CLA SSIC A BS FA ILURE SYMPTOMS:

- Mo st o f the tim e , the pro ble m is the ABS m o dule o r o ne o f the 4 whe e l spe e d se nso rs (& so m e tim e s the bra k e pre ssure se nso r)
- In m y 2002 BMW E39 DSC , thre e o ra nge (wa rning) cluste r displa y lights lit, ABS, Bra k e , & DSC
- T he 3 wa rning lights re se t whe n the ignitio n is turne d o ff, o nly to re pe a te dly re a ppe a r within m inute s o f no rm a l driving
- T he fa ult is o fte n inte rm itte nt le a ding yo u to fa lse ly be lie ve yo u've re so lve d the pro ble m (pro pe r dia gno sis is im po rta nt)
- So m e tim e s the fa ult o nly a ppe a rs whe n the e ngine is ho t; o the r tim e s o nly a t spe e ds o ve r 40 m ph
- C a rso ft m a y e rro ne o usly sho w a re a r spe e d se nso r fa ilure ; but just re pla cing the spe e d se nso r m a y m a k e no diffe re nce .
- All the wo rk is in co rre ct dia gno sis o f the pro ble m ; pa rts re pla ce m e nt is trivia l (fro m 1 to six bo lts in a fe w m inute s)
- He nce , this BMW E39 ABS 3-wa rning light DIY will co nce ntra te o n unde rsta nding a nd dia gno sis o f the pro ble m

FA LSE A LA RM SA NITY CHECK:

If yo u re ce ntly dro ve o n ice , a dyna m o m e te r, o r o n a no the r ve ry slippe ry surfa ce , the ca r m a y just think the syste m ha s
m a lfunctio ne d.
- Driving a fe w m ile s o n a re gula r surfa ce sho uld fix the pro ble m .
- Ano the r fix is to slo wly turn the ste e ring whe e l fro m co m ple te ly le ft to co m ple te ly right, the n ba ck a ga in.
- T he wa rning lights will re se t whe ne ve r yo u turn the ca r o ff (but go ba ck o n if the fa ult pe rsists)

BMW DESIGN PROBLEM:

- T he E39 ABS m o dule wa s m o unte d to o clo se to e ngine he a t ca using so lde r cra ck s & frie d e le ctro nics
- T he 4 whe e l se nso rs a nd wire s a re e x po se d to the e le m e nts a nd to sho ck s/vibra tio n
- T he 3 ste e ring ya w se nso rs se e m pre tty we ll pro te cte d fro m bo th ha za rds but the y m a y ne e d re ca libra tio n
Note: Apparently newer-model BMWs moved the ABS module further away from engine heat (need confirmation)

FLOW CHA RT OF RECOMMENDED A CTIONS:

0) W a tch, fo r a fe w da ys, spe e do , o do m e te r, tripm e te r, cruise co ntro l, tra nsm issio n, & ABS/BR AKE/DSC light a ctivity
1) If ABS/BR AKE/DSC co nsta ntly co m e s ba ck , te st the 4 whe e l se nso r circuits fro m the ABS m o dule co nne cto r
2) If a ny se nso r circuit sho ws up a s ba d, te st tha t spe cific se nso r itse lf a t tha t whe e l (o the rwise sk ip to ste p 5)
3) If the whe e l se nso r still sho ws up a s ba d, first re m o ve , cle a n, gre a se , a nd re -insta ll tha t se nso r
4) If it still te sts ba d, the n re pla ce the se nso r
...
5) If the se nso rs a re go o d, te st the ABS circuit with the C a rso ft o r P e a k e to o ls (o r just a ssum e a ba d ABS m o dule )
6) If the C a rso ft o r P e a k e to o ls indica te a diffe re nt se nso r, te st & re pla ce tha t se nso r (e .g., pre ssure , ya w, a cce le ra tio n, e tc.)
7) O the rwise , a ssum e yo ur ABS m o dule is the culprit (so m e sa y ge t yo ur ABS m o dule re built a nywa y a s it's go ing to go e ve ntua lly)
...
8) If yo ur ABS m o dule is suspe cte d, yo u ha ve o nly the fo llo wing 5 o ptio ns:
- O P T IO N 0: Yo u ca n do no thing a nd just no t ha ve ABS o r DSC (no t a go o d cho ice fo r a nyo ne o n this m e ssa ge bo a rd)
- O P T IO N 1: Yo u ca n a tte m pt a 3-pa rt re build yo urse lf (unfo rtuna te ly we do n't ha ve e no ugh info rm a tio n to he lp yo u ye t)
- O P T IO N 2: Yo u ca n se nd yo ur m o dule o ut fo r a re build (a bo ut 1/3 to 1/2 ca n be re built but yo u'll ha ve no spe e do in the inte rim )
- O P T IO N 3: Yo u ca n buy a re built m o dule (yo u'll ha ve to a dd a ppro x im a te ly $100 fo r a VIN re co de a t the de a le r)
- O P T IO N 4: Yo u ca n buy a bra nd ne w m o dule (yo u'll a ga in ha ve to pa y fo r a BMW de a le rship re co ding to yo ur VIN)
Note: Most people don't deal with testing the other 15 items; they just opt for sending their ABS module out to be rebuilt, which isn't necessarily
a bad thing because generally it is the ABS and even if it isn't, some argue it's not a bad idea to rebuild even a working ABS.

