MR293R193

Chassis
GENERAL
FRONT AXLE
REAR AXLE
WHEELS AND TYRES
STEERING
MECHANICAL ELEMENT CONTROLS
ELECTRONICALLY CONTROLLED SYSTEMS
77 11 190 850 NOVEMBER 1996 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the reference numbering system is forbidden without the prior written authority of
manufacturer in the production of the various component units and accessories Renault.
from which his vehicles are constructed."
C Renault 1996
EXPLODED VIEW
PRG30.1
Chassis
Contents
Page Page
30 GENERAL 33 REAR AXLE

General braking system Rear axle 33-1
circuit diagram 30-1 Brake drums 33-2
Tightening torques (in daN.m) 30-2 Wheel cylinders 33-4
Measuring points 30-6 Brake calipers 33-5
Underbody heights 30-8 Mechanical brake caliper
Parts that must be systematically control 33-7
replaced 30-9 Brake shoes (drum) 33-9
Brake fluid 30-9 Brake pads (disc) 33-23
Front anti-roll bar Brake discs 33-25
specifications 30-10 Hub bearings 33-26
Rear anti-roll bar Shock absorbers 33-30
specifications 30-11 Anti-roll bars on tubular rear axle 33-31
Rear suspension bar Half suspension arms on tubular 33-32
specifications 30-11 rear axle
Rear torsion bar Bearings on tubular rear axle 33-33
identification marks 30-12 Suspension bars tubular rear
Brake unions and axle 33-27
pipes 30-13 Underbody height tubular rear
The effect of geometry angles 30-13 axle 33-39
Principles of checking geometry 30-14 Torsion bars four bar rear
Checking and adjusting front 30-15 axle 33-40
axle geometry Underbody height four bar
Front axle fault finding 30-16 rear axle 33-42
Braking system fault finding 30-17 Four bar type rear axle 33-43
Bleeding the braking system 30-20 Suspension arm bearings 33-46
31 FRONT AXLE 35 WHEELS AND TYRES

Subframe 31-1 Specifications 35-1
Lower suspension arms 31-4 Wheel balancing 35-3
Lower suspension arm
rubber bushes 31-5
Lower suspension arm ball joint 31-6
Brake pads 31-7
Brake calipers 31-12
Brake disc 31-14
Stub axle carrier bearings 31-16
Stub axle carrier 31-19
Combined spring shock absorber
assembly 31-20
Spring and shock absorber assembly 31-21
Anti-roll bar 31-27
Contents
Page
36 STEERING 38 ELECTRONICALLY CONTROLLED

HYDRAULIC SYSTEMS
Axial ball joints 36-1
Manual steering box 36-3 BENDIX ABS system
Anti-rattle bearing on Location and composition 38-1
manual steering box 36-5 Electronic computer 38-6
Power assisted steering box Speed sensors and targets 38-6
Steering box plunger 36-11 Control relay of ABS
Steering column 36-12 device 38-7
Retractable steering column shaft 36-19 Operation 38-10
Regulation in defect mode 38-13
Pressure accumulator 38-14
Removal-refitting of
components 38-16
37 MECHANICAL ELEMENT CONTROLS Fault finding with XR25 38-32
Checking level - Bleeding 38-65
Fault chart 38-70
Master cylinder 37-1
Brake servo 37-2 BOSCH ABS system
Brake servo air filter - Identification of the system 38-87
Non-return valve 37-4 Location and composition 38-88
Pedal assembly 37-5 Operating principle 38-96
Handbrake lever 37-6 Summary of regulation principle 38-104
Handbrake control 37-7 Self-testing 38-106
Brake hoses 37-10 Fault finding with XR25 38-111
Brake compensator 37-11 Checking the wiring 38-125
Testing - Adjustment 37-13 Wiring diagram 38-126
Clutch cable 37-15 Connectors 38-128
Clutch automatic Removal and refitting of
wear take-up system 37-16 components 38-130
External gear control 37-19 Bleeding 38-135
Gear selection controls 37-25 Additional tests 38-137
Brake compensator
adjustment check 38-143
Replacement of compensator 38-144
Fault chart 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 fixed compensator which
with load sensitive compensator 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 1.3
M 10 x 100
Supply to rear wheel cylinders or 1.3
M 12 x 100
M 10 x 100
Master cylinder outlets or 1.3
M12 x 100
M 10 x 100
Compensator inlet or 1.3
M12 x 100
M 10 x 100
Compensator outlet or 1.3
M12 x 100
30-2
GENERAL
FRONT
AXLE
All types except B - C - L 539
B - C - D - L 53 D
DI3030
30-3
GENERAL
FRONT AXLE
B - C - L 539
B - C - D - L 53 D
DI3031
30-4
GENERAL
TUBULAR TYPE
REAR AXLE
DI3032
30-5
GENERAL
FOUR BAR TYPE
REAR AXLE
DI3033
30-6
GENERAL
FOUR BAR TYPE
REAR AXLE
91849R
30-7
GENERAL
Underbody heights 30
The underbody heights are measured with the Value in the section "Values and settings".
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.
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 30
- 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.
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
B - C - D - L - S 53 ALL TYPES
B - C - L - S 530
531 except
532
VEHICLE 53 W
TYPE B - C - L - S 530
53 H 531
532
53 W
53 H
DIAMETER - 23
30-10
GENERAL
Rear anti-roll bar specifications 30
TUBULAR REAR AXLE 4 BAR REAR AXLE
B- C - L - S B- C - L - S All types with ABS X 53

530 - 531 - 532 534, 536, 537, 53 A option and SPORTS
VEHICLE 53 H - 53 W 53 B, 53 B, 53 G, 53 J,53 R,53 S B, C, D, L, S VERSION
TYPE 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
DIAMETER 15 mm 17 mm 23.15 mm 24.75 mm
NUMBER OF SPLINES - - 31 31
AT BEARING END
NUMBER OF SPLINES AT - - 30 30
DOUBLE SHACKLE END
Rear suspension bar specifications
TUBULAR REAR AXLE 4 BAR REAR AXLE
B- C - L - S All types with ABS X 53

530, 531, 532, 534, 536, 537 option and SPORTS
VEHICLE 53 A, 53 B, 53 G, 53 H, 53 J, 53 R B, C, D, L, S VERSION
TYPE 53 S, 53 U, 53 W 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
DIAMETER 19.8 mm 21.7 mm 23 mm
NUMBER OF SPLINES AT 25 27 27
BEARING END
NUMBER OF SPLINES AT 24 26 26
DOUBLE SHACKLE or ARM
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 Differences in the variation of the parallelism
the steering of the vehicle and on its tyre wear. between the right and left hand wheels cause
(without any change in the position of the
CAMBER steering wheel):
It is the comparison between the left hand and - a pull to one side during acceleration,
right hand angles which is important. A - a pull to the other side during deceleration,
difference of more than one degree from one side - changes in course holding when the vehicle is
to the other causes the vehicle to pull to one side. driven over bumpy roads.
This has to be corrected at the steering wheel and
the result is abnormal tyre wear. PARALLELISM
CASTOR The steering must be in the straight ahead

position when this adjustment is carried out if a
Once again it is the comparison between the left detrimental effect on the road holding is to be
hand and right hand angles which is important. A avoided.
difference of more than one degree causes the
vehicle to pull to one side. This has to be It is to be noted :
corrected at the steering wheel and the result is
abnormal tyre wear. Itcan be identified by a pull, - that too much toe-out causes symmetrical
at constant speed towards the side on which the excessive wear on the inside edge of both
angle is smallest. tyres,
STEERING BOX HEIGHT - that too much toe-in causes symmetrical

This height affects the variation in the parallelism excessive wear on the outside edge of both
that occurs as the suspension moves. tyres.
30-13
GENERAL
Principles of checking the geometry 30
PRELIMINARY CHECKS
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, 82699R
• the bearing play.
In this position, fit the checking equipment, and

- The wheel run-out: this should not exceed 1.2 check the geometry.
mm (it will be compensated for by the
checking equipment). When adjusting the parallelism, ensure that both
lengths x on the track rod end casings are the
- That the underbody heights are the same on same.
both sides of the vehicle (the condition of the
suspension).
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 30
CHRONOLOGICAL ORDER OF OPERATIONS
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 manufacturer’s 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,
81940R
- bounce the suspension to bring it to its
nominal height,
- check that the lengths X on the track rod end 1 If both lengths X are the same :
casings 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
83098R
- zero the floating plates in this position,
- note the readings A on the scales. - check, in the following order :

• the castor,
• the kingpin,
• the camber,
• the parallelism.
30-15
GENERAL
Checking and adjusting the front axle geometry 30
ADJUSTING PARALLELISM
One of several cases may arise :
Parallelism Distribution Correction to be carried out
1 CORRECT INCORRECT 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.
2 INCORRECT CORRECT Adjust the parallelism by the same amount on the right
and left hand sides whilst ensuring that dimensions A
remain identical on both sides.
3 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 - Suspension arm bent

but, Camber incorrect
Kingpin incorrect - Side member bent
Camber correct
but - Stub axle carrier bent
Kingpin incorrect
Kingpin correct
but - Stub axle carrier bent
Camber incorrect
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 30
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 The effect as noted on the pedal

II The effect on the vehicle behaviour.
I THE EFFECT AS NOTED ON THE PEDAL
FAULT POSSIBLE CAUSE
Stiff pedal : - Assistance fault

Heavy pressure required to obtain poor
deceleration - 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: - Air in the system : incorrectly bled.
Note : as the servo effect on present day vehicles - Internal leakage within the braking circuit.
is very high, one frequently gets the impression
that the pedal is spongy. To determine whether - Insufficient fluid in the reservoir (braking
the brakes are effective or not, one of two tests system external leakage).
can be carried out.
1. With the vehicle moving

A subjective test: the ratio between the
pedal travel and braking effect.
2. 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.
30-17
GENERAL
Pedal travel excessive - Brake shoes incorrectly adjusted
This test is to be carried out with the vehicle Drum brakes

stationary and the engine switched off.
- Manual adjustment : shoes too far from the
Note : one must depress the brake pedal 5 times, drums.
to empty the brake servo, before the results of
this test can be considered as valid. 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 - Brake fluid leakage (check the system for leaks)
Test to be carried out with the vehicle stationary - Defective cup washer between the two master
and the engine switched off. cylinder circuits.
Note : one must depress the brake pedal 5 times, - Brake fluid boiling.
to empty the brake servo, before the results of
this test can be considered as valid.
II EFFECT ON VEHICLE BEHAVIOUR
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
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*.
*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 :
Rear sub-frame mounting bolt 8.5 - a threaded rod with two nuts.
- an extractor tube (A) with a washer (B),

Removing the connection stud on the vehicle.
Use a four post lift, taking the weight under the - a support ring (C) with shoulder.
body.
- a simple support ring (D).
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 31
Wedge a nut between the stud and the body, and Check that the sub-frame support ring, with
screw the threaded rod into it. 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 se-
cond nut.
Connection stud removed.
92708-2R 92708-3S
31-2
FRONT AXLE
Sub-frame 31
REFITTING Remove the sub-frame bolt and rings (C) and (D).
Refitting the connection stud on the vehicle. Tighten the sub-frame bolts to a torque of 8.5
daN.mm, with the connection stud pressed on.
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 9

Nuts on stub axle carrier keys 5.5
Anti-roll bar bearing nut 3.5
Lower ball joint joint 7.5
Wheel bolts 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 31
REFITTING
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
FRONT AXLE
GIRLING
Brake pads 31
Fre. 823 Piston return tool
TIGHTENING TORQUES (in daN.m) REFITTING
Wheel bolts 9 Push in the caliper piston using tool Fre. 823.
Brake caliper guide bolts 3.5
REMOVal
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 90130-1G
guides.
31-7
FRONT AXLE
GIRLING
Brake pads 31
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.
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 , star-
ting with the lower bolt.
90130-3R
* bolts supplied in the spares kit.
31-8
FRONT AXLE
BENDIX
Series IV Brake pads 31
Fre. 823 Piston return tool
Wheel bolts 9
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
FRONT AXLE
BENDIX
Fit the two anti-rattle clips (3) to the new pads. - correct direction of fitting :
- 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
FRONT AXLE
BENDIX
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).
82762R
Reconnect the wear warning light wire.

31-11
FRONT AXLE
Brake calipers 31
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.
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 31
TIGHTENING TORQUES (in daN.m) Tighten the bleed screw.
Wheel bolts 9 BENDIX Series IV

Caliper mounting bolts (BENDIX Series IV) 10 Place the caliper piston assembly on the stub axle
carrier and tighten the two bolts (A) to the
Guide bolts (GIRLING) 3.5
specified torque.
REMOVAL
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 (under-
neath head of bolts).
All types
Check the condition of the pads. If they are grea-

sy, replace them.
The system may be partially bled only if the brake

90149R fluid reservoir has not emptied during the opera-
tion. If it has, a complete bleed operation must be
All types carried out.
Unscrew the caliper piston from the hose Press the brake pedal a number of times to bring
(providing a container to catch the brake fluid). the pistons into contact with the pads.
Check the condition of the hose and replace it if REPAIR

necessary (see the section on replacing a hose).
Any scoring of the caliper bore automatically in-
REFITTING volves the replacement of the entire caliper.
Screw the new caliper cylinder on to the hose. Remove the brake caliper.
Loosen the bleed screw on the caliper cylinder and Take off the dust cover (there is a retaining ring
wait till brake fluid runs from it (ensure that there on the GIRLING assembly).
is enough fluid in the brake fluid reservoir).
31-13
FRONT AXLE
Brake discs 31
The brake discs cannot be reground. A disc which BENDIX Series IV
is heavily worn or scored must be replaced by a
new one.
Wheel bolts 9
Caliper mounting bolts 10
Caliper bracket mounting bolts
BENDIX Series IV 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.
31-14
FRONT AXLE
Brake discs 31
REPLACING
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 31
M.S. 580 Inertia tool

Rou. 15 -01 Shaft end protector
Rou. 604 -01 Hub lock
T.Av. 476 Ball joint extractor
T.Av. 1050-02 Hub extractor
T.Av. 1050-03 Adaptor
Shock absorber lower mounting bolt 11

Nuts on lower ball joint key 5.5
Track rod end nut 3.5
Brake caliper mounting bolt 10
Driveshaft nut 25
Wheel bolts 9
Checking the play
Mount a dial gauge on the hub and check that the

play is between 0 and 0.05 mm.
REMOVAL
Remove : 91752R1
- the brake disc (see the corresponding section),
- the driveshaft nut using tool Rou. 604-01.
91751R
Extract the hub using tool T.Av. 1050-02 + 1050-

03 + M.S. 580.
31-16
FRONT AXLE
Remove the inner track ring from the hub using a Remove :
jaw extractor type FACOM U53G +U53E and tool - the mounting bolts (1),
Rou. 15-01. - the nut and the key (2),
91754R
- the snap ring.

