Braking system

Anti-lock braking system

33.
The electronic control unit also has stored in memory deceleration and acceleration thresholds which
each individual wheel must never exceed. Thus the rolling of the braking tyre is monitored by means of a
systematic, continuous and very fast comparison of the wheel's skid, deceleration and acceleration val-
ues. As soon as the combined acceleration/deceleration, skid deceleration/acceleration and "split"
thresholds are exceeded, the electronic control unit intervenes, controlling the solenoids of the hydraulic
control unit in the three adjustmentstages:increase in pressure - decrease in pressure - maintenance
of pressure.

These stagesdeterminean intermittent but extremelyfast adjustmentcycle which is repeateduntil the

car stops.
The electronic control unit controls the various stages, providing the solenoids with pulses of different
current intensity.
It also applies to both rear wheels the same braking force which the computer supplies to the rear wheel
most prone to locking, i.e. the wheel with less grip.
Normally the system ceases to intervene at speeds of less than 5 km/h to permit complete locking of the
wheels when the vehicle is stopped.

NOTE Since the parameterscontrolled by the electronic control unit (wheel speedand acceleration)
are influenced by the inertia of the rim-tyre assembly,vehiclesequipped with anti-lock braking
systemmust only be fitted with rims, tyres and brake pads recommendedby the Manufac-
turer.

During aquaplaning,the electronic control unit detec~sfrom the speedsensorsa faulty condition during
normal unbraked driving, since the driving wheels tend to rotate faster than the vehicle speed, whereas
the driven wheels are slower.
This situation would make the electronic control unit impart an adjustment cycle which would not meet
requirements; for this reason, the anti-lock braking system switches itself off temporarily (without the
warning light necessarily coming on, in view of the brevity of the action), and switches itself on again as
soon as the aquaplaning ceases.
The electronic control unit also carries out the following self-checks:
1. After the ignition has been switched on and for about 2 seconds, it checks the operation of the two
processors and relays which operate the solenoids and the recycling pump motor.
2. After about 2 seconds and up to a speed of around 15 km/h, it detects changes in current on the
solenoids, checks the operation of the recycling pump motor and checks that the signals coming
from the speed sensors are correct.
3. Whenever the car stops and restarts up to a speed of around 25 km/h, it measures the change in cur-
rent on the solenoids and checks that the signals coming from the speed sensors are correct.
4. During driving, it continuously checks the actual wheel speeds with the reference speed stored in its
memory, it checks the memory conditions and supervises the operation of the two relays.
5. During driving, it constantly checks the battery voltage.
If the anti-lock braking system detects one of these faults, it switches itself off and this is indicated to the
driver by the fault warning light on the instrument panel coming on.

Copyright Fiat Auto 17

Braking system Fiat barchetta
Anti-lock brakinl! system

P3WO18DO2

Identification of pins on the electronic control unit and the relevant connector

~-~
=;.., W1re
I~ Wlr~
coJour Destination ..
AI9 c..,
co
"" 1 ""