REA D THE SHOP MA NUA L: ( http://www.be ntle ypublishe rs.co m /isb...179/inde x .htm l )
- Fo r DSC pino uts, se e Vo lum e II, pa ge ELE-15 o f ABS/DSC co ntro le m o dule (A65) (2 se nso rs in the fro nt a nd 2 in the re a r)
- Fo r ASC pino uts, se e Vo lum e II, pa ge ELE-21 o f ABS/ASC co ntro le m o dule (A52) (o nly 1 se nso r in the fro nt a nd 1 in the re a r)
- Fo r ABS/ASC /DSC syste m o pe ra tio n, se e Vo lum e I, pa ge 300-12 (it's no t a ll tha t use ful tho ugh)
- Fo r ABS/ASC /DSC syste m co m po ne nts, se e Vo lum e I, pa ge 340-26 (a ga in, no t a ll tha t use ful if yo u ha ve this)

REA D BMW MA NUA LS:

- Bo sch DSC pa rt 1, Bo sch DSC pa rt II (k indly supplie d by Ma x _VQ )

REA D THESE A RTICLES:

- http://www.m e e k ne t.co .uk /E38/ABS/Inde x .htm
- http://fo rum s.bim m e rfo rum s.co m /fo rum ...d.php?t=600452
- http://fo rum s.bim m e rfo rum s.co m /fo rum ....php?t=1230488
- http://cpa re nte .wo rdpre ss.co m /2008/1...o -a bs-pro ble m /
- https://www.bim m e rfe st.co m /fo rum s/sho ...d.php?t=363554
- https://www.bim m e rfe st.co m /fo rum s/sho ...39#po st4202239
etc.

UNDERSTA ND DIGITA L MULTIMETER (DMM) TEST BA SICS:

- http://www.a lla bo utcircuits.co m /vo l_3/chpt_3/2.htm l

GA THER SEA T-OF-THE-PA NTS DA TA :

- No te e x a ctly which wa rning indica to rs a re lit (e .g., ABS & BR AKE & DSC )
- No te whe the r cruise co ntro l is wo rk ing o r no t (so m e tim e s im plica te s the pa sse nge r-side re a r se nso r)
- No te whe the r the spe e do m e te r (he nce o do m e te r & tripm e te r) is wo rk ing (so m e tim e s im plica te s the drive r-side re a r se nso r)
- No te "fre e pla y", "de a d spo ts", & "ce nte ring" o f the ste e ring whe e l (so m e tim e s im plica te s ste e ring co lum n se nso rs)
- No te if no rm a l ABS pulsa tio n (ABS wo rk ing) o r sk idding (ABS no t wo rk ing) whe n ha rd bra k ing o n sa ndy sho ulde rs a t 15 m ph
- No te if vio le nt shudde r (ABS wo rk ing) o r scre e ch (ABS no t wo rk ing) whe n firm bra k ing o n to p o f spe e d bum ps a t 5m ph
No te : It's no t a lwa ys just the se nso r whe n the spe e do m e te r is a lso o ut with the 3 lights (the k e y is dia gno sis)

A CKNOW LEDGE A LL POSSIBLE (20) & MOST LIKELY (2) CULPRITS:

• 1 BO SC H DC III C o ntro l Mo dule 83 P in (co m bine d with the hydra ulic unit in m y E39, DSC III Bo sch 5.7) <==COMMON CULPRIT!
• 1 Hydra ulic Unit (co m bine d with the co ntro l m o dule in m y E39, DSC III Bo sch 5.7)
• Hydra ulic Unit co nta ins: 2 pre -cha rge so le no id va lve s
• Hydra ulic Unit co nta ins: 2 cha nge o ve r so le no id va lve s
• Hydra ulic Unit co nta ins: 4 inta k e so le no id va lve s
• Hydra ulic Unit co nta ins: 4 o utle t so le no id va lve s
• Hydra ulic Unit co nta ins: 1 re turn pum p
• 2 Fro nt W he e l Spe e d Se nso rs (Active Ha ll Effe ct) in the ste e ring k nuck le s, se cure d with two 4 m m a lle n bo lts <==COMMON CULPRIT!
• 2 R e a r W he e l Spe e d Se nso rs (Active Ha ll Effe ct) in the re a r whe e l be a ring ca rrie rs, se cure d with o ne 4 m m a lle n bo lt <==COMMON
CULPRIT!
• 1 Hydra ulic P re ssure Se nso r (a tta che d to the fro nt-bra k e hydra ulic unit in m y E39, DSC III Bo sch 5.7) <==MY PROBLEM!
• 1 Ste e ring Angle Se nso r (lo ca te d in the bo tto m o f the ste e ring co lum n, ne a r the fle x ible co upling)
• 1 R o ta tio n R a te , a k a Ya w Se nso r (co m bine d with the la te ra l-a cce le ra tio n se nso r in m y E39, DSC III Bo sch 5.7)
• 1 La te ra l Acce le ra tio n Se nso r (co m bine d with the ya w se nso r in m y E39, DSC III Bo sch 5.7)
• 1 DSC Switch (lo ca te d be lo w the ra dio in the co ck pit)
• 1 Ha nd Bra k e Switch (lo ca te d o n the ha nd bra k e a sse m bly)
• 1 Bra k e Switch (lo ca te d o n the bra k e -pe da l a sse m bly)
• 1 P re -C ha rging P um p
• 1 C ha rging P isto n (750iL o nly)

PHOTOGRA PH OF THE MOST LIKELY CULPRITS:

GA THER DESIRED TOOLS:
- P rint this DIY o ut, bring a pe ncil to m a rk do wn yo ur re a dings, a nd a drink
- Digita l m ulti m e te r (DMM) with a dio de -te st ca pa bility & lo ng, ve ry na rro w pro be s
- Abo ut six inche s o f 20 AW G stiff wire (to a tta ch to yo ur DMM pro be s a nd to the fe m a le ABS co nne cto r)
- A sm a ll pie ce o f white o r ye llo w ta pe so tha t yo u ca n la be l the po sitive stiff wire (to a vo id co nfusio n with the ne ga tive pro be )
- T 20 six -po int To rx bit in a 1/4" so ck e t with a 6" e x te nsio n fo r re m o ving the ABS co ntro l m o dule
- 4m m a lle n wre nch fo r re m o ving the fro nt whe e l se nso rs
- To rque wre nch (se e to rque ta ble s be lo w) fo r re pla cing co m po ne nts
- Fo r re a r se nso rs, a 10 m m so ck e t, 8 m m so ck e t, fla t-he a d scre wdrive r, a nd ne e dle -no se plie rs m ight be re quire d to re m o ve trim .
- 1/4-inch wide 6-inch lo ng sta nda rd fla the a d scre wdrive r fo r re m o ving ABS ha rne ss co nne cto r clip
- C R C cle a ne r (o r e quiva le nt bra k e cle a ne r)
- Sta bura gs NBU 12/K o r e quiva le nt gre a se (fo r spe e d se nso rs a nd co nne ctio ns in the ho usings)

GA THER OPTIONA L TOOLS:

- (m a ybe ) 10m m so ck e t fo r re m o ving a ir filte r bo x (e a sie r a cce ss fo r so m e E39 m o de ls)
- C a rso ft 6.5 o r P e a k e R e se a rch o r e quiva le nt O BDII dia gno stic sca nne r
- O scillo sco pe (lo o k fo r m illivo lt squa re wa ve s co m ing fro m po we re d se nso rs a s the whe e l turns)
- Note: Carsoft 6.5 can't perform encoding, activation, or steering adjustments.
- Note: Bad ABS modules often report erroneous indications of a bad RR sensor in the OBD scanner reports
- Note: You must use new bolts for the ABS Control Module (according to the Bentleys)

PRICE OEM PA RTS:

- R e pa ir k it, co ntro l unit DSC , $1,120 + $112 (~10% ta x ) = $1,232 (o fte n co llo quia lly re fe rre d to a s the "ABS co ntro l unit")
- W he e l se nso rs, fro nt, $134 x 2 = $268 + $27 (~10% ta x ) = $295 to ta l (so m e sugge ste d EAC tuning fo r whe e l se nso rs)
- W he e l se nso rs re a r, $201 x 2 = = $402 + $40 (~10% ta x ) = $442 to ta l (so m e sugge ste d Auto Ha uz fo r whe e l se nso rs)
- Fro nt bra k e pre ssure se nso r, $111 + 10% ta x = ~$125 (m e a sure s 0-250ba rs o f fro nt-bra k e pre ssure , o utputs 0-5 vo lts)
- Ste e ring a ngle (ya w) se nso rs (in the ste e ring whe e l co lum n o r unde r drive r's se a t) ~$250 e a ch (a lm o st ne ve r ne e de d)
- Hydro unit, DSC , $2,003 x 1 + $200 (~10% ta x ) = $2,013 (this "hydro unit" be hind the ABS co ntro l unit is a lm o st ne ve r a t fa ult)
Note: If you replace the ABS module, you'll also need a $100 dealership recoding to your VIN & steering angles calibrated (apparently)

PRICE REBUILDING OF YOUR A BS MODULE:

- Mo dule Ma ste rs ($105) http://www.m o dule m a ste r.co m /e n/a bs/a te _bm w_a sc.php
- BBA R e m a nufa cturing (8 da ys, $225) http://www.bba -re m a n.co m
- Auto & Truck Ele ctro nics ($105) EBAY se lle r's ID AT E1234, life tim e wa rra nty, fre e shipping, quick turna ro und
- Note: A rebuild of your ABS unit won't require VIN coding, activation, or steering angle calibration

PRICE A REBUILT A BS MODULE FROM A NOTHER VEHICLE:

- Fo r a re built pa rt, m o st sugge st o e m bim m e rpa rts.co m , o ne o f o ur spo nso rs , a t a bo ut $450 + $45 ta x = $500
- No te : A re built ABS unit fro m a no the r ve hicle re quire s a $100 de a le rship VIN re co ding e ffo rt
QUESTION: What happens if you don't code the VIN & check steering angles ... (does the car blow up?)

CONSIDER FIXING IT YOURSELF (we need much more details to make this option viable):
- O pe n up the m o dule & lo o k fo r bro k e n so lde r jo ints which ca n be suck e d a nd re so lde re d (ta k e picture s)
- Add po int-to -po int wiring whe re ne e de d (we ne e d m o re info rm a tio n to m a k e this a ctio na ble )
- R e pla ce dio de s a nd a ny o the r we a k pa rts with m o re ro bust pa rts (a ga in, no t ve ry use ful unle ss we k no w e x a ctly wha t)
- P o st be fo re a nd a fte r picture s so e a ch o f us ca n le a rn fro m the re st

CHECK BMW ERROR CODES:

- Lo ca te the O BDII po rt, by la w, in the co ck pit, within 3 fe e t o f the drive r (a bo ve the drive r's le ft k ne e in Am e rica n BMW s)
- Ho o k up C a rso ft o r P e a k e dia gno stic to o ls to the O BDII po rt to de te rm ine a ny e rro r co de s
- C ro ss re fe re nce C a rso ft e rro r co de s with the list o f Bo sch 5.7 e rro r co de s liste d be llo w (k indly supplie d by Ma x _VQ )
Note: Some say this check is of dubious value because a bad ABS module may show up as a bad rear sensor; always test the sensor itself!

BMW A BS/A SC Bosch 5.7 Table of error codes:

5 R ight R e a r W he e l Spe e d Se nso r
6 R ight Fro nt W he e l Spe e d Se nso r
7 Fro nt Le ft W he e l Spe e d Se nso r
14 So le no id Va lve R e la y (che ck fuse s 17 & 33)
15 P re ssure Se nso r/P um p Erro r
21 Mo dule Me m o ry Fa ilure - ABS/ASC m o dule is fa ulty
23 Inco rre ct C o ding - ABS/ASC m o dule is fa ulty
24 W ro ng Im pulse
30 Le ft R e a r W he e l Spe e d Se nso r
31 O pe n R ight R e a r W he e l Spe e d Se nso r
32 O pe n R ight Fro nt W he e l Spe e d Se nso r
33 O pe n Le ft Fro nt W he e l Spe e d Se nso r
50 R ight Fro nt O utle t Va lve - ABS/ASC m o dule is fa ulty
51 Le ft R e a r O utle t Va lve - ABS/ASC m o dule is fa ulty
54 Le ft Fro nt Inle t Va lve - ABS/ASC m o dule is fa ulty
55 ASC Inta k e Va lve - ABS/ASC m o dule is fa ulty
58 Ge a r Bo x C o ntro l Unit (C AN bus e rro r)
59 DMER 1 (C AN bus e rro r)
61 Ste e ring Angle Se nso r Ide ntifica tio n
66 Spe e d Se nso r Vo lta ge Supply
67 Inte rm itte nt Inte rfe re nce
75 Engine Spe e d Fa ult fro m DME
81 P re ssure Se nso r
82 O pe n Ya w R a te Se nso r
86 ASC C ut-o ff Va lve R e a r Ax le
88 P re cha rge P um p
89 Lo w Vo lta ge
90 Te m po ra ry Syste m De a ctiva tio n
94 DDE Fa ult/Ya w ra te se nso r
97 Ste e ring Angle Se nso r
10 Bra k e Light Switch
108 SN C o ntro l
112 O pe n C AN to Instrum e nt C luste r
114 P re ssure Se nso r O ffse t
117 Bra k e Light Switch Fa ilure
118 DME Sta tus-Inte rna l Erro r

