SPECIAL FEATURES

These instructions, valid at the time of publication, contain trouble-shooting

procedures Teves ABS Mark II for the following models:
VW Corrado 10.88 ->
ABS with 4 wheel-speed sensors and 3-channel hydraulic modulator featuring
7 solenoid valves.
The ABS control unit is equipped with self-diagnosis with 4-position flashing
code.
The fault memory is not cleared after switching off the ignition.
All faults occurring are stored and divided into 7 priority classes. The
controller is then completely or partially deactivated depending on priority
class.
The ABS system is fully deactivated in the event of priority 1 faults (for
example: solenoid valve defective).
A 35-pole plug is located at the controller.
Sensor ring gears with 43 teeth each.
The high-pressure pump motor may run continuously for a maximum of 2 min;
it should then be allowed to cool down for at least 10 min.
The solenoid valves can be directly actuated for brief periods. 1 = High-pressure pump with pressure accumulator and pressure switch
Switch-on time max. 10 s. 2 = Brake-fluid reservoir
3 = Main solenoid valve
ABS function 4 = Wheel brake cylinder
The main solenoid valve is always active with ABS controlled braking. It 5 = Inlet and outlet solenoid valve, front right
switches the accumulator pressure directly to the inlet and outlet solenoid 6 = Inlet and outlet solenoid valve, front left
valves by way of the collars of the brake master cylinder (collar overflow). In 7 = Inlet and outlet solenoid valve, rear
accordance with the lock-up tendency, pressure holding, pressure reduction or 8 = 2-circuit brake master cylinder
pressure build-up is implemented at the respective wheel brake cylinders by 9 = Hydraulic modulator
way of the inlet and outlet solenoid valves. 10 = Hydraulic brake booster
11 = Load-sensitive braking-force regulator
12 = Brake-pressure control valve

The brake booster is supplied by the pressure accumulator and simultaneously

acts on the rear-wheel brakes by way of a load-sensitive braking-force
regulator. There is no braking effect at the rear axle in the absence of
accumulator pressure.
Attention is therefore to be paid to the bleeding specification when bleeding the
brake system.

Bleeding specification:
Bleeding of the front wheel brakes is implemented normally with a - Yes: I 22/1 No: I 21/1 Fig.: I 20/2
charging/bleeding unit. Brief instructions may include several rows of coordinates.
- Attach bleeder bottle, front left and loosen the bleeder screw by one turn. I../. = first coordinate row
- Close bleeder screw when brake fluid emerges with no bubbles. II../. = second coordinate row
- Repeat procedure for brake cylinder, front right. III../. = third coordinate row etc.
- Check brake fluid level. .../1 = upper coordinate half
.../2 = lower coordinate half
Rear axle:
- Ignition off.
- Press brake pedal approximately 20 times (to empty high-pressure SAFETY MEASURES
accumulator) until there is a noticeable increase in pedal force. As regards the hydraulic modulator, safety reasons dictate that only the
- Attach bleeder bottle, rear left and loosen bleeder screw by one turn. compensating tank, pressure accumulator, pressure warning switch, high-
- Fully depress brake pedal and hold it down with pedal locking device. pressure pump and valve block may be replaced. Do not loosen any other
- Ignition on, high-pressure pump running (pay attention to running time max. screws on hydraulic modulator! Such a course of action could lead to fatal
2 min !). brake failure.
- Close bleeder screw when brake fluid emerges with no bubbles. Take care when handling brake fluid.
- Check brake fluid level. T O X I C!
- Release brake pedal. The ABS is a vehicle safety system.
- Wait until high-pressure accumulator is full (high-pressure pump switches Work on this system presupposes detailed system knowledge.
off). Testing may only be performed by trained personnel.
- Ignition off. After loosening hydraulic connections, bleed brake system and perform low-
- Attach bleeder bottle, rear right and loosen bleeder screw by one turn. pressure as well as high-pressure test.
- Press brake pedal slightly. Pay attention to special bleeding specification.
- Close bleeder screw when brake fluid emerges without bubbles. For further safety measures, refer to basic instructions of AUDI V8 10.88->
- Release brake pedal. (KFZ-00.)
- Ignition on.
- Wait until high-pressure accumulator is full (high-pressure pump switches
off).
- Check brake fluid level. WARNING LAMP FUNCTION
The ABS warning lamp must go out within 60 s after switching on ignition.
If the ABS warning lamp does not go out after starting or if it lights
STRUCTURE, USAGE (continuously or intermittently) whilst driving, there is a fault present and the
ABS system is completely or partially deactivated depending on the fault
These brief instructions essentially comprise vehicle-specific special features priority.
and set values. Intermittent faults (loose contacts) are likewise stored.
There is no detailed description of trouble-shooting in basic instructions. The flashing code must therefore always be read out first when performing
User prompting is provided on every page e.g.: trouble-shooting.
- Continue: I 17/1 The brake warning lamp is designed to give an indication of handbrake on, low
- Continue: II 18/1 Fig.: II 17/2 brake-fluid level or inadequate accumulator pressure.
- Yes: I 20/1 No: I 19/1
Either the accumulator pressure or the brake-fluid level is too low if both
warning lamps light simultaneously.
If the brake warning lamp lights, the conventional brake system is first to be
checked and repaired if necessary.