our
pest...inat.i.Qij

1 AR To fault warning light on instrument panel 9 RN To stop lights switch

2 M To rear left speed sensor 10 Spare
3 Spare 11 V To front right speed sensor

4 G To rear left speed sensor 12 AB To Fiat-Lancia Tester diagnostic socket

5 M To front right speed sensor 13 R To front left speed sensor

6 R To rear riQht speed sensor 14 M To rear right speed sensor

7 M To front left speed sensor 15 BR To Fiat-Lancia Tester diagnostic socket

8 Spare

18 Publication no 506586
Fiat barchetta Braking system
Anti-lock braking system

Operation of the electronic control unit

The speed sensors (A) generate an alternating voltage which is sent to an amplifier (1), located inside
the electronic control unit.
The amplifier generates a square-wave signal which is sent to the processors (2) and (3}, which in turn
calculate the wheel speeds and car speed.
If tlolewheels are tending to lock, the processors (2) and (3) drive the current regulators of the front
wheels (4) and rear wheels (5). These regulators generate control signals which are sent to the final
stages (6) and (7), which earth the circuit of the solenoids VL - VR (front) and H L - H R (rear) located in
the electrohydraulic control unit (B).
The module (8) receives the signal from the stop lights switch (C) and checks its electrical connection;
it also checks the supply voltage to the recycling pump motor (0) and sends information to the module
(9) which earths the circuits of the relays controlling the solenoids (E) and recycling pump (F), stabi-
lizes the battery voltage (G) and manages the operation of the fault warning light.
The module (10) serves to transmit data to the Fiat-Lancia Tester.

c ~
D ~
G E:3

p"wn190n1

Self-test
The electronic control unit comprisesa self-test systemwhich checksthe system'smain components;if
there are any faults, it intervenesand disablesthe anti-lock braking system and ensuresconventional
braking.

Fault diagnosis with Fiat-Lancia Tester

Faults in the components of the anti-lock braking system can be sought and identified using the Fi-
at-Lancia Tester with a specific memory.

Copyright Fiat Auto 19

Braking system Fiat barchetta
Anti-lock brakin~ system

2. Hydraulic control unit

The hydraulic control unit consists of the following components:

1. 4 solenoids.
2. 1 recycling pump for the two branches of the hydraulic circuit with ball type inlet valves.
3. 1 recycling pump relay.
4. 1 solenoid supply and safety relay.
It varies the pressure of the brake fluid in the caliper pistons (or rear wheel cylinders) in accordance with the
control signals received from the electronic control unit.
The electronic control unit drives both the solenoids and the recycling pump on the basis of the signals it re-
ceives from the four speed sensors.
The solenoids are of the 3-position type, and they are controlled by the electronic control unit via a signal
with different current values for the different positions to be assumed.

0 A = Pressure increase stage

1.9-2.3 A = Pressure maintenance stage
4.5-6 A = Pressure reduction stage

The recycling pump is activated, via the rele-

vant relay, by the electronic control unit during
operation of the anti-lock braking system. This
pump recycles brake fluid during the pressure
reduction stage, so that it is available upstream
of the solenoid for the subsequent pressure
loading stage.
The accumulators allow brake fluid to be ab-
sorbed during the pressure discharge phase.

View of the hydraulic control unit assembly

1. Solenoids for front and rear wheel brake

circuit
2. Recycling pump
3. Solenoid supply and safety relay
4. Recycling pump relay

Identification of outputs from the hy-

draulic control unit
H R = to the brake caliper or rear right wheel
cylinder
HL = to brake caliper or rear left wheel cylin-
der
VR = to front right brake caliper
VL = to front left brake caliper

20 Publication no. 506.586

 Fiat barchetta Braking system
Anti-lock braking system
33.

P3WO21 DO1 P3WO21 DO2

Identification of control unit pins Identification of the pins of the control unit's
connector
The hydraulic control unit cannot be overhauled and if a fault is detected, it must be replaced as an assembly.
Only the electronic control unit with the integrated relays can be replaced.
It is supplied as a spare part filled with brake fluid with the valves in the open position, and so the procedure
for bleeding and filling the braking system is the same as for a conventional braking system.

SPEED SENSORS
The speed sensors provide the electronic control unit, with the necessary continuity, all the required informa-
tion so that the hydraulic control unit is driven correctly.
They measure the driving speed, acceleration, deceleration and skidding of the wheels.
The sensors are inductive; they are mounted on special seats and are located on the front and rear wheel vertical
links.
The magnetic flow lines are closed through the teeth of a toothed wheel (phonic wheel) facing the sensor
and rotating with the wheel. The passage from full to empty, due to the presence or absence of the tooth,
causes a sufficient variation in the magnetic flow to create an induced electromotive force at the sensor's ter-
minals, and so an alternating electrical signal to the electronic control unit.

