the lever against the inclined plane on the casing, placing a 2 mm feeler gauge between them.

92450S

92080R1

At the same time pull the outer end of the tool downwards and swing it through 45 degrees until it makes contact with the lug on the housing.

In this position, tighten bolt (V). Remove the feeler gauge and refit the return spring (2).

92450-1R

92431R

37-23

MECHANICAL ELEMENT CONTROLS External gear control

Check the resulting clearance "Y" which should be between 2 and 5 mm.

37

DI3705

Remove special tool B.Vi. 1133. Check that the gears select correctly.

37-24

MB

MECHANICAL ELEMENT CONTROLS Gear selection controls

37

EXPLODED VIEW

DI3731

REMOVAL

REFITTING

Remove : Passenger compartment side: - knob (2) by pulling vigorously upwards. Under the vehicle - the protective cover. Dismantle the cable stops (7). Remove : - the four nuts (3) retaining control unit (5) and withdraw it from underneath, - the cable retaining clips (1).

It is essential to move the automatic transmission to position "D". Automatic transmission side Before refitting the cable, check dimension (A) between the support face of the cable on sheath stop (9) and mounting ball joint (10). A = 131 mm If necessary slacken the two nuts (12) to obtain this dimension.

37-25

MB

MECHANICAL ELEMENT CONTROLS Gear selection controls

37

ASSEMBLY

Assemble the cable : - on the automatic transmission (still in the "D" position), - on the control unit (5) (still in the "D" position), and tighten sheath stop (8) one quarter of a turn. Replace control unit (5) on the vehicle. Replace knob (2). Check that the gears select correctly and that the starter engages in the "P" and "N" positions, and check the "Park" function. If the adjustment is incorrect, loosen sheath stop (8), moving it one quarter of a turn, and pull or push the cable, depending on the adjustment required. Do not forget to retighten sheath stop (8) at the end of the operation.

93611R

Control unit side Place the selector in the "D" (Drive). Align the two screen and repeater reference marks before tightening the four bolts (11).

93612R

CHECKING THE CABLE

By moving it one quarter of a turn, loosen sheath stop (8) and make sure that the cable slides easily.

37-26

AD4

MECHANICAL ELEMENT CONTROLS Gear selection controls

37

EXPLODED VIEW

DI3732

REMOVING

REFITTING

Remove : Passenger compartment side: - knob (2) by pulling vigorously upwards. Under the vehicle - the protective cover. (6) Dismantle the cable stops (7). Remove : - the four nuts (3) retaining control unit (5) and withdraw it from underneath, - the cable retaining clips (1).

It is essential to move the automatic transmission to position "D". Automatic transmission side Before refitting the cable, check dimension (A) between the support face of the cable on sheath stop (9) and mounting ball joint (10). A = 131 mm If necessary slacken the two nuts (12) to obtain this dimension (see diagram below)

37-27

AD4

MECHANICAL ELEMENT CONTROLS Gear selection controls

37

CHECKING THE CABLE

By moving it one quarter of a turn, loosen sheath stop (8) and make sure that the cable slides easily.
ASSEMBLY

Assemble the cable : - on the automatic transmission (still in the "D" position), - on the control unit (5) (still in the "D" position), and tighten sheath stop (8) one quarter of a turn.
94898R1

Replace control unit (5) on the vehicle. Replace knob (2). Check that the gears select correctly and that the starter engages in the "P" and "N" positions, and check the "Park" function. If the adjustment is incorrect, loosen sheath stop (8), moving it one quarter of a turn, and pull or push the cable, depending on the adjustment required. Do not forget to retighten sheath stop (8) at the end of the operation.

A = 131 mm Control box (5) side Place the selector in the "D" (Drive). Align the two screen and repeater reference marks before tightening the four bolts (11).

93612R

37-28

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMSS Bendix ABS

LOCATION AND COMPOSITION (Left hand drive)

38

92736R

38-1

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

LOCATION AND COMPOSITION (Right hand drive)

38

92736-1R

38-2

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

The ABS system comprises the following components: 1 Brake pressure unit (BPU), comprising two "master cylinder" distributor assemblies (A) and a regulation unit (B). 2 Electric pump unit (EPU) . 3 Computer, incorporating a self-checking device. 4 Wheel rotation speed sensors. 5 Targets embedded in the driveshafts at the front, and in the disc hubs at the rear. 6 Two warning lights on the instrument panel. 7 Dual brake compensator. 8 Four disc brakes. 9 A diagnostic socket enabling the XR25 kit to be connected. 10 Wiring connection plate assembly

38

DI3883

38-3

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

LOCATION AND COMPOSITION (left hand drive)

38

DI3884

38-4

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

LOCATION AND COMPOSITION (right hand drive)

38

DI3885

38-5

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

LOCATION AND COMPOSITION FRONT SENSORS RADIAL AND NON-ADJUSTABLE

38

The hydraulic unit is of modular design and is fitted in place of the brake servo master cylinder assembly. It comprises : A brake pressure unit (1) (BPU), comprising two "master cylinder" distributor assemblies (A) and one regulation unit (B). An electric pump unit (2) (EPU), comprising a pump (C) driven by an electric motor, a pressure accumulator (D) and 3 pressostats (E). A reservoir with integrated nivocode (3).

This system operates without vacuum amplification.

COMPUTER (3)

This is located in the heating compartment opposite the battery. Targets (5) embedded in the hubs (cannot be removed) for the rear.

92721R

REAR SENSORS TANGENTIAL AND NON-ADJUSTABLE

91339R

It analyses the information from the wheel sensors and controls the electric inlet and outlet valves, depending on the information received.

SPEED SENSORS (4) AND TARGETS (5)

The speed sensors are mounted on the stub axle carriers and receive the information via toothed targets. Targets (5) embedded in to the driveshafts for the front wheels. Number of teeth on the targets : 48

92720R

38-6

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

ABS CONTROL RELAYS NOTE :

38

These are located on the connection plate.

The spare 25 A relays have a mounting bracket which must be removed before they are fitted to enable the cover to be fitted on to the plate. The computer is supplied with + 12 V after ignition by means of a 15 A fuse located on the accessories plate.

A 10 A fuse protects the supply to the warning lights (ABS etc...).

NOTE : the diagnostic socket is located in the

passenger compartment, underneath the dashboard, in the relay and fuse compartment.
93441R

A B C D E

Pressure alarm relay EPU control relay (301) 30 A fuse (260) EPU Starting cutout relay Safety relay, soldered (428)

25 A black 50 A green 25 A black

92733R

92827S

38-7

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

LOCATION AND COMPOSITION

38

The following are connected to the connection plate : - a 2 track connector for supplying the electric pump unit, - a 6 track connector for the pressure switches, - a 12 track connector for the regulating solenoid valves of the braking pressure unit.
NOTE : whenever work is done on this system the

The wiring loom is soldered to the connection plate located alongside the computer in the heating compartment.

wiring must always be correctly routed throughout the vehicle. It is necessary to remove the heating compartment partition to free the ABS wiring.

92735S

It comprises several connections which end: - at the computer by means of a 35 track connector, - at the instrument panel by means of a 6 track connector, - at the reservoir by means of a 4 track connector, - directly to the front sensors without intermediate connectors , - to the rear sensors by means of two 2 track connectors located near the left rear axle mounting.

93447R1

92723S

38-8

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

2nd assembly The components of the Bendix ABS for versions AC - PAS - ABS remain unchanged. Only the relay plate assembly (1) and the computer (2) have been moved and are now located in the engine compartment around the right front wheel arch.

38

96584R

38-9

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

PRINCIPLE OF OPERATION (hand brake lever in zero position)

38

When the ignition is switched on one of two cases arises: - The vehicle is in regular use, the warning light illuminates and extinguishes after about 3 secs.

- After the vehicle has been stationary for a long time, lights and illuminate simultaneously and extinguish after a time of up to 30 seconds: the time for the pressure in the accumulator to increase (> 90 bars). In these two cases the computer automatically initiates a self-checking and initialisation sequence.

The intensity of light Starting phase :

is not absolutely constant, but this is not regarded as a fault.

- If you have waited for the lights to extinguish, light is illuminated and extinguished after approx. 3 secs, and light is only illuminated during the starting phase.. - If you have not waited for the warning lights to extinguish, two cases arise : the vehicle is in regular use, the warning light remains illuminated and does not extinguish until you return to the start position (ignition key) after approximately 3 seconds. after the vehicle has been stationary for a long time, lights and are extinguished after a time of up to 30 seconds. and illuminate simultaneously

Whilst the vehicle is being driven : Pressing the brake pedal enables the pressure to be transferred from the electric pump unit to the brakes. The pressure is metered in proportion to the load applied to the brake pedal. During braking, if the computer is informed of a sudden deceleration by the sensors on one or more wheels, and if it detects that this wheel or wheels are tending to lock, it initiates the following procedure: - for a front wheel : fast pressure relief : slow pressure relief : the working solenoid valve closes the high pressure inlet and opens the return to the reservoir. the restrictive solenoid valve closes the direct return to the reservoir and forces the brake fluid to cross the calibrated openings to provide a slow fall in pressure.

- for the rear wheels : fast pressure relief : the working solenoid valve closes the high pressure inlet and opens the return to the reservoir. At the same time the difference between the high pressure and the pressure of return to the reservoir closes a mechanical valve.

38-10

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

OPERATING PRINCIPLE

38

If the wheels recover speed, there is : - for a front wheel : slow inlet: the working solenoid valve opens the high pressure and closes the return to the reservoir. fast inlet: the two solenoid valves are at rest, the high pressure passes directly to the brakes - for the rear wheels : slow inlet: the working solenoid valve opens the high pressure and closes the return to the reservoir. In parallel with the mechanical valve, which is always closed, the brake fluid passes through the calibrated openings until the pressure difference is zero.

The procedure is then repeated until the vehicle stops. It should also be noted that the rear axle assembly is regulated by the "Select Low" system, which means that the wheel with the lowest adherence causes the same regulation on both rear wheels. Faults: A fault which puts the regulation device out of action is indicated to the driver by the illumination of the warning lights on the instrument panel.

a) Illumination of warning light Depending on the type of fault detected by the computer, the vehicle has : - normal braking without ABS, - braking in defect mode (see table on following page). b) Illumination of warning light The illumination of this warning light alone indicates, apart from the handbrake is still applied, that there is a drop in the fluid level in the brake fluid reservoir. c) Illumination of warning lights +

A brake fluid leak will cause the illumination of the warning light , if the the fluid level continues to drop the warning light will illuminate and the system will enter defect mode. If the pump no longer operates, or operates without creating an increase in pressure, the braking pressure assembly will operate as two single master cylinders, operating side by side. In this case, braking is without assistance.

38-11

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

Safety: In the case of non-assisted braking it is normal for the brake pedal travel to be very long. The pressure in the brake circuits does not increase until the brake pedal is pressed very quickly at the end of its travel. It serves no purpose to pump it as in the case of a conventional master cylinder. In all cases where a fault is detected, the computer will lock the system in an irreversible operating mode called "defect mode" (see table on next page). The fault which has caused the warning light to illuminate may be displayed from the diagnostic socket by means of of the XR25 kit and the appropriate cassette. When a fault arises after the ignition is switched off, this is stored in the memory of the computer. This memory may be consulted at any time by means of the XR25 and the appropriate cassette. Important recommendation: On completion of the repair it is important to delete the fault memory by entering the following command in the XR25: GO**.

38

38-12

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

REGULATION IN DEFECT MODE

38

FAULTS

CONSEQUENCES

REMEDIES

1 front sensor

A single wheel checked on front axle Front axle not checked

W. light

illuminated

ABS no longer applied to this wheel W. light illuminated

2 front sensors

ABS no longer applied to front axle 1 rear sensor or 2 rear sensors "Select Low" reduced to 0 or speed incoherence More checking of rear axle As 1 As 2 As 3 Pressure reduced to 90 bars As 1 As 2 As 3 W. light ABS suppressed Entire brake system without h. pressure illuminated

Illumination of ABS not applied anywhere on the vehicle

1 front solenoid valve 2 front solenoid valves Rear solenoid valve Electric pump unit

High pressure braking pressure unit hose (fracture) Electric pump unit feed hose

No high pressure Fall in pressure

W. light ABS suppressed

illuminated

Entire brake system without h. pressure Loss of pressure to 90 bars W. light ABS suppressed Entire brake system without h. pressure illuminated

Electric pump unit feed hose

Reduction in fluid level in reservoir

Illumination of Pump stopped Illumination of

38-13

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

OPERATING PRINCIPLE

38

Pressure < 160 bars : - the 160 and 180 bar pressure switches are closed, - the hydraulic pump operates - relay (301) controlled.

Pressure accumulator The accumulator enables a certain pressure reserve to be maintained in order to limit the operating time of the hydraulic pump and guarantee braking in the event of failure. Pressure switches The purpose of the two pressure switches is to regulate the hydraulic pressure between 160 and 180 bars. A third 90 bar pressure switch alerts the computer and illuminates the ABS warning light if there is a considerable drop in the hydraulic pressure.

Pressure between 160 and 180 bars : - the 160 bar pressure switch is open, - the 180 bar pressure switch is closed, - the hydraulic pump operates - relay (301) remains controlled.

Pressure > 180 bars : - the 160 and 180 bar pressure switches are open, - the hydraulic pump does not operate (relay at rest)

Pressure drops below 180 bars (but > 160 bars). - the 180 bar pressure switch closes, - the hydraulic pump does not operate - relay (301) at rest.

94721R

Pressure drops below 160 bars : - the 160 bar pressure switch closes, - the hydraulic pump operates - relay (301) controlled.

Operating tolerance : +5 0 bars +5 0 bars +5 0 bars

A B C

90 160 180

38-14

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

Operating principle of dual alarm device incorporated in the brake fluid reservoir
NOTE : the alarm device is integrated in the

38

2nd test Switch off the ignition.

reservoir. If it does not operate replace the complete reservoir. 1. when the following warning light initially illuminates:

Lower the pressure in the accumulator by pressing the brake pedal about twenty times. Switch on the ignition and the pump will run to fill the accumulator. Press the plunger as far as it will go; the pump must stop. Release the plunger and it must restart.

2.

if the level continues to fall, the ABS warning light illuminates and since relay (301) is no longer being supplied with power, the electric pump unit does not operate in order not to consume, from a probable leakage, the remaining brake fluid, which may also supply the braking pressure unit in defect mode.

TESTS

1st test Switch on the ignition. The reservoir plug is fitted with a plunger which enables the float to be lowered. Using a screwdriver, press down this plunger and check that the nivocode warning light is illuminated (hand brake in position of rest).

92728S

38-15

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

REMOVING - REFITTING THE COMPONENTS I - FRONT WHEEL SENSOR REMOVAL

38

Disconnect the battery. Remove : - the wheel, - the sensor mounting bolt (1).

TIGHTENING TORQUES (in daN.m)

Wheel bolts Sensor mounting bolts

7 to 9 0.8 to 1

The front speed sensors are connected directly to the wiring loom soldered to the connection plate. Thus in order to replace them the existing wiring must be cut and the new sensor reconnected by means of a sealed "MIC" connector. The Parts Department supplies a repair kit, comprising : - a sensor fitted with a clip support connector, - a kit for making up the tab support connector.

92721R1

Unclip the wire from the supports, remove the ringed sheath. Cut the wire at the position of the connector (coloured zone). Remove the sensor.

REFITTING THE TAB SUPPORT CONNECTOR

Push the sensor wire into the heat shrinkable sleeve. Strip the wires over a length of 5 mm with a pair of PRONER pliers.
93448R

1 2 3 4 5

Sensor Tab support connector Tabs Split sealing sleeves Heat shrinkable sleeve

38-16

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

For correct crimping of the terminal connectors (as the original) use a pair of PRONER pliers Ele. 1146 , which can be ordered from the Parts Department under Part Number 00 00 114 600.

38

Arrange the heat shrinkable sleeve as high as possible on the connector. Using a hot air blow torch shrink the sleeve, starting at the top of the connector (rotate it as it heats up). Heat the bottom of the sleeve so that the sealant melts. WARNING: do not overheat, the insulation on the wires must not melt.

90899G

Fit the tab, with crimp connection (A) on the stripped wire and crimp connection (B) on the insulation. Select the correct crimp cut on the pliers and crimp the wire at (A), then move to the upper notch and crimp the insulation (B). Check that lug (C) has emerged completely. Insert the tabs right into the connector (clear locking sound). Arrange sealant sleeves on the wires 5 mm from the connector bushes.

90898-2S

IMPORTANT : extreme care must be taken when making this connection to ensure perfect sealing. The sealant must be melted behind the sleeve and the wires must be in perfect condition. REFITTING

Fit the sensor, previously coated with grease Multifunction 77 01 422 308, then clip the wire into its supports and reconnect it. Cut one end of the ringed sleeve if it is too long. The wiring and its mountings must be correctly routed.

90898-2S1

38-17

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

II - REAR WHEEL SENSORS REFITTING

38

TIGHTENING TORQUES (in daN.m)

Wheel bolts Sensor mounting bolts

REMOVAL

7 to 9 0.8 to 1

Fit the sensor, previously coated with grease Multifunction 77 01 422 308, then clip the wire into its supports and reconnect it. NOTE : to eliminate the risk of faults make sure that the connector is properly connected.

Remove : - the wheel, - the sensor mounting bolt (1), - the sensor from its mounting.
III - FRONT WHEEL TARGET

TIGHTENING TORQUES (in daN.m)

Wheel bolts Driveshaft nut

7 to 9 24 to 26

Because the target is embedded in the driveshaft, this operation is carried out after the driveshaft has been removed.
REMOVAL

Extract the target in the press using an extractor.