83348G
Push out the outer track ring, on the press, using

one of the inner track rings and leaving the ball
Disconnect the track rod using tool cages and seals in position.
T.Av. 476.
79057S
91753R
31-17
FRONT AXLE
REFITTING Fit the thrust washer (1) to the hub followed, on
the press, by the bearing, using a tube, taking the
Remove the two plastic protectors (A) from the weight on the inner track ring.
new bearing.
78624R 85902R
Fit the new bearing to the stub axle carrier, on the

press, together with the plastic ring (B), using a Refit the stub axle carrier to the vehicle.
tube. taking the weight on the outer track ring.
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
From then on carry out the removal operations in

reverse, tightening the nuts to the specified
torques.
79058-1S
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
Nuts on shock absorber rod 6

Shock absorber cup mounting bolt 3
Wheel bolts 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 bet-
ween 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
FRONT AXLE
Tooling
SUS 1052
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.
Sus. 1052 Tooling for working on front

springs and shock absorbers
Sus. 1052-02 R19 retaining shell;
Sus. 1052-03 R21 retaining shell
Use components (A) and (B) of tool

Sus. 1052.
90102S
Fit :
90100R - the spring-shock absorber assembly
positioning the 2 half cups (A) and the two 1/2
Upper and lower compression plates assembly.
shells (B),
A Thrust cup
B Retaining shell marked R19
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
FRONT AXLE
Tooling
SUS 1052
- the upper plate, Compress the spring by approximately 10 mm.
- the two bolts that retain the upper shock
absorber cup in the specified holes (the Remove the nut from the shock absorber rod.
vehicle references are engraved on the upper
plate),
90104-2S
90104R1
Gradually and evenly release the spring pressure.
- the three compression bolts, injecting copious Remove parts (1) to (6) in that order.
quantities of oil into the reservoirs provided.
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
FRONT AXLE
Tooling
SUS 1052
Assembly of Tool for B, C, D, L 539 AND 53 D
The upper plate (1) of these shock absorber as-

semblies is offset.
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
FRONT AXLE
Tooling
SUS 1052
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
FRONT AXLE
With spring com-
pressor 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 Type Description Cup
MG M90 Spring compressor M3
ZKL 2013 Spring compressor

ZI NO2
ZKL 0055 Vice
D83 Tool for removing the shock

FACOM
RENA absorber nut
Shock absorber upper mounting nut 6
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 re-

moving 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
FRONT AXLE
With spring com-
pressor 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 ma-

nually several times in the vertical position before
installing them on the vehicle.
If a spring requires replacing, and in order to faci-

litate 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
Bearing mounting nuts 3.5
To carry out this operation first remove :
- the exhaust downpipe,

- the gear control (manual gearbox).
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 31
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.
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
Bearing mounting nut 8

Wheel bolts 8
REMOVAL
With the vehicle on a two post lift, remove :

- the two shock absorber lower mounting bolts,
- the brake hoses,
- the handbrake secondary cables, 92214R
disconnecting them from the central control
under the vehicle.
REFITTING
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
REAR AXLE
BENDIX
180 X 40 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.
Emb. 880 Inertia extractor

Rou. 943 Hub plug extractor
Wheel bolts 8
Hub nut 16
REMOVAL
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.
90220G1 85 906
Pass a screwdriver through one of the wheel

mounting bolt holes on the drum and push the Remove :
handbrake lever to free the stud from the brake - the nut and washer from the stub axle,
shoe (E). - the drum.
Help to release the lever by pushing it backwards. Remove all dust from the drum and shoes.
33-2
REAR AXLE
Brake drum 33
REFITTING
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.
Wheel bolts 8 Remove all dust from the drums and the shoes.
Hub nut 16
Refitting is the reverse of removal (see section
Bleed bolt 0 .8
"Brake shoes").
Pipe union bolt 1 .3
REMOVAL
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
Wheel bolts 9 Retighten the rigid pipe union, without locking it.
Brake caliper mounting bolt 10
Fit the caliper, coat the bolts with Loctite
FRENBLOC and tighten them to torque.
REMOVAL
Lock the rigid pipe union.
Remove the brake shoes (see corresponding sec-
tion). Slacken the cylinder bleed screw and wait for the
brake fluid to run out (check that the compensa-
Release the rigid brake pipe on the cylinder side. tion reservoir level is sufficient).
Disconnect the handbrake cable. 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 comple-
tely 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 automa-

tically means replacement of the complete cali-
per.
It is not permitted to remove the inside of the pis-

88993R ton (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 33
Remove the piston by unscrewing it with a square Remove the sealing piston from its groove with a
section screwdriver. 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 dama-
ging 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
B. Vi.28-01 Claw extractor

Fre. 1047 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.
74439-2R
Remove :
- the pin (7) fitted with the dust cap (4) by - the spring (9),
pulling the lever, - the adjusting screw (10),
- the washer (11),
- the thrust pin (8). - the spring washers(6),
- the ring (12) using a pin punch,
- the O-ring (13).
Clean all the parts with methylated spirits.
33-7
REAR AXLE
Mechanical brake caliper control 33
REFITTING
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 sup-

port face is facing the bleed screw (P).
88311R
33-8
REAR AXLE
BENDIX
180 X 40 Brake shoes (drum brakes) 33

TIGHTENING TORQUES (in daN.m) REMOVAL
Wheel bolts 9 All the shoes or linings on a given axle must be re-
Hub nut 16 placed at the same time. Never fit linings of diffe-
rent makes or grades.
Composition of the Bendix 180x40 RAI brake Remove the lower spring (2) using brake shoe
(Automatic Wear Take-up System). pliers.
90217-1R
Fit a clip to the wheel cylinder piston.
90223R
A Leading shoe
B Trailing shoe
C Fixed point
P Brake shoe end
F RAI
1 Upper return spring
2 Lower (end) return spring
3 Side retaining spring
4 Handbrake lever return spring
33-9
REAR AXLE
BENDIX
Using a set of combination grips, remove the shoe On the work bench, remove the RAI and shoe as-
side retaining springs (R) whilst holding the sembly.
connecting rod (T) against the brake backing
plate. 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
REAR AXLE
BENDIX
Rotate the leading shoe (A), in the direction of the Marking and refitting the RAI component parts
arrow, so that the bolt head is released from the
RAI. This enables the upper spring (1) to be
removed without force. 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
REAR AXLE
BENDIX
Left-hand RAI assembly 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 Refit the bracket, the solid section of which must
position of the bracket. be positioned between the blade and the lever.
In both cases the clip attachment must not be

wedged between the bolt head and the toothed
nut. Leave a slight lateral clearance (J).
33-12
REAR AXLE
BENDIX
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 Place the upper spring (1) in the notches on the
two shoes, then pull in the direction of the
Refit the handbrake lever on the trailing shoe arrows. The bolt locator must be positioned in
with a new clip, then disarm the lever. that of the leading shoe (A).
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.
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
REAR AXLE
BENDIX
Attach clip (E) and re-arm the handbrake lever.
90217-1R1
ADJUSTMENT
93718R
Using a screwdriver adjust the diameter across the
shoes by turning the toothed wheel (F) to obtain a
REFITTING 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
REAR AXLE
BENDIX
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
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
REAR AXLE
BENDIX

TIGHTENING TORQUES (in daN.m) REMOVING
Wheel bolts 9 All the shoes or linings on a given axle must be

Hub nut 1 7.5 replaced at the same time. Never fit linings of
different makes or grades.
Composition of the BENDIX 203 x 38 RAI Remove:

(automatic wear take-up system). - the brake drum (see corresponding section),
- the lower spring (2) with brake shoe pliers.
98992R
A Leading shoe
98993R
B Trailing shoe
C Fixed point
P Brake shoe end Fit a clip to the wheel cylinder pistons.
F RAI
1 Upper return spring
2 Lower (end) return spring
3 Side retaining spring
4 Handbrake lever return spring
33-16
REAR AXLE
BENDIX
Using a set of combination grips, remove the shoe On the work bench, remove the RAI and shoe
side retaining springs (R) whilst holding the assembly.
connecting rod (T) against the brake backing
plate (E). 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
REAR AXLE
BENDIX
Rotate the leading shoe (A), in the direction of the Marking and refitting of the component parts of
arrow, so that the bolt head is released from the the RAI (automatic wear take-up system)
RAI. This enables the upper spring (1) to be
removed without force. 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
REAR AXLE
BENDIX
Left-hand RAI assembly Refitting the RAI
Make sure that the ratchet is in the correct
position.
98998R
98999S
Right-hand RAI assembly

Refit the bracket, the solid section of which must
be located between the blade and lever.
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).
33-19
REAR AXLE
BENDIX
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 right- 99002R
hand RAI.
On the bench, refit the RAI assembly and shoes Place the upper spring (1) in the notches on the
two shoes, then pull in the direction of the
Refit the handbrake lever on the trailing shoe arrows. The bolt locator must be positioned in
with a new clip, then disarm the lever. that of the trailing shoe (A).
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.
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
REAR AXLE
BENDIX
Attach the clip (E) and re-arm the handbrake
lever.
98993-1R
ADJUSTING
99003R
Using a screwdriver, adjust the diameter across
the shoes by turning the toothed wheel (F) to
REFITTING 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
REAR AXLE
BENDIX
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.
98992-1R1

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
Wheel bolts 9
REMOVAL REFITTING
Remove: Push in the caliper piston and tighten it using a

- the clip (1) square section screwdriver until it rotates but goes
- the key (2), in no further.
- the pads.
88992R 88311R
Check the condition of the dust cover (5) and the Position the piston so that the line (R) on its sup-
gaiters (6) that protect the caliper slides and port surface faces the bleed screw (P).
replace them if necessary. If they are replaced,
grease the end of the piston and both slides after
first cleaning them with methylated spirits.
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

33-24
REAR AXLE
Disk brakes 33

Wheel bolts 9
Hub nut 16
Caliper bracket 10
This vehicle is equipped with a hub/brake disc as-

sembly which cannot be reground. If heavily
worn or scored it must be replaced by a new as-
sembly.
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 tor-
que,
- the brake pads (see corresponding section).
88992R1
- the hub plug, tool Rou. 943+ Press the brake pedal a number of times to bring
Emb. 880, the piston into contact with the pads.
- the stub axle nut (3),
- the hub/disc/bearing assembly.
33-25
REAR AXLE
Hub bearings 33

Tav.1050-02 ‘ Hub extractor
TIGHTENING TORQUES (in daN.m) REMOVAL
Hub nut 16 Remove :

Wheel bolts 9 - 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 33
REFITTING
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

T.Av. 1050 Hub extractor
Wheel bolts 9
Hub nut 16
Brake caliper bracket 10
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.
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 33
VEHICLES EQUIPPED WITH DISCS
REFITTING
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 33
TIGHTENING TORQUES (in daN.m) - the shock absorber.
Upper securing nut 2

Lower securing bolt 6
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
Consequently, before fitting it to the vehicle, it
- the lower mounting (2). 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
Bar mounting bolt 4.5
REMOVAL
92211R
1 Mounting bolts
2 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 33
Bearing mounting nut 8 Check that the bearing tracks or the needle races
Anti-roll bar mounting securing bolt 4.5 are in perfect condition. If not, replace them (see
section entitled "Rear axle bearings - tubular type
Wheel bolts 9
rear axle".
Shock absorber lower mounting bolt 6 As the needle races are greased for life, it is not
necessary to regrease them.
REMOVAL NOTE: new suspension arms as supplied by the

Parts Department are fitted with bearing tracks
With the vehicle supported on a two post lift, or needle races (depending on the size).
remove : Insert the two half suspension arm assemblies one
- the anti-roll bar, into the other until the correct dimension (B) is
- the shock absorber lower mounting bolt, obtained.
- the handbrake secondary cable, disconnecting
it from the central control under the vehicle, NOTE: dimension (B) corresponds to the distance
- the brake hose, between the same anti-roll bar securing points on
- the two nuts that securing the bearing (A). 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.
Adjust the handbrake control (see section 37).
33-32
REAR AXLE
Bearings on tubular type rear axle 33
This operation is carried out after first removing the entire rear axle assembly and separating the two
suspension arms.
T. Ar. 960 Bearing extractor
T. Ar. 960-02 Bearing extractor + spacer
REMOVAL Grind almost through the bearing tracks on the

male arm (right hand), with a straight grinder,
Remove from the female arm (left hand): taking care not to mark the tube.
- the outer bush (6), using tool T.Ar. 960,
- the inner bush (7) using the small end of tool

T.Ar. 960.
90864S
Split the bearing tracks with a cold chisel and

remove them.
86182R
86180R
33-33
REAR AXLE
Bearings on tubular type rear axle 33
Cut and remove the seal (5). Fit :
- the small needle race to mandrel (A),
- mandrel (A) into the tube using mandrel (B) as

a guide.
90863R
REFITTING
90866R
Tool T.Ar. 960-05. is required to fit needle races
and their tracks. 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 : Push down, with the press until mandrel (B)
- the large needle race to 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 The bearing tracks have a lead chamfer at one
a guide. 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 33
Fit :
- the large bearing track into the sleeve (D),

- the assembly of sleeve (D) and (C) over the
tube.
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.
Fit : NOTE : It is not necessary to grease the needle

- the small bearing track in the sleeve (C), races. They are supplied ready greased.
- the sleeve (C) over the tube with sleeve (D)
acting as a guide. Then reconnect and refit the rear axle to the
vehicle (see corresponding section).
33-36
REAR AXLE
Suspension bars - tubular type rear axle 33
TIGHTENING TORQUES (in daN.m) A Nut 14 mm diameter