SELF-DIAGNOSIS

Each flashing code is initiated by way of a start pulse (lamp on) with duration
of approx. 2,5 s. The individual positions are separated in each case by an
interval (lamp off) of approx. 2,5 s.
Only the short flashing pulses are to be counted. The flashing code is
constantly repeated. The next flashing code is not output until the button is
pressed for approx. 3 s.
See picture: flashing code 1234.
Priority 1 faults are output first and halt further flashing-code output. Eliminate
fault and stimulate again.

Flashing code output:
- Lever gear-lever boot off center console.
- Connect KDAW 9975; see picture.
Note: The sequence of connectors (picture) does not have to coincide with that
in the vehicle.
Black plug (A) with bevel at top on both sides is always voltage supply.
Blue/white plug (B) beveled on side at top and bottom is stimulation lead (B/1).
Note: If the flashing code is not output, determine the correct diagnosis plug
from controller plug term. 26.
- Press button.
- Switch on ignition.
- ABS warning lamp lights.
- Release button after approx. 3 s.
- Flashing code is flashed up by way of ABS warning lamp and constantly
repeated.
- Read out entire fault memory and note down each individual flashing code.
The fault memory has been completely read out when the warning lamp flashes
continuously and uniformly in 2,5 second cycle (flashing code 0000).
A test drive is to be performed after repairing the ABS system. In doing so,
drive for at least 1 minute at a speed in excess of 40 km/h.

Note: Remove all diagnosis leads when performing test drive.