92720R1

Unclip the wire from its mountings.. Disconnect the sensor from its connector (2) under the vehicle close to the left rear axle mounting.

91663S

92722R

38-18

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

REFITTING REFITTING

38

Coat the target with LOCTITE SCELBLOC and refit it using a mallet, tapping lightly on the outside of the target. Make sure that you tap rap regularly to prevent the target from twisting, and check that it is pressed home on the driveshaft.
NOTE: the Parts Department supplies spare machined driveshafts not fitted with ABS targets. It will therefore be necessary to retain the target to realign the driveshafts. However, the target only is also available from the Parts Department.

Refit the three computer mounting bolts, then those of the plate. Reconnect the computer, making sure of a perfect connection of the 35-track connector (clipping). NOTE: exercise great care when refitting: the three mounting points = ABS earth.

V - BRAKING PRESSURE UNIT, ELECTRIC PUMP UNIT AND RESERVOIR ASSEMBLY (left-hand

drive)
TIGHTENING TORQUES (in daN.m)

IV - COMPUTER

Braking pressure unit on bulkhead

REMOVAL

This is located in the heating compartment (on the left-hand side).

Disconnect the battery Remove : - the bar between the shock absorber turret, - the air filter. NOTE : the operating pressure of the ABS system is between 160 and 180 bars. It is also necessary to reduce the pressure before carrying out any work on the hydraulic circuit. To do this bolt (5) located under the electric pump, and accessible from underneath the vehicle, must be slackened one turn.

92735S

REMOVAL

Switch off the ignition. Remove the seal and the protective case. Disconnect the connector. To facilitate removal of the computer it is recommended that the three bolts securing the plate to the body be removed in order to remove the plate - computer - relay box assembly, providing access to the bolts securing the computer to the plate.

92724R

NOTE: do not slacken bolt (5) more than 2 turns (this may damage the O ring)

38-19

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

It is possible to check that the accumulator is actually empty by checking the brake fluid level in the reservoir, which must be approximately at the upper reference mark (B). Remove: - the A.E.I., - heating compartment flap,

38

92729R1

93447R

Unclip the expansion bottle and remove it. If only the bottle is being removed, 2 clamps Mot. 453-01 should preferably be fitted to avoid emptying the pipes. Drain the reservoir at the unions (C).

- the 4 brake pipes and the high pressure union (E) after marking them.

92732R

92730R3

Disconnect the connector. Remove the 3 nuts (D). Remove the reservoir and disconnect the other 2 pipes.

38-20

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

Inside the vehicle, remove the pin from the clevis connecting the brake pedal to the thrust rod after removing the clip.

38

Release the wiring and disconnect it from the connection plate.

92735S

Remove the lower protective case, nuts (F).

94692R

Retain the spacer. Unscrew the braking pressure unit mounting nuts on the pedal assembly plate.

93445R

94693S

38-21

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

Remove wiring mounting bolt (2) and the 2 bolts (H).

38

94692R

93446R

Remove the braking pressure unit and electric pump unit assembly.
IMPORTANT :

- the two electric pump unit support mounting bolts (H), - the lower protective case, nuts (F), - the 4 brake pipes and the high pressure union (E) (marked when removed).

The interlocking of the 2 compensator rods in the braking pressure unit is designed specifically for the pedal support. Therefore, NEVER: handle the braking pressure unit by the compensator, separate the clevis - thrust rod assembly of the braking pressure unit. pull or push on the wiring.
REFITTING

Fit : - the braking pressure unit and electric pump unit assembly, not forgetting the reinforcing plate and the braking pressure unit connecting seal, - the four mounting nuts on the bulkhead, - the spacer, the pedal clevis pin and the locking clip.

92730R2

38-22

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

the heating compartment flap, with the wiring, the brake fluid bottle and connect the hoses, the A.E.I., the electrical wiring, bolts (G), and the positioning clips, - the air filter, - the bar between the shock absorber turrets.

38

93447R

Fill with brake fluid and proceed to bleed (see corresponding section)

38-23

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

ELECTRIC PUMP UNIT - ACCUMULATOR PRESSURE SWITCH ASSEMBLY

38

(right-hand drive)

It is possible to check that the accumulator is actually emptied by checking the brake fluid level in the reservoir, which must be approximately at the upper reference mark (B).

TIGHTENING TORQUES (in daN.m)

Drain plug Hose union eElectric pump unit lock nuts

0.8 to 1 1.3 0.8

NOTE : the operating pressure of the ABS system is between 160 and 180 bars. It is also essential to reduce the pressure before carrying out any work on the hydraulic circuit.

To do this the bolt (5) located under the electric pump unit, which is accessible underneath the vehicle, must be slackened one turn. Unclip the expansion reservoir and remove it.

92729R

Fit two clamps Mot. 453-01 to avoid emptying the pipes. Drain the reservoir from unions (C).

92724R

NOTE: do not slacken bolt (5) more than 2 turns (this may damage the O ring).

92732R

Disconnect the reservoir connector. If the reservoir has to be replaced, remove the three nuts (D). Release the reservoir.

38-24

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

Disconnect : - the other pipes, - the rigid pipe of the HP hose - the two upper mounting nuts.

38

94695R

94699R

To facilitate the operation remove the accumulator with tool Mot.445.

Remove: - the two lower mounting nuts,

94697R

94694R

Remove : - the heating partition, - the electric pump unit after releasing the wiring.

38-25

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

PRECAUTIONS :

38

1.

Do not knock against, or rest the part on : - the low pressure inlet pipe, - the pressure switches, - the accumulator. Do not pull or push on the wiring.

Removing the brake pressure unit involves prior removal of the engine and transmission assembly (see section 13).

TIGHTENING TORQUES (in daN.m)

2.

Braking pressure unit on pedal assembly plate Hydraulic union Drain plug

2 1.3 0.8 to 1

REFITTING

Fit : - the electric pump unit (without the accumulator), fitted with the hose, - the four mounting nuts, - the accumulator fitted with a new O ring, and lock it, - the rigid pipe on the HP hose, - the wiring and the heating compartment flap mountings,

NOTE : the operating pressure of the ABS system is between 160 and 180 bars. It is also essential to reduce the pressure before carrying out any work on the hydraulic circuit.

To do this the bolt (5) located under the electric pump unit, which is accessible underneath the vehicle, must be slackened one turn.

93447R 94699-1R

- the brake fluid bottle (if necessary), and connect the hoses, - the air filter. Fill with brake fluid and proceed to bleed (see the corresponding section).

Press the brake pedal twice.

38-26

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

It is possible to check that the accumulator is actually emptied by checking the brake fluid level in the reservoir, which must be approximately at the upper reference mark (B).

Remove : - the heat shields.

92729R

Drain the reservoir at the unions (C).

94700S

- the heating compartment flap.

92732R

93447R

38-27

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

Disconnect: - the four brake pipes and the high pressure union after marking them.

38

Slacken the nuts securing the braking pressure unit to the pedal assembly plate.

94696S

94693S

- the hoses. Inside the vehicle, remove the clevis pin connecting the brake pedal to the thrust rod, after removing the clip.

Release the wiring and disconnect it from the connection plate.

92735S

Remove the braking pressure unit.

94692R

Retain the spacer.

38-28

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

IMPORTANT :

38

- the four brake pipes and the high pressure union (marked when removed).

The interlocking of the 2 compensator rods in the braking pressure unit is designed specifically for the pedal support. Therefore, NEVER: handle the braking pressure unit by the compensator, separate the clevis - thrust rod assembly of the braking pressure unit .

94696R1

93446S1

REFITTING

the hoses, the heat shields, the wiring and the locking clips, the heating compartment flap.

Fit : - the braking pressure unit assembly, not forgetting the connecting seal, - the four mounting nuts on the pedal plate, - the spacer, - the pedal clevis pin and the locking clip

NOTE : when replacing the pipes it is essential to

replace the heat shields before proceeding to fit the threaded unions. Refit the engine and transmission assembly. Fill with brake fluid and proceed to bleed the system completely (see corresponding section).

94692R

38-29

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

REPLACEMENT OF ACCUMULATOR - PRESSURE SWITCHES

38

SPECIAL TOOLING REQUIRED

Mot. 445

Strap wrench

TIGHTENING TORQUES (in daN.m)

Right-hand drive 0.8 to 1 0.7- 1.3

Drain plug Pressure switch

NOTE : the operating pressure of the ABS system is between 160 and 180 bars. It is also essential to reduce the pressure before carrying out any work on the hydraulic circuit.

To do this the bolt (5) located under the electric pump unit, which is accessible underneath the vehicle, must be slackened one turn. Left-hand drive

94699-1R

REMOVAL

With the accumulator empty and the ignition off, remove the accumulator with an Mot.445 spanner.

92724R

94697R

38-30

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

REMOVING PRESSURE SWITCHES

38

The Parts Department supplies a kit of 3 pressure switches. For vital safety reasons never invert the wire connection on the pressure switches or their position on the electric pump unit.

94721R

90 bar pressure switch (A) : Grey wire - track C1 of the 6 track connector on the connection plate. 160 bar pressure switch (B): Black wire - track B1 of the 6 track connector on the connection plate. 180 bar pressure switch (C): Black and grey wires - tracks A2 and B2 of the 6 track connector on the connection plate. If the pressure switch wire loom is to be removed, make sure that the earth wire is connected to the pump body.

REFITTING

Fit the accumulator provided with a new O ring, and lock it. Proceed to bleed the entire braking system (see corresponding section).

38-31

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

XR25 FAULT FINDING

38

The XR25 is vital for all fault finding on the ABS, regardless of the origin of the faults. It has a microprocessor and allows all the information from the various sensors to be read , together with fault finding messages from the computer. It also allows the memory of the computer to be erased after each operation on the ABS.

92655R2

NOTE : the warning light "V" must be

extinguished. If it is illuminated, disconnect then reconnect the diagnostic socket. If it remains illuminated, check the XR25 wiring and the battery voltage.

92656S

Connect the XR25 to the vehicles diagnostic socket and set the selector to "S5".

38-32

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

Analysis of system operation using the XR25 and the latest cassette. Vehicle stationary, ignition on. Enter code D 0 5

38

The display shows:

(1 second) then

1 2X 5 or

BENDIX make Computer number Product tested - ABS

dialogue has not been established

Bargraph 1 RH side must be illuminated. It extinguishes during dynamic tests of the solenoid valves (key G..*). If one or more bargraphs are illuminated, a fault is present. If they are flashing, a fault is memorised.

38-33

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

FI21605

Bargraphs on a coloured background are fault bargraphs Bargraphs on a white background are status bargraphs

38-34

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

CODE PRESENT (only bargraph illuminated normally - no fault)

Illuminated: correct (extinguishes if key G is pressed). If it extinguishes after entering D 0 5 there is a communication fault between the XR 25 and the computer. Check: - Correct connection of the 2 ABS wires to the + battery terminal: - pump motor feed - feed to power circuit for main relay on ABS plate - Correct connection of connection R36 (ABS/dashboard) located near the battery; - The diagnostic connection to the computer: continuity between track 12 of computer and track 5 of diagnostic socket. If incorrect, check the following continuities: - between track 12 of computer and track A2 of connection R36; - between track A2 of R36 and track 5 of diagnostic socket. Check: - voltage at track 6 of diagnostic socket; - presence of earth at track 2 of diagnostic socket; - computer power supply: presence of earth at track 27. If not present, ensure continuity with earth M19; presence of voltage greater than 10 volts at track 2. If not present, check: - battery voltage; - ABS 15 A fuse n 13 on relay plate; - starter cut-out relay. Remove the starter cut-out relay and shunt terminals 3 and 4 on the base. Under these conditions, are there V > 10 volts at track 2 of the computer? NO: Break in wiring, check following continuities: - between track 2 of computer and 4 of starter cut-out relay base; - between track 3 of starter cut-out relay base and track A1 of ABS/dashboard connection R36; - between track A1 of R36 and track 2A of ignition switch via 15 A fuse. Check operation of ignition switch. YES: check for absence of voltage at terminal 2 of starter cut-out relay base: - if there is no voltage, replace the relay (contact faulty); - if voltage is present, check operation of the ignition switch.

38-35

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

2 Pressure fault (pressure < 90 bar).

Enter #06 and read the data displayed on the centre display of the XR 25. If LR is displayed: Break in pressure alert relay energising circuit; perform the following checks: - continuity between track 2 of computer and track 2 of pressure warning relay base; - continuity between track 9 of computer and track 1 of pressure warning relay base (via 27 k resistance on relay plate). Check continuity of the pressure alert relay coil between tracks 1 and 2 of the relay. Short circuit to earth on track 9 of computer. If LP is displayed: Check: - connections of 160 and 90 bar pressostat, 6-track pressostat connector on relay plate and Nivocode connector; - correct operation of pump motor - (see fault finding aid 1-4).

2 Supply voltage fault (V > 16.5 or < 9.5 volts).

Check computer power supply: Presence of earth at track 27. If not, ensure continuity with earth M19; presence of voltage greater than 10 volts at track 2. If not, check: - battery voltage; - ABS 15 A fuse n 13 on relay plate; - the starter cut-out relay:

no

Remove the starter cut-out relay and shunt terminals 3 and 4 on the base. Under these conditions, is V > 10 volts at track 2 of the computer?

yes

Break in wiring, check the following continuities: - between track 2 of computer and 4 of starter cut-out relay base; - between track 3 of starter cut-out relay base and track A1 of ABS/ dashboard R36 connection; - between track A1 of R36 and track 2A of ignition switch via 15 A fuse. Check operation of ignition switch.

Check that no voltage is present at terminal 2 of starter cut-out relay base: - if voltage is not present, replace the relay; - if voltage is present, check the operation of the ignition switch.

38-36

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

Computer cut off: first check the connectors connected to the connection plate and clean them with NETELEC, part n 77 11 171 287. Switch the ignition off and on again and erase the computer memory (GO**), re-enter D05. If 3L is still illuminated without illumination of 3R, 6R, 7R or 7L, replace the relay plate. Otherwise, deal with the other bargraphs.

3 Diode cut.
Replace the relay plate.

Permanent relay control Replace the computer.

Main relay (428) energising circuit fault. Disconnect the 35 track connector from the computer and measure the resistance of the main relay coil between tracks 8 and 19 on the connector.

5 - If the resistance is between 50 and 60 , check the connections on the 35 track connector. If
the fault persists replace the computer. - Otherwise check the lines between the computer and the main relay base: - 8 computer connector / 2 relay - 19 computer connector / 1 relay Repair the wiring if necessary. If the fault persists, replace the computer.

Main relay energising circuit fault (short circuit between tracks 8 and 19 of 35-track connector).

5
Check insulation between these tracks. If there is a short circuit, replace the relay plate.

38-37

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

6 Erase the computer memory (control G0**).

If the fault persists, replace the computer.

Internal computer control.

Fault on ABS warning light line. Check ABS warning light bulb. Check warning light wiring: continuity between warning light and track C1 of dashboard/ABS (R36) connection and between C1 of R36 and track 26 of computer connector.

Diode short-circuited Replace relay plate.

Solenoid valve control fault (system cut off) 8 FRH solenoid valve terminal 5 35-track connector 9 FLH solenoid valve terminal 22 35-track connector 10 RRH solenoid valve terminal 24 35-track connector. Ignition off, disconnect the 12 track connector from the solenoid valve assembly and measure the voltage on track B3 of the connector.

8 9 Do you read 0 Volts? 10

NO YES

Replace the relay plate Measure the resistance of the suspected solenoid valve between earth and the computer connector track specified above. What resistance value is measured? R = 0 short circuit on solenoid valve coil replace the brake pressure assembly 1 < R < 5 Test the connections on the 35 track connector. If the connector is correct, and if the fault persists, replace the computer.

8 9 10

Solenoid valve control fault (system cut off). 8 FRH restriction solenoid valve terminal 4 35-track connector 9 FLH restriction solenoid valve terminal 21 35-track connector 10 RLH solenoid valve terminal 23 35-track connector. Perform the same operations for illumination on the left.

38-38

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

11 12 13 14 15 16

FRH solenoid valve circuit fault, terminal 5 of 35-track connector FRH restriction solenoid valve circuit fault, terminal 4 of 35-track connector FLH solenoid valve circuit fault, terminal 22 of 35-track connector FLH restriction solenoid valve circuit fault, terminal 21 of 35-track connector RRH solenoid valve circuit fault, terminal 24 of 35-track connector RLH solenoid valve circuit fault, terminal 23 of 35-track connector Illuminated on left: circuit open - on right: short circuit.

17 18

FLH

FRH

Wheel sensor circuit fault. Check sensor connector if rear sensor fault. If connector is correct, check resistance of sensor between terminals 17 and 34 RRH - 15 and 32 RLH - 16 and 33 FRH - 18 and 35 FLH.

RLH RRH

If R = replace the sensor if it is a front sensor. On the rear sensor, repeat measurement on connector at sensor end located near left-hand mounting of rear axle. If R still =, replace the sensor. If 1 < R < 1.45 k, check wiring between sensor and 35-track connector.

38-39

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

Special notes for Renault 19 vehicles with AC - PAS - ABS

38

The introduction of a new computer with new monitoring modes for "wheel sensor information" (bargraph 19 on the Bendix ABS diagnostic fiche) means that the computer must be identified before beginning fault finding (after entering code D05). Identifying the computer D05 then : #14 : old version, central display shows 9 #14 : new version, central display shows 35 Old generation computers (# 14 9) Bargraph Fault finding Sensor info fault Enter #07 and read information on XR25 central display (2 cases possible) Front left 19 (if #14 9) Front right

Localisation of faulty front wheel Example If the fault is on the front left wheel dash displayed corresponds to the faulty wheel (left hand display) On cassette n 11, the horizontal dash for wheel localisation does not exist, but does exist on the following cassettes. This dash makes left / right identification easier. Localisation of the faulty wheel is followed either by or (examples above)

If

is displayed, preceded by the wheel localisation:

Coherence fault for at least one front wheel speed info : - Check target conformity. (number of teeth, not round...). - Check sensor fitting and tightness, as well as the air gap over one revolution. - Check the tyres on the vehicle are all the same. (identical rolling radius). - Check the wheel bearings do not have a high degree of play. If these points are correct, there is a short circuit in the sensor wiring , check the insulation of the sensor at fault on the 35 track connector. If correct, erase the memory and try to reproduce the fault. If the fault persists, replace the computer.