B Nut 12 mm diameter
Shock absorber upper mountings 2 C 12 mm diameter threaded rod 660 mm long
Shock absorber lower mountings 6 D Washers inside diameter 12 mm
E Spacer inside diameter 12.5 mm outside
diameter 20 mm, 60 mm long
REMOVAL F 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 33
Fit the tool in place of the shock absorber.
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 33
CHECKING Remove the bar.
Park the vehicle, unladen but with its fuel tank As 3 mm is the minimum adjustment that can be
full, on a flat horizontal surface. 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.
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 33
EXTRACTION OF THE BARS FROM THEIR SPLINES
Remove the wheels.
SUSPENSION BARS ANTI-ROLL BARS
Release the suspension bars from their splines Release the anti-roll bars using inertia extractor
using inertia extractor tool Emb. 880. tool Emb. 880.
92120-1R
92120R
33-41
REAR AXLE
Underbody height - four bar type rear axle 33
CHECKING
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 correct height on one side, but excessive

right/left hand difference,
B incorrect height and excessive right/left hand
difference,
C incorrect height, but correct right/left hand
difference.
33-42
REAR AXLE
Four bar type rear axle 33
ADJUSTING In this new position, refit :
- the anti-roll bar at the point where it will slide
1. AFTER REPLACING A REAR AXLE in freely and check the number of splines
offset on the arm and double shackle,
A The height is correct on one side but the - the two suspension bars without offsetting
difference between the LH and RH sides is the marks.
excessive Fit :
- the shock absorbers,
Any difference between the RH and LH sides must - the wheels.
always be taken up by adjusting the anti-roll bar
on the lowest side. With the vehicle resting on its wheels, check and if
necessary adjust the headlights.
NOTE: it is essential to adjust on the lowest side
and bring it up to the same as the highest side.
B If the heights are incorrect and the difference
Mark the positions in the bearings and in the between the RH and LH sides is excessive
double shackle:
- of the two suspension bars, The difference between the RH and LH sides must
- of the anti-roll bar on the lowest side. always be taken up by adjusting the anti-roll bar
Fit the tools set to the dimension "X" that on the lowest side.
corresponds to the vehicle type.
NOTE: it is essential to adjust on the lowest side
Remove: and bring it up to the same as the highest side.
- the suspension bars,
- the anti-roll bar which has been marked. Mark the positions in the bearings and in the
Measure the dimension between the centre of the double shackle:
wheel and the ground (on the side without an - of the two suspension bars,
anti-roll bar). - of the anti-roll bar on the lowest side.
Fit the tools set to the dimension "X" that
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
Reduce this dimension by the amount of Refit the suspension bars at the point at which
difference between the RH and LH sides already they will slide in freely.
measured by increasing dimension "X" on the
tool. Fit :
- the shock absorbers,
NOTE: do not alter the adjustment of the tool on - the wheels.
the other side.
With the vehicle resting on its wheels, check and
In this new position, refit the anti-roll bar at the if necessary adjust the headlights.
point where it will slide in freely.
2. READJUSTING THE SUSPENSION HEIGHT
Then, by adjusting both tools, reduce or increase ON A VEHICLE
the dimension between the centre of the wheel
and the ground, simultaneously on both sides, by When adjusting the suspension height on a
the height difference measured on the highest vehicle that has already seen service, it is
side when the vehicle was checked. essential to determine the point at which the bars
enter freely.
In this position, refit the suspension bars at the
point at which they will slide in freely. Remove the wheels and shock absorbers.
Fit : Fit the special tools in place of the shock

- the shock absorbers, absorbers, setting them at a dimension "X" that
- the wheels. corresponds to the free position of the suspension
arms.
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
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

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
A If the difference between the RH and LH sides B If the heights are incorrect but there is no
is excessive difference between the RH and LH sides
Mark the positions, in the bearings and the Mark the positions of the two suspension bars in
double shackles : the bearings and in the double shackle.
- of the two suspension bars,
- of the anti-roll bar on the lowest side. Remove the two bars using tool Emb.880.
Remove the three bars using tool Emb. 880.
92120-1R 92120R
Thoroughly clean and grease the anchor points Thoroughly clean and grease the anchor points
and the bars. and the bars.
Find, by altering dimension "Y" on the side on Adjust both tools simultaneously to determine the
which the anti-roll bar has been removed, the points at which the bars slide in freely, that
position at which the bar will slide in freely, that correspond to the position marks.
corresponds to the two position marks. From this
position, adjust both tools simultaneously to Tighten the tools at the dimensions "Y" thus
determine the position at which the suspension obtained.
bars will slide in freely , that corresponds to the
position marks. In this new position, carry out the normal
adjustment (see the section on "Adjusting after
Tighten the tools at the dimensions "Y" thus replacing the rear axle" *).
obtained.
(*) WARNING : when re-adjusting, it is the
In this new position, carry out the normal dimension "Y" that is to be used as the
adjustment procedure (see the section on starting point for this adjustment and not the
"Adjustment after replacing the rear axle"). dimension "X" stated in this manual.
33-45
REAR AXLE
TUBULAR REAR
AXLE
Suspension arm bearings 33
This operation is to be carried out after first Saw through the inner bush taking care not to cut
removing the suspension arms and suspension into the suspension arm tube.
bars from the vehicle.
REMOVAL
Totally immerse the bearing in brake fluid to

soften the rubber in the rubber bush.
75362S
REFITTING
The new bearing is fitted to the suspension arm,
on a press, ensuring that the bush is correctly
DI3309 positioned in the suspension arm at the correct
spacing.
Using a two or three arm extractor, remove the
outer part of the bearing by tearing the rubber. Position
Ensure that dimension "X" between the thrust
face of the bearing and the stub axle centreline is
correct.
All types
X = 15 mm
85909S 85910R
33-46
REAR AXLE
TUBULAR REAR
AXLE
Spacing
In this position, push the bearing into the arm

until the bearing dimension between centres is :
Y = 1268 ± 1 mm
DI3304R
Fit the suspension arm to the vehicle.
33-47
REAR AXLE
FOUR BAR TYPE
REAR AXLE
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
Spacing
90 241
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 92220R1

face of the bearing and the centre line of the stub
axle is correct. Fit the rear axle assembly to the vehicle and refit
the suspension bars (see the corresponding
All types section).
X = 24 mm
33-48
WHEELS AND TYRES
Specifications 35
WHEELS
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 B C D E F
NOMINAL ∅ Tyre Offset

WHEEL WIDTH RIM (in inches). At Number retaining in
TYPE (in inches) PROFILE tyre bead of holes profile mm
5 1/2 J 14
4 CH 36 5 1/2 J 14 4 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 35
TYRES
The identification marking may take one of two forms, for any given type of tyre.
Example : 175/70 S R 13
or 175/70 R 13 80 S
175 / 70 S R 13
1 2 3 4 5
175 / 70 R 13 80 S
1 2 4 5 6 3
85920R
Width of tyre : Expressed in millimetres (or in inches) and measured at

1 175 the widest point on the tyre.
l = 175 mm
Series or h/l ratio : h/l = 0.8 (normal) no inscription

2 70 h/l = 0.7 (low) 70
h/l = 06 (extra low) 60
Maximum speed : Up to 180 km/h S

3 S Up to 190 km/h T
Up to 200 km/h U
Up to 210 km/h H
Up to 230 km/h V
More than 230 km/h Z
Tyre structure : Cross ply no inscription

4 R Radial R
Bias belted B (Bias belted)
Wheel diameter Expressed in inches or in millimetres.

5 13
C = 13 inches
6 80 Reference stating the load that can be carried by each tyre.
35-2
WHEELS AND TYRES
Specifications 35
These tyres are of the tubeless type.
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 Pressed steel wheels

B Light alloy wheels
88659R
35-3
WHEELS AND TYRES
Specifications 35
Tightening Inflation
Run-out torque for pressure (1)
Types Wheels Tyres
(mm) wheel nuts
(daN.m) FRONT REAR
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 145 R 13 S
B 531 - B 53 W 5 x 13 1,2 8 165/70 R 13 T 2.0 2.2
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 5 1/2 x 13 175/70 R 13 T
L536 - C53V - 453D 175/70 R 13 H
B538 - B53Y - 453F 5 1/2 x 14 1,2 8 175/65 R 14 T 2.0 2.2
C538 - D53V - 553A 175/65 R 14 H
L538 - C53Y - 553C
B53C - D53Y - 553D
C53C - L53Y - 553F
D53C - 353A - 853A
L53C - 353C - 853F
B534 - B53J - B53Z

C534 - C53J - C53Z 5 x 13 1,2 8 165/70 R 13 T 2.2 2.2
L534 - L53J - L53Z 5 1/2 x 13 175/70 R 13 T
S534 - S53J
B532 - S537
C532 - B53B
L532 - C53B 155 R 13 T
B537 - L53B 5 x 13 1,2 8 165/70 R13T 2.0 2.2
C537 - B53H
L537 - L53H
B539 - C53D
C539 - D53D 6 1/2 x 15 1,2 8 195/50 R13V 2.2 2.2
L539 - L53D
B53D
B53K - B53T - 453H 165/70 R 13 T

C53K - C53T - 553H 5 1/2 x 13 1,2 8 175/70 R 13 T 2.2 2.2
L53K - L53T 5 1/2 x 14 175/65 R 14 T
S53K - S53T
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
Dir. 812 -01 Spanners for tightening axial

ball joints
or
Dir. 832 -01
Ball joint nut 3.5

Axial ball joint 5
Axial ball joints with flat locking washers.
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 re-
used. 85965R
Remove:
REMOVAL - the ball joint casing, counting the number of
threads engaged to be able to pre-adjust the
Loosen the lock nut (E) whilst holding the axial parallelism when refitting.
ball joint with an open ended spanner at (P). - the rack gaiter.
36-1
STEERING
Axial ball joints 36
Loosen the axial ball joint using spanner Dir. 812- NOTE : before tightening the ball joint using
01 or Dir. 832-01 whilst holding the stop washer spanner Dir. 812-01 or Dir. 832-01, check that the
(2) with a C spanner to prevent the rack rotating. 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
TIGHTENING TORQUES (in daN.m) Cut the ring (2) that retains the rubber protector.

Axial ball joint 5
Steering box mounting bolt 5
REMOVAL
Disconnect the ball joints using tool T.Av. 476.
92215R1
85965R
36-3
STEERING
Manual steering box 36
Push back the protective cover towards the To do this :
bulkhead and remove : - Loosen the lock nut (E) while holding the axial
- the eccentric bolt (1) on the steering column ball joint, using an open ended spanner at (P),
universal joint, - 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.
Check the parallelism.

85879R
- 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 36
Dir. 812 -01 Spanners for tightening

or the axial ball joints
Dir. 832 -01
Wheel bolts 8
Axial ball joints 5
REMOVAL
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

16193
longer projecting from its housing and thus
releases the anti-rattle bearing. 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
STEERING
ENGINE
TYPE F
Power assisted steering box 36
DI3606
Mot. 453-01 Hose clamps

TIGHTENING TORQUES (in daN.m) Remove the eccentric bolt (1) from the steering
column universal joint.
Axial ball joint 5
Steering box mounting bolt 5
REMOVAL
Disconnect the ball joints using tool T.Av. 476.
92059R
85965R
36-6
STEERING
ENGINE
TYPE F
Place a clamp Mot. 453-01 on each of the hoses - the mounting for the bracket securing the low
leading from the oil reservoir. pressure pipe.
92123R1
92121R
Remove :
- the air filter casing,
- the mounting for the bracket securing the - the piece of connecting hose from the low
high pressure pipe. pressure pipe,
92122R 92124R
36-7
STEERING
ENGINE
TYPE F
- the exhaust down pipe, disconnecting it from Fully unscrew the pipes leading to the cylinder
the manifold and its central connection under (have a container ready to catch the oil).
the vehicle.
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 NOTE : fit plugs to the take-offs on the steering
the high pressure pump to the rotary valve. box to prevent dirt entering the unit.
Entirely remove the low pressure pipe.
36-8
STEERING
ENGINE
TYPE F
Remove: To do this :
- bolt (2) from the right hand steering box - loosen the lock nut (E) whilst holding the axial
mounting, ball joint with an open ended spanner at (P),
- the four bolts that secure the steering box to - unscrew the ball joint casings, noting the
the sub-frame. 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
90145R
panel.
REFITTING
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
90060S them,
- the four steering box mountings, tightening
Never unscrew the axial ball joints from the rack them to the specified torque.
assembly unless they are to be replaced.
Tighten the pipes leading to the cylinder and the
If the steering box is to be replaced, the ball joint bolt on the right hand support.
casings at the stub axle carrier end will have to be
removed for fitting to the new one.
36-9
STEERING
ENGINE
TYPE F
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.
36-10
STEERING
Steering box plunger 36
ADJUSTING
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)
Steering wheel nut 4 Removing the Airbag cushion (without removing

Eccentric bolt 3 the steering wheel)
REMOVAL (without the Airbag option) WARNING : It is forbidden to handle pyrotechnic

systems (airbag and pre-tensioners) near a source
Remove : of heat or a flame; there is a risk of triggering
- the lower cover under the steering wheel, them.
- the steering column upper and lower half
cowlings, Remove the airbag by means of its two bolts
- the steering wheel after first marking its located behind the steering wheel (tightening
position. 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 36
- the eccentric bolt (2) on the universal joint. Remove :
- the four steering column mounting bolts,
POWER STEERING
92059R 92210R1
MANUAL STEERING - the lower left hand dashboard mounting (see

section 57),
Cut the ring that retains the rubber protector and - the lower cover from the heater controls,
push back the protector towards the bulkhead. - 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 36
REFITTING SPECIAL FEATURES FOR REFITTING THE STEERING
WHEEL EQUIPPED WITH AN AIRBAG
Check the length of the retractable shaft (see the
corresponding section). • It is essential to replace its nut (prebonded
nut) and tighten it to the specified torque (4.5
Fit the steering column. daN.m).
Lift the dashboard and insert the clip (3) in its • Reconnect the batteries
location.
IMPORTANT : before reconnecting the driver’s air-
Power steering bag cushion the following procedure must be car-
ried out for checking operation of the system :
Engage the gaiter (E) on the bulkhead. • Check that the warning light flashes when the
battery box is connected to the computer.
• Connect :
- the dummy ignition module to the connec-
tor of the driver’s airbag cushion and check
that the warning light is extinguished,
- the driver’s 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 en-
DI3608 titled "Airbag and belt pre-tensioners" (first
generation) Part Number 77 11 176 120, and
check the system with the XRBAG module (Elé.
1288).
Resecure :
- the steering column, • Tighten the two airbag cushion mounting bolts
- the dashboard. to a torque of 0.5 daN.m.
Reconnect the steering lock switch.

