Abs Esp 3520a

TECHNICAL NOTE 3520A

XAXX

ABS/ESP (Electronic Stability Program)

Bosch 5.7

77 11 305 002

"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

JUNE 2001

All copyrights reserved by Renault.

EDITION ANGLAISE

Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.

© RENAULT 2001

ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMABS/ESP Bosch 5.7 38138ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMABS/ESP Bosch 5.7

INTRODUCTION

The ESP (Electronic Stability Program) is a mechanism that complements the ABS system.

AFTER ANY OPERATIONS ON THE ESP SYSTEM, YOU MUST ROAD TEST THE VEHICLE TO CONFIRM REPAIR.

DESCRIPTION

The ESP (Electronic Stability Program) is made up of the following elements:– a brake servo assembly,– a pump assembly made up of:

– a hydraulic pump,– a pressure modulation unit (twelve solenoid valves),– a computer,– a pressure sensor.

– a steering wheel angle sensor,– the yaw and transverse acceleration sensor,– the four wheel sensors,– a disconnection button.

OPERATING PRINCIPLE

The ESP (Electronic Stability Program) establishes reference conditions for the vehicle and applies corrective braking action when these references are deviated from.

The reference conditions are continually monitored from measurements taken from the vehicle and refer to the desired correct behaviour.

These measurements are:– the wheel speed,– the steering wheel angle.

These reference conditions are compared to the actual condition of the vehicle, determined by measuring:– the yaw speed,– the tranverse acceleration.

The ESP (Electronic Stability Program) assesses the difference between these measurements to calculate the braking force to apply to one or more wheels according to the distribution strategy selected.

The resultant forces applied by braking generate rotation moments on the vehicle which restore it to a course corresponding to the behaviour desired.

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ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMABS/ESP Bosch 5.7 38

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When does ESP intervene?

Steering selected by the driver

Calculation of the driver's intention

Where is the vehicle going?

Course determined

Determine DEVIATION from COURSE

CORRECTIVE MEASURES BRAKES AND ENGINE


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1 Hydraulic unit2 Computer3 Mechanical component-based brake servo4 Steering wheel angle sensor5 Yaw speed and transverse acceleration sensor6 Vehicle speed7 CAN network8 Wheel sensor9 Diagnostic socketA CAN network on the steering wheel angle sensor


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YAW SPEED AND TRANSVERSE ACCELERATION SENSOR

ALLOCATION OF SENSOR TRACKS

1 Yaw speed sensor reference signal2 Yaw sensor test signal3 +12 V after ignition supply4 Yaw speed signal5 Transverse acceleration signal6 Transverse acceleration sensor and yaw speed

sensor earth

This sensor is located in the central console, in front of the handbrake lever.It houses both a transverse acceleration sensor and a yaw speed sensor.

REMOVAL

Disconnect the battery.

Remove the mounting bolts (1) from the sides of the central console.Unclip the sides of the central console where indicated by the arrow (2) and then remove them by pulling in the direction shown by the arrow.

IMPORTANT:Handle this sensor with care.This sensor must be positioned in the direction of movement of the vehicle to work correctly (see the arrow on the sensor facing the front of the vehicle).

IMPORTANT: you must handle the sensor with care.

TIGHTENING TORQUES (in daNm)

Sensor mounting nut 0.8 ± 0.1


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Remove:– the ice box mounting bolts (3),– the ice box.

Unclip:– the gear lever gaiter (4),– the trim surrounding the central console storage

compartment (5).

Disconnect the transverse acceleration and yaw speed sensor.

Remove:– the sensor mounting nuts (6),– the sensor.

REFITTING

Refit the sensor, ensuring that it is facing in the right direction (arrow 7 should be pointing towards the front of the vehicle).Torque tighten the sensor mounting nuts to 0.8 ± 0.1 daNm.

Refit in the reverse order to removal for the other refitting operations.

You must road test the vehicle to confirm the repair.

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STEERING WHEEL ANGLE SENSOR

The ESP uses a steering wheel angle sensor to measure the course selected by the driver. This signal is interpreted as a command made by the driver.

The steering wheel angle sensor is more than a simple sensor. It should be considered as a computer in its own right. It has two processors which, being redundant, ensure that the signal delivered on a private CAN network is reliable.


1 Earth2 +12 V supply delivered by the ESP computer3 CAN H4 CAN L

This sensor is located on the steering column. It is clipped to the lower section of the upper body of the column, next to the upper universal joint.

REMOVAL

Before attempting any operations on the air bag systems, you must lock the computer using the diagnostic tools (see section 88).

Once the air bag system computer is locked, disconnect the battery.

Remove:– the driver's air bag,– the steering wheel.

– the three mounting bolts (1) from the lower half cowling,

– the lower cowling,– the fuse box cover (2).

IMPORTANT: this sensor must be calibrated after removal or replacement.

TIGHTENING TORQUES (in daNm)

Steering wheel bolt 4.5

Steering column universal joint eccentric bolt 2.5

Steering column intermediate shaft bolt 2.1

Steering column mounting nut 2

IMPORTANT: All operations on air bag and pretensioner systems must be carried out by qualified, trained personnel.