38-40

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

Bargraph If Fault finding is displayed, preceded by the wheel localisation:

38

Sensor info excess frequency fault : - there may be electrical interference : check the routing of the wiring for the faulty sensor (ensure it avoids all high frequency generating units). - there may be mechanical interference : check the sensor is tight (vibration) and the sensor / target air gap (risk of interference). Front wheels air gap: 0.15 / 1.15 mm

19 (if #14 9)

Sensor information fault This fault is taken into account for a speed greater than 15 mph (24 km/h). Check the conformity, mounting and tightness of the sensor / toothed wheel assemblies at the rear and the air gap over one revolution. Rear wheels air gap : 0.20 / 0.80 mm Check the insulation of the sensors via the intermediate connector at the rear left. If correct, there is a fault on the 2 front sensors (simultaneously). Check the conformity and mounting of the sensor / toothed wheel assemblies at the front and the air gap over one revolution. Front wheels air gap: 0.15 / 1.15 mm Check the insulation at the 35 track connector. Erase the memory and try to reproduce the fault on a road test. If the fault reappears, carry out a complete check of the ABS wiring and replace the computer if the fault persists.

38-41

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

New generation computers (# 14 35)

38

Bargraph

Fault finding Wheel sensor information fault. Enter #07 and read the display of the XR25 (4 cases are possible)

Front left 19 (if #14 35)

Front right

Localisation of the faulty wheel

Rear left

Rear right

Example If the fault is on the front left wheel the dash displayed corresponds to the faulty wheel (display at the top left). On cassette n 11, the horizontal dash for wheel localisation does not exist, but does exist on the following cassettes. This dash makes left / right identification easier. Localisation of the faulty wheel is followed either by or (examples above)

If

is displayed, preceded by the wheel localisation:

Coherence fault for at least one wheel speed info : - Check target conformity. (number of teeth, not round...). - Check sensor fitting and tightness, as well as the air gap over one revolution. - Check the tyres on the vehicle are all the same. (identical rolling radius). - Check the wheel bearings do not have a high degree of play.

38-42

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

Bargraph Fault finding

38

If these points are correct, there is a short circuit in the sensor wiring , check the insulation of the sensor at fault on the 35 track connector. For the rear sensors, check the insulation via the intermediate connector located at the rear left. If correct erase the memory and try to reproduce the fault.

If

is displayed, preceded by the wheel localisation:

Sensor info excess frequency fault : - there may be electrical interference : check the routing of the wiring for the faulty sensor (ensure it avoids all high frequency generating units). - there may be mechanical interference : check the sensor is tight (vibration) and the sensor / target air gap (risk of interference). Front wheels air gap: Rear wheels air gap: 0.15 / 1.15 mm 0.20 / 0.80 mm

19 (if #14 35)

This fault is taken into account for a speed greater than 15 mph (24 km/h). Information fault for the 4 sensors. This indication on the XR25 shows a fault on the 4 speed sensors, either a coherence fault for the speed information or a sensor signal excess frequency fault. This fault is taken into account under conditions of extreme use or during external interference. Erase the computer memory and try to reproduce the fault on a road test. If the fault reappears, carry out a complete check of the ABS wiring and replace the computer if the fault persists.

20

Present if XR 25 memorisation function is in use.

The XR 25 memorisation function enables the various values of parameters accessible via the # key (followed by 2 figures) to be fixed and stored in memory for future use. Once communication between the XR 25 and the computer has been established, enter at the required time to obtain this function. 0 This memory is erased by entering D 0 5

38-43

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

HYDRAULIC TEST

Key G (control mode enabling solenoid valves to be checked and activated).

Raise the vehicle so that the wheels can be turned and check that they turn freely.

Hold the pedal down to prevent the wheel being tested from turning if driven manually (do not exert excessive pressure on the brakes, so that the wheel is at the unlocking point).

Enter D05 then G01* (1: rear left-hand wheel)

The wheel should be temporarily released for approximately 1 second.

yes

no

Incorrect
Switch the ignition off then on. Enter D05 (pay no attention to bargraph 3L flashing). Pressure on brake pedal too high. Repeat test using reduced pressure.

Repeat this test on the other wheels. To do so, enter the following codes:
G02* : RRH G03* : FRH G04* : FLH

When G01* is entered, slight noise from the movement of the solenoid valve should be heard (3 times), then at the end of the cycle, bargraph 3 left should illuminate (computer cuts out).

G05* : FRH restriction G06* : FLH restriction

if No locking No solenoid valve noise Hydraulic problem Replace braking pressure hydraulic unit

At the end of tests on all 4 wheels, erase the computer memory

38-44

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

ADDITIONAL TESTS

38

After initialising the system, on the keyboard enter:

front right-hand wheel speed (in km/h)

XXX
# 0 2
front left-hand wheel speed

XXX
# 0 3
rear right-hand wheel speed

XXX
# 0 4
rear left-hand wheel speed

XXX
# 0 5
vehicle speed

XXX
These checks enable the wheel speeds to be displayed (target and sensor check) and the sensor allocation to be checked. enables the origin of the incident to be located - pressure fault when bargraph 2 left is illuminated.

enables the origin of the sensor data fault to be determined when bargraph 19 right or left is illuminated.

38-45

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

ERASING THE MEMORY

38

Switch on the ignition without starting the engine. On the keyboard enter the code:

Connect the XR 25 to the diagnostic socket on the vehicle and set the selector to "S5".

D
The display shows:

Then:

XX
Enter:

G
The display shows:

92655R

Validate the erase request using

A second later the centre display shows:

The memory has been erased.

38-46

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

FAULT FINDING

38

SPECIAL TOOLING REQUIRED

M.S. 1048

Bornier for testing using the XR25 or a multimeter

This is a base of 35 contacts identical to those on the ABS computer on a printed circuit with electrical contacts numbered from 1 to 35. Each number corresponds to an electrical connection in the vehicle wiring and is marked on the operational diagrams. It is used to allow rapid access without reference errors for testing all the electrical connections at the main ABS connector.

89024R2

A B

Vehicle wiring Contacts giving access points for testing

NOTE:

Never disconnect the computer when the circuit has a voltage applied. Testing of earths and resistances must be carried out with the battery disconnected.

38-47

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

CONNECTION TO VEHICLE

38

Allocation of diagnostic socket terminals 1 2 3 4 5 6 7 8 9 10 11 12 Fault finding information AT "A4" Earth Foolproofing Cruise control fault finding information ABS fault finding information + 12 Volts after ignition Fault finding information AT "M" To electronic fault warning light Injection fault finding information Not allocated

With the ignition switched off, disconnect the ABS computer from its base and connect the bornier in position.

The diagnostic socket allows the connection of the XR25 test kit for microprocessor systems.

92726S

Principle of the checking method : Place the testing pin of the XR25 or of the multimeter in contact with the numbers indicated on the bornier. Control units which can be used: XR 25 : - measurement of continuity using the buzzer, - voltage measurement using the voltmeter. Multimeter : - resistance measurement, - voltage measurement. Resistance of the solenoid valves : 1 to 5 Resistance of the sensors : 1 000 to 1 400 Sensor signal : 1 turn/second, "Alternating " voltage between 50 and 2 000 mv Control of safety relay (E) on board (425): between tracks 8 and 19 of the 35 track bornier 50 to 60

88113S

38-48

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

Allocation of the computer connector pins
PIN No. ALLOCATION

38

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Not connected + 12 volt after ignition input Electric earth Front right restriction modulator Front right inlet/pressure relief modulator Not connected Not connected ABS safety relay contact 90 bar pressure switch Not connected Not connected Diagnostic socket Not connected Not connected Rear left hand wheel sensor Front right hand wheel sensor Rear right hand wheel sensor Front left hand wheel sensor ABS safety relay contact Electric earth Front left hand restriction modulator Front left inlet/pressure relief modulator Rear left inlet/pressure relief modulator Rear right inlet/pressure relief modulator Not connected ABS warning light return Electric earth Electric earth Not connected Not connected Not connected Rear left wheel sensor Front right wheel sensor Rear right wheel sensor Front left wheel sensor
DI3835

38-49

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

6 track connector for pressure switch board connection
WIRING DIAGRAM NOMENCLATURE

38

104 107 118 150 151 152 153 156 207 225 247 260 301
94717R

Ignition switch Battery ABS computer Rear right wheel sensor Rear left wheel sensor Front right wheel sensor Front left wheel sensor Hand brake switch Nivocode sensor Diagnostic socket Instrument panel Fuse ABS electric pump unit relay ABS hydraulic system ABS board Main relay (soldered) ABS solenoid valve assembly ABS earth ABS electronic earth Dashboard /rear right connection Pedal assembly/dashboard connection ABS/dashboard connection Pressure alarm relay Ignition cutout relay

361 425

12 track connector for braking pressure unit board connection

428 435 M18 M19 R1 R35 R36 A D

94718S

38-50

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

DI94918

38-51

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

ADDITIONAL CHECKS II - Checking rear wheel sensor connectors

38

I - Target/sensor air gap (Place the target so that the top of one tooth is parallel with the sensor) Front sensor X = 0.15 to 1.15 mm

If the ABS warning light illuminates intermittently, check as a priority the wheel sensor connectors and clean them with NETELEC, Part Number 77 01 408 464.

92722S

(Check the front sensor connectors if necessary).

92721-1R

Rear sensor X = 0.20 to 0.81 mm

92720-1R

Target conformity : Number of target teeth : 48

38-52

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

III - Marking the pipes (left-hand drive )

IV - Marking the pipes (right-hand drive )

92730R2

94696R1

View from underneath

For obvious safety reasons it is essential never to invert the braking pressure unit pipes and sensor connectors.

DI3806

38-53

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

To carry out the different pressure checks (IV to VI) it is necessary beforehand to fit a pressure gauge, proceeding as follows:

38

SPECIAL TOOLING REQUIRED

Fre. 1085

Complete brake system test kit

TIGHTENING TORQUES (in daN.m)

Fit end piece (D) and pressure gauge Fre. 1085. 0.8 - 1 0.6-0.8

Drain plug Bleed screw

FITTING OF PRESSURE GAUGE

Depressurise the accumulator by slackening bolt (5) at least one turn, then retightening it, and pressing the brake pedal once.

94698R

92724R

Place a pipe connected to a reservoir on the pressure gauge bleed screw. Open the bleed screw.

Remove the bolt indicated in the diagram below. Switch on the ignition and press the brake pedal. Wait until the fluid flows without bubbles, and close the screw. Switch off the ignition and release the brake pedal.

DI3886

38-54

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

IV - Checking the accumulator

38

CHECKS

CORRECT VALUES

ADDITIONAL CHECKS

Checking the accumulator Reduce the pressure (bolt 5). Check electric pump unit priming.

92724R1

Retighten bolt (5). Switch on the ignition. The pressure increases to a value of between 50 and 70 bars.

The pressure gauge needle must stabilise at this value before continuing to rise.

If the value is incorrect, replace the accumulator.

91582S1

Checking hydraulic accumulator depressurising time (engine warm, system temperature 60 to 80o C). Switch on the ignition. Wait until the pump stops. Check the time it takes to resume operation (without pressing the brake pedal).

Check : - the tightness of the pressure release screw, - for the absence of an external leak. If the value is incorrect, replace the electric pump unit assembly. Minimum time : 2 mm Maximum time : 9 mm

38-55

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

V - Checking charging times and 160 and 180 bar pressure switches

38

CHECKS

CORRECT VALUES

ADDITIONAL CHECKS

Accumulator charging time Switch off the ignition. Reduce the pressure (bolt 5). Check : - the operation of the pump, - the condition of the filter in the Banjo union, Charging time 40 to 60 seconds - the condition of the high pressure hose and pipes.

92724R1

Retighten bolt (5). Switch on the ignition. Pressure between 180 and 190 bars

If the pressure value is incorrect ( > 190 bars), replace the 180 bar pressure switch.

91582S1

Press the brake pedal several times. The pressure must be between 155 and 165 bars If the pressure value is incorrect, replace the 160 bar pressure switch.

NOTE : the pump restarts after 2 to 4

presses of the brake pedal.

91583S1

Check the pressure at which the pump restarts.

Re-inflation time 160 / 180 bars 3 to 10 seconds

38-56

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

VI - Checking 90 bar pressure switch

38

CHECKS

CORRECT VALUES

ADDITIONAL CHECKS

Checking 90 bar pressure switch. Switch on the ignition. Wait for the pump to stop. Switch off the ignition. Disconnect the supply to the electric pump unit motor (2 track connector on board 425). Switch on the ignition again and press the brake pedal several times. Check : - warning light bulbs, - warning light fuses, - pressure alarm relay, Warning lights extinguished. + - continuity.

91583S1

Check that the warning lights + illuminated for a pressure of : 90 +5 0 bars

If the value is incorrect, replace the pressure switch.

Reconnect the 2 track connector to the board (425).

The pump operates, the warning lights + are extinguished

38-57

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

VII - Checking for internal leaks

38

CHECKS

CORRECT VALUES

ADDITIONAL CHECKS

Checking for internal leaks Fit 2 pressure gauges on the front wheel calipers.

After 5 minutes there must be no loss of pressure (1 bar max.)

Check for the absence of an external leak. Replace the braking pressure unit assembly.

91563-4R3

Switch on the ignition.

91582S1

Wait for the pump to stop. Switch off the ignition. Using a pedal press, adjust the pressure on the front wheels to 100 bars.
REMOVING THE PRESSURE GAUGES

After a pressure gauge has been removed it is necessary to bleed the hydraulic circuit at the point where it was connected.

38-58

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

VIII - Checking the alarm device

38

CHECKS

CORRECT VALUES

ADDITIONAL CHECKS

Checking operation of dual alarm device incorporated in the brake fluid reservoir. Switch on the ignition. Using a screwdriver, press the plug plunger enabling the float to be lowered.

Check : - the warning light bulb, Check that the nivocode warning light illuminates (hand brake in position of rest) - the continuity of the electrical circuit. The alarm device is integrated in the reservoir, if it fails to operate, replace the complete reservoir.

92728S1

2nd check Switch off the ignition. Reduce the pressure in the accumulator by pressing the brake pedal about twenty times. Switch the ignition on, the pump operates to fill the accumulator. Press the plunger as far as it will go Release the pump must stop the pump must restart In case of failure (pump does not stop), replace the reservoir.

38-59

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

BRAKE COMPENSATOR

38

Principle of checking operation These vehicles are equipped with a load sensitive brake compensator. The pressure readings are taken in an X configuration, by comparing the pressure at the rear wheels with a given pressure at the front wheels. These dual compensators have two totally separate bodies which act in an X configuration on one front wheel and one rear wheel. It is essential to test both circuits. I II front right/rear left hand circuit front left / rear right hand circuit

Load sensitive compensator On the load sensitive compensators the adjusting system enables the rear pressure to be adjusted as a function of the front pressure. The adjusting system acts simultaneously on the two bodies. If the pressure on one of the two bodies is incorrect, replace the compensator.

85925S

38-60

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

BRAKE COMPENSATOR

38

Checking - Adjusting

92 719

93449G

To adjust : slacken nut (A) and alter the position of rod (B) in sleeve (C).

NOTE : it is not permissible to alter the position of nut (F).

38-61

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

Vehicle type

Fuel tank (driver in vehicle)

Test pressure (Bar) Front Rear +0 -4

All types with fixed compensator integrated in the wheel cylinder

60

34

B, C, L

533 53C 53Y 534 53J 53K

With ABS (after 05/92)

B, C, L

53T 53V 53Z

With ABS

3, 4, 5

53A 53B 53F

With ABS

90966S1

Full

100

40

+0 -8

B, C, L, S

53F 538 53K 53T 53Z

Without ABS (after 11/94)

3, 4, 5

53C 53D 53H

Without ABS (after 11/94)

38-62

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

Vehicle type

Fuel tank (driver in vehicle)

Test pressure (Bar) Front Rear +0 -8

B, C, L, D

539 53D

(before 05.92)

60

47

B, C, L

53A 53S 53B 538

With ABS

B, C, L

53F

With ABS (after 05.92)

100

52

+0 -8

3, 4, 5

53C 53D 53H

With ABS

90966S1

D53D (after 05.92 853C

Full

B, C, L, S

53F 538 53K 53T 53Z

Without ABS (after 11/94) +0 -8

100 3, 4, 5 53C 53D 53H Without ABS (after 11/94)

49

38-63

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

Vehicle type

Fuel tank (driver in vehicle)

Test pressure (Bar) Front Rear

B, C, L, D, S

533 53C 53F 534 53J 53K 53Y

With ABS (before 05/92)

100

43

+0 -8

B, C

53M

ABS

B, C, L

53D

(After 05.92) Full

90966S1

53C 53Y

With ABS (after 05.92)

100

52

+0 -8

D 8

53V 53A 53F

With ABS

38-64

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

CHECKING LEVEL - BLEEDING I - CHECKING THE LEVEL SPECIAL TOOLING REQUIRED II - COMPLETE BLEEDING

38

The brake fluid level is checked with the ignition switched on: accumulator filled to MAXIMUM reference mark. Switch on the ignition and wait for the pump to stop. If necessary top up the fluid level to the MAXIMUM mark (B) (vehicle with new shoes or linings)

M.S.