WARNING :
Fit : • Failure to follow these instructions may pre-
- the two bolts (3), vent the systems from operating normally
- the control switches to the steering column and even result in accidental triggering.
and reconnect them,
- the upper and lower steering column half • It is not permitted to carry out work on the
cowlings, airbag cushion or pretensioners with an ohm-
- the lower cover under the steering wheel, meter or other electrical measuring instru-
- the lower cover for the heater control ment as this may result in triggering of the
assembly, system.
- the steering wheel in the position marked
during dismantling,
- the eccentric bolt (1).
36-15
STEERING
Steering column 36
Manual steering
Refit the rubber protector and secure with a new

PVC ring.
92215R
36-16
STEERING
Steering column 36
ADJUSTING THE CLEARANCE UNDERNEATH THE 3 In all cases, before tightening eccentric bolt
STEERING WHEEL (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 pi-
nion are in line when tightening.
93707R
2 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 36
REMOVAL - REFITTING
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 Manual steering

L = 408 ± 1 mm L = 406 ± 1 mm
Power steering Power steering

L = 355.5 ± 1 mm L = 354.5 ± 1 mm
36-19
Master cylinder 37
M 10 x 100 1.3
M 12 x 100 1.3
Brake servo mounting bolt 1.3
REMOVAL
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.
37-1
Brake servo 37
REFITTING
Before refitting, check:

All left hand drive types :
Master cylinder to brake servo 1.3 - dimension L = 124.5 mm, adjustable on
Brake servo to bulkhead 2 certain models by means of rod (C),
- dimension X = 22.3 mm, adjustable on certain
models by means of stud (P).
The brake servo cannot be repaired. The only
operations that can be carried out on it are All right hand drive types :
replacing : - dimension L = 117.5 mm, adjustable on
- the air filter, certain models by means of rod (C),
- the non-return valve. - dimension X = 22.3 mm, adjustable on certain
models by means of stud (P).
REMOVAL
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).
90383R
37-2
Brake servo 37
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 If the vacuum falls by more than 33 mbars (25
vehicle, with the hydraulic system in operating mm/Hg) in 15 seconds, there is a leak which may
condition. be at either:
Connect the NAUDER* vacuum pump between - the non-return valve (replace it by a new one),
the brake servo and a vacuum source (the inlet
manifold) using a "T" union and a piece of pipe - the thrust rod diaphragm (in this case replace
which is as short as possible. the brake servo).
Run the engine at idling speed for one minute.

If the brake servo fails, the braking system will still
Pinch flat the pipe (clamp Mot. 453-01) between operate but the pressure required at the pedal
the "T" union and the vacuum source. will be much higher to give the same amount of
braking as would be obtained with servo assisted
Stop the engine. brakes.
*use as vacuum gauge.
37-3
Brake servo air filter - Non-return valve 37
REPLACING THE NON-RETURN VALVE
This operation can be carried out on the vehicle.

REPLACING THE AIR FILTER
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 REFITTING

replace its air filter (F).
Check the condition of the sealing washer and the
Extract the old filter (F) from under the pedal non-return valve.
assembly, using a screwdriver or metal hook. Cut
the new filter at A (see illustration) and place it Replace any faulty parts.
round the rod. Then push it into its location
ensuring that it covers the entire bore to avoid the Refit the assembly.
possibility of unfiltered air entering.
37-4
Pedal assembly 37
SPECIAL FEATURES
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
Handbrake lever 37
REPLACING
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
Handbrake control 37
Remove :
- both rear wheels,

ADJUSTING
- both drums.
If the handbrake is incorrectly adjusted, with the
cable too tight :
- the automatic brake shoe wear take-up sys-

tem cannot operate,
Check that the automatic wear take-up system is
- the brake pedal travel is too long. 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
Under no circumstances are the cables to be re- teeth.
tensioned to remedy this fault.
It will only reappear in a very short time.
BENDIX
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 ope-

rations is forbidden.
With the vehicle raised on a lift that locates under

the body, slacken nut (1) to release the central 90 328
brake compensator fully.
92217R2
90223G1
37-7
Ensure :
- that the cables slide freely,
- that the handbrake levers (B) locate correctly
on the shoes.
BENDIX
90 328
90223G

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
DISC BRAKES
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 adjus-

ter 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
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.
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 Place the caliper in position on the brake assembly
the hose (2) to the point at which the spring (3) is and screw the hose into it, tightening it to a
released. This will free the hose from the splines torque of 1.3 daN.m.
(4).
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.
85536R
Unscrew the hose from the caliper and, when

applicable, remove the caliper.
37-10
Brake compensator 37
TESTING PRINCIPLE
These vehicles are equipped with fixed brake

compensators that are integral with the wheel cy-
linders.
The pressure readings are taken in an X configura-

tion, 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 : front right / rear left hand circuit
II : 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 sepa-

rate bodies which act in an X configuration on
one front wheel and one rear wheel.

I : front right / rear left hand circuit
II : front left / rear right hand circuit
Load sensitive compensator

On load sensitive compensators the adjusting sys-
tem enables the rear pressure to be adjusted ac-
cording 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
Brake compensator 37
ESSENTIAL TOOLING REQUIRED
Fre. 244 -04 Pressure gauge for testing

or the compensator pressure
Fre. 1085 settings
TESTING TEST PRESSURES
Connect two pressure gauges (A) Fre. 244-04 or The compensators on these vehicles can only be
Fre. 1085 : tested. If the readings are incorrect, replace the
- one to the front right hand wheel, entire wheel cylinder.
- the other to the rear left hand wheel.
See the section "Values and settings" for the
Bleed the pressure gauges : screw (P). 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
Testing - Adjusting 37
The brake compensator must be tested and
adjusted with the vehicle on the ground,
unladen, and with one person on board the
vehicle.
Fre. 1085 Pressure gauge for testing

the compensator pressure settings
Since the compensator has two separate bodies, ADJUSTING

it is essential to test them one after the other.
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:
Gradually press down the brake pedal until the
test pressure (see pressure chart) is obtained at - release nut (A) and alter the position of rod
the front wheels. Then read the corresponding (B) in sleeve (C).
pressure at the rear wheels; correct it if
necessary.
37-13
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
Clutch cable 37
REMOVAL REFITTING
Unhook the cable from the fork, in the engine From inside the engine compartment, feed the
compartment. cable through into the passenger compartment.
Inside the vehicle, remove the transverse Inside the vehicle, check that the rockers (1) and
ventilation ducting. (2) can freely return to their released position.
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 .
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
Clutch automatic wear take-up system 37
SECTION
85872-1S
EXPLODED VIEW
DI3728
37-16
PRINCIPLE OF OPERATION TESTING
WEAR TAKE-UP To ensure that the system operates correctly,

check :
Spring (R) applies a constant tension to the wear 1 that the toothed cam (C) pivots round its pin,
take-up quadrant (S). 2 that the rockers (1) and (2) return freely to the
released position.
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
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
4 Check the fork movement. It should be :
X = 17 to 18 mm
91830R1
These tests must be carried out before any

rectification work on the actual clutch unit.
37-18
External gear control 37
The vehicles are equipped with a double locking PRINCIPLE OF OPERATION
external gear control that prevents any possibility
of selecting reverse instead of first without the The upper latch (A) operates through a cable (C)
latch being lifted. 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
EXPLODED VIEW AND TIGHTENING TORQUES
DI3729
1 Link
2 Return spring on 3rd/4th line
3 Casing
4 Pad
5 Lever and latch assembly
6 Protective gaiter
7 Gear lever knob
8 Circlip
9 Bush
10 Sleeve
37-20
SPECIAL TOOLING REQUIRED CONSUMABLES
Nuts mounting casing to body 1.5 Grease grade 33 Medium :

Bolt mounting link to clevis 3 Shift lever pivot point
REMOVAL REFITTING (Special operations)
From inside the vehicle, release the gaiter (6) from Coat the shift lever pivot points with grease grade
the console. 33 Medium.
Under the vehicle, disconnect : Bond the knob (7) to the lever.
- the flexible exhaust pipe mountings,
- the return spring (2), Adjust the gear control.
- 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
B.Vi. 1133 Tool for locking the type JB

gearbox input lever in 1st
Bolt securing link to clevis 3
ADJUSTING
Select 1st gear at the gearbox.
92079R
DI3702
37-22
Fit tool B.Vi. 1133 to take up the play. 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 In this position, tighten bolt (V).
downwards and swing it through 45 degrees until
it makes contact with the lug on the housing. Remove the feeler gauge and refit the return
spring (2).
92450-1R 92431R
37-23
Check the resulting clearance "Y" which should
be between 2 and 5 mm.
DI3705
Remove special tool B.Vi. 1133.
Check that the gears select correctly.
37-24
MB
Gear selection controls 37
EXPLODED VIEW
DI3731
REMOVAL REFITTING
Remove : It is essential to move the automatic transmission

to position "D".
Passenger compartment side:
- knob (2) by pulling vigorously upwards. Automatic transmission side
Before refitting the cable, check dimension (A)
Under the vehicle between the support face of the cable on sheath
- the protective cover. stop (9) and mounting ball joint (10).
Dismantle the cable stops (7). A = 131 mm
Remove : If necessary slacken the two nuts (12) to obtain

- the four nuts (3) retaining control unit (5) and this dimension.
withdraw it from underneath,
- the cable retaining clips (1).
37-25
MB
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
93611R push the cable, depending on the adjustment
required.
Control unit side
Do not forget to retighten sheath stop (8) at the
Place the selector in the "D" (Drive). end of the operation.
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
EXPLODED VIEW
DI3732
REMOVING REFITTING
Remove : It is essential to move the automatic transmission

to position "D".
Passenger compartment side:
- knob (2) by pulling vigorously upwards. Automatic transmission side
Before refitting the cable, check dimension (A)
Under the vehicle between the support face of the cable on sheath
- the protective cover. (6) stop (9) and mounting ball joint (10).
Dismantle the cable stops (7). A = 131 mm
Remove : If necessary slacken the two nuts (12) to obtain

- the four nuts (3) retaining control unit (5) and this dimension (see diagram below)
withdraw it from underneath,
- the cable retaining clips (1).
37-27
AD4
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.
A = 131 mm
Replace knob (2).
Control box (5) side
Check that the gears select correctly and that the
Place the selector in the "D" (Drive). starter engages in the "P" and "N" positions, and
check the "Park" function.
Align the two screen and repeater reference
marks before tightening the four bolts (11). 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.
93612R
37-28
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMSS
Bendix ABS 38
LOCATION AND COMPOSITION (Left hand drive)
92736R
38-1
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS
Bendix ABS 38
LOCATION AND COMPOSITION (Right hand drive)
92736-1R
38-2
Bendix ABS 38
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
DI3883
38-3
Bendix ABS 38
LOCATION AND COMPOSITION (left hand drive)
DI3884
38-4
Bendix ABS 38
LOCATION AND COMPOSITION (right hand drive)
DI3885
38-5
Bendix ABS 38
LOCATION AND COMPOSITION FRONT SENSORS
RADIAL AND NON-ADJUSTABLE
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 92721R

opposite the battery.
Targets (5) embedded in the hubs (cannot be

removed) for the rear.
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 92720R
targets.
Targets (5) embedded in to the driveshafts for the Number of teeth on the targets : 48
front wheels.
38-6
Bendix ABS 38
ABS CONTROL RELAYS NOTE :
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 Pressure alarm relay 25 A → black

B EPU control relay (301) 50 A → green
C 30 A fuse (260) EPU
D Starting cutout relay 25 A → black
E Safety relay, soldered (428)
92733R 92827S
38-7
Bendix ABS 38
LOCATION AND COMPOSITION The following are connected to the connection
plate :
The wiring loom is soldered to the connection
plate located alongside the computer in the - a 2 track connector for supplying the electric
heating compartment. 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

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 93447R1
intermediate connectors ,
- to the rear sensors by means of two 2 track
connectors located near the left rear axle
mounting.
92723S
38-8
Bendix ABS 38
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.
96584R
38-9
Bendix ABS 38
PRINCIPLE OF OPERATION (hand brake lever in zero position)
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 is not absolutely constant, but this is not regarded as a fault.
Starting phase :
- 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 illuminate simultaneously
and are extinguished after a time of up to 30 seconds.
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 the working solenoid valve closes the high pressure inlet and opens the return to the
relief : reservoir.
• slow pressure the restrictive solenoid valve closes the direct return to the reservoir and forces
relief : the brake fluid to cross the calibrated openings to provide a slow fall in pressure.
- for the rear wheels :
• fast pressure the working solenoid valve closes the high pressure inlet and opens the return to
relief : 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
Bendix ABS 38
OPERATING PRINCIPLE
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
Bendix ABS 38
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**.
38-12
Bendix ABS 38
REGULATION IN DEFECT MODE
FAULTS CONSEQUENCES REMEDIES
1 front sensor A single wheel checked on W. light illuminated

➜
front axle ABS no longer applied to this wheel
2 front sensors Front axle not checked W. light illuminated

➝
ABS no longer applied to front axle
1 rear sensor "Select Low" reduced to 0 or

or speed incoherence Illumination of
➞ ABS not applied anywhere on the vehicle
2 rear sensors More checking of rear axle
➟ 1 front solenoid valve As 1 As 1
⑤ 2 front solenoid valves As 2 As 2
➐ Rear solenoid valve As 3 As 3
Electric pump unit Pressure reduced to 90 bars W. light illuminated

ABS suppressed
Entire brake system without h. pressure
High pressure braking No high pressure W. light illuminated

➠ pressure unit hose Fall in pressure ABS suppressed
(fracture) Entire brake system without h. pressure
Electric pump unit feed Loss of pressure to 90 bars W. light illuminated

➡ hose ABS suppressed
Entire brake system without h. pressure
Electric pump unit feed Reduction in fluid level in Illumination of

⑩ hose reservoir Pump stopped
Illumination of
38-13
Bendix ABS 38
OPERATING PRINCIPLE • Pressure < 160 bars :
Pressure accumulator - the 160 and 180 bar pressure switches are
closed,
The accumulator enables a certain pressure
reserve to be maintained in order to limit the - the hydraulic pump operates - relay (301)
operating time of the hydraulic pump and controlled.
guarantee braking in the event of failure.
Pressure switches • Pressure between 160 and 180 bars :
The purpose of the two pressure switches is to - the 160 bar pressure switch is open,
regulate the hydraulic pressure between 160 and
180 bars. - the 180 bar pressure switch is closed,
A third 90 bar pressure switch alerts the computer - the hydraulic pump operates - relay (301)
and illuminates the ABS warning light if there is a remains controlled.
considerable drop in the hydraulic pressure.
• 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.
• Pressure drops below 160 bars :

94721R
- the 160 bar pressure switch closes,
Operating tolerance : - the hydraulic pump operates - relay (301)

controlled.
+5
A 90 0 bars
+5
B 160 0 bars
+5
C 180 0 bars
38-14
Bendix ABS 38
Operating principle of dual alarm device 2nd test
incorporated in the brake fluid reservoir
Switch off the ignition.
NOTE : the alarm device is integrated in the
reservoir. If it does not operate replace the Lower the pressure in the accumulator by pressing
complete reservoir. the brake pedal about twenty times.
1. when the following warning light initially Switch on the ignition and the pump will run to
illuminates: 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
Bendix ABS 38
REMOVING - REFITTING THE COMPONENTS REMOVAL
I - FRONT WHEEL SENSOR Disconnect the battery.
Remove :
TIGHTENING TORQUES (in daN.m) - the wheel,
- the sensor mounting bolt (1).
Wheel bolts 7 to 9
Sensor mounting bolts 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 Sensor
2 Tab support connector
3 Tabs
4 Split sealing sleeves
5 Heat shrinkable sleeve
38-16
Bendix ABS 38
For correct crimping of the terminal connectors Arrange the heat shrinkable sleeve as high as
(as the original) use a pair of PRONER pliers Ele. possible on the connector.
1146 , which can be ordered from the Parts
Department under Part Number 00 00 114 600. 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). 90898-2S
Check that lug (C) has emerged completely. IMPORTANT : extreme care must be taken when
making this connection to ensure perfect sealing.
Insert the tabs right into the connector (clear The sealant must be melted behind the sleeve and
locking sound). the wires must be in perfect condition.
Arrange sealant sleeves on the wires 5 mm from REFITTING

the connector bushes.
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
Bendix ABS 38
II - REAR WHEEL SENSORS REFITTING
Fit the sensor, previously coated with grease