Note: - Check solenoid valve resistance at controller plug. X1 term. 11 -> X1 term.
Fault memory is automatically cancelled during test drive. The only faults to be 35
cancelled are those, which have previously been read out at least once. Set value: 5...7 Ohm
Read out fault memory again. If flashing code 4444 is output, there are no - Check solenoid valves and leads for short to ground/short to positive, open
further faults stored in the ABS controller. If no flashing code is output or the circuit and loose contacts as per circuit diagram.
flashing code is not listed in the table, refer to component/functional test. - Check contacts of connectors.
SELF-DIAGNOSIS FLASHING CODE 1112...1222
Test instructions: - Remove solenoid valve relay.
Do not use test prods for measurements at all equipment plugs, but rather make - Check function of valve relay.
use of suitable test plugs from Bosch test cable set 1 687 011 208 as otherwise - Check ground connection, valve relay. K1 term. 87a -> body ground Set
contacts could be damaged. value: < 0,5 Ohm
- Check voltage supply, valve relay. K1 term. 87 -> body ground
SELF-DIAGNOSIS FLASHING CODE TABLE Set value: 10...15 V
- Check lead from valve relay to controller plug. K1 term. 30 -> X1 term. 3, 20
0000 End of output/controller - Controller defective.
END OF OUTPUT/controller
- Remove all diagnosis leads. 1114 Inlet valve VR
- Following repair, perform test drive for at least 1 min. at a speed in excess of SELF-DIAGNOSIS FLASHING CODE 1114
40 km/h. Inlet valve, front right
- Repeat self-diagnosis. - Ignition off.
- Pull plug off controller.
1111 Controller - Check solenoid valve resistance at controller plug.X1 term. 11 -> X1 term. 15
SELF-DIAGNOSIS FLASHING CODE 1111 Set value: 5...7 Ohm
Controller - Check solenoid valves and leads for short to ground/short to positive, open
- Check all fuses. circuit and loose contacts as per circuit diagram.
- Ignition off. - Check contacts of connectors.
- Pull plug off controller. SELF-DIAGNOSIS FLASHING CODE 1112...1222
- Check ground connections at controller plug. X1 term. 1, 11 -> body ground - Remove solenoid valve relay.
Set value: < 0,5 Ohm - Check function of valve relay.
- Ignition on and start engine. - Check ground connection, valve relay. K1 term. 87a -> body ground
- Check voltage supply at controller plug. X1 term. 2 -> body ground Set value: < 0,5 Ohm
Set value: 11...15 V - Check voltage supply, valve relay. K1 term. 87 -> body ground
- Controller defective. Set value: 10...15 V
- Check lead from valve relay to controller plug. K1 term. 30 -> X1 term. 3, 20
1112 Inlet valve VL - Controller defective.
SELF-DIAGNOSIS FLASHING CODE 1112
Inlet valve, front left
1122 Inlet valve HA
- Ignition off. SELF-DIAGNOSIS FLASHING CODE 1122
- Pull plug off controller. Inlet valve, rear
- Ignition off. 1134 Outlet valve VR
- Pull plug off controller. SELF-DIAGNOSIS FLASHING CODE 1134
- Check solenoid valve resistance at controller plug. X1 term. 11 -> X1 term. Outlet valve, front right
17 - Ignition off.
Set value: 5...7 Ohm - Pull plug off controller.
- Check solenoid valves and leads for short to ground/short to positive, open - Check solenoid valve resistance at controller plug. X1 term. 11 -> X1 term.
circuit and loose contacts as per circuit diagram. 34
- Check contacts of connectors. Set value: 3...5 Ohm
SELF-DIAGNOSIS FLASHING CODE 1112...1222 - Check solenoid valves and leads for short to ground/short to positive, open
- Remove solenoid valve relay. circuit and loose contacts as per circuit diagram.
- Check function of valve relay. - Check contacts of connectors.
- Check ground connection, valve relay. K1 term. 87a -> body ground SELF-DIAGNOSIS FLASHING CODE 1112...1222
Set value: < 0,5 Ohm - Remove solenoid valve relay.
- Check voltage supply, valve relay. K1 term. 87 -> body ground - Check function of valve relay.
Set value: 10...15 V - Check ground connection, valve relay. K1 term. 87a -> body ground
- Check lead from valve relay to controller plug. K1 term. 30 -> X1 term. 3, 20 Set value: < 0,5 Ohm
- Controller defective. - Check voltage supply, valve relay. K1 term. 87 -> body ground
Set value: 10...15 V
1132 Outlet valve VL - Check lead from valve relay to controller plug. K1 term. 30 -> X1 term. 3, 20
SELF-DIAGNOSIS FLASHING CODE 1132 - Controller defective.
Outlet valve, front left
- Ignition off. 1142 Outlet valve HA
- Pull plug off controller. SELF-DIAGNOSIS FLASHING CODE 1142
- Check solenoid valve resistance at controller plug. X1 term. 11 -> X1 term. Outlet valve, rear