815 Fre. 1 085

Bleeding device Complete kit for brake system

Precaution to be taken before carrying out any work on the bleed screws: NEVER open the wheel cylinders : foot on the brake pedal, accumulator full. The accumulator is loaded to 180 bars. Before carrying out any operation it is essential to determine whether or not it needs to be emptied by reducing the pressure as follows: Reducing the pressure in the accumulator The accumulator pressure is reduced by slackening bolt (5) one turn. This bolt can be reached from underneath the vehicle.

92729R1

Left-hand drive
NOTE : the capacity of the brake fluid reservoir is

intended to compensate for the fluid flowing from the accumulator when it is emptied.

92724R

38-65

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

Right-hand drive

91582S

94699-1R

Remove the protective plate (right-hand drive). Fill the high pressure(HP) hose by slackening union (E) (braking pressure unit connection) several turns.

Tightening torque of bolt (5) : from 0.8 to 1 daN.m. When the pedal is pressed, the different bleed screws must always be slackened and tightened progressively. Between each operation check the level of the brake fluid in the reservoir.

Left-hand drive

1. Priming of the electric pump unit Depressurise the accumulator by means of bolt (5). Fill the reservoir with brake fluid. Switch on the ignition. If the electric pump unit does not operate, first check that the float in the reservoir is not stuck in the bottom position by retightening the plug and pressing the plunger.

92730R

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

Right-hand drive

38

2. Bleeding the electric pump unit and the failure chamber Fill the reservoir with brake fluid. Connect bleed screws (3) and (4) to M.S. 815 and slacken them.

94696R

DI3886R

Allow to drain. Retighten union (E). Switch off the ignition. Retighten bolt (5).

Switch on the ignition, electric pump unit operates. Allow to drain until the emulsion has disappeared. Retighten (3) and (4) with the engine running. Allow to run until stopped by pressure switch. Switch off the ignition. Depressurise the accumulator by means of bolt (5). Allow the brake fluid to stand for about 3 minutes. Retighten bolt (5) and restart the above operation 3 times in succession (complete elimination of the emulsion on releasing the accumulator pressure).

94699-1R

38-67

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

3. Bleeding the braking pressure unit (simulation spring zone) Depressurise the accumulator by means of bolt (5), then retighten it. Press the brake pedal. Open bleed screws (3) and (4). With the pedal pressed, retighten (3) and (4). Release the brake pedal. Repeat the operation as many times as necessary until the emulsion disappears. The result of the operation may be considerably improved by pressing slowly and gently on the brake pedal. 4. Bleeding at the plate bolts

38

Refit the protective braking pressure unit plate (right-hand drive).

94700R

The pump is used as a circulator. Depressurise the accumulator by means of bolt (5), then retighten it. Slacken bolts (1) and (2) one turn. 5. Bleeding at the calipers The pump is used as a circulator. Depressurise the accumulator by means of bolt (5), then retighten it. Place a hose, connected to a bottle, on the bleed screw concerned. Open the bleed screw. Switch on the ignition and press the brake pedal. Wait until the fluid is flowing without bubbles, and close the screw. Switch off the ignition and release the brake pedal (avoids inflating the accumulator between each wheel). Carry out the same procedure for the other wheels.

DI3886R1

Press the brake pedal. Switch on the ignition, the electric pump unit operates. After 30 seconds tighten bolts (1) and (2), with the engine running. Switch off the ignition. Release the brake pedal.

38-68

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

6. Checking bleeding Depressurise the accumulator by means of bolt (5), then retighten it. Connect two pressure gauges Fre. 1 085 to the front wheels.

38

Press the brake pedal sharply, it should have a minimum pressure of approximately 30 bars in the front wheel cylinders. If you do not have 30 bars, check the bleeding of the pressure gauges, if it is correct, restart operation 3.

7. Topping up reservoir See level check. Warning : the Parts Department supplies the braking pressure unit and electric pump unit with bolts (1), (2) and (5) slackened a maximum of 2 turns.
III - PARTIAL BLEEDING

When one or more calipers are to be replaced, partial bleeding is possible. Point 5 of the complete bleeding method must be repeated (bleeding at the calipers).

92727R1

91563-4R3

38-69

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

38

FAULT CHART FOR

ABS BENDIX

EFFECT OBSERVED ON OPERATION OF ABS AND BRAKE WARNING LIGHTS

1 - When the ignition is switched on/engine is started/engine running 1.1 - ABS warning light not illuminated during initialisation 1.2 - ABS warning light not illuminated during initialisation + illumination of brake warning light 1.3 - ABS warning light remains illuminated after initialisation without illumination of brake warning light 1.4 - ABS warning light remains illuminated after initialisation + illumination of brake warning light (after 30 s) 1.5 - Dim illumination of ABS warning light 2 - While driving/braking without ABS regulation 2.1 2.2 2.3 2.4 2.5 Illumination of ABS warning light alone Illumination of ABS warning light + brake warning light Random illumination of ABS warning light Illumination of brake warning light alone Illumination of ABS warning light only at high speed, always in same speed bracket

3 - While braking with ABS regulation 3.1 - Illumination of ABS warning light during ABS braking (with or without prior extinguishing) 3.2 - Illumination of ABS warning light at end of ABS braking or delayed after ABS braking. 4 - Other cases 4.1 - Warning light remains illuminated after ignition is switched off

38-70

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

2

38

EFFECTS OBSERVED ON OPERATION OF ABS BRAKES WITHOUT ILLUMINATION OF WARNING LIGHT

1 - Locking of one or more wheels 2 - Divergence from trajectory 2.1 - Pulling 2.2 - Wandering 3 - Unexpected operation of ABS (while driving) 3.1 3.2 3.3 3.4 On poor roads On good roads At low speed When using special equipment (car telephone, CB radio, etc.) 3.5 - Other cases linked to the external environment 4 - Effects on brake pedal 4.1 - Erratic/spongy pedal 5 - Noise 5.1 - From pump, unit or piping 6 - Other effects 6.1 - Frequent pump motor operation 6.2 - Prolonged activation of pump motor

38-71

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

1 Effect on operation of ABS and brake warning lights

38

1 - When ignition is switched on/engine is started/engine running 1.1 - ABS warning light not illuminated during initialisation

Connect the XR 25 to the vehicles diagnostic socket. Set the ISO unit to position S5, and use the latest version of the XR 25 cassette. Switch on the ignition and enter the code D05 on the keyboard. Does bargraph 1 illuminate? yes Is bargraph 7 illuminated? yes no Recheck your diagnosis On the left: ABS warning light line interruption. - Check 10 A stop light fuse n 29. - Check continuity between track 26 of computer and track C1 of ABS/dashboard R36 connection. - Check continuity between track C1 of R36 and warning light. - Check condition of warning light bulb and for presence of + after ignition at warning light. On the right: The diode on the plate has shortcircuited. - Replace the relay plate. no Communication fault between XR 25 and ABS computer: Check connection of R36 connection (ABS/dashboard) located near battery; Check connection between diagnostic socket and computer: continuity between track 12 of computer and track 5 of diagnostic socket. If incorrect, check following continuities: - Between track 12 of computer and track A2 of the ABS/dashboard connection; - Between track A2 of ABS/dashboard R36 connection and track 5 of diagnostic socket. Check voltage at track 6 of diagnostic socket (V > 10 volts). Check for the presence of earth at track 2 of diagnostic socket. Check computer supply: - Presence of earth at tracks 3, 20, 27 and 28. If not, check continuity with earth M19. - Presence of voltage > 10 volts at track 2. If not, check: - Battery voltage; - ABS 15 A fuse n 13 of relay plate; - Starter cut-out relay: remove starter cut-out relay and shunt terminals 3 and 4 on the base. Under these conditions, is V > 10 volts at track 2 of computer? no A 38-72 yes B

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

1 Effect on operation of ABS and brake warning lights

38

(continued)

Break in wiring. Check following continuities: - Between track 2 of computer and 4 of starter cut-out relay base; - Between track 3 of starter cut-out relay base and track A1 of ABS/ dashboard R36 connection; - Between track A1 of R36 and track 2A of ignition switch via 15 A fuse. Check operation of ignition switch.

- Check for absence of voltage at terminal 2 of starter cut-out relay base: - If no voltage is present, replace the relay (contact faulty); - If voltage is present, check operation of ignition switch.

Additional checks

Check operation of brake warning light by applying the handbrake. If it does not illuminate, push down the button on the reservoir using a screwdriver. Does the brake warning light illuminate? no Check warning light bulb and for presence of + after ignition at warning light. Check continuity of brake warning light lines. yes Check operation of handbrake switch and continuity between it and the warning light. If it illuminates, check operation of 90 bar pressostat: ignition off, drain the high pressure system (at the pedal or via drain plug n 5) and switch on the ignition. If, in addition to the ABS warning light, the brake warning light does not illuminate either, disconnect the one-track connector from the 90 bar pressostat and check earth continuity at pressostat end. Is there continuity? no Replace 90 bar pressostat (tightening torque: 0.7 to 1.3 daNm). yes Reconnect 90 bar pressostat and check operation/supply of pressure warning relay and corresponding continuities.

38-73

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

1 Effect on operation of ABS and brake warning lights 1 - When the ignition is switched on/engine is started/engine running 1.2 - No illumination of ABS warning light during initialisation + illumination of brake warning light

38

Use XR 25 to check illumination of bargraph n 7 (for non-illumination of ABS warning light) + check brake fluid level, Nivocode operation and insulation of brake warning light lines (for illumination of brake warning light).

1.3 - ABS warning light remains illuminated after initialisation, without illumination of brake warning light

Use XR 25 to check for illumination of bargraphs. Check earth insulation of ABS warning light line. Switch off the ignition. Disconnect R36 connection (ABS/dashboard) located near the battery and switch the ignition on again. Does the warning light illuminate again?

yes

no

Check insulation of ABS warning light line between R36 and warning light.

Switch off the ignition. Reconnect the R36 connection and disconnect the computer connector. Connect bornier M.S. 1048 and a voltmeter between terminals 20 and 26. Switch on the ignition. What is the voltage measured? Between 0.5 and 1 V approximately: the connections are correct; main relay or computer faulty: - Switch off the ignition and reconnect the computer. - Disconnect the 12-track solenoid valve connector on the plate and switch on the ignition. What is the voltage at track A2 of the 12-track connector. . V battery: main relay contact correct Replace the computer. . 0 volts: relay contact faulty Replace the plate. 0 volts: earth insulation fault on line or diode short-circuited. - Disconnect 6-track solenoid valve connector from plate and measure voltage at diode terminals with ignition on (between track 26 of computer and A2 of 12-track). What is the voltage measured? . 0.5 < V < 1 volt: Earth insulation fault on line between track 26 of computer and C1 of R36 connection. . 0 volt: diode short-circuited. Replace the plate. Continued over 38-74

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

1 Effect on operation of ABS and brake warning lights

38

Checking the computer supply

Presence of earth at tracks 3, 20, 27 and 28. If not present, check continuity with earth M19. Presence of voltage > 10 volts at track 2. If not present, check: - battery voltage; - ABS 15 A no. 13 fuse on relay plate; - starter cut-out relay; remove the starter cut-out relay and shunt terminals 3 and 4 on the base. Under these conditions, is V > 10 volts at track 2 of computer? NO - Break in wiring; check following continuities: - Between track 2 of computer and 4 of starter cut-out relay base; - Between track 3 of starter cut-out relay base and track A1 of ABS/dashboard R36 connection; - Between track A1 of R36 and track 2A of ignition switch via 15 A fuse; - Check operation of ignition switch. YES - check absence of voltage at terminal 2 of starter cut-out relay base. - If voltage is not present, replace the relay (contact faulty). - If voltage is present, check the operation of the ignition switch.

Checking the operation of starter cut-out relay during starting phase

In starting phase, check for absence of voltage at terminal 2 of computer. If voltage is present: fault on the starter cut-out relay energising circuit; check for the presence of voltage at terminal 2 of relay base during starting phase. If not, check, with ignition off: - continuity between terminal 2 of relay base and track B1 of R36; - continuity between track B1 of R36 and terminal 2B of ignition switch; - operation of ignition switch. If so, check continuity between earth M18 and terminal 1 of relay base. If earth is correct, replace starter cut-out relay.

Checking the operation of the main relay (contact sticking)

Disconnect the connector from the solenoid valve unit. With the ignition on, measure the voltage at terminal B3 of the connector, harness end. Is the voltage > 10 volts? no Replace the relay plate. yes Recheck your diagnosis

38-75

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

1 Effect on operation of ABS and brake warning lights

38

1 - When the ignition is switched on/engine is started/engine running 1.4 - The ABS warning light remains illuminated after initialisation, with illumination of brake warning light

(after 30 seconds) Use XR 25 to check for illumination of bargraphs (certainly bargraph 2 left for pressure fault). If bargraph 2 is illuminated on left, enter #06 and read information on XR 25 centre display. If LP is displayed - Check connections of 160 and 90 bar pressostat, of 6-track connector of pressostat on relay plate and Nivocode connector. - Check operation of pump motor: - Switch off the ignition; - Drain the high-pressure circuit: unscrew drain plug n 5 a maximum of 1 turn and depress the brake pedal once. - Switch on the ignition. Does the pump motor turn? no B - Check operation of Nivocode: Disconnect connector from Nivocode and check level is correct, continuity between tracks 2 and 3 of Nivocode. If incorrect, replace the reservoir. - Check motor supply: Disconnect 2-track connector from motor and measure the voltage. - If the voltage is > 10 volts, replace the elect. pump assembly.. - If voltage = 0, disconnect 160 bar pressure switch connector and earth the track. Does the motor turn? no A yes Replace 160 bar pressostat. If LR is displayed Check coil or pressure warning relay coil circuit.

yes

38-76

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

1 Effect on operation of ABS and brake warning lights (continued)

38
B

A - Check 30 A fuse on relay plate. - If it has blown, replace it after switching off the ignition and repeating the motor operation test. - If the fuse blows again, look for a short circuit on the pump motor line. - If it does not blow, check the current consumed by the motor by checking that no other consumer units are connected. It should be < 25 A. It if it higher, replace the elect. pump assembly. - Check for the presence of voltage at track 1 of the motor connector. If not present, check continuity between + BAT and this track 1 via 30 A fuse. - Check continuity between earth and track 2 of motor connector. If no continuity, check operation of motor relay. Disconnect motor relay and shunt tracks 3 and 5 of base. Does the motor operate? - NO - Check continuity between earth and terminal 3 of motor relay base and between terminal 5 and track 2 of motor connector. - YES - Check for presence of voltage at terminal 1 of motor relay base (ignition on). If not present, check continuity between this terminal 1 and terminal 2 of Nivocode. If these checks are correct, replace the relay plate.

Drain circuit and measure operating time of pump motor.

40 < T < 60 seconds:

- Pump brake pedal with ignition on and monitor change in travel. Does it become spongy? - NO: Normal elect. pump assembly. operation - YES: Check condition of filter at pump output.
1 < T < 1.5 minutes:

- Check operation of pressostats: Switch off ignition and redrain the HP circuit. Fit pressure gauge Fre. 1085 + union in place of one of the brake pressure assembly bleed screws. Switch on ignition and measure pressure in the circuit when the pump stops. - If the pressure is not between 180 and 190 bar, replace 180 bar pressostat (tightening torque 0.7 to 1.3 daNm). - If the pressure is correct, depress the brake pedal and reduce the pressure. The pump should restart at a value between 155 and 165 bar. If not, replace 160 bar pressostat. - Check tightness of screw 5 (0.8 to 1 daNm). If pump is worn, replace elect. pump assembly.
T > 1.5 minutes:

Check tightness of elect. pump assembly. drain plug (screw n 5 at torque 0.8 to 1 daNm). Check that connecting pipe between reservoir and pump is not clamped or blocked. Pump deprimed: reprime + bleed. Fracture of motor/pump mechanical connection. Pump worn, replace elect. pump assembly.

If fault (bargraph 2) persists, check operation of 90 bar pressostat. If there is continuity between earth and track C1 of 6-track connector on relay plate (system under pressure), replace 90 bar pressostat (tightening torque: 0.7 to 1.3 daNm). 38-77

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

1 Effect on operation of ABS and brake warning lights

38

1 - When the ignition is switched on/engine is started/engine running 1.5 - ABS warning light dimly illuminated

The brightness of the ABS warning light is not strictly constant, but this does not mean there is a fault. If there is a fault, it is due to the ABS earth. Check the mounting of the computer/relay plate support bracket (self-tapping screw). Earths M18 and M19 are taken from this support bracket.

2 - While driving/braking without ABS regulation 2.1 - Illumination of ABS warning light alone

Check the system using the XR 25. If there is no obvious fault, check using the XR 25 during a road test.

2.2 - Illumination of ABS warning light + brake warning light

Same as test 1.4.

2.3 - Random illumination of ABS warning light

Check the system using the XR 25. Check the electrical connections, particularly on the level of +supply and earth, since a cut-out could be interpreted as a contact interruption.

2.4 - Illumination of brake warning light

Check position of handbrake. Check fluid level in reservoir and operation of Nivocode: insulation between tracks 1 and 4. Replace reservoir if faulty. Check correct operation of handbrake switch. Check earth insulation of brake warning light lines.

38-78

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

1 Effect on operation of ABS and brake warning lights

38

2 - While driving/braking without ABS regulation 2.5 - Illumination of ABS warning light, only at high speed, always in same speed bracket.