TIGHTENING TORQUES (in daN.m) Multifunction 77 01 422 308, then clip the wire
into its supports and reconnect it.
Wheel bolts 7 to 9
Sensor mounting bolts 0.8 to 1
NOTE : to eliminate the risk of faults make sure
that the connector is properly connected.
REMOVAL
Remove :
- the wheel,
- the sensor mounting bolt (1),
- the sensor from its mounting.
III - FRONT WHEEL TARGET
Wheel bolts 7 to 9
Driveshaft nut 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
Bendix ABS 38
REFITTING REFITTING
Coat the target with LOCTITE SCELBLOC and refit Refit the three computer mounting bolts, then
it using a mallet, tapping lightly on the outside of those of the plate.
the target.
Reconnect the computer, making sure of a perfect
Make sure that you tap rap regularly to prevent connection of the 35-track connector (clipping).
the target from twisting, and check that it is
pressed home on the driveshaft. NOTE: exercise great care when refitting: the
three mounting points = ABS earth.
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 V - BRAKING PRESSURE UNIT, ELECTRIC PUMP
only is also available from the Parts Department. UNIT AND RESERVOIR ASSEMBLY (left-hand
drive)
IV - COMPUTER Braking pressure unit on bulkhead 2
This is located in the heating compartment (on

the left-hand side). REMOVAL
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
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 92724R
computer to the plate.
NOTE: do not slacken bolt (5) more than 2 turns
(this may damage the O ring)
38-19
Bendix ABS 38
It is possible to check that the accumulator is Remove:
actually empty by checking the brake fluid level in - the A.E.I.,
the reservoir, which must be approximately at the - heating compartment flap,
upper reference mark (B).
92729R1 93447R
Unclip the expansion bottle and remove it. - the 4 brake pipes and the high pressure union
(E) after marking them.
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).
92732R 92730R3
Disconnect the connector.
Remove the 3 nuts (D).
Remove the reservoir and disconnect the other 2

pipes.
38-20
Bendix ABS 38
Inside the vehicle, remove the pin from the clevis Release the wiring and disconnect it from the
connecting the brake pedal to the thrust rod after connection plate.
removing the clip.
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
Bendix ABS 38
Remove wiring mounting bolt (2) and the 2 bolts
(H).
94692R
- the two electric pump unit support mounting

bolts (H),
93446R
- the lower protective case, nuts (F),
- the 4 brake pipes and the high pressure union
Remove the braking pressure unit and electric (E) (marked when removed).
pump unit assembly.
IMPORTANT :
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 :
92730R2
- 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.
38-22
Bendix ABS 38
- 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.
93447R
Fill with brake fluid and proceed to bleed (see

corresponding section)
38-23
Bendix ABS 38
ELECTRIC PUMP UNIT - ACCUMULATOR - It is possible to check that the accumulator is
PRESSURE SWITCH ASSEMBLY actually emptied by checking the brake fluid level
(right-hand drive) in the reservoir, which must be approximately at
the upper reference mark (B).
Drain plug 0.8 to 1

Hose union 1.3
eElectric pump unit lock nuts 0.8

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 92729R

pump unit, which is accessible underneath the
Unclip the expansion reservoir and remove it.
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
Bendix ABS 38
Disconnect : - the two upper mounting nuts.
- the other pipes,
- the rigid pipe of the HP hose
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
Bendix ABS 38
PRECAUTIONS : Removing the brake pressure unit involves prior
removal of the engine and transmission assembly
1. Do not knock against, or rest the part on : (see section 13).
- the low pressure inlet pipe,
- the pressure switches,
- the accumulator. TIGHTENING TORQUES (in daN.m)
2. Do not pull or push on the wiring. Braking pressure unit on pedal

assembly plate 2
Hydraulic union 1.3
Drain plug 0.8 to 1
REFITTING
Fit : is between 160 and 180 bars. It is also essential to
- the electric pump unit (without the on the hydraulic circuit.
accumulator), fitted with the hose,
- the four mounting nuts,

To do this the bolt (5) located under the electric
- the accumulator fitted with a new O ring, and pump unit, which is accessible underneath the
lock it, vehicle, must be slackened one turn.
- the rigid pipe on the HP hose,
- the wiring and the heating compartment flap

mountings,
93447R
94699-1R
- the brake fluid bottle (if necessary), and
connect the hoses, Press the brake pedal twice.
- the air filter.
Fill with brake fluid and proceed to bleed (see the

38-26
Bendix ABS 38
It is possible to check that the accumulator is Remove :
actually emptied by checking the brake fluid level - the heat shields.
in the reservoir, which must be approximately at
the upper reference mark (B).
92729R
Drain the reservoir at the unions (C).

94700S
- the heating compartment flap.
92732R
93447R
38-27
Bendix ABS 38
Disconnect: Slacken the nuts securing the braking pressure
- the four brake pipes and the high pressure unit to the pedal assembly plate.
union after marking them.
94693S
94696S
- the hoses. Release the wiring and disconnect it from the

connection plate.
Inside the vehicle, remove the clevis pin
connecting the brake pedal to the thrust rod,
after removing the clip.
92735S
Remove the braking pressure unit.
94692R
Retain the spacer.
38-28
Bendix ABS 38
IMPORTANT : - 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
- the hoses,
- the heat shields,
REFITTING - the wiring and the locking clips,
- the heating compartment flap.
Fit :
- the braking pressure unit assembly, not NOTE : when replacing the pipes it is essential to
forgetting the connecting seal, replace the heat shields before proceeding to fit
- the four mounting nuts on the pedal plate, the threaded unions.
- the spacer,
- the pedal clevis pin and the locking clip Refit the engine and transmission assembly.
Fill with brake fluid and proceed to bleed the

system completely (see corresponding section).
94692R
38-29
Bendix ABS 38
REPLACEMENT OF ACCUMULATOR - PRESSURE SWITCHES
Mot. 445 Strap wrench
TIGHTENING TORQUES (in daN.m) Right-hand drive
Drain plug 0.8 to 1

Pressure switch 0.7- 1.3

is between 160 and 180 bars. It is also essential to
on the hydraulic circuit.
To do this the bolt (5) located under the electric

pump unit, which is accessible underneath the
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
Bendix ABS 38
REMOVING PRESSURE SWITCHES
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

38-31
Bendix ABS 38
XR25 FAULT FINDING
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 vehicle’s diagnostic

socket and set the selector to "S5".
38-32
Bendix ABS 38
Analysis of system operation using the XR25 and the latest cassette.
Vehicle stationary, ignition on.
Enter code D 0 5
The display shows:
1 BENDIX make
(1 second) then 2X Computer number
5 Product tested - ABS
or
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
Bendix ABS 38
FI21605
Bargraphs on a coloured background are fault bargraphs

Bargraphs on a white background are status bargraphs
38-34
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;
1
- 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
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 kΩ 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:
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?
no yes
Break in wiring, check the following Check that no voltage is present at

continuities: terminal 2 of starter cut-out relay
- between track 2 of computer and 4 of base:
starter cut-out relay base; - if voltage is not present, replace
- between track 3 of starter cut-out relay base the relay;
and track A1 of ABS/ dashboard R36 - if voltage is present, check the
connection; operation of the ignition switch.
- between track A1 of R36 and track 2A of
ignition switch via 15 A fuse.
Check operation of ignition switch.
38-36
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
3
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

4
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 Ω, 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
Bendix ABS
38
Internal computer control.

6 Erase the computer memory (control G0**).
If the fault persists, replace the computer.
Fault on ABS warning light line.

7 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
7
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
8 the voltage on track B3 of the connector.
9 Do you read 0 Volts?
10
NO Replace the relay plate
YES Measure the resistance of the suspected solenoid valve between earth and the
computer connector track specified above.
What resistance value is measured?
R = 0Ω short circuit on solenoid valve coil replace the brake pressure assembly
1Ω < R < 5Ω Test the connections on the 35 track connector. If the connector is correct,
and if the fault persists, replace the computer.
Solenoid valve control fault (system cut off).

8 8 FRH restriction solenoid valve terminal 4 35-track connector
9 9 FLH restriction solenoid valve terminal 21 35-track connector
10 10 RLH solenoid valve terminal 23 35-track connector.
Perform the same operations for illumination on the left.
38-38
Bendix ABS
38
11 FRH solenoid valve circuit fault, terminal 5 of 35-track connector

12 FRH restriction solenoid valve circuit fault, terminal 4 of 35-track connector
13 FLH solenoid valve circuit fault, terminal 22 of 35-track connector
14 FLH restriction solenoid valve circuit fault, terminal 21 of 35-track connector
15 RRH solenoid valve circuit fault, terminal 24 of 35-track connector
16 RLH solenoid valve circuit fault, terminal 23 of 35-track connector
Illuminated on left: circuit open - on right: short circuit.
17 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
18 RLH RRH
34 RRH - 15 and 32 RLH - 16 and 33 FRH - 18 and 35 FLH.
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 kΩ, check wiring between sensor and 35-track connector.
38-39
Bendix ABS 38
Special notes for Renault 19 vehicles with AC - PAS - ABS
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 Front right
19
(if #14 → 9)
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 (examples above)
or
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.
38-40
Bendix ABS 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 Sensor information fault

This fault is taken into account for a speed greater than 15 mph (24 km/h).
(if #14 → 9)
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.
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
Bendix ABS 38
New generation computers (# 14 → 35)
Wheel sensor information fault.

Enter #07 and read the display of the XR25 (4 cases are possible)
Front left Front right
19
(if #14 → 35)
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 (examples above)
or
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
Bendix ABS 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.
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).

Rear wheels air gap: 0.20 / 0.80 mm
19 This fault is taken into account for a speed greater than 15 mph (24 km/h).
(if #14 → 35) 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 0 at the required time to obtain this function.
This memory is erased by entering

D 0 5
38-43
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. Pressure on brake pedal too high. Repeat
Enter D05 (pay no attention to test using reduced pressure.
bargraph 3L flashing).
When G01* is entered, slight noise from

the movement of the solenoid valve should
be heard (3 times), then at the end of the
Repeat this test on the other wheels. cycle, bargraph 3 left should illuminate
To do so, enter the following codes: (computer cuts out).
G02* : RRH
G03* : FRH
G04* : FLH
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
Bendix ABS 38
ADDITIONAL TESTS
After initialising the system, on the keyboard enter:
# 0 1 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
# 0 6 2 left is illuminated.
enables the origin of the sensor data fault to be determined when bargraph 19
# 0 7 right or left is illuminated.
38-45
Bendix ABS 38
ERASING THE MEMORY 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 0 5
The display shows:
Then:
XX
Enter:
G 0 *
The display shows:
92655R
Validate the erase request using *
A second later the centre display shows:
The memory has been erased.
38-46
Bendix ABS 38
FAULT FINDING
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 Vehicle wiring
B 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
Bendix ABS 38
CONNECTION TO VEHICLE Allocation of diagnostic socket terminals
1 Fault finding information AT "A4"

With the ignition switched off, disconnect the 2 Earth
ABS computer from its base and connect the 3 Foolproofing
bornier in position. 4 Cruise control fault finding
information
5 ABS fault finding information
6 + 12 Volts after ignition
7 Fault finding information AT "M"
8 To electronic fault warning light
9 Injection fault finding information
10
11 Not allocated
12
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, 88113S
- voltage measurement using the voltmeter.
Resistance of the solenoid valves :
• Multimeter : 1 Ω to 5 Ω
- resistance measurement,
- voltage measurement. Resistance of the sensors :
1 000 Ω to 1 400 Ω
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 Ω to 60 Ω
38-48
Bendix ABS 38
Allocation of the computer connector pins
PIN No. ALLOCATION
1 Not connected
2 + 12 volt after ignition input
3 Electric earth
4 Front right restriction modulator
5 Front right inlet/pressure relief modulator
6 Not connected
7 Not connected
8 ABS safety relay contact
9 90 bar pressure switch
10 Not connected
11 Not connected
12 Diagnostic socket
13 Not connected
14 Not connected
15 Rear left hand wheel sensor
16 Front right hand wheel sensor
17 Rear right hand wheel sensor
18 Front left hand wheel sensor
19 ABS safety relay contact
20 Electric earth
21 Front left hand restriction modulator
22 Front left inlet/pressure relief modulator
23 Rear left inlet/pressure relief modulator
24 Rear right inlet/pressure relief modulator
25 Not connected
26 ABS warning light return
27 Electric earth
28 Electric earth
29 Not connected
30 Not connected
31 Not connected
32 Rear left wheel sensor
33 Front right wheel sensor
34 Rear right wheel sensor
35 Front left wheel sensor
DI3835
38-49
Bendix ABS 38
6 track connector for pressure switch ↔ board WIRING DIAGRAM NOMENCLATURE
connection
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
156 Hand brake switch
207 Nivocode sensor
225 Diagnostic socket
247 Instrument panel
260 Fuse
301 ABS electric pump unit relay
94717R 361 ABS hydraulic system

425 ABS board
12 track connector for braking pressure unit ↔ 428 Main relay (soldered)
board connection 435 ABS solenoid valve assembly
M18 ABS earth
M19 ABS electronic earth
R1 Dashboard /rear right connection
R35 Pedal assembly/dashboard connection
R36 ABS/dashboard connection
A Pressure alarm relay
D Ignition cutout relay
94718S
38-50
Bendix ABS 38
DI94918
38-51
Bendix ABS 38
ADDITIONAL CHECKS II - Checking rear wheel sensor connectors
I - Target/sensor air gap If the ABS warning light illuminates intermittent-

ly, check as a priority the wheel sensor connectors
(Place the target so that the top of one tooth is and clean them with NETELEC, Part Number 77 01
parallel with the sensor) 408 464.
Front sensor X = 0.15 to 1.15 mm
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
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
Bendix ABS 38
To carry out the different pressure checks (IV to VI) it is necessary beforehand to fit a pressure gauge,
proceeding as follows:
Fre. 1085 Complete brake system test kit
TIGHTENING TORQUES (in daN.m) Fit end piece (D) and pressure gauge
Fre. 1085.
Drain plug 0.8 - 1
Bleed screw 0.6-0.8
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
Place a pipe connected to a reservoir on the

92724R 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
Bendix ABS 38
IV - Checking the accumulator
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 If the value is incorrect, replace the

must stabilise at this value accumulator.
before continuing to rise.
91582S1
Checking hydraulic accumulator

depressurising time (engine warm, Check :
system temperature 60 to 80o C). - the tightness of the pressure
release screw,
Switch on the ignition. - for the absence of an external leak.
Wait until the pump stops. If the value is incorrect, replace the
electric pump unit assembly.
Check the time it takes to resume
operation (without pressing the Minimum time : 2 mm
brake pedal). Maximum time : 9 mm
38-55
Bendix ABS 38
V - Checking charging times and 160 and 180 bar pressure switches
Accumulator charging time

Check :
Reduce the pressure (bolt 5).
- the operation of the pump,
- the condition of the filter in the

Banjo union,
Charging time - the condition of the high pressure

40 to 60 seconds hose and pipes.
92724R1
Retighten bolt (5). If the pressure value is incorrect ( >

Pressure between 190 bars), replace the 180 bar
Switch on the ignition. pressure switch.
180 and 190 bars
91582S1
Press the brake pedal several times.
The pressure must be between If the pressure value is incorrect,

155 and 165 bars replace the 160 bar pressure switch.
NOTE : the pump restarts after 2 to 4

presses of the brake pedal.
91583S1
Re-inflation time
Check the pressure at which the 160 / 180 bars
pump restarts. → 3 to 10 seconds
38-56
Bendix ABS 38
VI - Checking 90 bar pressure switch
Checking 90 bar pressure switch.