16 - Ignition off.
Set value: 3...5 Ohm - Pull plug off controller.
- Check solenoid valves and leads for short to ground/short to positive, open - Check solenoid valve resistance at controller plug. X1 term. 11 -> X1 term.
circuit and loose contacts as per circuit diagram. 33
- Check contacts of connectors. Set value: 3...5 Ohm
SELF-DIAGNOSIS FLASHING CODE 1112...1222 - Check solenoid valves and leads for short to ground/short to positive, open
- Remove solenoid valve relay. circuit and loose contacts as per circuit diagram.
- Check function of valve relay. - Check contacts of connectors.
- Check ground connection, valve relay. K1 term. 87a -> body ground SELF-DIAGNOSIS FLASHING CODE 1112...1222
Set value: < 0,5 Ohm - Remove solenoid valve relay.
- Check voltage supply, valve relay. K1 term. 87 -> body ground - Check function of valve relay.
Set value: 10...15 V - Check ground connection, valve relay. K1 term. 87a -> body ground
- Check lead from valve relay to controller plug. K1 term. 30 -> X1 term. 3, 20 Set value: < 0,5 Ohm
- Controller defective. - Check voltage supply, valve relay. K1 term. 87 -> body ground
Set value: 10...15 V
- Check lead from valve relay to controller plug. K1 term. 30 -> X1 term. 3, 20 - Turn wheel, front left and check voltage at controller plug (alternating
- Controller defective. voltage). X1 term. 5 -> X1 term. 23
Set value: > 75 mV
1222 Main valve - Wheel-speed sensor loose or not flat on mount.
SELF-DIAGNOSIS FLASHING CODE 1222 - Ring gear defective (e.g. corroded, dirty, damaged or loose).
Main valve, - Check number of teeth.
- Ignition off. Set value: 43
- Pull plug off controller. - Controller defective.
- Check solenoid valve resistance at controller plug. X1 term. 11 -> X1 term.
18 1241 Wheel-speed sensor VR
Set value: 2...5 Ohm SELF-DIAGNOSIS FLASHING CODE 1241
- Check solenoid valves and leads for short to ground/short to positive, open Wheel-speed sensor, front right
circuit and loose contacts as per circuit diagram. - Ignition off.
- Check contacts of connectors. - Pull plug off controller.
SELF-DIAGNOSIS FLASHING CODE 1112...1222 - Check wheel-speed-sensor winding resistance at controller plug. X1 term. 7 -
- Remove solenoid valve relay. > X1 term. 25
- Check function of valve relay. Set value: 0,8...1,4 kOhm
- Check ground connection, valve relay. K1 term. 87a -> body ground - Check wheel-speed sensor and leads for short to ground/short to positive,
Set value: < 0,5 Ohm mix-up, open circuit and loose contacts at controller plug. X1 term. 7 -> X1
- Check voltage supply, valve relay. K1 term. 87 -> body ground term. 25
Set value: 10...15 V - Check condition of connectors.
- Check lead from valve relay to controller plug. K1 term. 30 -> X1 term. 3, 20 - Excessive wheel bearing clearance.
- Controller defective. SELF-DIAGNOSIS FLASHING CODE 1241
- Turn wheel, front right and check voltage at controller plug (alternating
1233 Wheel-speed sensor VL voltage). X1 term. 7 -> X1 term. 25
SELF-DIAGNOSIS FLASHING CODE 1233 Set value: > 75 mV
Wheel-speed sensor, front left - Wheel-speed sensor loose or not flat on mount.
- Ignition off. - Ring gear defective (e.g. corroded, dirty, damaged or loose).
- Pull plug off controller. - Check number of teeth.
- Check wheel-speed-sensor winding resistance at controller plug. X1 term. 5 - Set value: 43
> X1 term. 23 - Controller defective.
Set value: 0,8...1,4 kOhm
- Check wheel-speed sensor and leads for short to ground/short to positive, 1243 Wheel-speed sensor HR
mix-up, open circuit and loose contacts at controller plug. X1 term. 5 -> X1 SELF-DIAGNOSIS FLASHING CODE 1243
term. 23 Wheel-speed sensor, rear right
- Check condition of connectors. - Pull plug off controller.
- Excessive wheel bearing clearance. - Check wheel-speed-sensor winding resistance at controller plug. X1 term. 4 -
SELF-DIAGNOSIS FLASHING CODE 1233 > X1 term. 22
Set value: 0,8...1,4 kOhm
- Check wheel-speed sensor and leads for short to ground/short to positive, 1312 Pressure warning switch and warning contact
mix-up, open circuit and loose contacts at controller plug. X1 term. 4 -> X1
term. 22
- Check condition of connectors.
- Excessive wheel bearing clearance.
SELF-DIAGNOSIS FLASHING CODE 1243
- Turn wheel, rear right and check voltage at controller plug (alternating
voltage). X1 term. 4 -> X1 term. 22
Set value: > 75 mV
- Wheel-speed sensor loose or not flat on mount.
- Ring gear defective (e.g. corroded, dirty, damaged or loose).
- Check number of teeth.
Set value: 43
- Controller defective.