Check the system using the XR 25 for probable illumination of bargraph 19. This phenomenon is often caused by mixing tyres of different sizes or using special equipment (snow tyres, etc.). - Check that the vehicle is fitted with four identical tyres. - Check whether there is excess play in the wheel bearings and repair if necessary. - Check whether there are any damaged teeth on the targets. - Check the air gaps and the mounting of the speed sensors. If the fault persists, road test the vehicle to reproduce the fault. During the test, use functions #01, 02, 03 and 04 to detect a potential sensor fault. After the test, repeat the check using the XR 25.

3 - While braking with ABS regulation 3.1 - Illumination of ABS warning light during ABS braking

(with or without prior extinguishing) Check the system using the XR 25 for probable illumination of bargraphs 17, 18 or 19. Check operation of solenoid valves (test explained under Wheel locking).

3.2 - Illumination of ABS warning light at end of ABS braking, or delayed after ABS braking

Check the system using the XR 25 for probable illumination of bargraph 2 right, linked to a battery charging fault.

4 - Other cases 4.1 - ABS warning light remains illuminated after the ignition is switched off

Since the warning light line is usually earthed by the main relay, the fault can only be caused by the warning light positive supply. - Check operation of the ignition switch. - Check supply only at warning light + after ignition. 38-79

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

2 Effects observed on operation of ABS brakes without illumination of warning light

38

1 - Locking of one or more wheels

Remember:

Immobilisation of the wheels of a vehicle with ABS brakes, or tyre squeal which feels to the customer like locking, can be linked to a normal system reaction and should not always be assumed to be faults: - Locking authorised below 4 mph (6 km/h) (system not active). - Braking with ABS regulation on very poor road surfaces (loud squealing).

On the other hand, if the wheel(s) is/are truly locked Possible inversion of speed sensor connections. Check sensor voltages: - Raise the vehicle so that the wheels can be turned. Connect a multimeter in AC voltage position between terminals 17 and 34 of the bornier. - Turn the rear right-hand wheel sharply. Is the alternating current between 0.5 and 3 volts? no Check: - Sensor mounting - Air gap (0.2 to 0.81 mm) - Target mounting. If there is still no value measured, turn the other wheels to confirm any possible electrical inversion of the sensors and repair the wiring. yes Perform the same test on the other wheels: - Front left-hand wheel: between tracks 18 and 35 (air gap 0.15 to 1.15 mm) - Front right-hand wheel: between tracks 16 and 33 (air gap 0.15 to 1.15 mm) - Rear left-hand wheel: between tracks 15 and 32 (air gap 0.2 to 0.81 mm). Before reconnecting the sensors, smear them with Multi-purpose grease, part n 77 01 422 308

Continued over

38-80

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

2 Effects on operation of ABS brakes without illumination of warning light

38

(continued)

If the fault persists:

Possible reversal of hydraulic unit piping. Check operation of solenoid valves and ensure consistency of results obtained (locking of the correct wheels). Raise the vehicle so that the wheels can be turned and check that they turn freely. Hold the brake pedal down to prevent the wheel to be tested from turning when driven manually. Enter D05 then G01* (for RLH wheel). Is the RLH wheel temporarily released for 1 second? no yes Switch the ignition off then on. Enter D05 (pay no attention to flashing of bargraph 3L). Repeat the test on the other wheels: enter the following codes: - G03* : FRH - G05* : FRH restriction - G02* : RRH - G04* : FLH - G06* : FLH restriction When all 4 wheels have been tested, erase the computer memory (function GO**)

Brake pedal pressure too high. Repeat the test with lower pressure. When request G01* is made, the movement of the solenoid valve (3 times) should be just audible then bargraph 3L may illuminate at the end of the cycle. - If there is no release, switch the ignition off then on, enter D05 and reuse the same code, watching to see if another wheel is released (confirming reversed piping: repair). - If there is no release and no solenoid valve noise there is a hydraulic fault, replace the braking pressure unit.

38-81

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

2 Effects on operation of ABS brakes without illumination of warning light

38

2 - Divergence from trajectory 2.1 - Pulling

Connect XR 25 , enter D05 to deactivate the ABS and road test the vehicle without ABS. Does the fault persist under these conditions? yes Check tyre pressures, front axle, calipers and pads or, possibly, for leaks in the circuit. no

Check: Possible inversion of speed sensor connections. - Test sensor voltage (see test for 1st case of wheel locking ) Possible inversion of hydraulic unit piping - Test operation of solenoid valves (see test for 1st case of wheel locking). Check balance of pressure on front calipers: - De-pressurise accumulator by loosening drain plug (n 5) by one turn and then retighten. - Connect 2 pressure gauges Fre. 1085 to the front caliper bleed screws and bleed them (by switching on the ignition and depressing the brake pedal). - Depress the brake pedal hard and compare the pressures at both calipers. Are the pressures identical? (L/R difference: max 4 bar). no yes Recheck your diagnosis

Replace the brake pressure assembly (imbalance in travel of limiter rods).

38-82

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

2 Effects on operation of ABS brakes without illumination of warning light

38

2 - Divergence from trajectory 2.2 - Wandering

Connect XR 25 , enter D05 to deactivate the ABS and road test the vehicle without ABS. Does the fault persist under these conditions? no Normal behaviour linked to operation of system in regulation phase, mainly on surfaces with uneven adherence. If the fault is particularly significant, check adjustment of brake limiter. yes

Road-holding fault not linked to ABS system. Check tyre pressures, front axle, calipers and pads or, possibly, for the presence of leaks in the circuit.

38-83

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

2 Effects on operation of ABS brakes without illumination of warning light

38

3 - Unexpected ABS operation

(while driving)

3.1 - On poor road surfaces

On poor road surfaces it is normal to hear louder squeal than on good road surfaces. The resulting impression is of a variation in efficiency, which is normal. This phenomenon is accentuated on vehicles with highly reduced efficiency shock absorbers Check shock absorbers + condition of tyres.

3.2 - On good road surfaces

Check conformity of wheel targets. Check adjustment of brake compensator.

3.3 - At low speed

(fault similar to loss of brakes) Check mounting of speed sensors and air gaps (air gap front wheel: 0.15 to 1.15 mm; rear wheel: 0.2 to 0.81 mm). Check conformity of speed sensors.

3.4 - When using special equipment

(car telephone, CB radio, etc.).

Check that the equipment has been correctly installed, without modifying the original wiring, especially the ABS wiring.

3.5 - Other cases linked to the external environment

Near radars, radio transmitters or in highly metallic zones, the ABS system may be disrupted by interference. If the drivers foot is on the brake pedal, he may notice and be surprised by the ABS system operating when it should not.

38-84

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

2 Effects on operation of ABS brakes without illumination of warning light

38

4 - Effects on brake pedal 4.1 - Erratic / spongy pedal

Check visually for any external leaks and repair leaking parts. It is possible that the filter on the Banjo connection screw at the brake pressure assembly end of the HP pipe is clogged: replace the screw.

5 - Noise 5.1 - Noise from pump, pipes or unit

- Unit vibration: Check presence and condition of units mountings. - Piping vibration: check that all pipes are correctly clipped into their mounting clips and that there is no contact between pipes or between pipes and bodywork. Check that there is no contact between any element in the engine compartment and the brake pressure assembly, the elect. pump assembly. and the HP pipe.

6 - Other cases 6.1 - Very frequent pump motor operation

A) Check correct torque tightness of drain plug n 5 (0.8 to 1 daNm). B) Check accumulator operation. - Switch off the ignition and drain the HP circuit by loosening screw n 5 by one turn. - Fit a pressure gauge Fre. 1085 + union in place of bleed screw n 4 of brake pressure assembly and bleed the pressure gauge (by switching on the ignition and depressing the brake pedal). - With screw n 5 retightened, switch on the ignition and monitor the pressure gauge. Does the pressure increase immediately to between 50 and 70 bar and continue increasing after a few seconds? - NO - If the pressure remains very low, check elect. pump assembly. priming. If it immediately rises to a high pressure, replace the accumulator. Continued over 38-85

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bendix ABS

2 Effects on operation of ABS brakes without illumination of warning light

38

Continued

- YES C) Check operation of 160 and 180 bar pressostats. - Switch off the ignition and redrain the HP circuit via screw n 5. - With screw n 5 retightened, switch on the ignition and measure the pressure in the circuit when the pump stops. If the pressure is not between 180 and 190 bar (160 bar), check connection of 180 bar pressostat and replace it if necessary (tightening torque: 0.7 to 1.3 daNm). If the pressure is correct, depress the brake pedal and reduce the pressure. The pump should restart at a value between 155 and 165 bar (recharging time should be between 3 and 10 seconds). If not, replace 160 bar pressostat. D) Check losses of pressure in the pump: - Drain the circuit via drain plug n 5. - Screw n 5 retightened, switch on the ignition and wait until the pump has been stopped for 3 minutes. - Measure the pressure in the circuit. - Check the loss of pressure after 5 minutes. If the loss of pressure is > 1 bar, replace the pump. Otherwise, the operating frequency is normal.

6.2 - Prolonged activation of pump motor

Check that piping is not clamped between reservoir and pump. Check that there are no external leaks. Check the operating time and the pressures obtained as a function of the time. Increase in pressure 0 -- 180 bar: 40 to 60 s. Pump reactivation at 155/160 bar with rise to 180 bar in 10 seconds maximum.

If these times are not obtained, replace the electric pump assembly.

38-86

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

Identification of Renault 19 vehicles fitted with BOSCH ABS From now on Renault 19 vehicles will be fitted with BOSCH ABS except for: - automatic transmission versions, - Turbo Diesel versions , - the 16 valve version (X53D) with air conditioning. These models (AT, Turbo Diesel and X53D/AC) will retain the BENDIX ABS system.

38

Introduction The BOSCH ABS 2E system comprises a hydraulic unit with an integral computer and four inductive sensors which measure the speed of each wheel via a toothed wheel. The hydraulic assemble is located in the engine compartment. The brake pipes connect the dual master cylinder to the various wheels via the hydraulic assembly. The flow, delivered by the two master cylinder circuits, at the moment of braking, passes via three solenoid valves. These ensure the independent regulation of the front left hand wheel, the front right hand wheel and the rear axle wheels. The vehicle has an X pattern braking circuit and so there is separation between the two rear brakes using a mechanical device known as the piston plunger. The device comprises four separate channels. The two rear channels operate at the same pressure according to the select Low principle; the lowest adherence wheel causes the same regulation on the rear wheels.

38-87

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

LOCATION AND COMPOSITION

38

94917R1

NOTE : The diagram is a general diagram only; it should never be used as a reference for the take off points

and circuit allocations. When replacing one of the component parts of the braking circuit on a vehicle, always mark the pipes before removal to ensure they are reconnected in the same position.

38-88

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

LOCATION AND COMPOSITION

38

Apart from the braking components: - brake calipers, - dual master cylinder (with non-return valves), - dual load sensitive compensator (5), which are conventional parts, the ABS system comprises: - one wheel speed sensor per wheel (3), - four targets (4), embedded : - at the front on the driveshafts - at the rear on the hubs, - a hydraulic assembly (1) comprising : - one regulation solenoid valve for each front wheel, - one solenoid valve and a piston plunger for the rear axle, - and a hydraulic pump, - a computer (2) (integral in the hydraulic assembly) with a self-test facility, - a warning light on the instrument panel, - a diagnostic socket allowing connection of the XR 25.

ABS 2 E - 4 channels - 4 sensors

DI3818

38-89

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

LOCATION AND COMPOSITION

38

DI3887

38-90

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

LOCATION AND COMPOSITION

38

Front wheels Targets embedded in the driveshafts. Radial, non-adjustable sensors.

Speed sensor (3) and target (4)

A magnetic sensor is composed of a permanent magnet, a polar mass and a coil. The magnet creates a magnetic flux which is channelled by the polar mass. This flux is disturbed by the variation in air gap (when a tooth passes near the polar earth), creating an electrical voltage at the terminals of the coil. The sensors deliver an alternating electrical voltage. The frequency of the signal is proportional to the speed of the wheel.

94868R

Rear wheels Targets embedded in the hubs (cannot be removed). Tangential, non-adjustable sensors.
DI3888

1 2 3 4

Magnet Field lines Polar mass Target

The speed sensors are mounted on the stub axle carriers and receive information via the toothed targets (26 teeth at the front and the rear).

96955S

38-91

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

The speed sensors are connected to the computer via connectors located: For the front: On the side of the shock absorber turret in the engine compartment. For the rear:

38

Next to the left hand mounting for the rear axle assembly.

96954S

NOTE : only the length of the polar core is

96953-1R

different between the front and rear sensors.

Connector for front left hand speed sensor (A).

Fitting precautions The sensor must be pressed in by hand, after coating it with multipurpose grease, Part Number 77 01 422 308. Do not tap the sensor to fit it, or pull or push on the wiring.

96956-1R

Connector for front right hand speed sensor (B).

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LOCATION AND COMPOSITION

38

The computer

It analyses the information from the wheel sensors and controls the regulation solenoid valves depending on this information.
NOTE : the diagnostic socket is located in the

The integral computer is mounted on the hydraulic assembly pump motor.

passenger compartment, under the dashboard, in the relay and fuse compartment.

94640S

It includes, amongst others, two microprocessors which independently carry out the same programme to give a maximum level of safety. As soon as a wheel is tending to lock, the solenoid valves and the pump motor are activated via the two relays mounted on the top of the computer. The integration of the electronic function into the hydraulic assembly and corresponding reduction in weight has lead to reduction in wiring and number of connectors (hence greater reliability) and makes the unit easier to fit to the vehicle. The main functions carried out by the computer are: - preparation of the signal, - regulation, - self-testing (safety monitoring), - fault finding. This allows connection of the XR25 for testing microprocessor systems.

92827S

Communication between the computer and the fault finding equipment allows: the computer to be identified. memorised fault information to be read system parameters to be read (wheel speeds, voltage...). the solenoid valves, pump motor and warning light bulb to be operated. the memory to be erased.

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LOCATION AND COMPOSITION

38

The hydraulic assembly

The hydraulic assembly with integral computer is located in the engine compartment on the left hand side under the master cylinder.

94640R1

96953S

It comprises: - three regulating solenoid valves, - a piston plunger (P) to ensure hydraulic separation of the the two rear brakes , - a pump driven by an electric motor (special note: reduced power - limitation of maximum pressure). It should be noted that the role of the pump is to return the fluid during the "elimination" phase to the master cylinder in order to generate the required drop in pressure; this causes the characteristic pedal movement.

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ABS 2 E HYDRAULIC ASSEMBLY

38

DI3889

1 2 3 4 5 6 7

Solenoid valves Pump relay Solenoid valves relay Motor Pumping component Accumulator Piston plunger

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OPERATING PRINCIPLE

38

Regulating solenoid valves

The hydraulic pressure from the two master cylinder circuits at the moment of braking passes via three solenoid valves and a piston plunger to ensure independent regulation of the front left, front right and rear channels. The three way solenoid valves have the same operating principle as before; a variable current passes through the coil, depending on the phase of regulation allowing either: - phase 1 : communication between the master cylinder and the brake cylinder (normal braking), - phase 2 : this communication to be cut, preventing the increase in pressure in the brake cylinder, - phase 3 : communication between the brake cylinder and the return pump,which drops the pressure in the brake cylinder and "releases the brakes" at the wheel.

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PRESSURE INCREASED PHASE (PHASE 1)

38

DI3890

the force at the pedal is directly applied to the wheel, the current at the solenoid valve is zero, the ABS does not operate, the wheel deceleration does not exceed the limit of adherence.

1 2 3 4

Computer Accumulator Motor Pump

5 6 7 8

Solenoid valve Master cylinder Wheel sensor Target

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PRESSURE MAINTAINED PHASE (PHASE 2)

38

DI3890R

- the deceleration threshold is exceeded, - the current in the solenoid valve (5) equals "i" average, - the hydraulic circuit between the solenoid valve and the wheel is isolated, - deceleration increases as well as slip.

1 2 3 4

Computer Accumulator Motor Pump

5 6 7 8

Solenoid valve Master cylinder Wheel sensor Target

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PRESSURE REDUCED PHASE (PHASE 3)

38

DI3890R1

the slip threshold is exceeded, the current in the solenoid valve equals "i" maximum, the pump (4) operates, the pressure drops, the wheel deceleration reduces.

1 2 3 4

Computer Accumulator Motor Pump

5 6 7 8

Solenoid valve Master cylinder Wheel sensor Target

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OPERATING PRINCIPLE

38

Rear circuits (Special note) Braking at the rear wheels is regulated according to the Select Low principle, which means that the two rear channels operate at the same pressure; the wheel with the lower adherence causes the same regulation at both rear wheels.

Hydraulic separation The vehicle has an X pattern braking circuit. Separation between the two rear brakes is ensured by a mechanical device known as the piston plunger (P).

Precaution : The bleeding procedure must be observed (order of bleeding). If this order is not observed, air may enter the plunger which will cause the pedal travel to lengthen.

The piston plunger In connection with the rear regulation solenoid valve (E), this ensures the equivalent regulation at the other wheel at the same time. The pressures in the rear brake cylinders are approximately identical to within friction forces. There are three operating phases depending on the position of the rear solenoid valve 1. 2. 3. Braking without regulation Pressure maintained Pressure reduced

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OPERATING PRINCIPLE

38

Braking without regulation

DI3891

C E P CL P1 P2 P3

Compensator Rear regulation solenoid valve Piston plunger Valve Position 1 Position 2 Position 3

1 2 3 4 5

Front left brake cylinder (via solenoid valve) Front right brake cylinder (via solenoid valve) Rear left brake cylinder Rear right brake cylinder Rear axle assembly

In the braking without regulation phase, the piston plunger is not operational (position 1 of rear solenoid valve (E) and valve (CL) open).