REMOVE A BS-MODULE CONNECTOR:

- Fa cing the e ngine , slide the pla stic re ta ining clip to the right with a 1/4 inch fla the a d scre wdrive r.
- It is a pla stic re ta ining clip, so do be ca re ful no t to bre a k it; it slide s o ve r a bo ut 1 1/4 inche s o r so .
- O nce the clip is fully to the right, lift the e le ctrica l co nne cto r up
- No tice the fe m a le (blue ) co nne cto r with 42 ho le s (a nd ve ry tiny le tte ring)
- DO NO T ST IC K Y O UR T EST LEAD INT O T HE SQ UAR E HO LES!
(Only put test leads into the larger rectangular holes next to the square holes.)

NOTE A BS-MODULE PINOUT: (notice the test lead holes)

- Ea ch whe e l se nso r circuit ha s a se t o f two wire s in the ABS co nne cto r ( pino ut k indly supplie d by 540im a n)
- ABS-co nne cto r pins 13,29 = Le ft re a r whe e l se nso r (a lso a ffe cts spe e do m e te r & o do m e te r & tripm e te r)
- ABS-co nne cto r pins 30,31 = R ight re a r whe e l se nso r (a lso a ffe cts cruise co ntro l)
- ABS-co nne cto r pins 28,12 = Le ft fro nt whe e l se nso r (so m e sa y it a lso a cts a s a ste e ring a ngle se nso r)
- ABS-co nne cto r pins 15,16 = R ight fro nt whe e l se nso r (te lls ge a rbo x e le ctro nics ho w fa st yo u're go ing )
Note: These pinouts are in the same order of the diode action of each sensor (do not reverse these numbers)
Note: Don't confuse with the brake pad wear sensor, which is only located on the front left & rear right wheel & which uses a black connector.
Note: ASC cars have only two sensors, one on the front right and the other on the rear left wheel.

UNDERSTA ND W HEEL SPEED SENSORS:

Note: The wheel speed sensors are two-wire hall effect transducers which send a digital square wave signal with a low of .75 volts and a high of
2.5 volts to the DSC control unit. Each sensor receives a well-regulated 8 volt power supply from the control module through one wire. The ground
path for the sensor is through the second wire back to the control module. The signal is generated by a pulse wheel affecting the voltage flow
through the hall element in the sensor. The pulse wheel is integrated into the wheel bearing assembly, behind the seal. This protects the trigger
wheel from foreign substances which may affect the wheel speed signal.

