4 AS ELECTRIC SYSTEM re 55.308 ABS SYSTEM (BOSCH 5.3 ABS with "EBD") INHALTSVERZEICHNIS ELEKTRISCHES SCHALTBILD .......... oe sae . .. 39B-2 ALLGEMEINE BESCHREIBUNG . . oa : eer . 398-3 FUNKTIONSBESCHREIBUNG........- Bee cet 398-3 KOMPONENTEN UND VERBINDER ee eee cee. SOB ANORDNUNG DER KOMPONENTEN... 2-0. 022 ee ee ee + 39B6 DEFEKTSUCHE pee govegnoo000000u00 398-7 From Model Year ’98 replaces the pre- vious 5.3 system. 4493000000009 ote 12.1997—) U — ELECTRIC SYSTEM DIAGNOSIS 5 55.308 An Al ABS WIRING DIAGRAM PA493000000012 -2- 2.1999ELECTRIC SYSTEM DIAGNOSIS ABS 55-398 GENERAL DESCRIPTION The electronic anti wheel locking systen (BOSCH 5.3 ABS) adjusts the braking pressure transmitted to the wheels preventing lack of grip under all conditions of the tyres and road surfaces. In this version, the control unit also controls dis- tribution of the braking load also on the rear axle, replacing the mechanical braking distributor used previously ("EBD" function: Electronic Brake Dis- tribution”). ‘The system has been designed to integrate and not replace the normal mechanical braking sys- tem, thereby ensuring effective safety in the event of faults: the device works on the same brake fluid as the conventional, mechanical circuit. Four sensors, on the four wheels, constantly signal to the electronic contro! unit the speed of each wheel, thus recording wheel locking, skidding and loss of grip conditions. In these situations the control unit suitably controls the solenoid valves which modulate the pressure in the hydraulic circuit, eliminating locking and bringing the vehicle back to the grip limit, which makes it possible to obtain the shortest braking distance possible, with- out losing control over steering. In this version of the system there are two adjustment solenoid valves (one for pressure load and one for pressure relief) for each wheel. For further details on how the hydraulic system works, see GROUP 33-BRAKES. Components The system comprises: —four magnetic induction sensors which read the speed of the wheels: L28; L29; L30; L31 ‘The sensors are of the “active” type, i.e. they contain a Hall-effect pick-up device which faces a magnetic coder integrated in the hub bearing: in these condi- tions, the signal is less affected by electromagnetic interferences and by temperature, ~ the integrated electronic and hydraulic control unit N51, which houses the following: + the electronic control module (CPU) + eight solenoid valves + two brake fluid pumps with associated motor + two damping accumulators and two reservoirs + asafety valve ~ the standardised corinector for self-diagnosis T20 = the brake switch H3 (the same one that tums on the braking lights) which signals the braking condition to the system. PA493000000012 ‘The ABS includes a sell-diagnosis system which con- tinuously keeps all the system components and par- ‘meters under controt:in the event of faults or failures, the system cuts itself off automatically, while however leaving the conventional mechanical power-assisted system operational: the driver is alerted of this situ- ation by the special "ABS" €) warning light on the instrument cluster (C10). This telltale light is the so-called "intelligent" type: : it turns on not only ifthe system detects an anomaly, but also in cases of lack of contact or short circuit to earth of the circuit that connects the telltale light to the relative control unit thanks to a special internal pilot circuit which checks proper connection. ‘A fault in the "EBD" function turns on the "handbrake on* warning light (2. Connector T8 also allows connection to the system with the Diagnosis tools available for the Service Network. FUNCTIONAL DESCRIPTION System supply: With a line protected by fuse F15 of the fusebox G1, the "key-operated" voltage supplies pin 15 of the AB control unit N51, the battery voltage reaches pin 17 and 18 of N51 from the line protected by wander fuse G125b (60A). The electronic contro! unit is connected to earth via pin 19 of N51, while the pump is earthed through pin 16. Sensors and solenoid valves The module is connected, directly inside the contro! unit N51, with the adjustment solenoid valves, which modulate the pressure on the brakes of the four wheels; outside it is connected with the four sensors L28 - L29- L30- L31 (pin 3-4, 6-7, 1-2 and 8-9) which signal the speed of the single wheels, and with the brake switch H3. (pin 14) which sends an enable signal: in fact, operation of the ABS system is cut offi the brake pedal