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OPERATING PRINCIPLE

38

Pressure maintained

DI3891R

(Position 2 of the rear solenoid valve) The pressure in chamber B and that in the rear brake cylinder (4) is stable. The piston plunger moves to the left under the action of the pressure at A (master cylinder). Valve (CL) is now closed. This movement continues until the pressures at B and C are equalised (A and D are at master cylinder pressure). The pressures in the two rear brake cylinders are stable and identical (to within friction values).

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OPERATING PRINCIPLE

38

Pressure reduced

DI3891R1

(Position 3 of the rear solenoid valve) The pump partially returns the volumes of chamber B and the rear brake cylinder (4) to the master cylinder. The drop in pressure at B allows the piston plunger to move to the left. Valve (CL) remains closed. The increase in volume at C causes a drop in pressure in the rear brake cylinder (3). The pressures in the rear brake cylinders (4) and (3) are identical to within friction values.

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REGULATION

38

SUMMARY OF PRINCIPLE

Sensor signal

Wheel speed

Analysis of the signal

Regulation strategy

Order of regulation

Hydraulic intervention

Modification of speed

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REGULATION

38

The target / sensor assembly monitors the movement of the wheel. If a wheel is tending to lock, deceleration and slip increase quickly. When certain critical thresholds are exceeded the regulation cycle begins to operate. Determining the reference speed The computer permanently receives signals from the sensors from which the wheel speeds are calculated. When the vehicle is not braking, the vehicle speed corresponds to the speed of the non-driven wheels. When the vehicle is braking, all the wheels are slipping to a greater or lesser extent and their speed will therefore differ from the vehicle speed. Two reference speeds are calculated: - the "vehicle" reference speed allows calculation of the deceleration of the vehicle(speed of the fastest wheel), - the "slip" reference speed allows calculation of slip (speed of the 2nd fastest wheel). To begin regulation, a certain wheel instability threshold must have been exceeded. If the wheel deceleration threshold is reached, regulation begins by moving the solenoid valve to the pressure maintained position. During this very brief period, the vehicle deceleration is calculated and the type of adherence evaluated (high or low). If the slip threshold defined by the reference slip is exceeded, the drop in pressure is initiated until the wheel has reaccelerated to a value allowing the pressure to be increased again by stages. If the wheel instability returns, the second regulation cycle is begun with a drop in pressure and so on until the vehicle stops. During braking with ABS regulation, this cycle may be repeated from 4 to 10 times a second. The system will operate after only a few tenths of a second. Each time the system operates the brake pedal pulsates to a greater or lesser extent, accompanied by the characteristic noises caused by the modulation in braking pressure between the hydraulic pump and the regulating solenoid valve, and by any tyre squeal.

Special note: When braking on non-symmetrical ground, a side slip torque appears which tends to turn the vehicle towards the side with the high adherence coefficient. The driver must react to this at the steering wheel. To avoid this phenomenon, these vehicles are fitted with a side slip torque time delay. In this case, the braking pressure of the wheel with high adherence increases in stages to its maximum value. This reduces the reaction required to keep the vehicle on course and allows the driver to remain in control of the situation.

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SELF TESTING

38

Safety - Monitoring

A certain number of tests are carried out when the ignition is turned on and each time the vehicle starts, under the following conditions:

1.

Test after switching the ignition on or initialisation test During this phase, the following points are checked: - internal microprocessor tests. - tests of connections (voltage supply, solenoid valve relays, disconnection, solenoid valve connections and electrical continuity of the motor). - fault memory operation. This phase leads to the "ABS" warning light being extinguished after two seconds if all the tests are correct.

2.

Tests carried out after the vehicle has moved off for the first time This concerns the first few rotations of the wheels after the ignition has been switched on. This test is carried out as soon as the perceived vehicle speed reaches 3.75 mph (6 km/h). - checking the operation of the solenoid valve pressure drop (the three solenoid valves are operated* for a few ms). - in this phase, the system checks that all the solenoid valves operate identically and that their electrical resistance is within the permitted limits. - test of the pump motor*. In this phase the return information from the pump motor is checked after operation of the motor for a few ms. - checking the speed sensor signals (monitoring after moving off for the first time and disconnection of the ABS at 7.5 mph (12 km/h) if a fault is detected). These tests are completed before the vehicle reaches 9 mph (15 km/h). (*) Note: this self test generates pulses which may be felt at the brake pedal and this phenomenon should in no way be considered as a fault.

3.

Tests carried out when the vehicle moves off at other times: These tests are carried out after moving off when the vehicle speed exceeds 3.75 mph (6 km/h) on condition that the vehicle speed exceeded 12.5 mph ( 20 km/h) the last time the vehicle moved off. - test of solenoid valve current patterns. - test of the pump motor. - test of the speed sensor signals (monitoring and disconnection of the ABS at 12.5 mph (20 km/h) if a fault is detected). These tests are completed before the vehicle reaches 15.5 mph (25 km/h).

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Faults The fault detected by the self test immediately switches the circuit off or does so after ABS regulation, depending on the case. The driver is shown this information by the ABS warning light.

38

Summary table for ABS 2E self testing Fault memorised

Component tested

Test type

Test conditions

Customer complaint

ABS warning light

Visual

Warning light illuminates for 2 seconds after switching ignition on As soon as ignition on for V > 6km/h for V > 6 km/h As soon as ignition on

Does not illuminate

No

Solenoid valve connections: front left, front right and rear

CO CC CC+
CC - (CP)

No ABS + warning light illuminated

Yes

Sensor connections: front left, front right, rear left and rear right

Outside regulation: Detection when ignition switched on During regulation: Fault on 1 front wheel (up to end of regulation) Logical or resistance monitoring Then for V > 20 km/h (after starting again) Fault on 1 rear wheel (up to end of regulation)

No ABS + warning light illuminated

Yes

ABS retained for other wheels. Braking pressure increases up to master cylinder pressure at faulty wheel.

No ABS + warning light illuminated ABS retained for 2 front wheels (rear pressure = 0) No ABS + warning light illuminated

Yes

Then for V > 20 km/h (after starting again)

Yes

Stop switch connections

CO (computer track 9 stop bulb earth)

As soon as ignition on

No ABS + warning light illuminated

Yes

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38
Yes

Pump motor connections

CO (computer, pump motor earth via pump motor) CC

As soon as ignition on

No ABS + warning light illuminated

For V > 6 km/h

No ABS + warning light illuminated

Yes

Pump motor relay connections

CC power circuit

(Pump motor permanent control) As soon as ignition on

No ABS + warning light illuminated No ABS + warning light illuminated No ABS + warning light illuminated No ABS + warning light illuminated

Yes Yes

CC control circuit For V > 6 km/h

CO power circuit For V > 6 km/h

Yes

CO control circuit

For V > 6 km/h

Yes

Fault finding connection

CC -

As soon as ignition on if line "L" is earthed

Warning light flashing

No

Feed

Voltage drop U battery < 9.4 V

1. Vehicle speed< 6 km/h If under voltage< 1 min If under voltage> 1 min 2. Vehicle speed> 6 km/h Taken into account immediately

No ABS + warning light illuminated No ABS + warning light illuminated

No Yes

No ABS + warning light illuminated No ABS + warning light illuminated No ABS + warning light illuminated No ABS + warning light illuminated No ABS + warning light illuminated

Yes

Solenoid valve relay connection

CC power circuit

As soon as ignition on

Yes

CC control circuit As soon as ignition on after 30 seconds filtering CO power circuit As soon as ignition on after 30 seconds filtering CO control circuit As soon as ignition on after 30 seconds filtering

Yes

Yes

Yes

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38
Yes

Toothed wheel

Coherence

1. Fault declared after 2 min filtering If speed of one wheel > 25 % of reference speed 2. If regulation continues for more than 60 seconds

No ABS + warning light illuminated

No ABS + warning light illuminated

Yes

Key: Electrical connection or component in open circuit Electrical connection or component in short circuit Electrical connection or component to + 12 V CC - (CP) Electrical connection or component in short circuit to earth or permanent control CO CC CC+

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If there is a fault, after switching the ignition off,this fault is stored in the computers memory.

38

This memory may be consulted at any time using the XR25 and the appropriate cassette. Switching the ignition off and on again however may modify the interpretation of the bargraphs in certain cases. To avoid any confusion, carry out a road test with the vehicle showing a fault (intermittent or permanent illumination of the ABS warning light) before reading the diagnostic signal, without switching the ignition off. The fault mechanism is as follows: A maximum of three faults may be stored: Definition of a fault a) Permanent fault: A fault is declared to be "permanent" when it appears (ABS warning light illuminated) (shown on the XR25 by the fixed illumination of a bargraph other than 1 and 4). b) Intermittent fault: A fault is declared to be "intermittent" after it has been stored and has disappeared (shown on the XR25 by the bargraph flashing). Operation: A counter allocated to each memory allows the system to distinguish between a permanent fault and an intermittent fault. When a fault appears, the counter is set to 20. If the fault is then recognised as being intermittent, the counter decreases each time the ignition is switched on. In this way, if the fault no longer appears, the fault will be automatically erased from the memory after the ignition has been switched on for 20 times. There is no fault hierarchy, but if a permanent fault appears, it will take the place of an intermittent fault with the lowest counter count if all three memory slots are occupied.If several faults appear at the same time, only one will be memorised. It is therefore important to carry out a new check after a road test, after repairing this fault. Condition for entering fault finding: - If no faults are present Speed < 6 mph (10 km/h) - If faults are present Possible regardless of speed

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FAULT FINDING WITH THE XR25

38

The XR25 is vital for all fault finding on the ABS, regardless of the origin of the fault. Communication between the computer and the
XR25 allows:

- the computer to be identified - memorised fault information to be read. - system parameters to be read (wheel speed, voltage...). - the solenoid valves, pump motor and ABS warning light to be operated. - the memory to be erased (to be carried out after every operation on the ABS)
92656S

Initialising dialogue: After connecting the XR25 at the end of a road test without switching the ignition off after completing the test - Set the ISO selector to S8. - Contact the computer using :

sends a signal on the 2 lines (K and L) at the same time

When dialogue has been initialised, the ABS warning light should illuminate, confirming that the ABS is in fault finding mode (ABS warning light is illuminated before entering fault finding mode if there is a permanent fault).

92655R

NOTE : Warning light "V" must be extinguished. If

it is illuminated, disconnect then reconnect the diagnostic socket and if it remains illuminated, check the XR25 wiring and the battery voltage.

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38

Analysis of system operation using the XR25 and the latest cassette after a road test where the ABS warning light illuminated. At the end of the test, without switching off the ignition, connect the XR25. Enter code D 1 1

Position the ISO selector on S8. The central display shows:

(1 second) then

2 XX 5

Bosch make Computer number Product tested is ABS

or
Shows dialogue has not been established If the initialisation procedure has been carried out correctly: the ABS warning light on the instrument panel must be illuminated, regardless of its previous status: illuminated (permanent fault present) or extinguished (no permanent fault present) the central display should show
ABS WITH NO FAULT

(2 bargraphs illuminated) Bargraph n 1 RH side: code present Bargraph n 4 RH side: stop circuit - pedal not depressed
ABS WITH FAULT(S) IMPORTANT DEFINITIONS :

Intermittent fault: is a fault which occurred (ABS warning light on instrument panel illuminated) and disappeared by itself at a given moment (after the ignition had been switched off and on again). This type of fault is shown by a flashing bargraph. Permanent fault: is a fault which is present when fault finding using the XR25. This type of fault is shown by a permanently illuminated bargraph

IMPORTANT :if

is entered when the computer is in the test sequence, the fault finding may appear after anything up to 40 seconds. To reduce this time, enter : G13* (beep ), then D 1 1

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38

FI21611

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38

The following fault finding is only to be used after a road test causing the ABS warning light to illuminate. The XR 25 must only be connected at the end of the road test, without having switched off the ignition after the test.

CODE PRESENT: ILLUMINATED: CORRECT (extinguishes if key G is used).

If it is extinguished after having entered D11, check: - that the ISO selector switch is in the correct position: S8; - that you are using the correct XR 25 cassette version and the correct code (D11); - that the battery voltage is > 9.4 0.4 volts; - that the ABS 15 A fuse on the relay plate has not blown; - that the computer is in accordance with the vehicle type; - that the R36 connection (black and grey) is correctly connected (next to the battery); - the continuity and insulation of the diagnostic socket/computer connection lines: . track 10, diagnostic socket and 12, computer, via R36 grey track B . track 11, diagnostic socket and 15, computer, via R36 black track B2; - that track 2 of the diagnostic socket is earthed; track 6 to + battery; - that the computer is correctly supplied: Earth on track 3 of 4 track connector, + after ignition at 1 and + before ignition at 2 of same connector. If the fault persists after these checks, replace the computer.

COMPUTER FAULT

FLASHING: STEADY:

Erase memory (GO**) and confirm the fault. Check the 4 and 15 track connectors on the ABS plate and the ABS electronic earth. If the fault persists, replace the computer.

SUPPLY FAULT

Check: - the battery voltage (> 9.4 0.4 volts), - the computer feed voltage using # 06, - connection of the 4 and 15 track connectors on the ABS plate; - presence of earth at track 3 of 4 track connector - presence of + before ignition between terminals 3 and 2 of 4 track connector - presence of + after ignition between terminals 3 and 1 of 4 track connector. If the fault persists after testing replace the computer.

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38

STOP CIRCUIT ILLUMINATED ON LEFT: ILLUMINATED ON RIGHT: CORRECT IF PEDAL DEPRESSED CORRECT IF PEDAL NOT DEPRESSED.

By depressing the brake pedal, check alternating RIGHT/LEFT illumination of bar graph 4. YES NO : Normal circuit operation. : What fault is noted in the operation of bargraph 4 ?

BARGRAPH 4 PERMANENTLY ILLUMINATED ON LEFT : The stop lights are permanently

illuminated. Adjust stop switch or replace if necessary. Otherwise check the wiring downstream from the switch (insulation).
BARGRAPH 4 EXTINGUISHED ON LEFT FOR FULL LOAD: do the stop lights illuminate when the

brake pedal is pressed? NO : Check the condition and adjustment of the stop switch and the 10 A lights fuse. Check connection R35 (dashboard / pedal mounting) : presence of + after ignition on track B1 and the following continuities: - between track B1 and track 3 on the stop switch, - between track A4 and track 1 on the stop switch. : Bargraph 4 should not be illuminated on the right for no load and bargraphs 7, 8, 9 and 10 should be illuminated. There is a break between track 9 of the computer and track A4 of connection R35 (dashboard / pedal mounting) via black connection R36 (ABS/dashboard) track C2.

YES

BARGRAPH 4 EXTINGUISHED ON RIGHT FOR NO LOAD+ BARGRAPHS 7, 8, 9 and 10 ILLUMINATED:

When the brake pedal is depressed, does bar graph 4 illuminate on left? : Stop lights do not illuminate : - the two stop lights bulbs have blown. - there is a poor earth on the stop lights bulbs, - there is a break between track B5 of connection R35 (dashboard / pedal mounting) and track C5 of R1 (dashboard/ rear right). Check the connections on connection R35 and the presence of a shunt between tracks A4 and B5. NON : The stop lights illuminate. There is a break between track 9 of the computer and track A4 of connection R35 (dashboard / pedal mounting) via black connection R36 (ABS/dashboard) track C2. YES

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38

PUMP MOTOR CIRCUIT FAULT BAR GRAPHS 5 + 8, 9 AND 10 ILLUMINATED

Erase the computer memory (G0**). Enter the code for ending fault finding (G13*). Switch the ignition off then on again. Enter code D11 again. Is bar graph 5 illuminated ? - YES : Check the earth of the pump motor (earth wire on motor). Remove the cowling from the hydraulic assembly and check the tightness of the Torx bolt marked "+". If the fault persists, remove the computer plate and feed the pump motor directly (single terminal under plate). Does the pump motor operate? - NO : replace the hydraulic assembly. - YES: replace the computer. : Switch the ignition off, replace the pump motor relay and carry out a road test. Replace the computer if bar graph 5 illuminates again.

- NO

SOLENOID VALVE RELAY CIRCUITS ONLY BAR GRAPH 6 ILLUMINATED OR BAR GRAPHS 6 + 8, 9 AND 10 ILLUMINATED

Replace relay. If the fault persists, replace the computer.

STOP SWITCH FAULT ONLY BAR GRAPH 7 ILLUMINATED OR BAR GRAPHS 7 + 8, 9 AND 10 ILLUMINATED

When the brake pedal is activated, does bar graph 4 illuminate on left? YES : Stop lights do not illuminate : - the two stop lights bulbs have blown. - there is a poor earth on the stop lights bulbs, - there is a break between track B5 of connection R35 (dashboard / pedal mounting) and track C5 of R1 (dashboard/ rear right). Check the connections on connection R35 and the continuity between tracks A4 and B5 (stop switch side). NON : The stop lights illuminate. There is a break between track 9 of the computer and track A4 of connection R35 (dashboard / pedal mounting) via black connection R36 (ABS/dashboard) track C2.

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38

PERMANENT CONTROL SOLENOID VALVES (these bar graphs indicate a status, not a fault) BAR GRAPH 8 FRONT LEFT-HAND SOLENOID VALVE BAR GRAPH 9 FRONT RIGHT-HAND SOLENOID VALVE BAR GRAPH 10 REAR SOLENOID VALVE

Bar graphs 8, 9 and 10 are never illuminated alone under given test conditions:

8 9 10

Bar graphs 8, 9 and 10 illuminated with bar graph 5:. deal with bar graph 5; Bar graphs 8, 9 and 10 illuminated with bar graph 6:. deal with bar graph 6; Bar graphs 8, 9 and 10 illuminated with bar graph 7:. deal with bar graph 7; Bar graphs 8, 9 and 10 illuminated with bar graph 11, 12 or 13: . deal with bar graph 11, 12 or 13; - Bar graphs 8, 9 and 10 illuminated with bar graph 17 or 18: . deal with bar graph 17 or 18.