1311 Wheel-speed sensor HL

SELF-DIAGNOSIS FLASHING CODE 1311
Wheel-speed sensor, rear left
- Ignition off.
- Pull plug off controller.
- Check wheel-speed-sensor winding resistance at controller plug. X1 term. 6 -
> X1 term. 24
Set value: 0,8...1,4 kOhm
- Check wheel-speed sensor and leads for short to ground/short to positive,
mix-up, open circuit and loose contacts at controller plug. X1 term. 6 -> X1
term. 24
- Check condition of connectors. SELF-DIAGNOSIS FLASHING CODE 1312
- Excessive wheel bearing clearance. Pressure warning switch and warning contact
SELF-DIAGNOSIS FLASHING CODE 1311 - Ignition off.
- Turn wheel, rear left and check voltage at controller plug (alternating - Detach plug from controller.
voltage). X1 term. 6 -> X1 term. 24 - Connect up ohmmeter to controller plug term. 9 and 10. (Pressure
Set value: > 75 mV accumulator must be charged).
- Wheel-speed sensor loose or not flat on mount. Set value: < 5 Ohm
- Ring gear defective (e.g. corroded, dirty, damaged or loose). - Unscrew closing cover of reservoir and move float.
- Check number of teeth. - The warning contact S6 (picture) opens if the float with magnet M2 is moved
Set value: 43 towards the lower stop.
- Controller defective. Contact S5 first switches on brake warning lamp by way of magnet M1.
4444 No fault stored - Check brake-fluid level and top up brake fluid if necessary.
- If brake warning lamp is always lit, consecutively pull off plugs at
compensating tank and pressure switch.
Replace corresponding component if warning lamp goes out.
COMPONENT/FUNCTIONAL TEST - No brake warning lamp function.
Checking controller voltage supply Check fuses.
- Check all fuses. Check lamp.
- Ignition off. Use circuit diagram to check leads.
- Pull plug off controller.
- Check ground connections at controller plug. X1 term. 1, 11 -> body ground Checking motor relay
Set value: < 0,5 Ohm - Ignition off.
- Ignition on and start engine. - Pull plug off controller.
- Check voltage supply at controller plug. X1 term. 2 -> body ground - Check leads from controller plug term. 14 and 32 to hydraulic modulator plug
Set value: 11...15 V as per circuit diagram.
- Check leads for loose contacts. - Check pump motor resistance.
Set value: < 1 Ohm
ABS warning lamp does not light or flashing codes are not output - Check resistance of solenoid (motor relay). K2 term. 85 -> K2 term. 86
- Ignition off. Set value: 50...100 Ohm
- Pull off controller plug. - Check diode in motor relay.
- Check ABS bulb. - Check all ground connections.
- Check diode in valve relay.
- Check following leads and connectors as per circuit diagram for open circuit, Check pressure switch, hydraulic pump and high-pressure accumulator
loose contacts, short to positive or short to ground. - Check all fuses.
* Diagnosis plug connections - Ignition off.
* ABS warning-lamp leads to controller and valve relay - Detach controller plug.
* Ground connection, valve relay - Press brake pedal approximately 20 times (to empty high-pressure
accumulator) until there is a noticeable increase in pedal force.
Checking stop-lamp switch - Connect up ohmmeter to controller plug term. 9 to 10.
- Ignition off. Note: Reading greater than 1 MOhm corresponds to contact open and less than
- Pull plug off controller. 5 Ohm to closed.
- Check voltage at controller plug:
X1 term. 12 -> body ground
* Brake not pressed: < 1 V
* Brake pressed : > 10 V
- Check stop-lamp switch.
- Check leads from controller plug to stop-lamp switch and fuse.

Brake warning lamp function

- Ignition on.
- Release hand brake.
 - Dissipate accumulator pressure.
* ABS contact in pressure warning switch opens at 100...110 bar.
Brake warning lamp lights.
- Check lead from controller plug term. 9 to ABS warning lamp unit as per
circuit diagram.

Check solenoid valves for proper function and mix-up.

Perform test consecutively for each individual wheel.
Turn appropriate wheel by hand or drive vehicle on roller dynamometer.
Only connect up inlet and outlet valve of one wheel to controller plug.
- Ignition off.

Note: Switch-on duration of solenoid valves max. 10 s.