Check :
Wait for the pump to stop.
- warning light bulbs,
- warning light fuses,
Disconnect the supply to the electric
pump unit motor (2 track connector - pressure alarm relay,
on board 425).
Warning lights extinguished.
- continuity.
Switch on the ignition again and +
press the brake pedal several times.
91583S1
Check that the warning lights If the value is incorrect, replace the
pressure switch.
+
illuminated for a pressure

+5
of : 90 0 bars
Reconnect the 2 track connector to

the board (425). The pump operates,
the warning lights
are extinguished
38-57
Bendix ABS 38
VII - Checking for internal leaks
Checking for internal leaks
Fit 2 pressure gauges on the front

wheel calipers.
After 5 minutes there must be Check for the absence of an external

no loss of pressure leak.
(1 bar max.)
Replace the braking pressure unit
assembly.
91563-4R3
91582S1
Wait for the pump to stop.
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
Bendix ABS 38
VIII - Checking the alarm device
Checking operation of dual alarm

device incorporated in the brake
fluid reservoir.
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 - the continuity of the electrical
(hand brake in position of rest) circuit.
The alarm device is integrated in the

reservoir, if it fails to operate, replace
the complete reservoir.
92728S1
2nd check
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 the pump must stop In case of failure (pump does not
stop), replace the reservoir.
Release the pump must

restart
38-59
Bendix ABS 38
BRAKE COMPENSATOR
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.
I front right/rear left hand circuit
II 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
Bendix ABS 38
BRAKE COMPENSATOR
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
Bendix ABS 38
Fuel tank Test pressure (Bar)

Vehicle type (driver in vehicle)
Front Rear
All types with fixed compensator +0

integrated in the wheel cylinder 60 34 -4
B, C, L 533
53C
53Y With ABS
534 (after
53J 05/92)
53K
B, C, L 53T
53V With ABS
53Z
3, 4, 5 53A 90966S1
53B With ABS +0
Full 100 40 -8
53F
B, C, L, S 53F
538 Without
53K ABS
53T (after
53Z 11/94)
3, 4, 5 53C Without
53D ABS (after
53H 11/94)
38-62
Bendix ABS 38

Front Rear
+0
B, C, L, D 539 (before 60 47 -8
53D 05.92)
B, C, L 53A
53S With ABS
53B
538
With ABS
B, C, L 53F (after +0
05.92) 100 52 -8
3, 4, 5 53C
53D With ABS
53H
90966S1
Full
D53D (after 05.92
853C
B, C, L, S 53F
538 Without
53K ABS
53T (after
53Z 11/94)
+0
100 49 -8
3, 4, 5 53C Without
53D ABS
53H (after
11/94)
38-63
Bendix ABS 38

Front Rear
B, C, L, D, S 533
53C +0
100 43 -8
53F With ABS
534 (before
53J 05/92)
53K
53Y
B, C 53M ABS
B, C, L 53D (After
05.92) 90966S1
Full
With ABS
D 53C (after
53Y +0
05.92) 100 52 -8
D 53V
8 53A With ABS
53F
38-64
Bendix ABS 38
CHECKING LEVEL - BLEEDING II - COMPLETE BLEEDING
I - CHECKING THE LEVEL

The brake fluid level is checked with the ignition
switched on: accumulator filled to MAXIMUM M.S. 815 Bleeding device
reference mark. Fre. 1 085 Complete kit for brake system
Switch on the ignition and wait for the pump to

stop.
If necessary top up the fluid level to the Precaution to be taken before carrying out any
MAXIMUM mark (B) (vehicle with new shoes or work on the bleed screws:
linings)
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
Bendix ABS 38
Right-hand drive
91582S
94699-1R Remove the protective plate (right-hand drive).
Tightening torque of bolt (5) : from 0.8 to 1 Fill the high pressure(HP) hose by slackening
daN.m. union (E) (braking pressure unit connection)
several turns.
When the pedal is pressed, the different bleed
screws must always be slackened and tightened
progressively. Left-hand drive
Between each operation check the level of the

brake fluid in the reservoir.
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 re-
tightening the plug and pressing the plunger.
92730R
38-66
Bendix ABS 38
Right-hand drive 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. Switch on the ignition, electric pump unit

operates.
Retighten union (E).
Allow to drain until the emulsion has
Switch off the ignition. disappeared.
Retighten bolt (5). Retighten (3) and (4) with the engine running.
Allow to run until stopped by pressure switch.

(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
Bendix ABS 38
3. Bleeding the braking pressure unit (simulation Refit the protective braking pressure unit plate
spring zone) (right-hand drive).

(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

94700R
The pump is used as a circulator.
Depressurise the accumulator by means of bolt 5. Bleeding at the calipers

The pump is used as a circulator.
Slacken bolts (1) and (2) one turn.
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
DI3886R1
each wheel).
Press the brake pedal. Carry out the same procedure for the other
wheels.
Switch on the ignition, the electric pump unit
operates.
After 30 seconds tighten bolts (1) and (2), with the

engine running.
Release the brake pedal.
38-68
Bendix ABS 38
6. Checking bleeding Press the brake pedal sharply, it should have a
minimum pressure of approximately 30 bars in the
Depressurise the accumulator by means of bolt front wheel cylinders.
If you do not have 30 bars, check the bleeding of
Connect two pressure gauges Fre. 1 085 to the the pressure gauges, if it is correct, restart
front wheels. 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
Bendix ABS 38
FAULT CHART FOR ABS BENDIX
1 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

+ illumination of brake warning light
1.3 - ABS warning light remains illuminated after initialisa-
tion without illumination of brake warning light
1.4 - ABS warning light remains illuminated after initialisa-
tion + 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 - Illumination of ABS warning light alone

2.2 - Illumination of ABS warning light + brake warning light
2.3 - Random illumination of ABS warning light
2.4 - Illumination of brake warning light alone
2.5 - 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
Bendix ABS 38
2 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 - On poor roads

3.2 - On good roads
3.3 - At low speed
3.4 - 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
Bendix ABS 38
1 Effect on operation of ABS and brake warning lights
1 - When ignition is switched on/engine is started/engine running

Connect the XR 25 to the vehicle’s 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 no
Is bargraph 7 illuminated? Communication fault between XR 25 and

ABS computer:
yes no
- Check connection of R36 connection
(ABS/dashboard) located near battery;
Recheck - Check connection between diagnostic
your socket and computer: continuity between
diagnosis track 12 of computer and track 5 of
diagnostic socket.
If incorrect, check following continuities:
• On the left: - Between track 12 of computer and
ABS warning light line track A2 of the ABS/dashboard
interruption. connection;
- Check 10 A stop light fuse n° 29. - Between track A2 of ABS/dashboard
- Check continuity between track R36 connection and track 5 of
26 of computer and track C1 of diagnostic socket.
ABS/dashboard R36 - Check voltage at track 6 of diagnostic
connection. socket (V > 10 volts).
- Check continuity between track - Check for the presence of earth at track 2
C1 of R36 and warning light. of diagnostic socket.
- Check condition of warning - Check computer supply:
light bulb and for presence of - Presence of earth at tracks 3, 20, 27
+ after ignition at warning and 28. If not, check continuity with
light. earth M19.
- Presence of voltage > 10 volts at track
• On the right: 2.
The diode on the plate has short- If not, check:
circuited. - Battery voltage;
- Replace the relay plate. - 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 yes
A B
38-72
Bendix ABS
38
(continued)
A B
Break in wiring. - Check for absence of voltage at terminal

- Check following continuities: 2 of starter cut-out relay base:
- Between track 2 of computer and 4 - If no voltage is present, replace the
of starter cut-out relay base; relay (contact faulty);
- Between track 3 of starter cut-out - If voltage is present, check operation
relay base and track A1 of ABS/ of ignition switch.
dashboard R36 connection;
- Between track A1 of R36 and track
2A of ignition switch via 15 A fuse.
- 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 yes
Check warning light bulb Check operation of handbrake switch and continuity
and for presence of + after between it and the warning light.
ignition at warning light. If it illuminates, check operation of 90 bar pressostat:
Check continuity of brake ignition off, drain the high pressure system (at the
warning light lines. 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?
yes
no
Reconnect 90 bar pressostat and

Replace 90 bar pressostat check operation/supply of pressure
(tightening torque: 0.7 to warning relay and corresponding
1.3 daNm). continuities.
38-73
Bendix ABS 38

1.2 - No illumination of ABS warning light during initialisation + illumination of brake
warning light
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.
Disconnect R36 connection (ABS/dashboard) yes
located near the battery and
switch the ignition on again.
Does the warning light illuminate again?
no Check insulation of ABS warning light line

between R36 and warning light.

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
Bendix ABS 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 yes
Replace the relay plate. Recheck your diagnosis
38-75
Bendix ABS
38

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 If LR is displayed
- Check connections of 160 and 90 bar Check coil or pressure warning relay
pressostat, of 6-track connector of pressostat coil circuit.
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.
yes
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 yes
A Replace 160 bar

pressostat.
38-76
Bendix ABS 38
(continued)
A B
- 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
Bendix ABS 38

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.

2.1 - 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
Bendix ABS 38

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
Bendix ABS 38
2 Effects observed on operation of ABS brakes without illumination of warning light
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 yes
Check: Perform the same test on the other

- Sensor mounting wheels:
- Air gap (0.2 to 0.81 mm) - Front left-hand wheel: between
- Target mounting. tracks 18 and 35 (air gap 0.15 to
If there is still no value measured, turn 1.15 mm)
the other wheels to confirm any - Front right-hand wheel: between
possible electrical inversion of the tracks 16 and 33 (air gap 0.15 to
sensors and repair the wiring. 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
Bendix ABS
38
2 Effects on operation of ABS brakes without illumination of warning light
(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
Brake pedal pressure too high. Switch the ignition off then on.
Repeat the test with lower pressure. Enter D05 (pay no attention to flashing of
When request G01* is made, the bargraph 3L).
movement of the solenoid valve (3 times) Repeat the test on the other wheels:
should be just audible then bargraph 3L enter the following codes:
may illuminate at the end of the cycle. - G03* : FRH
- If there is no release, switch the - G05* : FRH restriction
ignition off then on, enter D05 and - G02* : RRH
reuse the same code, watching to see - G04* : FLH
if another wheel is released - G06* : FLH restriction
(confirming reversed piping: repair).
- If there is no release and no solenoid When all 4 wheels have been tested,
valve noise there is a hydraulic fault, erase the computer memory (function
replace the braking pressure unit. GO**)
38-81
Bendix ABS 38
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 no
Check tyre pressures, front

axle, calipers and pads or,
possibly, for leaks in the
circuit.
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
Replace the brake pressure Recheck your

assembly (imbalance in travel diagnosis
of limiter rods).
38-82
Bendix ABS
38
2.2 - Wandering
Connect XR 25 ,
enter D05 to deactivate the ABS and road test the
vehicle without ABS.
no yes
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.
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
Bendix ABS 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 driver’s foot is on the brake pedal, he may notice and be surprised by
the ABS system operating when it should not.
38-84
Bendix ABS 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 unit’s 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
Bendix ABS 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
Bosch ABS 38
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.
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
Bosch ABS 38
LOCATION AND COMPOSITION
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
Bosch ABS 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
Bosch ABS 38
DI3887
38-90
Bosch ABS 38
LOCATION AND COMPOSITION Front wheels
• Speed sensor (3) and target (4) Targets embedded in the driveshafts.
A magnetic sensor is composed of a permanent Radial, non-adjustable sensors.

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 Magnet
2 Field lines
3 Polar mass
4 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
Bosch ABS 38
The speed sensors are connected to the computer For the rear:
via connectors located:
Next to the left hand mounting for the rear axle
For the front: assembly.
On the side of the shock absorber turret in the

engine compartment.
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).
38-92
Bosch ABS 38
LOCATION AND COMPOSITION It analyses the information from the wheel
sensors and controls the regulation solenoid
• The computer valves depending on this information.
The integral computer is mounted on the NOTE : the diagnostic socket is located in 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. 92827S
As soon as a wheel is tending to lock, the solenoid

valves and the pump motor are activated via the This allows connection of the XR25 for testing
two relays mounted on the top of the computer. microprocessor systems.
The integration of the electronic function into the Communication between the computer and the
hydraulic assembly and corresponding reduction fault finding equipment allows:
in weight has lead to reduction in wiring and
number of connectors (hence greater reliability) • the computer to be identified.
and makes the unit easier to fit to the vehicle. • memorised fault information to be read
The main functions carried out by the computer • system parameters to be read (wheel speeds,
are: voltage...).
- preparation of the signal, • the solenoid valves, pump motor and warning
light bulb to be operated.
- regulation,
• the memory to be erased.
- self-testing (safety monitoring),
- fault finding.
38-93
Bosch ABS 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.
38-94
Bosch ABS 38
ABS 2 E HYDRAULIC ASSEMBLY
DI3889
1 Solenoid valves
2 Pump relay
3 Solenoid valves relay
4 Motor
5 Pumping component
6 Accumulator
7 Piston plunger
38-95
Bosch ABS 38
OPERATING PRINCIPLE
• 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.
38-96
Bosch ABS 38
PRESSURE INCREASED PHASE (PHASE 1)
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 Computer 5 Solenoid valve

2 Accumulator 6 Master cylinder
3 Motor 7 Wheel sensor
4 Pump 8 Target
38-97
Bosch ABS 38
PRESSURE MAINTAINED PHASE (PHASE 2)
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.