SOLENOID VALVE CIRCUIT FAULTS BAR GRAPH 11 BAR GRAPH 12 BAR GRAPH 13 FRONT LEFT SOLENOID VALVE

(tracks 1 and 2 of 6 track connector)

FRONT RIGHT SOLENOID VALVE

(tracks 3 and 4 of 6 track connector)

11 12 13

REAR SOLENOID VALVE

(tracks 5 and 6 of 6 track connector) Bar graph 11, 12 or 13 + bar graphs 8, 9 and 10: Check connection of 6 track connector to hydraulic unit. Check resistance of faulty solenoid valve coil. Correct value: approximately 1 . If incorrect, replace hydraulic unit. If correct, replace computer.

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38

17 18

FLH

FRH

WHEEL SENSOR CIRCUIT

RLH RRH

Check connector of faulty sensor. If connector is correct, check resistance of sensor at 20 C If value is other than 1.2 k 0.5, replace sensor.

Check continuities between connector of sensor in question and computer: Front left sensor : track 2 sensor / track 1 sensor / track 2 sensor / track 1 sensor / track 1 sensor / track 2 sensor / track 2 sensor / track 1sensor / 7 computer 13 computer 5 computer 10 computer 6 computer 14 computer 2 computer 4 computer

Front right sensor : Rear right sensor : Rear left sensor :

Check: - the insulation between the two sensor lines. - the quality of the sensor mounting (tightening torque: 9 Nm) - the target / sensor gap over 1 revolution of the wheel in question : Front wheel : 0.40 mm < air gap < 1.20 mm ; Rear wheel : 0.40 mm < air gap < 1.90 mm. After the operation, check the operation of the sensor using functions #01, #02, #03 and #04 of the XR 25: #01: front right wheel speed #02: front left wheel speed #03: rear right wheel speed #04: rear left wheel speed
BAR GRAPH 17 OR 18 FLASHING

Check: mounting of sensor. sensor connections. Check routing and mounting of cables.

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38

INCORRECT TOOTHED WHEEL

19 Check:

- the coherence of the wheel speeds using a dynamic test (use functions #08 and #09 on the XR25), - the quality of the sensor mountings. Check: - the air gaps

Front 0.4 mm < air gap < 1.2 mm Rear 0.4 mm < air gap < 1.9 mm - the conformity of the targets: - condition of the teeth, - 26 tooth target.

20 Present if XR 25 memorisation function in use.

The memorisation function using the XR 25 enables the values of of the various parameters accessible via key # (followed by 2 figures) to be fixed and memorised for future use.

Once communication between the XR 25 and the computer has been established, to obtain this function, enter when required by the user. 0 This memory is erased by entering D 1 1

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DISPLAY OF BAR GRAPHS ON XR 25 AFTER ROAD TEST + SWITCHING IGNITION OFF AND ON

38

Bar graphs 1, 2, 3 and 4 Bar graph 5 flashing Bar graph 6 only or bar graphs 6 + 8/9 and 10 Bar graph 7 Bar graph 8 + 9 and 10 Bar graph 11 or 12 or 13 flashing on right and left hand sides Bar graph 17 or 18 flashing on right or left hand sides Bar graph 19 flashing

: same function as without switching ignition off : as for bar graphs 5 + 8, 9 and 10 without switching the ignition off (ABS warning light is extinguished) : as for bar graphs 6 + 8, 9 and 10 without switching the ignition off (ABS warning light is illuminated) : same function as without switching ignition off : shows ABS system is not operational and a road test is required to determine what component is at fault : as for bar graph 8, 9 and 10 + 11 or 12 or 13 (ABS warning light is extinguished) : as for bar graph 17 or 18 + 8, 9 and 10 (ABS warning light is extinguished)

: as for bar graph 19 without switching ignition off

AFTER REPLACEMENT OF A HYDRAULIC ASSEMBLY:

Check the system using the "G" function on the XR25 : G3* G4* G5* G7* G8*
FRONT LEFT SOLENOID VALVE FRONT RIGHT SOLENOID VALVE REAR SOLENOID VALVE ABS WARNING LIGHT PUMP - MOTOR RELAY

AFTER ANY OPERATION ON THE ABS SYSTEM :

- Re-initialise the system (switch the ignition off then on again), - Carry out a road test then check using the XR25, - Erase the computer memory (G0**). Validate the end of the test : G13*.

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ADDITIONAL TESTS

38

After initialising the system, enter

front right wheel speed (in km/h)

front left wheel speed

rear right wheel speed

rear left wheel speed

battery voltage (volts), example : maximum voltage read = 12.06 (computer voltage regulation)

front left wheel speed (XX) and front right wheel speed (YY) in km/h from 0 to 99 km/h : direct reading > 100 km/h : no hundreds

Same as for #08, for rear wheels

These tests allow : (1) the wheel speeds to be displayed and sensor allocation to be checked (checking of target and sensor pairing), (2) the feed voltage to the solenoid valves after the solenoid valve relay to be displayed.
IMPORTANT: when communication between the computer and the XR25 has been established, the warning

light is illuminated and the ABS function is no longer ensured.

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Command mode
IMPORTANT: to use the command mode, the ABS system must be operational ( no faults present).

38

Hydraulic test : button G (command mode allowing checking of the operation of the solenoid valves)

Lift the vehicle so the wheels may be turned and check they turn freely.

Hold down the brake pedal to prevent the wheel being tested from turning when turned by hand (do not press too hard on the brake to ensure the wheel is at the locking limit.)

Enter

D G

1 3

1 *

The display shows:

Then

The front left wheel releases temporarily (5 times)

Same for

G
and

4 5

* *

Front right wheel solenoid valve

Solenoid valve for rear left and right hand wheels

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

Checking the ABS warning light

38

Enter

the warning light should extinguish for 2 seconds

Checking operation of the relay and pump Enter

the pump motor should operate for 2 seconds

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ERASING THE MEMORY

38

Switch the ignition on but do not start the engine. Enter code D 1 1

The display shows:

then:

Enter :

The display shows:

Validate the erase request using A moment later, the display shows:

The memory has been erased. Validate the end of the test: G 1 3 *

The display shows:

then:

A moment later the ABS warning light should extinguish: (if no faults are apparent). - switch the ignition off - disconnect the XR25 - refit the diagnostic socket cover.

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CHECKING THE WIRING

38

SPECIAL TOOLING REQUIRED

El. 1286

Bornier for testing the wiring using the XR25 or multimeter

This is a base with 15 contacts identical to those on the ABS computer, on a printed circuit with electrical contacts numbered from 1 to 15. Each number corresponds to an electrical connection in the vehicle wiring and is indicated on the diagram on the next page. It is used for quick and accurate testing of all the electrical connections on the main ABS connector.

Connection Ignition off, disconnect the ABS computer from its base and connect bornier El. 1286 in its place. Principle of the testing method Apply the test pin of the XR25 or the multimeter to the numbered indicated on the bornier. Test equipment which may be used XR 25 : - measure continuity using the buzzer, - measure voltage using the voltmeter. Multimeter - measure resistance, - measure voltage.

Solenoid valve coil resistance : approximately 1.2 . Pump / motor coil resistance: approximately 0.5 to 1 . Sensor resistance (at 20C) approximately 1.2 k. Pump / motor relay: Coil resistance approximately 55 . Solenoid valve relay: Coil resistance approximately 55.

96953S

NOTE:

Never disconnect the computer when a voltage is applied to the circuit. Earths and resistances should be measured with the battery disconnected.

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38

DI96913

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

WIRING DIAGRAM KEY

38

Allocation of the 15 track computer connector pins 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ABS warning light Rear left sensor earth Rear left sensor signal Front right sensor earth Rear right sensor signal Front left sensor earth Stop switch Front right sensor signal Diagnostic line L Front left sensor signal Rear right sensor earth Diagnostic line K

Components: 104 Ignition switch 107 Battery 118 ABS computer 150 Rear right wheel sensor 151 Rear left wheel sensor 152 Front right wheel sensor 153 Front left wheel sensor 160 Stop switch 172 Rear right light 173 Rear left light 225 Diagnostic socket 247 Instrument panel 260 Fuse box 361 "ABS" hydraulic assembly 425 ABS plate

Connections: R1 Dashboard/rear right R35 Dashboard/ pedal mounting R36 ABS / Dashboard(grey and black) Earth: ME Bodywork earth Resistance of the solenoid valve coils: approximately 1.2
94716R

Resistance of the sensors (at 20C) : approximately 1.2 k

NOTE:

Never disconnect the computer when a voltage is applied to the circuit. Earths and resistances should be measured with the battery disconnected.

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CONNECTORS

38

Connection R36 black (2) R36 grey (1) R35 black R1 brown

Allocation ABS/dashboard dashboard/ pedal mounting dashboard/rear right

Location on the vehicle Next to the battery (see diagram below)

Passenger compartment front left pillar Passenger compartment front right pillar

96956R

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

Allocation of diagnostic socket terminals

38

Position of the relays on the computer plate

94640R

A B
88113S

Solenoid valve relay Pump / motor relay

4 track connector (361) on computer plate 1 2 3 4 5 6 7 8 9 10 11 AT A4 diagnostic connection Earth Mechanical foolproofing Not used Not used + 12 V after ignition
AT M diagnostic information

To electronic fault warning light Injection fault finding information Diagnostic line "L" (ABS) Diagnostic line "K" (ABS)

DI3892

1 2 3 4

+ after ignition (UZ) + before ignition (Bat +) Earth (-) ABS warning light (Sila)

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REMOVING - REFITTING THE COMPONENTS 1 - FRONT WHEEL SENSOR

38

TIGHTENING TORQUES (in daN.m)

Wheel bolt Sensor mounting bolt

9 0.8 to 1

REMOVAL

Remove: - the wheel, - the sensor mounting bolt.

96953-1R

Front left speed sensor connector (A).

94868S

Release the wire from the mountings. Disconnect the connector on the side of the shock absorber turret in the engine compartment.
96956-1R

Front right speed sensor connector (B). Remove the sensor.

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2 - REAR WHEEL SENSOR

38

TIGHTENING TORQUES (in daN.m)

Wheel bolt Sensor mounting bolt

9 0.8 to 1

REMOVAL

Remove: - the wheel, - the sensor mounting bolt (1), - the sensor from its mounting.

96954S

REFITTING THE SENSORS (front or rear)

Fit the sensor after coating it in Multipurpose grease Part Number 77 01 422 308 then clip the wire into its mountings and reconnect it. Check the recommended air gap over one revolution of the wheel using feeler gauges.

NOTE : ensure the connector is correctly connected, to avoid the risk of faults.

96955R

Release the wire from its mountings. Disconnect the sensor from its connector located under the vehicle, near the left hand mounting for the rear axle assembly.

The sensor must be fitted by hand. Do not hit it during fitting. Do not pull or push on the wiring.

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3 - FRONT WHEEL TARGET 4 - REAR WHEEL TARGET Target (4) embedded in the hub (cannot be removed).

38

TIGHTENING TORQUES (in daN.m)

Wheel bolt Driveshaft nut

9 24 to 26

The target is embedded in the driveshaft so this operation takes place after removal of the driveshaft.
REMOVAL

Extract the target using an extraction tool on the press.

94862-1R

91663S

REFITTING

Coat the target with Loctite SCELBLOC and refit it using a mallet, tapping progressively on the outside of the target. Take care to tap evenly to avoid the target twisting and check it is correctly fitted in the driveshaft. NOTE: The Parts Department supplies machined driveshafts without the ABS target. The target must therefore be retained to refit to a new driveshaft. Separate targets are however also available from the Parts Department.

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5 - COMPUTER
TIGHTENING TORQUES (in daN.m)

38

Remove the 6 mounting bolts and remove the computer - relay plate.

Computer mounting bolt

REMOVAL

1.5

Disconnect the battery. Remove the upper cover.

94640S

REFITTING

Ensure the plate mounting bolts are correctly + which tightened, especially bolt (D) marked ensures the + 12 Volts feed to the pump motor. Take care to ensure the wiring is correctly routed. Check the system using the G functions on the XR25 .
94865S

Disconnect: - the 4 track connector (1), - the 15 track connector (2), - the 6 track connector (3).

Carry out : - a road test then check using the XR25, - erase the computer memory (G0**). Validate the end of the test : G13*.

DI3892R

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6 - HYDRAULIC ASSEMBLY

38

Remove the 3 hydraulic assembly mounting bolts. Remove the hydraulic assembly / mounting assembly. Plug the assembly openings.
REFITTING

TIGHTENING TORQUES (in daN.m)

Pipe bolts

1.2 to 1.6

REMOVAL

Disconnect the battery. Remove: - the air filter unit, - the strap retaining the cooling circuit reservoir bottle and move it to one side. Disconnect the 15 track connector. Remove the upper cover. Disconnect: - the 4 track connector, - the 6 track connector. Release the 3 mounting bolts on the hydraulic assembly mounting (necessary to remove the master cylinder).

Fit the hydraulic assembly ensuring the pipes are correctly located.

DI3893

VL VR HL HR

Front left (yellow) Front right (green) Rear left (blue) Rear right (red)

Connect the connectors. Fit: - the upper cover, - the earth wire on the pump / motor. Ensure the wiring and connections are correctly routed. Refit the master cylinder and bleed the hydraulic circuit, following the order of operations (see following page).
NOTE : never reconnect the battery and switch

96953-1S

Remove the master cylinder. Slacken the 4 unions on the hydraulic assembly, using a pipe wrench. Disconnect the earth wire on the pump motor.

the ignition on unless the complete hydraulic circuit has been fully bled.

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BLEEDING
IMPORTANT

38

The order of operations for bleeding the ABS hydraulic circuit MUST be observed: 1 2 3 4 Front left wheel caliper Front right wheel caliper Rear left wheel caliper Rear right wheel caliper

94917R

The anti-lock system should never be made to operate if the system has not been bled. If the return pump takes in air, it is extremely difficult, if not impossible to bleed it. For this reason, the hydraulic assembly supplied by the Parts Department is supplied filled with brake fluid.

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BLEEDING USING A BLEEDING KIT BLEEDING WITHOUT A BLEEDING KIT

38

Connect the bleeding kit to the brake fluid reservoir. 1. Attach the tube to the bleed screw of the corresponding wheel cylinder. Open the corresponding bleed screw and wait until the fluid flowing out contains no bubbles (approximately 30 seconds). Shut the bleed screw.

The sequence of operations is the same as opposite and must also be followed. Connect the tube to the bleed screw of the corresponding wheel cylinder. Open the bleed screw in question. Depress the pedal several times until there are no more bubbles. During the bleeding procedure, make sure that the fluid level is always between minimum and maximum marks.

It is essential to follow the sequence of bleeding operations: a) Bleed, from the master cylinder towards front left; b) from the master cylinder towards front right; c) from the master cylinder towards rear left; d) from the master cylinder towards rear right. b) Follow the bleeding procedure using the pedal, making sure that the brake fluid level is always between minimum and maximum marks, during the procedure. The sequence of operations given under 1) must also be carefully followed. Connect the tube to the bleed screw of the corresponding wheel cylinder. Open the bleed screw in question. Depress the pedal approximately 20 times. Check and top up the brake fluid level as necessary.

COMPENSATOR CONTROL (Special notes)

When the vehicle is with its wheels "hanging free", this type of control allows force to maintained at the lever so the compensator remains with the "valves open" during the bleeding operation.

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ADDITIONAL TESTS 1 - TARGET / SENSOR GAP

38

2 - CHECKING THE WHEEL SENSOR CONNECTORS If the ABS warning light illuminates intermittently, first check the wheel sensor connectors and clean them with NETELEC Part Number 77 01 408 464.

(Position the target so that the top of one tooth is parallel to the sensor). Front sensor: X = 0.40 to 1.20 mm

DI3894

96954S

Rear sensor: X = 0.40 to 1.90 mm

NOTE:

When disconnecting the connectors, avoid using a sharp tool which could damage the retaining lugs on the 2 parts of the connector. Take care to observe the correct wiring routing and connections (the reliability of the ABS system depends on this).

96955-1S

Sensor resistance : approximately 1.2 k

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

Hydraulic assembly pipe markings

38

DI3893

VL VR HL HR

: : : :

Front left Front right Rear left Rear right

(yellow) (green) (blue) (red)

For obvious safety reasons, never incorrectly connect the sensor connectors or the hydraulic assembly pipes.

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COMPENSATOR OPERATING PRINCIPLE

38

These vehicles are fitted with a load sensitive compensator. The pressure is read in an X pattern, by comparison between the pressure at the rear wheels and a given pressure at the front wheels. These dual compensators have two totally separate bodies which operate in an X pattern on one front wheel and one rear wheel. Both circuits must be checked: - I : front right/ rear left - II : front left/ rear right

On the load sensitive compensators, the adjustment allows the rear pressure to be altered in relation to the front pressure. The adjustment acts simultaneously on both bodies. If the pressure is incorrect on one of the two bodies, replace the compensator.