P3WO13DO5

Position of front wheel speed sensor Position of rear wheel speed sensor

Copyright Fiat Auto 21

~
Braking system Fiat barchetta
Anti-lock braking system

The front phonic wheels (1) are press-fitted on the constant velocity joints, wheel side, while the rear
nhnni~ wheels are mess-fitted on the wheel hubs.

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I P3WO22DO2
P3WO22DO1
Position of front phonic wheel (1) Position of rear phonic wheel

The specified gap for obtaining correct signals between the end of the sensor and the phonic wheel
must be comprised in the fol.lowing ranges:

This gap is not adjustable, so if it is outside the tolerance limits, check the condition of the sensor and
the phonic wheel.
If one or several phonic wheels break or are deformed, causing a difference in speed of 25% in relation to
the reference speed, the electronic control unit switches off the device and the fault warning light comes
on. The time for detecting the fault is about 120 seconds with a car speed of over 6 km/h.
p'Wn77nn!;

n n..nn. P3WO22DO4
ro..u"uuo
1. Front wheel speed sensor 1. Rear wheel speed sensor
2. Electrical connector 2. Electrical connector
The electronic control unit recognizes faults attributable to the speed sensors when the speed of one or
several wheels remains at the minimum value for over 20 seconds, and at a car speed of over 12 km/h.
Under these conditions, the anti-lock braking system is disabled and the fault warning light comes on.
If the fault affects all 4 speed sensors simultaneously, the problem is not indicated by the fault warning
light coming on and the anti-lock braking system remains disabled.

22 Pllhlication no- 506_586

Fiat barchetta Braking system
Anti-lock braking system
33.
ABS SYSTEM FAILURE WARNING LIGHT

With the ignition on, the ABS fault warning light (red) comes on for about 2 seconds; after this period,

the warning light should go out. If it stays on, there is a fault in one or several of the components of the

anti-lock braking system; braking therefore takes place in the conventional manner.

If the warning light does not come on, the fault should be sought in the lamp's wiring connection, the

protective fuse and the electrical connection between the ignition switch and the electronic control unit.

Anti-lock braking system fault warning

light
P3WO23DO1

STOP LIGHTS SWITCH

With the gear engaged and the brake pedal pressed, the electronic control unit receives the signal that
the driver is braking, and the anti-lock braking system is activated.
This information is particularly useful when the road surface is irregular (bumps, steps) which can cause
changes
the in wheel
electronic speeds
control for reasons not associated with braking, so preventing incorrect information
unit. . to

Stop lights switch

Copyright Fiat Auto 23

Braking system Fiat barchetta
Anti-lock braking system
33.
DESCRIPTION OF OPERATION OF ANTI-LOCK BRAKING SYSTEM

On the basis of the signals received from the front and rear wheel speed sensors, the electronic control
unit drives the hydraulic control unit, which in turn varies the pressure of the brake fluid sent to the
calipers, going through the three stages described below.

Pressure increase stage

When the vehicle's driver presses the brake pedal, the pressure generated by the brake pump (6) reaches
the brake calipers without being changed, since the solenoids (5) of the hydraulic unit are not ener-
gized.
When the solenoids (5) are not energized, their pistons are subjected to the action of the spring alone
and they place the pipes of the brake pump (6) and the brake calipers rn direct communication.
As the braking force increases, the wheel deceleration also decreases, or the wheel decelerates faster
than the car (i.e. the wheel creep increases).
The creep value must not exceed particular thresholds, beyond which the wheel loses grip with the
ground and begins to slip, no longer providing direction control and lengthening braking distances.

The wheer speed sensor (7) indicates that deceleration values have been reached which could impair
wheel grip, and at this point the control unit intervenes to reduce the braking force and allow the wheel
to increase speed to recover its grip.