is not pressed. Self-diagnosis: When the contro! unit detects problems through the self: diagnosis function associated with the "ABS" system, it sends a signal to the instrument cluster C10 which turns on the "ABS failure" warming light: this signal is sent from pin 20. If the problems involve the "EBD" function, the hand- brake warning light is turned on, from pin 21 The diagnosis connector T8 connected to pin 11 and 12 allows connection of the control unit with the diag- nosis tools of the Service Network, 21999SI = ELECTRIC SYSTEM DIAGNOSIS 55 lea) ABS -39B COMPONENTS AND CONNECTORS Instrument cluster ad Fusebox |e WHT-BUX + GI2¢ ~<-WHT-BLK 4 UIB-WT +5224 258LK-ED + — 18K K+ GSD) ‘ABS system connector Giza rar CE 3 ee0-ou if vaw-auk- CSD 2 war-aux» Cash) ‘ABS system fuse | Kar xe0- GD «0-5 cD. GD) ko seo Pasga00000001. <4 2.1999145 ELECTRIC SYSTEM DIAGNOSIS 55.398 ABS GENERAL DESCRIPTION The electronic anti wheel locking systen (BOSCH 5.3 ABS) adjusts the braking pressure transmitted to the wheels preventing lack of grip under all conditions of the tyres and road surfaces. In this version, the control unit also controls dis- tribution of the braking load also on the rear axle, replacing the mechanical braking distributor used previously ("EBD* function: Electronic Brake Dis- tribution"). The system has been designed to integrate and not replace the normal mechanical braking sys- tem, thereby ensuring effective safety in the event of faults: the device works on the same brake fluid as the conventional, mechanical circuit. Four sensors, on the four wheels, constantly signal to the electroni¢ control unit the speed of each wheel, thus recording wheel locking, skidding and loss of grip conditions. In these situations the control unit suitably controls the solenoid valves which modulate the pressure in the hydraulic circuit, eliminating locking and bringing the vehicle back to the grip limit, which makes it possible to obtain the shortest braking distance possible, with- out losing control over steering, Inthis version of the system there are two adjustment solenoid valves (one for pressure load and one for pressure relief) for each wheel. For further details on how the hydraulic system works, see GROUP 33-BRAKES, Components ‘The system comprises: ~four magnetic induction sensors which read the speed of the wheels: L28; L29; L30;L31. From chassis no.__ the sensors aré of the “active” type. i.e. they contain a Halleffect pick-up device which faces a magnetic coder integrated in the hub bearing: in these conditions, the signal is less at- fected by electromagnetic interferences and by tem- perature. = the integrated electronic and hydraulic contro! unit N51, which houses the following: + the electronic control module (CPU) + eight solenoid valves + two brake fluid pumps with associated motor + two damping accumulators and two reservoirs + a safety valve ~ the standardised connector for self-diagnosis T20 4493000000010 = the brake switch H3 (the same one that turns on the braking lights) which signals the braking condition to the system. The ABS includes a self-diagnosis system which con- tinuously keeps all the system components and par- ameters under control: in the event of faults or failures, the system cuts itself off automatically, while however leaving the conventional mechanical power-assisted system operational: the driver is alerted of this situ- ation by the special "ABS" (2) warning light on the instrument cluster (C10), ‘A fault in the "EBD" function turns on the “handbrake on warning light #3) Connector 720 also allows connection to the system with the Diagnosis tools available for the Service Network. FUNCTIONAL DESCRIPTION System supply: With a line protected by fuse F15 of the fusebox G1, the "key-operated” voltage supplies pin 15 of the AB control unit N51, the battery voltage reaches pin 17 and 18 of N51 from the line protected by wander fuse G125b (60) The electronic control unit is connected to earth via pin 19 of N51, while the pump is earthed through pin 16. Sensors and solenoid valves The module is connected, directly inside the control unit NS1, with the adjustment solenoid valves, which modulate the pressure on the brakes of the four wheels; outside it is connected with the four sensors L28-L29 - L30- L31 (pin 3-4, 6-7, 1-2 and 8-9) which signal the speed of the single wheels, and with the brake switch H3 (pin 14) which sends an enable signal: in fact, operation of the ABS system is cut off it the brake pedal is not pressed. Self-diagnosi ‘When the control unit detects problems through the sel!