85925S

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

38

Vehicle type

Fuel tank (driver on board)

Test pressure (Bar) Front Rear +0 -4

All types with fixed compensator integrated in the wheel cylinder

60

34

B, C, L

533 53C 53Y 534 53J 53K

With ABS (after 05/92)

B, C, L

53T 53V 53Z

With ABS

3, 4, 5

53A 53B 53F

With ABS

90966S1

Full

100

40

+0 -8

B, C, L, S

53F 538 53K 53T 53Z

Without ABS (after 11/94)

3, 4, 5

53C 53D 53H

Without ABS (after 11/94)

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

38

Vehicle type

Fuel tank (driver on board)

Test pressure (Bar) Front Rear +0 -8

B, C, L, D

539 53D

(before 05/92)

100

47

B, C, L

53A 535 53B 538

With ABS

B, C, L

53F

With ABS (after 05/92)

100

52

+0 -8

3, 4, 5

53C 53D 53H

With ABS

90966S1

D53D (after 05/92 853C

Full

B, C, L, S

53F 538 53K 53T 53Z

Without ABS (after 11/94) +0 -8

100 3, 4, 5 53C 53D 53H Without ABS (after 11/94)

49

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

38

Vehicle type

Fuel tank (driver on board)

Test pressure (Bar) Front Rear

B, C, L, D, S

533 53C 53F 534 53J 53K 53Y

With ABS (before 05/92)

100

43

+0 -8

B, C

D53M

ABS

B, C, L

53D

(after 05/92)

90966S1

Full

53C 53Y

With ABS (after 05/92)

100

52

+0 -8

D 8

53V 53A 53F

With ABS

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38

Checking and adjustment of the braking compensator must be carried out with the vehicle on the ground and one person on board.

SPECIAL TOOLING REQUIRED

Fre.

1085

Pressure gauge for checking brake limiter adjustment

As the compensator has two separate bodies, one must be checked after the other.

If the difference is great (values exceed tolerances), replace the compensator; no operations are permitted.

CHECKING

Connect two pressure gauges Fre. 1085 : - one at the front left, - one at the rear right. Bleed the circuit (the pressure gauge is bled through screw P).

ADJUSTMENT

94589R

Slacken nut (A) and move adjuster (N) to tighten or slacken the spring (R) until the correct value is obtained.

94593R

Progressively press the brake pedal to obtain the adjustment pressure for the front wheels (see table of values). Read the corresponding pressure for the rear wheels and correct it if necessary. Carry out the same process on the other circuit.

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REPLACING THE COMPENSATOR

38

The Parts Department supplies pre-set compensators fitted with a spacer. Ensure: - the vehicle meets the conditions for adjusting, - fit the new compensator in position. Slacken nut (A). Attach the spring loop (R) to the suspension. Press lever (L) and tighten the adjuster (N) until it touches the lever. Tighten the lock nut (A). Remove the spacer (E). Bleed and check the circuit (see "Checking Adjusting").

94641R

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

38

BOSCH 2E ABS FAULT FINDING CHART

FAULTS NOTED IN THE OPERATION OF THE ABS WARNING LIGHT

1 - When the ignition is turned on 1.1 - The warning light does not illuminate 1.2 - Permanent illumination of the warning light 1.3 - The warning light is dimly illuminated 1.4 - The warning light flashes 1.5 - The warning light illuminates again after a delay (after 5 seconds)

2 - When the engine is started 2.1 - The warning light does not extinguish 2.2 - The warning light illuminates again 2.3 - The warning light flashes

3 - When the vehicle first moves off 3.1 - The warning light illuminates when the vehicle starts moving 3.2 - The warning light flashes when the vehicle starts moving

4 - During braking with ABS regulation 4.1 - The warning light illuminates when ABS regulation is complete 4.2 - The warning light flashes during ABS braking 4.3 - The warning light illuminates during ABS braking 4.4 - The warning light illuminates after a delay when ABS regulation is complete 5 - While driving The warning light illuminates

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38

BOSCH 2E ABS FAULT CHART

FAULTS NOTED IN ABS OPERATION WITHOUT ILLUMINATION OF THE WARNING LIGHT

1 - One or more wheels lock

2 - Direction not maintained 2.1 - Pulling to one side 2.2 - Wandering

3 - Unexpected ABS operation 3.1 - When first moving off at 6 km/h (3.75 mph) (after the engine has been started) 3.2 - While driving 3.2.1 at low speeds / pedal only slightly depressed 3.2.2 on poor road surfaces 3.2.3 when using special equipment (car phone, CB...) 3.2.4 other cases connected with the external environment 4 - Reactions felt at the brake pedal 4.1 - Hard pedal 4.2 - Spongy pedal 4.3 - Long pedal travel 4.4 - Vibrations /jerky pedal operation

5 - Noises From the pump, the hydraulic assembly or the hydraulic pipes.

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1 Faults noted in the operation of the ABS warning light 1 - When the ignition is turned on 1.1 - The warning light does not illuminate

38

Connect the XR25 to the vehicles diagnostic socket. Set the ISO switch to position S8 and use the latest XR25 cassette . Enter code D11 on the keyboard. Does the warning light illuminate after the initialisation period ? (5 seconds) no Is bargraph 1 illuminated ? yes Check the continuity of the 2 warning light lines : between the warning light and track 4 of the 4 track connector on the hydraulic assembly and between the warning light and track 1 of the 15 track computer connector. Also check the 10 A fuse and the bulb. Does the fault still persist? yes Earth track 4 of the 4 track connector for the hydraulic assembly or track 1 on the 15 track connector. Does the warning light illuminate? no Recheck your diagnosis yes The warning light circuit is correct. Replace the computer. Does the fault persist? no Correct yes Recheck your diagnosis no Correct

yes

Use function G7* on the XR25. Does the warning light extinguish for 2 seconds ? yes Recheck your diagnosis no Replace the computer

no

Communication fault between the XR25 and the ABS computer. Check the battery voltage (> 9.4 0.4 volts) and the 15 A fuse on the accessories board. Check for an earth on track 2 on the diagnostic socket and + before ignition on track 6. Check the insulation from earth of the lines between the computer and the diagnostic socket as well as the continuity of these lines : - between track 10 on the diagnostic socket and track 12 on the computer and - between track 11 on the diagnostic socket and track 15 on the computer. Check the connection of the 2 connectors R36 (ABS/dashboard) and the computer feed on the 4 track connector : - earth on track 3, - + after ignition on track 1, - + before ignition on track 2. After repair, re-enter code D11. Does the warning light illuminate after the initialisation period ? (5 seconds) yes no Recheck your diagnosis

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

1 Faults noted in the operation of the ABS warning light

38

1 - When the ignition is turned on 1.2 - Permanent illumination of the warning light

Connect the XR25 to the vehicles diagnostic socket. Set the ISO switch to position S8 and use the latest XR25 cassette . Enter code D1 on the keyboard. Are only bargraphs 1 and 4 illuminated ? (normal situation with no fault)

no

Locate the fault corresponding to the fault bargraph and repair. Road test the vehicle and retest with the XR25. Is a new fault shown ?

no

yes

yes yes Use function G7* on the XR25 and watch the ABS warning light. Does it extinguish for about 2 seconds ? no Does the fault persist? no yes Correct

Check: - battery voltage ( > 9.4 0.4 volts), - the insulation of the two warning light circuit lines : - between the warning light and track 4 on the 4 track connector and - between the warning light and track 1 on the 15 track connector . Check the 2 connections ABS/dashboard R36. (One of these lines may be earthed). After repair, does the fault persist ? no yes

Correct

Replace the computer

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

1 Faults noted in the operation of the ABS warning light 1 - When the ignition is turned on 1.3 - The warning light is dimly illuminated

38

Connect the XR25 to the vehicles diagnostic socket. Set the ISO switch to position S8 and use the latest XR25 cassette . Enter code D11 on the keyboard. Are only bargraphs 1 and 4 illuminated ? (normal situation with no fault)

no

Locate the fault corresponding to the fault bargraph and repair. Road test the vehicle and retest with the XR25. Is a new fault shown ?

no

yes

yes

yes

Does the fault persist?

Check the insulation of the two warning light circuit lines : - between the warning light and track 4 on the 4 track connector and - between the warning light and track 1 on the 15 track connector . (One of these lines may be earthed). Also check the condition of the ABS earths and the 4 and 15 track connectors. After repair, does the fault persist ?

no

Correct

Correct

Replace the computer

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

1 Faults noted in the operation of the ABS warning light 1 - When the ignition is turned on 1.4 - The warning light flashes

38

Connect the XR25 to the vehicles diagnostic socket. Set the ISO switch to position S8 and use the latest XR25 cassette . Turn the ignition on and enter code D11 on the keyboard. Does bargraph 1 remain illuminated ?

Communication fault between the XR25 and the ABS computer no Check the wiring for diagnostic lines K and L (earth). Does the fault persist?

yes yes

no

Correct Are only bargraphs 1 and 4 illuminated ? (normal situation with no fault) yes

no

Locate the fault corresponding to the fault bargraph and repair. Road test the vehicle and retest with the XR25. Is a new fault shown ?

no

yes

Does the fault persist?

yes

no

Check the insulation of the two warning light circuit lines : - between the warning light and track 4 on the 4 track connector and - between the warning light and track 1 on the 15 track connector . (One of these lines may be earthed). Also check the condition of the ABS earths and the 4 and 15 track connectors. After repair, does the fault persist ? no yes

Correct

Correct

Replace the computer

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS Bosch ABS

1 Faults noted in the operation of the ABS warning light 1 - When the ignition is turned on 1.5 - The warning light illuminates again after a delay (after 5 seconds)

38

Connect the XR25 to the vehicles diagnostic socket. Set the ISO switch to position S8 and use the latest XR25 cassette . Turn the ignition on and enter code D11 on the keyboard. Bargraph 5 should be illuminated to show a fault in the pump motor circuit.

2 - When the engine is started 2.1 - The warning light does not extinguish

As for 1.2

2 - When the engine is started 2.2 - The warning light illuminates again

Connect the XR25 to the vehicles diagnostic socket. Set the ISO switch to position S8 and use the latest XR25 cassette . Enter code D11 on the keyboard. Are only bargraphs 1 and 4 illuminated ? (normal situation with no fault)

no

Locate the fault corresponding to the fault bargraph and repair. Road test the vehicle and retest with the XR25. Is a new fault shown ?

no

yes

yes yes Incorrect contact between connectors. Battery voltage too low (< 9.4 0.4 volts). Does the fault persist? no Correct

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1 Faults noted in the operation of the ABS warning light

38

2 - When the engine is started 2.3 - The warning light flashes

As for 1.4

3 - When the vehicle first moves off 3.1 - The warning light illuminates

As for 1.3

3 - When the vehicle first moves off 3.2 - The warning light flashes

As for 1.4 and 2.3

4 - During braking with ABS regulation 4.1 - The warning light illuminates when ABS regulation is complete

XR25

For verification of feed in particular.

If the fault persists, check the battery voltage (minimum : 9.4 0.4 volts) and check the wiring.

4 - During braking with ABS regulation 4.2 - The warning light flashes during ABS braking

As for 4.1

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1 Faults noted in the operation of the ABS warning light

38

4 - During braking with ABS regulation 4.3 - The warning light illuminates during ABS braking

XR25

Check the wiring (intermittent breaks in the circuit).

If the fault persists: there is probably some external interference.

4 - During braking with ABS regulation 4.4 - The warning light illuminates after a delay when ABS regulation is complete

XR25

5 - While driving The warning light illuminates

XR25 If the fault persists: there is probably some external interference.

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2 Faults noted in ABS operation without illumination of the warning light

38

1 - One or more wheels lock

Reminder: the locking of the wheels on a vehicle fitted with ABS or tyre squeal which the customer takes to be the wheels locking may be part of a normal system reaction and should not be automatically considered as a fault : - wheel permitted to lock below 1.72 mph (2.75 km/h) (system is not active), - ABS regulated braking on very poor road surfaces (high degree of tyre squeal).

On the other hand, if the wheel(s) are actually locking, lift the vehicle so the wheels may be turned and check : - for a possible inversion of the wheel sensor connectors. Use functions #1 #2 #3 and #4 while turning the appropriate wheel and check the coherence of the results obtained. If no speed is shown on the XR25, turn the other wheels to confirm the sensor connectors have been incorrectly connected and then reconnect them correctly. - Check for a possible incorrect connection of the pipes on the hydraulic assembly. Use functions G3* G4* and G5* while pressing the brake pedal and check for temporary releasing of the brakes on the wheel or wheels in question. If the 5 cycles are not performed on the wheel being tested, (wheel free to turn during the test), check the cycles are not being applied to another wheel (confirms the hydraulic pipes are incorrectly connected). If the 5 cycles are not performed on another wheel and the pipes are correctly connected, replace the hydraulic assembly. Also check the sensor / target air gap over one turn of each wheel : Front wheels : 0.4 mm < air gap < 1.2 mm Rear wheels : 0.4 mm < air gap < 1.9 mm If the fault persists, replace the hydraulic assembly.

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2 Faults noted in ABS operation without illumination of the warning light

38

2 - Direction not maintained 2.1 - Pulling to one side

Remove the ABS fuse from the accessories board and carry out a road test with the ABS non-operational. Does the fault persist under these conditions?

yes

no

If the pedal travel is relatively long, bleed the braking circuit following the recommended order. If pedal travel is correct, check the tyre inflation pressures, the front axle assembly or check for a possible leak in the braking circuit.

Lift the vehicle so the wheels may be turned and check : - for a possible inversion of the wheel sensor connectors. Use functions #1 #2 #3 and #4 while turning the appropriate wheel and check the coherence of the results obtained. If no speed is shown on the XR25, turn the other wheels to confirm the sensor connectors have been incorrectly connected and then reconnect them correctly. - Check for a possible incorrect connection of the pipes on the hydraulic assembly. Use functions G3* G4* and G5* while pressing the brake pedal and check for temporary releasing of the brakes on the wheel or wheels in question. If the 5 cycles are not performed on the wheel being tested, (wheel free to turn during the test), check the cycles are not being applied to another wheel (confirms the hydraulic pipes are incorrectly connected). If the 5 cycles are not performed on another wheel and the pipes are correctly connected, replace the hydraulic assembly. Also check the sensor / target air gap over one turn of each wheel : Front wheels : 0.4 mm < air gap < 1.2 mm Rear wheels : 0.4 mm < air gap < 1.9 mm If the fault persists, replace the hydraulic assembly.

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2 Faults noted in ABS operation without illumination of the warning light

38

2 - Direction not maintained 2.2 - Wandering Remove the ABS fuse from the accessories board and carry out a road test with the ABS nonoperational. Does the fault persist under these conditions? no Normal behaviour caused by the ABS system during the regulation phase, especially for non-symmetrical adherence or poor road surfaces.

yes

Roadholding fault not connected with the ABS system

3 - Unexpected ABS operation 3.1 - When first moving off at 6 km/h (3.75 mph) (after the engine has been started)

System reaction for checking of various components felt at the brake pedal as vibration : normal operation.

3 - Unexpected ABS operation 3.2 - While driving 3.2.1 At low speeds or when pedal only slightly depressed

Connect the XR25 to the vehicles diagnostic socket. Set the ISO switch to position S8 and use the latest XR25 cassette . Turn the ignition on and enter code D11 on the keyboard. Are only bargraphs 1 and 4 illuminated ? (normal situation with no fault) yes

no

Locate the fault corresponding to the fault bargraph and repair. Turn the ignition off and on again. Is a new fault shown ?

no

yes

It is possible that vibration being felt at the brake pedal is due to the system reacting to the following particular conditions : - crossing speed bumps, - going round a tight bend where the rear inside wheel lifts off the ground. If the problem is different, check the speed sensor connectors (micro breaks in the circuit) and check the air gaps.

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2 Faults noted in ABS operation without illumination of the warning light

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3 - Unexpected ABS operation 3.2 - While driving 3.2.2 On poor road surfaces

On poor road surfaces it is normal to feel jerky operation and vibration of the brake pedal as well as increased tyre squeal compared to driving on good road surfaces. The resulting impression of variation in the efficiency of the system is normal.

3 - Unexpected ABS operation 3.2 - While driving 3.2.3 When using special equipment (car phone, CB ...)

Check that this equipment has been correctly fitted and the original wiring, in particular for the ABS system, has not been altered.

3 - Unexpected ABS operation 3.2 - While driving 3.2.4 Other cases connected with the external environment

When driving near to radars, radio emitters or in areas where there is a large amount of metal, the ABS system may be affected by interference. The driver may be surprised by unexpected regulation felt at the brake pedal.

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2 Faults noted in ABS operation without illumination of the warning light 4 - Reactions felt at the brake pedal 4.1 -Hard pedal

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Remove the ABS fuse from the accessories board and carry out a road test with the ABS nonoperational. Does the fault persist under these conditions? no

yes

Fault is not in the ABS system

Check the speed sensor connectors for micro cut-outs in the circuit and check the air gaps over one turn of the wheel : Front wheels: air gap between 0.4 and 1.2 mm Rear wheels : air gap between 0.4 and 1.9 mm

4 - Reactions felt at the brake pedal 4.2 - Spongy pedal

There is air in the braking circuit. Bleed the circuit following the special order for bleeding at the wheels. After the operation does the fault persist or has the pedal travel been extended? yes

no

Correct

Air in the piston plunger. Carry out a specific bleeding operation for this fault. Does the fault persist after this second bleeding operation? yes Replace the hydraulic assembly

no

Correct

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2 Faults noted in ABS operation without illumination of the warning light

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4 - Reactions felt at the brake pedal 4.3 - Long pedal travel

Air in the primary braking circuit. Bleed following the manufacturers instructions.

4 - Reactions felt at the brake pedal 4.4 - Vibrations and/or jerky pedal operation

Reaction at the brake pedal due to self testing of various components at 3.75 mph (6 km/h) when the vehicle first moves away, or during an ABS regulation phase.

5 - Noises From the pump, the hydraulic assembly or the hydraulic pipes

- Assembly vibration : check the presence and condition of the assembly rubber mountings. - Pipe vibration: check that all the pipes are correctly clipped into their mounting hooks and they do not touch each other or neighbouring components. To determine what is causing the noise, the functions G3* G4* and G5* on the XR25 may be used.

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