P3WO24DO2 P3WO24DO1

1. Electronic control unit 5. Solenoids

2. Accumulator 6. Brake pump
3. Recycling pump motor 7. Wheel speed sensor
4. Recycling pump 8. Phonic wheel

24 Publication no. 506.586

Fiat barchetta Braking system
Anti-lock braking system

Pressure reduction stage

The electronic control unit detects the wheel's tendency to lock, and controls the intervention of the an-
ti-lock braking system.
It also sends the energization signal to the solenoids (5) (sending a 5 amp. current), and the pistons
within them move upwards and interrupt the hydraulic connection between the brake pump (6) and
brake calipers, at the same time opening the connection between the brake caliper and recycling pump
(4) (in this way some of the brake fluid is taken away from the brake calipers).
At the same time, the control unit sends the control signal tothe recycling pump (4), which enables the
hydraulic fluid taken from the brake calipers to be recirculated in the main circuit.
During this stage, a series of pressure waves (or hydraulic thrusts) are generated, noticeable by the driv-
er on the brake pedal, which should be considered normal during intervention of the anti-lock braking
system.
The accumulator (2) present in the circuit stores some of the brake fluid of the secondary circuit (so
some pressure remains available upstream of the solenoid), and the pump can therefore be rated for a
low average flow rate.
During this stage, because of the reduction in braking force, the wheel begins to acceleration, increasing
its speed of rotation.

P3WO26DO2 P3WO26DO1

1. Electronic control unit 5. Solenoid

2. Accumulator 6. Brake pump
3. Recycling pump motor 7. Rpm sensor
4. Recycling pump 8. Phonic wheel

Copyright Fiat Auto 25

Braking system Fiat barchetta
Anti-lock braking system
33.
Pressure maintenance stage
During this stage, the electronic control unit sends an energization signal with a low yalue (about 2
amp.) to the solenoid (5).
The connection between brake pump (6) and brake caliper is still interrupted (waiting position).
The pressure sent to the brake caliper is kept constant by the accelerator pump (4), whatever the pres-
sure exerted on the brake pedal. The wheel continues to accelerate and increases its speed until the
wheel speed sensor signal transmits a wheel rotation value equal to the vehicle's speed; only then does
the control unit cease to energize the solenoid (5) and the pressure of the brake pump (6) can again
reach the brake caliper, starting the cycle from the beginning.
The cycle is repeated from the first stage until the pressure on the brake pedal ceases, or when the vehi-
cle stops (at 5 km/h the system switches itself off to allow the vehicle to stop).

p,wn,.nn, p,wn,.nn1

1. Electronic control unit 5. Solenoid

2. Accumulator 6. Brake pump
3. Recycling pump motor 7. Wheel speed sensor
4 Recvclina oumo ,Q. Phnni~ \/I/hAAI

?~ P"hli""tinn nn i;nR i;RR

Fiat barchetta Braking system
Anti-lock braking system
33.
REMOVING-REFITTING STOP LIGHTS
SWITCH

1 Disconnect the supply connector.

2. Rotate the stop lights switch and with-

draw it from its seating.
3. Fit the spare switch complete with bush
(2) and spacer (3) in its seat, in accor-
dance with the following procedure:

- keep the pedal pressed, then insert the

switch in the position of engagement on
the bracket (4);
- rotate the switch in a clockwise direction to
the end of its travel; you will hear a click as
the retaining lug (5) engages in its seat (6);

- release the brake pedal to the rest position: the switch will position it-
self automatically in relation to the bush (2);
- press the pedal in order to remove and break the service spacer (3)
used as a protection during adjustment.
NOTE The service spacer (3) frees an internal stop lug which prevents
any further movement between the switch and bush.