4 Pump 8 Target
38-98
Bosch ABS 38
PRESSURE REDUCED PHASE (PHASE 3)
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.

4 Pump 8 Target
38-99
Bosch ABS 38
OPERATING PRINCIPLE
• 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. Braking without regulation
2. Pressure maintained
3. Pressure reduced
38-100
Bosch ABS 38
OPERATING PRINCIPLE
Braking without regulation
DI3891
C Compensator 1 Front left brake cylinder (via solenoid valve)

E Rear regulation solenoid valve 2 Front right brake cylinder (via solenoid valve)
P Piston plunger 3 Rear left brake cylinder
CL Valve 4 Rear right brake cylinder
P1 Position 1 5 Rear axle assembly
P2 Position 2
P3 Position 3
In the braking without regulation phase, the piston plunger is not operational (position 1 of rear solenoid
valve (E) and valve (CL) open).
38-101
Bosch ABS 38
OPERATING PRINCIPLE
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).
38-102
Bosch ABS 38
OPERATING PRINCIPLE
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.
38-103
Bosch ABS 38
REGULATION
SUMMARY OF PRINCIPLE
Sensor Wheel
signal speed
Analysis of the
signal
Regulation
strategy
Order of
regulation
Hydraulic
intervention
Modification
of speed
38-104
Bosch ABS 38
REGULATION
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.
38-105
Bosch ABS 38
SELF TESTING
• 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).
38-106
Bosch ABS 38
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.
Summary table for ABS 2E self testing
Fault
Component tested Test conditions
Test type Customer complaint memorised
ABS warning light Visual Warning light illuminates Does not illuminate No
for 2 seconds after
switching ignition on
Solenoid valve
connections: front CO As soon as ignition on
CC for V > 6km/h No ABS + warning light Yes
left, front right
CC+ for V > 6 km/h illuminated
and rear
CC - (CP) As soon as ignition on
Sensor Outside regulation:

connections: front Detection when ignition No ABS + warning light Yes
left, front right, switched on illuminated
rear left and rear
right During regulation:
Fault on 1 front wheel (up ABS retained for other
to end of regulation) wheels.
Braking pressure increases
up to master cylinder
Logical or pressure at faulty wheel.
resistance
monitoring
Then for V > 20 km/h No ABS + warning light Yes
(after starting again) illuminated
Fault on 1 rear wheel (up to ABS retained for 2 front

end of regulation) wheels
(rear pressure = 0)
Then for V > 20 km/h No ABS + warning light Yes

(after starting again) illuminated
Stop switch CO (computer As soon as ignition on No ABS + warning light Yes

connections track 9 stop bulb illuminated
earth)
38-107
Bosch ABS 38
Pump motor CO (computer, As soon as ignition on No ABS + warning light Yes
connections pump motor illuminated
earth via pump
motor)
CC For V > 6 km/h No ABS + warning light Yes

illuminated
Pump motor relay CC power circuit (Pump motor permanent

connections control) No ABS + warning light
As soon as ignition on illuminated Yes
CC control circuit For V > 6 km/h No ABS + warning light Yes

illuminated
CO power circuit For V > 6 km/h No ABS + warning light Yes

illuminated
CO control For V > 6 km/h No ABS + warning light Yes

circuit illuminated
Fault finding CC - As soon as ignition on if Warning light flashing No

connection line "L" is earthed
Feed Voltage drop 1. Vehicle speed< 6 km/h No ABS + warning light

U battery If under voltage< 1 min illuminated No
< 9.4 V
If under voltage> 1 min No ABS + warning light Yes
illuminated
2. Vehicle speed> 6 km/h

Taken into account No ABS + warning light Yes
immediately illuminated
Solenoid valve CC power circuit As soon as ignition on No ABS + warning light Yes
relay connection illuminated
CC control circuit As soon as ignition on after No ABS + warning light Yes

30 seconds filtering illuminated
CO power circuit As soon as ignition on after No ABS + warning light Yes

30 seconds filtering illuminated
CO control As soon as ignition on after No ABS + warning light Yes

circuit 30 seconds filtering illuminated
38-108
Bosch ABS 38
Toothed wheel Coherence 1. Fault declared after 2 No ABS + warning light Yes
min filtering illuminated
If speed of one wheel >
25 % of reference
speed
2. If regulation continues No ABS + warning light Yes

for more than 60 seconds illuminated
Key:
CO Electrical connection or component in open circuit

CC Electrical connection or component in short circuit
CC+ Electrical connection or component to + 12 V
CC - (CP) Electrical connection or component in short circuit to earth or permanent control
38-109
Bosch ABS 38
If there is a fault, after switching the ignition off,this fault is stored in the computer’s memory.
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
38-110
Bosch ABS 38
FAULT FINDING WITH THE XR25
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

92656S
after every operation on the ABS)
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

D 1 1 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
92655R
light is illuminated before entering fault finding
mode if there is a permanent fault).
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.
38-111
Bosch ABS 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:
2 Bosch make
(1 second) then XX Computer number
5 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 D 1 1 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
38-112
Bosch ABS 38
FI21611
38-113
Bosch ABS 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;
1 - 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
2 FLASHING: Erase memory (GO**) and confirm the fault.

STEADY: 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,
3 - 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.
38-114
Bosch ABS 38
STOP CIRCUIT
ILLUMINATED ON LEFT: CORRECT IF PEDAL DEPRESSED

ILLUMINATED ON RIGHT: CORRECT IF PEDAL NOT DEPRESSED.
By depressing the brake pedal, check alternating RIGHT/LEFT illumination of bar graph 4.
YES : Normal circuit operation.
NO : 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
4 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.
YES : 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.
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?
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 presence of a shunt between
tracks A4 and B5.
NON : The stop lights illuminate.
38-115
Bosch ABS 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
5
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.
- NO : Switch the ignition off, replace the pump motor relay and carry out a road test.
Replace the computer if bar graph 5 illuminates again.
SOLENOID VALVE RELAY CIRCUITS
ONLY BAR GRAPH 6 ILLUMINATED OR BAR GRAPHS 6 + 8, 9 AND 10 ILLUMINATED

6
Replace relay.
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.
7 - 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.
38-116
Bosch ABS 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 - 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;
9
- Bar graphs 8, 9 and 10 illuminated with bar graph 7:. deal with bar graph 7;
10
- 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 FRONT LEFT SOLENOID VALVE

(tracks 1 and 2 of 6 track connector)
BAR GRAPH 12 FRONT RIGHT SOLENOID VALVE
BAR GRAPH 13 REAR SOLENOID VALVE
11
12
13 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 Ω.

If incorrect, replace hydraulic unit.
If correct, replace computer.
38-117
Bosch ABS 38
17 FLH FRH WHEEL SENSOR CIRCUIT
Check connector of faulty sensor.

If connector is correct, check resistance of sensor at 20 °C
18 RLH RRH
If value is other than 1.2 kΩ ± 0.5, replace sensor.
Check continuities between connector of sensor in question and computer:
Front left sensor : track 2 sensor / 7 computer

track 1 sensor / 13 computer
Front right sensor : track 2 sensor / 5 computer
Rear right sensor : track 1 sensor / 6 computer
Rear left sensor : track 2 sensor / 2 computer
track 1sensor / 4 computer
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.
38-118
Bosch ABS 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 0 when required by the user.
D 1 1
This memory is erased by entering
38-119
Bosch ABS 38
DISPLAY OF BAR GRAPHS ON XR 25 AFTER ROAD TEST
+ SWITCHING IGNITION OFF AND ON
Bar graphs 1, 2, 3 and 4 : same function as without switching ignition off
Bar graph 5 flashing : as for bar graphs 5 + 8, 9 and 10 without switching the ignition off (ABS
warning light is extinguished)
Bar graph 6 only or : as for bar graphs 6 + 8, 9 and 10 without switching the ignition off (ABS
bar graphs 6 + 8/9 and 10 warning light is illuminated)
Bar graph 7 : same function as without switching ignition off
Bar graph 8 + 9 and 10 : shows ABS system is not operational and a road test is required to
determine what component is at fault
Bar graph 11 or 12 : as for bar graph 8, 9 and 10 + 11 or 12 or 13 (ABS warning light is

or 13 flashing extinguished)
on right and left hand sides
Bar graph 17 or 18 : as for bar graph 17 or 18 + 8, 9 and 10 (ABS warning light is extinguished)
flashing on right or
left hand sides
Bar graph 19 : as for bar graph 19 without switching ignition off

flashing
AFTER REPLACEMENT OF A HYDRAULIC ASSEMBLY:
Check the system using the "G" function on the XR25 :
- G3* FRONT LEFT SOLENOID VALVE

- G4* FRONT RIGHT SOLENOID VALVE
- G5* REAR SOLENOID VALVE
- G7* ABS WARNING LIGHT
- G8* 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*.
38-120
Bosch ABS 38
ADDITIONAL TESTS
After initialising the system, enter
# 0 1 front right wheel speed (in km/h)
# 0 2 front left wheel speed
# 0 3 rear right wheel speed
# 0 4 rear left wheel speed
# 0 6 battery voltage (volts), example :
maximum voltage read = 12.06

(computer voltage regulation)
# 0 8 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
# 0 9 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.
38-121
Bosch ABS 38
Command mode
IMPORTANT: to use the command mode, the ABS system must be operational ( no faults present).
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 1 1 The display shows:
Then G 3 *
The front left wheel

releases temporarily (5 times)
Same for
G 4 * Front right wheel solenoid valve
and
G 5 * Solenoid valve for rear left and right
hand wheels
38-122
Bosch ABS 38
Checking the ABS warning light
the warning light

Enter G 7 * should extinguish for
2 seconds
Checking operation of the relay and pump

the pump motor
Enter G 8 * should operate for 2
seconds
38-123
Bosch ABS 38
ERASING THE MEMORY
Switch the ignition on but do not start the engine.
Enter code D 1 1
The display shows:
then:
Enter : G 0 *
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.
38-124
Bosch ABS 38
CHECKING THE WIRING
Elé. 1286 Bornier for testing the wiring using

the XR25 or multimeter
This is a base with 15 contacts identical to those Connection

on the ABS computer, on a printed circuit with
electrical contacts numbered from 1 to 15. Ignition off, disconnect the ABS computer from its
base and connect bornier Elé. 1286 in its place.
Each number corresponds to an electrical
connection in the vehicle wiring and is indicated Principle of the testing method
on the diagram on the next page.
Apply the test pin of the XR25 or the multimeter
It is used for quick and accurate testing of all the to the numbered indicated on the bornier.
electrical connections on the main ABS connector.
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 Ω.
Pump / motor coil resistance:

approximately 0.5 to 1 Ω.
Sensor resistance (at 20°C)

approximately 1.2 kΩ.
Pump / motor relay:

Coil resistance approximately 55 Ω.
Solenoid valve relay:

96953S Coil resistance approximately 55Ω.
NOTE:
• Never disconnect the computer when a

voltage is applied to the circuit.
• Earths and resistances should be measured

with the battery disconnected.
38-125
Bosch ABS 38
DI96913
38-126
Bosch ABS 38
WIRING DIAGRAM KEY Allocation of the 15 track computer connector
pins
Components:
104 Ignition switch 1 ABS warning light
107 Battery 2 Rear left sensor earth
118 ABS computer 3 -
150 Rear right wheel sensor 4 Rear left sensor signal
151 Rear left wheel sensor 5 Front right sensor earth
152 Front right wheel sensor 6 Rear right sensor signal
153 Front left wheel sensor 7 Front left sensor earth
160 Stop switch 8 -
172 Rear right light 9 Stop switch
173 Rear left light 10 Front right sensor signal
225 Diagnostic socket 11 -
247 Instrument panel 12 Diagnostic line L
260 Fuse box 13 Front left sensor signal
361 "ABS" hydraulic assembly 14 Rear right sensor earth
425 ABS plate 15 Diagnostic line K
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 Ω
94716R
Resistance of the sensors (at 20°C) :
approximately 1.2 kΩ
NOTE:
Never disconnect the computer when a voltage is

applied to the circuit.
Earths and resistances should be measured with
the battery disconnected.
38-127
Bosch ABS 38
CONNECTORS
Connection Allocation Location on the vehicle
R36 black (2) Next to the battery (see diagram below)

ABS/dashboard
R36 grey (1)
R35 black dashboard/ pedal mounting Passenger compartment front left pillar
R1 brown dashboard/rear right Passenger compartment front right pillar
96956R
38-128
Bosch ABS 38
Allocation of diagnostic socket terminals Position of the relays on the computer plate
94640R
A Solenoid valve relay

B Pump / motor relay
88113S
4 track connector (361) on computer plate
1 AT A4 diagnostic connection
2 Earth
3 Mechanical foolproofing
4 Not used
5 Not used
6 + 12 V after ignition
7 AT M diagnostic information
8 To electronic fault warning light

9 Injection fault finding information
10 Diagnostic line "L" (ABS)
11 Diagnostic line "K" (ABS)
DI3892
1 + after ignition (UZ)

2 + before ignition (Bat +)
3 Earth (-)
4 ABS warning light (Sila)
38-129
Bosch ABS 38
REMOVING - REFITTING THE COMPONENTS
1 - FRONT WHEEL SENSOR
Wheel bolt 9
Sensor mounting bolt 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

96956-1R
absorber turret in the engine compartment.
Front right speed sensor connector (B).
Remove the sensor.
38-130
Bosch ABS 38
2 - REAR WHEEL SENSOR
Wheel bolt 9
Sensor mounting bolt 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
The sensor must be fitted by hand. Do not hit it
Release the wire from its mountings. during fitting.
Disconnect the sensor from its connector located Do not pull or push on the wiring.
under the vehicle, near the left hand mounting
for the rear axle assembly.
38-131
Bosch ABS 38
3 - FRONT WHEEL TARGET 4 - REAR WHEEL TARGET
TIGHTENING TORQUES (in daN.m) Target (4) embedded in the hub (cannot be
removed).
Wheel bolt 9
Driveshaft nut 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.
38-132
Bosch ABS 38
5 - COMPUTER Remove the 6 mounting bolts and remove the
computer - relay plate.
Computer mounting bolt 1.5
REMOVAL
Disconnect the battery.