TEST W HEEL SENSOR CIRCUIT FROM THE A BS CONNECTOR (a lso che ck s wiring circuit):
O P T IO NAL: Ja ck ca r up (so tha t a ll fo ur whe e ls ca n be spun to te st vo lta ge & re sista nce fluctua tio ns o f the ha ll-e ffe ct se nso rs)
- Turn the ca r o ff a nd re m o ve the k e y fro m the ignitio n.
- TEST 1: Switch the DMM into the dio de te st po sitio n
- W ra p a stiff 20AW G wire o nto the e nds o f yo ur DMM pro be fo r stick ing into ABS-co nne cto r pins
- La be l the po sitive 20AW G wire with white ta pe so tha t yo u wo n't ge t co nfuse d a s yo u switch ba ck a nd fo rth
- Stick the e nds o f the wire into the a ppro pria te fe m a le ho le s o f the ABS co nne cto r (13-29, 30-31, 28-12, 15-16)
- In o ne dire ctio n, yo u sho uld se e 1.7 to 1.8 vo lts (no te the pino uts m e ntio ne d a re in o rde r, po sitive to ne ga tive )
- In the o the r dire ctio n, yo u sho uld se e O L o r so m e o the r infinite re a ding (o pe n circuit)
- TEST 2: Switch the DMM into re sista nce che ck ing m o de (o ptio na l)
- Yo u sho uld se e a ro und 3.3 Me ga o hm s in o ne dire ctio n & a ppro x im a te ly twice tha t in the o the r dire ctio n ( but so m e sa y m o re )
- TEST 3: If de sire d spin the whe e l a t a bo ut 1 re vo lutio n pe r se co nd , by ha nd (the re sista nce sho uld fluctua te a s the whe e l spins )
- TEST 4: Switch the DMM into m illivo lt m o de (o ptio na l) & a ga in spin the tire & whe e l a sse m bly by ha nd (te st-le a d po la rity wo n't
m a tte r)
- Yo u sho uld re a d be twe e n 1 a nd 5 m V whe n yo u spin the hub (no vo lta ge im plica te the se nso r o r circuit)
- O P T IO NAL T EST S BELO W R EQ UIR E FLY ING LEADS W IT H T HE IGNIT IO N SY ST EM ABS SY ST EM C O NNEC T ED & P O W ER ED UP :
- TEST 5: Swith the DMM into the 10v a nd a tta ch flying le a ds to the se nso rs with the po we r o n
- Yo u sho uld se e the vo lta ge go ing to the se nso r a nd the re turn signa l
- Ex pe ct a ba se line vo lta ge o f a bo ut +5 to +12 vo lts de pe nding o n the ABS syste m (do e s a nyo ne k no w this va lue ?)
- Ex pe ct tha t ba se line vo lta ge to the se nso r to cha nge (by ho w m uch?) a s yo u spin the whe e ls
- TEST 6: Ho o k a n o scillo sco pe with "flying le a ds" to the ABS se nso rs (no tice tha t the ABS syste m m ust be po we re d)
- Yo u sho uld se e nice cle a n squa re wa ve s ge ne ra te d a s yo u ha nd spin the whe e ls a t a bo ut 1 re vo lutio n pe r se co nd.
No te : T he o scillisco pe ca n de te ct pro ble m s tha t ca n't e a sily be fo und with a DMM (A scope pattern for a wheel speed sensor should show a
classic sine wave alternating current pattern that changes both in frequency and amplitude with wheel speed. As the wheel is turned faster, signal frequency
and amplitude should both increase. Damaged or missing teeth on the sensor ring will show up as flat spots or gaps in the sine wave pattern. A bent axle or
hub will produce an undulating pattern that changes as the strength of the sensor signal changes with every revolution. If the scope pattern produced by the
sensor is flattened (diminished amplitude) or is erratic, it usually indicates a weak signal caused by an excessively wide air gap between the tip of the sensor
and its ring, or a buildup of metallic debris on the end of the sensor. A weak signal can also be caused by internal resistance in the sensor or its wiring circuit,
or loose or corroded wiring connectors.)
INTERPRET DIODE-TEST RESULTS:
- If the DMM, in dio de m o de , re a ds infinity ("O L") in bo th dire ctio ns, yo u've go t a ba d se nso r o r circuit
- If the DMM, in re sista nce m o de , re a ds m uch gre a te r tha n 7Mo hm s, yo u've go t a ba d se nso r o r circuit
- If a ll 4 se nso rs re a d O K, it's m o st lik e ly the ABS co ntro l unit.
- If yo u think yo u fo und two ba d se nso rs, yo u pro ba bly m e sse d up.
- R a re ly is the ca use due to ba d ste e ring a ngle (ya w/le w) se nso rs
- R a re ly is the ca use due to a ba d hydro unit
- T he pro ble m is a lm o st a lwa ys a whe e l ro ta tio n se nso r o r the ABS co ntro l unit

A CTUA L RESULTS ON MY 2002 E39 THIS MEMORIA L DA Y W EEKEND:

DOUBLECHECK W HEEL SENSORS A T THE W HEEL:

No te : Yo u ca n run this te st w/o re m o ving the whe e l but a cce ss to the se nso r co nne cto r is e a sie r with the whe e ls o ff the E39
- If o ne o r m o re se nso r circuits te st ba d in a ny o f the thre e te sts a bo ve ... the n ...
- Lo ca te the se nso r blue co nne cto r in the re a r o f e a ch fro nt whe e l we ll by turning the fro nt whe e ls
- Ea sie st to first lo ca te the se nso r (bo lte d o n the whe e l ca rrie r ne a r the hub) a nd tra ce its wire ba ck to a bla ck pla stic hinge d bo x
ho using
- O pe n the lo ck e d hinge d pla stic re cta ngula r bla ck bo x with a sm a ll fla the a d scre wdrive r
- Lo ca te the blue whe e l se nso r co nne cto r (ne x t to a bla ck bra k e we a r se nso r co nne cto r)
- P ull the blue whe e l se nso r co nne cto r o ut o f the bo x a nd disco nne ct the two side s
- R e -che ck the se nso r the re with the dio de functio n o f the DMM