1. Hexagonal section of the switch

2. Bush
3. Spacer
4. Bracket
5. Retaining lug
P3WO27DO3

Copyright Fiat Auto 27

 Braking system Fiat barchetta
Anti-lock braking system

1 FRONT WHEEL SPEED SENSOR

,.-~- ~
~
~ i

---
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/
/

~
P3WO28DO1

0
Removing - refitting
1. Undo the screw and remove the electrical
connector's mounting from the body shell.
2. Release the connector's lugs and discon-
"""I
/ nect the electrical connector.
J 3. Undo the socket-headed screw and with-
:; draw the sensor from its seat.
I', 4. Check the gap between the speed sensor
and phonic wheel. The gap is not ad-
'I
justable since no shims are supplied as
/ spare parts. If the gap is outside the speci-
..-/,
fied tolerance, check the condition of the
/ sensor and the phonic wheel teeth.
P3WO28DO2

4
~
-~
~

7 ---
4 """'. \
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>

\\\

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28 Publication no. 506.586

~
 Fiat barchetta B~aking system
Anti-lock brakin~ system

, \
'\ REAR WHEEL SPEED SENSOR

.-----l
~

-=.,
P3WO29DO1

21 ,,...,.

Removing - refitting

1. Remove the connector from its seat and

detach the electrical connector.
2. Undo the nut shown in the figure and re-
move the cable from its mountings and
protective channel.
3. Undo the screw and remove the speed
sensor.
4. Check the gap between the speed sensor
and phonic wheel. The gap is not ad-
justable since no shims are supplied as
~'"
\1::::;))
" spare parts. If the gap is outside the speci-
fied tolerance.. check the condition of the
sensor and the phonic wheel teeth.
"'"
P3WO29DO2

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3 ~

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~. 7
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/
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/

/~

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P3WO29DO3

Copyright Fiat Auto 29

~
Braking system Fiat barchetta
Anti-lock braking system

PRECAUTIONS TO BE OBSERVED ON VEHICLES FITTED WITH ANTI-LOCK BRAKING SYSTEM

Before carrying out welding work with electric arc welders, the connector must be disconnected from
the electronic control unit.
During painting operations,the electroniccontrol unit can only be subjectedfor a short period to a tem-
perature of 95°C, and for a longer period (about 2 hours) to a maximum temperature of 85°C. So if the
above-mentioned operations will take longer, the electrohydraulic control unit must be removed.

When the battery is fitted, the terminals must be perfectly tight

Before dismantlinq the electrohydraulic control unit, the battery's negativecable must be disconnected

Also, after any repair affecting the electrical system of the anti-lock
braking system or the wheel speed
sensors, both specific interventions and during dismantling or replacement of mechanical parts (such as
spring-damper assembly, constant velocity joints, drive shafts and wheel hubs), a short road test must
be carried out as follows:

a. Increase the vehicle's speed to over 12 km/h and maintain this speed, without braking, for 20 sec-
onds in order to allow the electronic control unit to conduct a dynamic check on the sensors and to
detect any faults, insecure contacts, incorrect positions or the absence of a phonic wheel.

b. After carrying out the aboveoperation,if the warning light does not indicatea fault, continue the test
at a speed of 50 - 60 km/h for 10 minutes, using the brakesnormally but avoiding abrupt braking.
This check stage allows the electronic control unit to recognizethe presenceof an inappropriate
phonic wheel.

Key
20. Sensor on front left wheel (A.B.S.)
21. Sensor on front right wheel (A.B.S.)
22. Sensor on rear left wheel (A. B.S.)
23. Sensor on rear right wheel (A. B.S.)
24. Fusebox
Fuse 2 60A
Fuse 5 50A
25. Front cable/ ABS cable connection
26. Control unit for ABS electrohydraulic unit
27. Connection for diagnosis of ABS
28 Main earth
29. Main earth
30. Instrument panel
I. Anti-lock braking system fault warning light
31. Junction unit
32. Dashboard cable/front cable connection
33. Ignition switch
39. Battery earth
40. Battery
44. Stop lights switch
47. 10 A fuse for ABS
101. Stalk unit
N.D. Connector blocks

30 Publication no 506.586
Fiat barchetta Braking system
Anti-lock braking system

WIRING DIAGRAM

P3WO31 DO1

Copyright Fiat Auto 31