Remove the upper cover.
94640S
REFITTING
Ensure the plate mounting bolts are correctly

tightened, especially bolt (D) marked + which
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
Carry out :
Disconnect: - a road test then check using the XR25,
- the 4 track connector (1), - erase the computer memory (G0**).
- the 15 track connector (2),
- the 6 track connector (3). Validate the end of the test : G13*.
DI3892R
38-133
Bosch ABS 38
6 - HYDRAULIC ASSEMBLY Remove the 3 hydraulic assembly mounting bolts.
Remove the hydraulic assembly / mounting

TIGHTENING TORQUES (in daN.m) assembly.
Pipe bolts 1.2 to 1.6 Plug the assembly openings.
REFITTING
REMOVAL
Fit the hydraulic assembly ensuring the pipes are
Disconnect the battery. correctly located.
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).
DI3893
VL Front left (yellow)

VR Front right (green)
HL Rear left (blue)
HR Rear right (red)
Connect the connectors.
Fit:
- the upper cover,
- the earth wire on the pump / motor.
Ensure the wiring and connections are correctly

96953-1S routed.
Remove the master cylinder. Refit the master cylinder and bleed the hydraulic
circuit, following the order of operations (see
Slacken the 4 unions on the hydraulic assembly, following page).
using a pipe wrench.
NOTE : never reconnect the battery and switch
Disconnect the earth wire on the pump motor. the ignition on unless the complete hydraulic
circuit has been fully bled.
38-134
Bosch ABS 38
BLEEDING
IMPORTANT
The order of operations for bleeding the ABS

hydraulic circuit MUST be observed:
1 Front left wheel caliper
2 Front right wheel caliper
3 Rear left wheel caliper
4 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.
38-135
Bosch ABS 38
BLEEDING USING A BLEEDING KIT BLEEDING WITHOUT A BLEEDING KIT
Connect the bleeding kit to the brake fluid The sequence of operations is the same as
reservoir. opposite and must also be followed.
1. Attach the tube to the bleed screw of the • Connect the tube to the bleed screw of the
corresponding wheel cylinder. corresponding wheel cylinder.
Open the corresponding bleed screw and wait • Open the bleed screw in question.
until the fluid flowing out contains no
bubbles (approximately 30 seconds). • Depress the pedal several times until there are
no more bubbles.
Shut the bleed screw.
• During the bleeding procedure, make sure
It is essential to follow the sequence of that the fluid level is always between
bleeding operations: minimum and maximum marks.
a) Bleed, from the master cylinder towards COMPENSATOR CONTROL (Special notes)
front left;
b) from the master cylinder towards front When the vehicle is with its wheels "hanging
right; free", this type of control allows force to
c) from the master cylinder towards rear maintained at the lever so the compensator
left; remains with the "valves open" during the
d) from the master cylinder towards rear bleeding operation.
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.
38-136
Bosch ABS 38
ADDITIONAL TESTS 2 - CHECKING THE WHEEL SENSOR CONNECTORS
1 - TARGET / SENSOR GAP If the ABS warning light illuminates

intermittently, first check the wheel sensor
(Position the target so that the top of one tooth is connectors and clean them with NETELEC Part
parallel to the sensor). Number 77 01 408 464.
Front sensor:
X = 0.40 to 1.20 mm
DI3894
96954S
Rear sensor: NOTE:

X = 0.40 to 1.90 mm
• 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 kΩ
38-137
Bosch ABS 38
Hydraulic assembly pipe markings
DI3893
VL : Front left (yellow)

VR : Front right (green)
HL : Rear left (blue)
HR : Rear right (red)
For obvious safety reasons, never incorrectly

connect the sensor connectors or the hydraulic
assembly pipes.
38-138
Bosch ABS 38
COMPENSATOR
OPERATING PRINCIPLE
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
38-139
Bosch ABS 38
Fuel tank (driver on Test pressure (Bar)

Vehicle type board)
Front Rear
All types with fixed compensator +0

integrated in the wheel cylinder 60 34 -4
B, C, L 533
53C
53Y With ABS
534 (after
53J 05/92)
53K
B, C, L 53T
53V With ABS
53Z
3, 4, 5 53A 90966S1
53B With ABS +0
Full 100 40 -8
53F
B, C, L, S 53F
538 Without
53K ABS
53T (after
53Z 11/94)
3, 4, 5 53C Without
53D ABS
53H (after
11/94)
38-140
Bosch ABS 38

Vehicle type board)
Front Rear
+0
B, C, L, D 539 (before 100 47 -8
53D 05/92)
B, C, L 53A
535 With ABS
53B
538
With ABS
B, C, L 53F (after +0
05/92) 100 52 -8
3, 4, 5 53C
53D With ABS
53H
90966S1
Full
D53D (after 05/92
853C
B, C, L, S 53F
538 Without
53K ABS
53T (after
53Z 11/94)
+0
100 49 -8
3, 4, 5 53C Without
53D ABS
53H (after
11/94)
38-141
Bosch ABS 38

Vehicle type board)
Front Rear
B, C, L, D, S 533
53C +0
100 43 -8
53F With ABS
534 (before
53J 05/92)
53K
53Y
B, C D53M ABS
B, C, L 53D (after 90966S1

05/92) Full
+0
D 53C With ABS 100 52 -8
53Y (after
05/92)
D 53V
8 53A With ABS
53F
38-142
Bosch ABS 38
Checking and adjustment of the braking compensator must be carried out with the vehicle on the ground
and one person on board.
Fre. 1085 Pressure gauge for checking

brake limiter adjustment
As the compensator has two separate bodies, one If the difference is great (values exceed
must be checked after the other. tolerances), replace the compensator; no
operations are permitted.
CHECKING
ADJUSTMENT
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).
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.
38-143
Bosch ABS 38
REPLACING THE COMPENSATOR
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
38-144
Bosch ABS 38
BOSCH 2E ABS FAULT FINDING CHART
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

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
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
38-145
Bosch ABS 38
BOSCH 2E ABS FAULT CHART
2 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.
38-146
Bosch ABS 38
1 Faults noted in the operation of the ABS warning light

1.1 - The warning light does not illuminate
Connect the XR25 to the vehicle’s

diagnostic socket. Set the ISO switch to Use function G7* on the XR25.
position S8 and use the latest XR25 Does the warning light extinguish for 2
cassette . yes
seconds ?
Enter code D11 on the keyboard.
Does the warning light illuminate after
the initialisation period ? (5 seconds) yes no
no Recheck Replace the computer

your diagnosis
Is bargraph 1 illuminated ? no
yes
Check the continuity of the 2 warning Communication fault between the XR25 and the ABS
light lines : between the warning light computer.
and track 4 of the 4 track connector on the Check the battery voltage (> 9.4 ±0.4 volts)
hydraulic assembly and between the and the 15 A fuse on the accessories board.
warning light and track 1 Check for an earth on track 2 on the diagnostic socket
of the 15 track computer connector. and + before ignition on track 6.
Also check the 10 A fuse and the bulb.
Check the insulation from earth of the lines between
Does the fault still persist?
the computer and the diagnostic socket as well as the
continuity of these lines :
yes no - between track 10 on the diagnostic socket and track
12 on the computer and
- between track 11 on the diagnostic socket and track
Earth track 4 of the 4 track Correct 15 on the computer.
connector for the hydraulic
assembly or track 1 on the Check the connection of the 2 connectors R36
15 track connector. Does the (ABS/dashboard) and the computer feed on the 4
warning light illuminate? track connector : - earth on track 3,
- + after ignition on track 1,
- + before ignition on track 2.
no yes
After repair, re-enter code D11.
Does the warning light illuminate after the
Recheck The warning light circuit is initialisation period ? (5 seconds)
your correct.
diagnosis Replace the computer. Does yes no
the fault persist?
no yes Recheck
your
diagnosis
Correct Recheck
your
diagnosis
38-147
Bosch ABS 38

1.2 - Permanent illumination of the warning light
Locate the fault corresponding to the

Connect the XR25 to the vehicle’s fault bargraph and repair.
diagnostic socket. Set the ISO switch to Road test the vehicle and retest with the
position S8 and use the latest XR25 XR25.
cassette . no
Is a new fault shown ?
Enter code D1 on the keyboard.
Are only bargraphs 1 and 4 illuminated ?
(normal situation with no fault)
no yes
yes
yes Does the fault persist?
Use function G7* on the XR25 and no

watch the ABS warning light.
Does it extinguish for about 2 yes
seconds ? Correct
no
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
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
38-148
Bosch ABS 38

1.3 - The warning light is dimly illuminated
Connect the XR25 to the vehicle’s Locate the fault corresponding to the
diagnostic socket. Set the ISO switch to fault bargraph and repair.
position S8 and use the latest XR25 Road test the vehicle and retest with the
cassette . no XR25.
Enter code D11 on the keyboard. Is a new fault shown ?
no yes
yes yes Does the fault persist?
no
Check the insulation of the two warning light circuit
lines :
track connector and Correct
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 ?
38-149
Bosch ABS 38

Connect the XR25 to the vehicle’s Communication fault between the XR25 and the
diagnostic socket. Set the ISO switch to ABS computer
position S8 and use the latest XR25
Check the wiring for diagnostic lines K and L
cassette . no
(earth).
Turn the ignition on and enter code
D11 on the keyboard. Does the fault persist?
Does bargraph 1 remain illuminated ?
yes no
yes
Correct
Are only bargraphs 1 and 4
illuminated ? 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 Check the insulation of the two warning light circuit lines :
persist? yes - 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).
no
Also check the condition of the ABS earths and the 4 and 15
track connectors. After repair, does the fault persist ?
Correct
no yes
38-150
Bosch ABS 38

1.5 - The warning light illuminates again after a delay (after 5 seconds)
Connect the XR25 to the vehicle’s 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.

2.1 - The warning light does not extinguish
As for 1.2

2.2 - The warning light illuminates again
Connect the XR25 to the vehicle’s Locate the fault corresponding to the
diagnostic socket. Set the ISO switch to fault bargraph and repair.
position S8 and use the latest XR25 Road test the vehicle and retest with the
cassette . no XR25.
Enter code D11 on the keyboard. Is a new fault shown ?
no yes
yes
yes Does the fault persist?
Incorrect contact between connectors. no

Battery voltage too low
(< 9.4 ± 0.4 volts).
Correct
38-151
Bosch ABS 38

As for 1.4

3.1 - The warning light illuminates
As for 1.3

As for 1.4 and 2.3

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.

4.2 - The warning light flashes during ABS braking
As for 4.1
38-152
Bosch ABS 38

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.

4.4 - 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.
38-153
Bosch ABS 38
2 Faults noted in ABS operation without illumination of the warning light
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.
38-154
Bosch ABS 38

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. yes
If the pedal travel is relatively long, bleed the braking circuit

following the recommended order.
no 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.
38-155
Bosch ABS 38

2.2 - Wandering

and carry out a road test with the ABS non-
operational. yes
no Roadholding fault not connected with the ABS system
Normal behaviour caused by the ABS system during

the regulation phase, especially for non-symmetrical
adherence or poor road surfaces.

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.

3.2 - While driving
3.2.1 At low speeds or when pedal only slightly depressed
Connect the XR25 to the vehicle’s diagnostic socket.

Set the ISO switch to position S8 and use the latest Locate the fault corresponding to the
XR25 cassette . Turn the ignition on and enter code fault bargraph and repair.
D11 on the keyboard. Are only bargraphs 1 and 4 no Turn the ignition off and on again.
illuminated ? Is a new fault shown ?
yes 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.
38-156
Bosch ABS
38

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.

3.2 - 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.

3.2 - 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.
38-157
Bosch ABS 38

4.1 -Hard pedal

and carry out a road test with the ABS non-
operational. yes
no
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

4.2 - Spongy pedal
There is air in the braking circuit. Bleed the circuit follo-

wing the special order for bleeding at the wheels.
After the operation does the fault persist or has the pedal no Correct
travel been extended?
yes
Air in the piston plunger.

Carry out a specific bleeding operation for this fault.
Does the fault persist after this second bleeding opera- no Correct
tion?
yes
Replace the hydraulic assembly
38-158
Bosch ABS 38

4.3 - Long pedal travel
Air in the primary braking circuit.

Bleed following the manufacturer’s instructions.

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.
38-159

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Chassis

WHEELS AND TYRES

MECHANICAL ELEMENT CONTROLS

ELECTRONICALLY CONTROLLED SYSTEMS

77 11 190 850 NOVEMBER 1996 Edition Anglaise

30 GENERAL 33 REAR AXLE

31 FRONT AXLE 35 WHEELS AND TYRES

36 STEERING 38 ELECTRONICALLY CONTROLLED

"X" TYPE BRAKING SYSTEM "X" TYPE BRAKING SYSTEM

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 1.3

• of the front axle sub-frame,

BRAKE FLUID CHANGE PERIODS

Topping up the fluid level

Officially approved brake fluids

B- C - L - S B- C - L - S All types with ABS X 53

DIAMETER 15 mm 17 mm 23.15 mm 24.75 mm

Rear suspension bar specifications

TUBULAR REAR AXLE 4 BAR REAR AXLE

B- C - L - S All types with ABS X 53

DIAMETER 19.8 mm 21.7 mm 23 mm

- marks on their ends

LEFT HAND BAR RIGHT HAND BAR

The pipes between the master cylinder, the front

Consequently, it is important only to use the parts

- THE SHAPE of the ends of the steel or copper

- THE SHAPE of the THREADED LOCATIONS in

- the fact that the pipe UNIONS are GREEN or

The effect of the geometry angles

CASTOR The steering must be in the straight ahead

STEERING BOX HEIGHT - that too much toe-in causes symmetrical

Before checking the axle geometry, check the

- That the tyres on any given axle are the same

- At the hinge and pivot points :

In this position, fit the checking equipment, and

DETERMINING THE STEERING CENTRE POINT

Before checking and adjusting the front axle

Turn the steering to full lock in one direction.

Make a mark (A) at the top of the steering wheel

Move the steering to full lock in the other

Return to half the number of turns (and fractions

Because of the design of the front axle, a change

It is therefore essential to carry out the

- dimension A should be the same on both

2 If the lengths X are not the same :

- note dimensions A on the right and left hand

Turn the track rods to even-out the dimensions A

- zero the floating plates in this position,

- note the readings A on the scales. - check, in the following order :

One of several cases may arise :

Parallelism Distribution Correction to be carried out

Front axle fault finding

DEFECT POSSIBLE CAUSE

Castor incorrect - Suspension arm bent

Camber + kingpin correct - Suspension arm bent

Suspension arm bent

Parallelism incorrect by more than 6 mm. - RH or LH stub axle carrier bent.

During fault finding notice is only to be taken of

The fault finding sequence can be broken down

I The effect as noted on the pedal

I THE EFFECT AS NOTED ON THE PEDAL

FAULT POSSIBLE CAUSE

Stiff pedal : - Assistance fault