CHECK W HEEL SENSORS OFF THE VEHICLE:

- If a ny se nso r still che ck s ba d, pull the se nso r o ff the ve hicle fo r a clo se r inspe ctio n
- C ho ck whe e ls a nd ja ck E39 BMW a nd ja ck sta nd a t the 4 ja ck pa d lo ca tio ns
- R e m o ve 4m m a lle n he a d bo lts to se nso r re te ntio n scre w (two re ta ining bo lts fo r fro nts, 1 bo lt fo r the re a rs)
- P ull whe e l se nso r o ut o f hub a sse m bly, stra ight up.
- C le a n with C R C e le ctro nic cle a ne r
- C he ck with DMM dio de -te st m e te r a s be fo re
- Gre a se with Sta bura gs NBU 12/K o r e quiva le nt gre a se
- R e pla ce se nso r ba ck into hub a sse m bly, snug tighte n to 6 fo o t po unds
- R e pla ce re a r whe e l, tighte n to 82 to 96 fo o t po unds
Note: You might wish to swap sensors on the same axle when replacing so as to obtain further diagnostic information should an anomaly occur.
Note: Here is a picture of a dirty and cleaned sensor (magnetic particle buildup)

TEST BRA KE PRESSURE SENSOR (aka HYDRA ULIC UNIT PRESSURE SENSOR):
- T his te st pro ce dure k indly sugge ste d by Ma x _VQ :
- Give n 250 ba r = 3,626 psi, a nd give n 0-5 vo lts line a r pro po rtio na l o utput, 3,626 psi/ 5v = 725.2 psi/vo lt o r 1.3 m V pe r psi.
- W ith the ignitio n o n, m e a sure the vo lta ge o n the pre ssure se nso r while so m e o ne is pre ssing ha rd o n the bra k e pe da l
- My gue ss is tha t sho uld cre a te a bo ut 3,000 psi o f fo rce a nd sho uld sho w a ro und 4.13 vo lts.
- At re st it sho uld sho w ve ry clo se to 0 vo lts
Note: The front-brake pressure sensor provides a 0-5 volt linear voltage signal to the DSC III control module which is proportionate to how hard
the driver is pressing on the brake pedal, from zero to 250 bars (3,626 psi), spanning (a) no braking, to (b) partial braking, and to (c) near-ABS-
regulation state braking. This brake pressure sensor has three pins (a) power, (b) ground and (c) the 0-5 volt proportionate signal.
Note: By way of comparison, the Corvette also has a brake pressure sensor to indicate how hard the brakes are being applied; it monitors
pressure from 0 to 2000psi generating a corresponding signal of 0.20 volts to 4.80 volts .

LOCA TION OF FRONT-BRA KE PRESSURE SENSOR:

• DSC III 5.3 (740i/iL a nd 540i) - T he bra k e pre ssure se nso r is lo ca te d in the cha rge pum p a sse m bly.
• DSC III 5.3 (750iL) - T he se nso r is lo ca te d o n the cha rge pisto n unit.
• DSC III 5.7 (ALL) - T he se nso r is lo ca te d o n the hydra ulic unit o n m y 2002 E39.

TEST ROTA TION RA TE & LA TERA L A CCELERA TION SENSOR:

- W e do no t ye t ha ve a te st fo r this se nso r; a de scriptio n o f o pe ra tio n is a ll we ha ve a t the m o m e nt (ple a se sugge st a te st pro ce dure
so a ll be ne fit)
- O n Bo sch DSC III (Bo sch 5.7) the R o ta tio n R a te se nso r (ya w) a nd the La te ra l Acce le ra tio n se nso r ha ve be e n co m bine d into o ne unit
lo ca te d unde r the drive rs se a t unde r the ca rpe t
- T he de gre e o f ro ta tio n ra te (ya w) tra nsduce r o utputs a re fe re nce signa l o f 2.5 vo lts a nd a line a r vo lta ge o f 0.7 to 4.3 vo lts
- T he la te ra l a cce le ra tio n o utput signa l sho uld be 1.7 vo lts while the ca r is sitting still o n a fla t surfa ce co rre spo nding to 0 G side
fo rce s.
- T he la te ra l a cce le ra tio n tra nsduce r o utputs a line a r vo lta ge o f 0.5 to 4.5 vo lts co rre spo nding to a G-Fo rce ra nge o f -1.5 to +3.5 G
side fo rce s de pe nding o n the m o tio n o f a fix e d ca pa cito r pla te re la tive to a flo a ting ca pa cito r pla te .