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Remove:– the mounting bolts (3) from the steering column trim,– the steering column trim,– the mounting bolts (4) from the switch support,– the switch support, by disconnecting the connectors.

Disconnect:– the ignition switch connector (5),– the steering wheel angle sensor connector (6), then

unclip the switch from its support.

Remove:– the steering column mounting nut (7),– the metal protector mounting bolts (8),– the steering wheel angle sensor metal protector (9),– the two bolts (10) and then disconnect the tie-rod

from the sensor and remove the tie-rod.


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Remove:– the accelerator pedal (11),– the accelerator stop (12).

Move the carpet aside and remove the gaiter (13) from the intermediate shaft.

Remove:– the steering column intermediate shaft bolt (14),– the universal joint eccentric bolt (15),– the steering column intermediate shaft.

Unclip and remove the steering wheel angle sensor.

Note: the sensor has three clips. It may be necessary to turn the steering column to reach the clips at the back.


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REFITTING

Refit the sensor, ensuring that the indexing pin (1) is correctly positioned in the plastic insert on the steering column.

Also make sure that the three clips (2) on the steering wheel angle sensor are fitted correctly to the steering column.

Refit the other components in the reverse order to removal.

IMPORTANT: the steering wheel splines are fitted with foolproofing devices. The steering wheel should slip easily into the splines. Be careful not to damage them.

The steering wheel bolt must be replaced and torque tightened after each removal operation.

IMPORTANT:

Remember to lock the air bag computer using the diagnostic tools (see section 88).

You must calibrate the sensor after any operations (removal or replacement) on the steering wheel angle sensor itself.

You must road test the vehicle to confirm the repair.

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STEERING WHEEL ANGLE SENSOR CALIBRATION

You must calibrate the sensor after any operations on the steering wheel angle sensor itself, the steering column or the front axle.

For calibrating the steering wheel angle sensor, you MUST place the vehicle on an axle assembly repair bench, to determine the steering centre point as precisely as possible.

Steering wheel angle sensor calibration:! connect a diagnostic tool (NXR, OPTIMA 5800 or

CLIP),! switch on the ignition,

1 Select the Renault vehicle fault finding menu.2 Select and confirm the vehicle type.3 Select and validate the system to be diagnosed ABS/

ABR.4 Choose the Command mode menu.5 Select the Parameter menu.6 Select and confirm the line VP 003 or Steering

wheel angle sensor.7 Use the following procedure described on the axle

assembly repair bench and the diagnostic tool:– turn the steering wheel to the left and then to the

right, as described on the repair bench,– position the vehicle with its wheels straight and

align the steering to centre point with the help of the repair bench (with a tolerance on the angle of ± 5°),

– use the parameter command on the diagnostic tool to set the sensor parameters.

8 Return to the main menu to select the List of parameters menu.

9 Check that parameter PR 033 or Steering wheel angle falls between -5° and +5°. If it does not, exit fault finding mode, switch off the ignition for a few seconds and then restart the steering wheel angle sensor calibration procedure.

Clear any faults that have been stored in the computer.

ROAD TEST THE VEHICLE TO CONFIRM REPAIR.


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PRESSURE SENSOR


1 Earth2 Pressure signal3 Stabilized supply

The pressure sensor (1) informs the computer of the brake fluid pressure at the hydraulic unit intake.

REPLACEMENT

If you replace the sensor, you must also replace the hydraulic unit (see the hydraulic unit removal-refitting method).

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FRONT WHEEL SENSOR

The target/sensor air gap should be between 0.3 mm and 1.4 mm.

REMOVAL

Remove:– the wheel,– the T30 sensor mounting bolt (1) (with star-shaped

indentation).

Remove the connector from the support.

Disconnect the wheel sensor connector.

Remove the sensor.

REFITTING

Coat the sensor with multi-purpose lubricant, part number: 77 01 422 308.

Refit the sensor in the reverse order to removal.

Check the air gap over one revolution of the target with a set of shims.

The sensor must be fitted manually. Do not knock it during installation.

Do not use the wiring harness to lever up or take the weight of components.

TIGHTENING TORQUE (in daNm)

Sensor mounting bolt 0.8 ± 0.2

NOTE: It is vital to make sure the connectors are perfectly connected to prevent risk of breakdowns.


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REAR WHEEL SENSOR

The target/sensor air gap should be between 0.3 mm and 1.4 mm.

REMOVAL

Remove:– the wheel,– the T30 sensor mounting bolt (1) (with star-shaped

indentation).

Remove the connector from the support.

Disconnect the wheel sensor connector.

Remove the sensor.

RIGHT-HAND SIDE

LEFT-HAND SIDE


Sensor mounting bolt 0.8 ± 0.2


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REFITTING

Coat the sensor with multi-purpose lubricant, part number: 77 01 422 308.

Refit the sensor in the reverse order to removal.