Check pressure reduction, front left wheel:
- Connect up button of KDAW 9975 to controller plug term. 2 to term. 35 and
jumper term. 35 with 16.
- Ignition on.
- Install (see picture) ATE pressure test connection, part no. 03.9305-0145.2 - Press brake pedal.
between pressure accumulator and hydraulic modulator. * Wheel blocks.
- Connect up pressure gauge (250 bar). - Press button.
- Bleed brake system and pressure gauge. * Wheel can be turned.
- Pressure accumulator must have been discharged. - Ignition off.
- Ignition on. - Disconnect button.
* Pressure-gauge reading switches to initial pressure of pressure accumulator
Set value: 40...90 bar Note: Switch-on duration of solenoid valves max. 10 s.
- Check pressure warning switch 9 at controller plug term. 10 and term. S3. Check pressure holding, front left wheel:
* Brake warning lamp goes out and ABS contact in pressure warning switch - Connect up button of KDAW 9975 to controller plug term. 2 to 35.
closes at 130...150 bar - Ignition on.
* Cut-out pressure, - Press button.
Set value: 170...190 bar - Press brake pedal.
- Dissipate accumulator pressure. * Wheel can be turned.
* Renewed cut-in pressure, - Release button.
Set value: 130...150 bar * Wheel blocks.
* Pressure build-up time between cut-in and cut-out pressure, - Ignition off.
Set value: < 25 s - Disconnect button.
- Ignition off.
- Pull plug off pump motor. Note: Switch-on duration of solenoid valves max. 10 s.
Ignition on. Check pressure reduction, front right wheel:
- Check ABS warning contact in closing cover of reservoir. - Connect up button of KDAW 9975 to controller plug term. 2 to term. 15 and
* ABS warning contact opens if float makes contact with lower stop. jumper term. 15 with 34.
- Ignition on. * Wheel blocks.
- Press brake pedal. - Ignition off.
* Wheel blocks. - Disconnect button.
- Press button.
* Wheel can be turned. Note: Switch-on duration of solenoid valves max. 10 s.
- Ignition off. Function, main solenoid valve:
- Disconnect button. - Connect up button of KDAW 9975 to controller plug term. 2 to 18.
- Ignition on.
Note: Switch-on duration of solenoid valves max. 10 s. - Press brake pedal slightly.
Check pressure holding, front right wheel: - Briefly press button several times.
- Connect up button of KDAW 9975 to controller plug term. 2 to 15. * Brake pedal must pulsate.
- Ignition on. - Ignition off.
- Press button. - Disconnect button.
- Press brake pedal.
* Wheel can be turned. If set values are not attained:
- Release button. - Use circuit diagram to check leads for loose contact and open circuit.
* Wheel blocks. - Check for leaks in hydraulic connections (visual inspection).
- Ignition off. - Pull off plug at hydraulic modulator.
- Disconnect button. - Check plug and spring contacts for corrosion.
- Check ground connection of hydraulic modulator (both screw connections).
Note: Switch-on duration of solenoid valves max. 10 s. - Check ground connection of pump motor.
Check pressure reduction, rear axle:
- Connect up button of KDAW 9975 to controller plug term. 2 to term. 17 and Check wheel-speed sensors and ring gear
jumper term. 17 with 33. - Ignition off.
- Ignition on. - Detach controller plug.
- Press brake pedal. - Start engine.
* Wheel blocks. - Measure with Motortester special input at controller plug.
- Press button. * Wheel, front left term. 5 and 23
* Wheel can be turned. * Wheel, front right term. 7 and 25
- Ignition off. * Wheel, rear right term. 4 and 22
- Disconnect button. * Wheel, rear left term. 6 and 24
Set value: Picture, sinusoidal signal
Note: Switch-on duration of solenoid valves max. 10 s. 1 = Wheel-speed sensor
Check pressure holding, rear axle: 2 = Ring gear
- Connect up button of KDAW 9975 to controller plug term. 2 to 17. 3 = Motortester oscilloscope
- Ignition on.
- Press button.
- Press brake pedal.
* Wheel can be turned.
- Release button.
 ADDITIONAL TEST STEPS
* Specified tire size fitted?
* If ABS warning lamp lights up from time to time when driving (e.g. after
switching on loads) and goes out again automatically, check battery and
voltage supply (alternator, regulator and voltage dips).
* Check tightness of ground strap between engine block and vehicle frame.
* Spring contacts must be properly engaged.
* All plug contacts ok?

Perform test drive as final check:

Drive for at least 1 min. at a speed of in excess of 40 km/h.
Warning lamp must not light.