- diagnosis function associated with the "ABS" system, ii sends a signal to the instrument cluster C10 which turns on the "ABS failure’ warning light: this signal is sent from pin 20. It the problems involve the "EBD" function, the hand- brake warning light is tured on, from pin 21 The diagnosis connector T20 connected to pin 11 allows connectioh of the control unit with the diagnosis tools of the Service Network 1-198145 ELECTRIC SYSTEM DIAGNOSIS ABS 55.398 COMPONENTS AND CONNECTORS Instrument cluster Fusebox ed WAT~BLK» 6126 <> WeT-BUK 4D r Urb 24 LH engine compartment earth oP S&S 288tK-RED = CHE) ~O— 48K ABS system connector | Giza aya H+ Law Go) B ‘ABS system fuse o@> «200-101 ko 0 Paa93000000009 4 12-1997“A ELECTRIC SYSTEM DIAGNOSIS U Z, ABS 55-39 B COMPONENTS AND CONNECTORS (cont.d) Brake light switch |_ CHS _|_ RH front phonic whee! inductive sensor ‘reo-cen- CD) A a/ LH front phonic wheel inductive sensor IH rear phonic wheel inductive sensor (*) (*) sac (H rear phonic whee! industve sensor | CSD | Standardised diagnosis connector eux-BLU +6124 (#) ABS control unit wD (*) Version with "ACTIVE SENSORS" PAa93000000010 “5+ 1-1984 Al = ELECTRIC SYSTEM biacnose 55.398 LOCATION OF COMPONENTS 4493000000008 -6- 12.1997{AS ELECTRIC SYSTEM DIAGNOSIS 55-398 ABS COMPONENTS AND CONNECTORS (cont.d) Brake light switch o> FH front phonic wheel inductive sensor | Ze veo-er- Co) 4 \ Sia ecm CoS rn 6273 BAN C273 RN ‘ann 6273 —— LH front phonic wheel inductive sensor BH rear phonic wheel inductive sensor | war +273, RN G273 WaT «G27 BRN G27s. —— se RED 6273 ——~ e0 6273 —~ aR +6273 BRN- 6275 LH rear phonic wheel inductive sensor em | Connector for ALFA TESTER (ABS) vel -G273 —— fare 6273 ABS control unit ee) 2850 pm 48K + C53 nue wr« Gary ee 2 te DO | AK + | ven Ca) -— «0-GD-— | | wa! () Version with "ACTIVE SENSORS asaannannany” ERED -BIK +9124 —— apr LK «ci24 =" win it ‘GO . 1990VANES) LOCATION OF COMPONENTS ELECTRIC SYSTEM DIAGNOSIS 55 ABS -39B PA493000000009 -6- 12-1997Barus wy ussas bak EI.ECTRIC SYSTEM DIAGNOSIS. 1AS ABS 55.398 FAULTFINDING N.8.: When the control unit detects an eror in the AUTOMATIC CHECK AT SWITCH ON: when the car is started the "ABS tailure” warning light on the instru- ment cluster turns on for approx. 2 sec., then it goes, ‘oul to indicate correct operation of the system I the warning light stays on, carry out diagnosis con- necting the Service Network diagnosis too! to cannec: tor 720. Ii the light fails to turn on, carry out test 8. Pa493000000009 "ABS" @ function and turns on the warning light at the same time it deactivates the system, there- fore the vehicle brakes with the conventional sys- tem only. When the control unit also detects an error in the “EBD" function’, it turns on both warning lights © ef . in these conditions rear braking dis- tribution contro! is also deactivated and the car should be driven very carefully. 12-199724/08 08:45 FAX {45 ELECTRIC SYSTEM DIAGNOSIS ‘Boos 55-308 ABS PRELIMINARY SYSTEM CHECK TESTA TEST PROCEDURE RESULT CORRECTIVE ACTION at | CHECK FUSES (0K) | Carry out step a2 ~ Check that wander tuses F15 and G126® are (OR) | Repiace me uses A F15 (158) - GY25b (604) ‘42 | CHECK VOLTAGE (0K) & | Cary out step as = Check or 12 V al pin 17 and 18 of N51 Flestore the wiring between pin 17 and 18 of NS1 and use G125b ‘a3 | CHECK VOLTAGE = Turn the key and check for 12 V at Carry out step Aa Restore the wiring between pin 15 of NSt and the control box G1 aa | CHECK EARTH — Check that pin 16 of NS1 is earthed Carry out step AS: Restore the wiring between pin 16 of NSt ang Gssb as | CHECK EARTH Check that pin 19 of NS1 # earthed CONTINUE DIAGNOSIS USING THE DIAGNOSIS Tos Restore the wiring between pin 19 of NS1 and earth G59b PAa93000000009 12-1997145 ELECTRIC SYSTEM DIAGNOSIS. ABS 55.308 "ABS" WARNING LIGHT NOT WORKING (*) TEST B ‘TEST PROCEDURE RESULT CORRECTIVE ACTION B1 | CHECK CONTINUITY of 78 Ber >| Cony out step 82 Restore the wiring between N51 and connector TB 82 | CHECK EARTH SIGNAL pin B3 of the instrument cluster C10 = Turn the key and check for OV, for a fow seconds at | wr B3 | CHECK EARTH SIGNAL pin 20 of N51 Turn the key and check for OV, for a few seconds at (8) >| Replace the electronic contol unit N51 (*) To check whether the "EBD" warning light is working, simply pull the handbrake! In the event of a fault, proceed as described in the “Instrument Cluster’ section. PA493000000012 2-199