TEST STEERING A NGLE SENSOR:

- W e do n't ye t k no w ho w to te st the ste e ring-a ngle se nso r (ple a se a dvise )
Note: The steering angle sensor, mounted at the bottom of the steering column near the flexible coupling, utilizes two potentiometers to
determine the steering angle and the rate of steering angle change, which are are the two raw signals the CAN bus microprocessor utilizes to
create the steering angle signal for broadcast over the CAN bus. The DSC III logic compares the stored plausibility of the steering angle sensor
against other DSC III inputs (front wheel speeds, rotation rate and lateral acceleration sensors).

STEERING A NGLE SENSOR:

REMOVE A BS MODULE:
- R e m o ve the six T 20 To rx scre ws ho lding the ABS m o dule to the hydro unit
- P ull the ABS m o dule stra ight o ut to wa rds the pa sse nge r side he a dlight.
- C o ve r the hydro unit with a lum inum fo il to pro te ct it fro m the e le m e nts
- Yo u ca n drive the ca r but yo u wo n't ha ve a spe e do m e te r o r o do m e te r
- Use a po rta ble GP S unit with a spe e d displa y a s yo ur te m po ra ry spe e do m e te r
- Yo u m a y no t ha ve cruise co ntro l (ne e d to te st this)
- O f co urse , yo u wo n't ha ve ABS e ithe r but yo u didn't ha ve tha t a nywa y

HINTS TO HELP OTHERS:

- C o nside r ta k ing a pa rt yo ur ABS m o dule a nd po sting be fo re re build a nd a fte r re build picture s
- C o nside r pa ying re builde rs the e x tra $10 to re turn ABS m o dule s tha t fa ile d (so yo u ca n ta k e it a pa rt & po st picture s)
- C o nside r se lling yo ur o ld m o dule to the re builde rs if yo u buy a ne w o r re built ABS m o dule fro m a no the r ve hicle
- A po rta ble GP S unit do uble s a s a spe e do m e te r in the inte rim while yo ur ABS m o dule is be ing re built

REINSTA LL A BS MODULE:
- No te : T he re is a ga sk e t a tta che d to the ne w unit.
- C a re fully pla ce the ne w m o dule o ve r the co ntro l a ctua to rs.
- Lo o se ly re pla ce the six ne w T 20 To rx scre ws include d with the ne w m o dule .
- T ighte n snug tight, a nd the n a little m o re to se a t the ga sk e t.
- R e po sitio n the ABS e le ctrica l co nne cto r
- P re ss do wn o n the ABS co nne cto r while pushing the re ta ining clip to the le ft
- R e a sse m ble the Air Filte r bo x & MAF (if it wa s disa sse m ble d fo r To rx a cce ss).

INITIA LIZE A BS MODULES:

- No te : T his ste p is o nly ne ce ssa ry if yo u insta lle d a n ABS m o dule tha t wa sn't o rigina lly in the ca r in the first pla ce
- Ta k e the E39 to a n Indy to e nco de the VIN (I'm no t sure wha t ha ppe ns if yo u do n't do this)
- Ta k e the E39 to a n Indy to che ck a nd a djust the ste e ring a ngle (I'm no t sure why)
- So m e sa y the ste e ring a ngle se nso r m a y ha ve to be re ca libra te d whe n yo u put o n a re m a nufa cture d o r ne w ABS m o dule .

TORQUE TA BLE:
- 4m m whe e l se nso r bo lts (two e a ch fo r the fro nt se nso rs, 1 e a ch fo r the re a r se nso rs) = 6 fo o t po unds
- C o m bina tio n la te ra l a cce le ra tio n/ro ta tio na l ra te se nso r (unde r drive r se a t) = 6 fo o t po unds
- DSC bo lts to the hydra ulic unit (ne w bo lts o nly) = 26 inch po unds
- Hydra ulic unit to bo dy = 6 fo o t po unds
- Hydra ulic unit m o unting bra ck e t = 6 fo o t po unds
- Bra k e line s to hydra ulic unit = 13 fo o t po unds
- W he e l lug nuts = 82 to 96 fo o t po unds

DIA GRA M OF THE 2002 E39 DSC III BOSCH 5.7 SYSTEM:
USE THIS CHA RT TO DETERMINE W HICH A BS SYSTEM YOU HA VE:
,