SET VALUES
- Turn corresponding wheel. ABS inlet solenoid valves
If available, drive wheels on brake dynamometer (maximum speed and rock - Set value: 5...7 Ohm
vehicle heftily). ABS outlet solenoid valves
Note: The wheel-speed-sensor output signal must produce a sinusoidal curve, - Set value: 3...5 Ohm
the amplitude and period of which change as a function of rotational speed. The ABS main solenoid valve
amplitude is additionally influenced by the air gap. It decreases with increasing - Set value: 2...5 Ohm
air gap. Note: Winding resistances at -10...+120 Grad C ambient temperature.

The maximum permissible fluctuation in amplitude for all wheel-speed sensors Solenoid, motor relay
is 25 %. - Set value: 50...100 Ohm
In the event of deviation, check: Solenoid, valve relay
- Wheel-bearing clearance. - Set value: 50...100 Ohm
- Ring gear for freedom of movement, eccentricity error and damage. Solenoid, wheel-speed sensor
- Air gap at several locations. - Set value, front: 0,8...1,4 kOhm
- Wheel-speed-sensor lead for loose contacts. - Set value, rear : 0,8...1,4 kOhm
- Interference voltage in ABS wiring harness (e.g. distance from ignition cable Note: Winding resistances at -10...+120 Grad C ambient temperature.
must be more than 5 cm).
Switching ranges of 5-pole pressure warning switch:
A test drive is to be performed after repairing the ABS system. In doing so, - S2 pump motor
drive for at least 1 minute at a speed in excess of 40 km/h. Cut-out pressure: 170...190 bar
Then read out flashing code to ensure that there are no further faults in the ABS Renewed cut-in pressure: 130...150 bar
system. - S3 ABS warning switch
Cut-in pressure: 120...150 bar
Renewed cut-out pressure: 100...110 bar
- S4 brake warning switch
Cut-out pressure: 120...150 bar
Renewed cut-in pressure: 100...110 bar
Max. perm. switch-on duration:
- of pump motor: 2 min
- solenoid valves 10 s

Number of ring gear teeth

- Set value, front 43 teeth
- Set value, rear 43 teeth

Air gap between wheel-speed sensor and ring gear cannot be adjusted.

Tightening torques:
Wheel-speed-sensor fastening screws
- Set value: 10 Nm
Wheel-brake-cylinder bleeder screws
- Set value: 7...9 Nm

Wheel-hub fastening screws ELECTRICAL TERMINAL DIAGRAM

- Set value: 265 Nm
Tightening torques, front wheel brake:
Fastening screws for brake anchor plate
- Set value: 125 Nm
Tightening torques, rear wheel brake:
Fastening screws for brake anchor plate
- Set value: 65 Nm
Brake-caliper fastening screws
- Set value: 35 Nm
Note: Renew self-locking screws or tighten with locking compound.

Tightening torque for fastening nuts or bolts at hydraulic modulator.

Set value:
1 = 15 Nm
2 = 25 Nm
3 = 25 Nm
4 = 25 Nm
5 = 10 Nm
6 = 45 Nm
B1 = Wheel-speed sensor K2 = Pump-motor relay
HL = rear left M1 = Pump motor
HR = rear right S2 = Pressure switch, pump motor
VL = front left S3 = Pressure switch, ABS warning lamp
VR = front right S4 = Pressure switch, brake warning lamp
H3 = Stop lamp S5 = Warning switch, brake warning lamp
S1 = Stop-lamp switch S6 = Warning switch, ABS system
W1 = Ground connection next to controller S7 = Warning switch, hand brake
X1 = Controller plug (35-pole) W2 = Ground connection, negative battery terminal
X2...X3 = Wheel-speed-sensor plugs with built-in capacitor X6 = Plug at pump motor
X4...X5 = Wheel-speed-sensor plugs X7 = Plug at pressure warning switch
X11...X12 = Diagnosis plug Y3 = Closing cover, brake-fluid compensating tank

W3 = Ground connection, transmission to hydraulic modulator

Y1 = Hydraulic modulator
A = Inlet valve, ABS front left
B = Outlet valve, ABS front left
F1 = Fuse, pump motor C = Inlet valve, ABS rear
H2 = Brake warning lamp D = Outlet valve, ABS rear
 E = Outlet valve, ABS front right
F = Inlet valve, ABS front right
G = Main valve, ABS
Y2 = Warning lamp unit
F2 = Fuse, solenoid valves
H1 = ABS warning lamp
K1 = Solenoid valve relay
X8 = Plug, solenoid valves
X9 = Plug, main solenoid valve
X10 = Plug, warning lamp unit 5-pole
INSTALLATION POSITION OF COMPONENTS
The installation locations always
refer to the direction of travel.
1 = ABS controller
2 = Wheel-speed sensor
3 = Relay and fuse box
4 = ABS warning lamp
5 = Stop-lamp switch
6 = ABS hydraulic modulator
ABS controller:
- In footwell, front left at A-pillar.
- Screw out fastening screws and remove controller.
- Remove controller plug.
Diagnosis plug:
- Underneath gear-lever boot of center console.
Stop-lamp switch:
- Above brake pedal.
Stop-lamp-switch adjustment:
- Slightly depress brake pedal.
- Hold 1 mm thick feeler gauge between pedal and stop-lamp switch.
- Pull back brake pedal by hand as far as it will go.
- Check function of stop lamps.
ABS and brake warning lamp
The ABS warning lamp is located on the right in the instrument panel.
It can be removed from the front.
The brake warning lamp is located in the instrument panel.
Remove cover from relay fuse box (driver's-side footwell).
Fuse location:
16 = Fuse, ABS warning lamp
1 = Compensating tank
20 = Fuse, stop lamp
2 = Warning switch, brake-fluid level for ABS system
3 = Warning switch, brake-fluid level
Relay location:
4 = Pressure accumulator
13 = Motor relay K2 (No. 78)
5 = Pressure warning switch
14 = Valve relay K1 (No. 79)
6 = Ground, hydraulic modulator
19 = Fuse, F1 pump motor
7 = Plug, pump motor
20 = Fuse, F2 solenoid valves
8 = Plug, solenoid valves
Note: Numbers are only featured by OEM relays (installation numbers).
9 = Plug, main solenoid valve
Hydraulic modulator with brake master cylinder:
Removal and installation of hydraulic modulator
- On left in engine compartment at bulkhead.
Removal:
- Compensating tank, pressure accumulator and pressure warning switch
- Switch off ignition and disconnect ground strap at battery.
can be replaced with hydraulic modulator in situ.
- Dissipate accumulator pressure (press brake pedal approx. 20 times).
- Detach all plugs and ground connections at hydraulic modulator.
- Draw brake fluid out of reservoir.
- Unscrew brake lines at hydraulic modulator and seal with suitable plugs.
Removal:
- Remove tray on left beneath instrument panel.
- Remove pin and clevis of pushrod at brake pedal.
- Unscrew fastening nut at hydraulic modulator (bulkhead) and take out
hydraulic modulator.
Dismantling and assembly of hydraulic modulator:
Note: Renew all seals and O-rings at hydraulic modulator when performing
repairs.
Installation:
- Installation is performed in reverse order.
- Bleed brake system; refer to Section - Special features -

Note: As of 01.90 the pressure switch is installed in the hydraulic-pump

housing. On replacing the hydraulic pump, the opening in the brake master
cylinder is to be sealed with a screw plug (commercially available) and the
pressure switch is to be screwed into the housing of the hydraulic pump.

Recommendation: For safety reasons, renew the corresponding relays in the

event of a defect in the solenoid valves or hydraulic pump.

1 = Tandem brake master cylinder

2 = Solenoid-valve block
3 = High-pressure pump
4 = Main solenoid valve
5 = Brake-line connection, wheel-brake cylinder, rear axle
6 = Brake-line connection, wheel-brake cylinder, front left
7 = Brake-line connection, wheel-brake cylinder, front right
8 = Pressure regulator; only installed with rear disk brakes

For safety reasons, do not further disassemble components, but rather only
replace complete.
Wheel-speed sensors/ring gear, front axle:
Wheel-speed sensors (1) are located in left-hand and right-hand steering
knuckle (see picture). The connectors are located on the corresponding spring-
strut dome in the engine compartment. Only the fastening screw (2) is to be
loosened on removal.
Note: The air gap cannot be adjusted.
The front wheel brake including wheel hub must be removed on replacing the
ring gear (3); refer to picture.
Wheel-speed sensors/ring gear rear axle:
Wheel-speed sensors (1) are located in left-hand and right-hand rear-axle beam
(see picture). The connectors are located beneath the rear bench seat. Only the
fastening screw (2) is to be loosened on removal.
Note: The air gap cannot be adjusted.
The brake disk has to be removed when replacing the ring gear (3). Lever off
ring gear from inside of brake disk (see picture).