Check the air gap over one revolution of the target with a set of shims.

The sensor must be fitted manually. Do not knock it during installation.

Do not use the wiring harness to lever up or take the weight of components.

NOTE: It is vital to make sure the connectors are perfectly connected to prevent risk of breakdowns.


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HYDRAULIC UNIT

The Bosch 5.7 hydraulic unit is made up of twelve solenoid valves.

The computer is fitted with a more powerful processor (it manages more parameters).

The hydraulic unit is positioned on the front right-hand side of the vehicle, behind the front bumper.

A Master cylinder (primary circuit)B Master cylinder (secondary circuit)C Rear left wheel outputD Rear right wheel outputE Front right wheel outputF Front left wheel output


Brake pipes on unit 1.4


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REMOVAL

Put the vehicle on a two post lift.

Disconnect the battery.

Remove:– the front wheels,– the two wheel arch protector bolts (A),– move the wheel arches aside carefully to make way

for the spanner and remove the side mounting bolts on the bumper,

– the two bolts from the front section of the underbody protection,

– the bolt in the centre of the bumper.

Remove and disconnect the fog lights, if fitted.

Remove:– the bumper,

– the two mounting bolts (1) from the right-hand wing reinforcing bracket,

– the right-hand wing reinforcing bracket,– the three mounting bolts (2) from the right-hand lens

unit,– the lens unit and disconnect it.


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Disconnect:– the petrol vapour absorber solenoid valve,– the petrol vapour absorber pipes.

Remove:– the petrol vapour absorber mounting nuts (3),– the petrol vapour absorber.

Fit a pedal press to limit brake fluid flow when opening the circuits.

Disconnect the braking pressure sensor (4).

Disconnect the hydraulic unit brake pipes.

IMPORTANT: remember to anticipate that brake fluid will flow out; protect the mechanical parts and bodywork around the braking system to prevent damage.

Disconnect the ABS/ESP computer connector (5).

Remove:– the hydraulic unit mounting bolts (6),– the hydraulic unit.

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REFITTING

Refitting is the reverse of removal.

Proceed to the braking system bleed operation (refer to the bleeding method).


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ABS/ESP COMPUTER

REPLACEMENT

If you replace the ABS/ESP computer, you must also replace the entire hydraulic unit (see the hydraulic unit removal-refitting method).

REFITTING

Refitting is the reverse of removal.

After refitting a new computer, you must calibrate the steering wheel angle sensor and configure the vehicle type and the vehicle's tachometric index.

To do this:! connect a diagnostic tool (NXR, OPTIMA 5800 or

CLIP),! switch on the ignition,

1 Select the Renault vehicle fault finding menu.2 Select and confirm the vehicle type.3 Select and validate the system to be diagnosed ABS/

ABR.4 Select the Command mode menu.5 Select the Parameter menu.

Select and confirm these lines in succession to configure the computer:

1 Select and confirm the line VP 003 or Steering wheel angle sensor and follow the procedure described on the tool for calibrating the steering wheel angle sensor.

2 Select and confirm the line VP 007 or Tachometric index and follow the procedure described on the tool for configuring the tachometric index.

3 Select and confirm the line VP 004 or Vehicle parameter and follow the procedure described on the tool for configuring the vehicle type.

Clear any faults that have been stored in the computer.

ROAD TEST THE VEHICLE TO CONFIRM REPAIR.


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ALLOCATION OF ABS/ESP (Electronic Stability Program) COMPUTER TRACKS

12567891011131415161721

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Pump earth+ battery (protected by a 60 A fuse)Computer earth+ battery (protected by a 60 A fuse)ABS fault warning light controlTransverse acceleration sensor signalYaw speed sensor test signalYaw speed sensor reference supplyFault finding lineFront left wheel speed sensor earthRear left wheel speed sensor signalFront right wheel speed sensor earthFront right wheel speed sensor signalBrake fault warning light controlTransverse acceleration sensor/yaw speed sensor and steering wheel angle sensor earthESP multi-function fault warning light control

2324

252627282930313233373839

40

4142

+ after ignitionSteering wheel angle sensor CAN H multiplex connectionPressure sensor earthPressure sensor signalESP on/off push-buttonFront left wheel speed sensor signalRear left wheel speed sensor earthRear right wheel speed sensor earthRear right wheel speed sensor signalBrake switch signal (on closing)Vehicle speed signalBrake switch signal (on opening)Handbrake signalTransverse acceleration sensor/yaw speed sensor and steering wheel angle sensor +12 V supplySteering wheel angle sensor CAN L multiplex connection Yaw speed sensor signalPressure sensor stabilized supply


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BLEEDING PROCEDURE

NOTE: the hydraulic unit is pre-filled.

This bleeding procedure must be used when one of the following components has been removed:– the hydraulic unit,– the master cylinder,– the pipework (between the hydraulic unit and the master cylinder).

NOTE: the braking circuit with ABS must be free from faults and must operate correctly. If it does not, the ABS circuit must be repaired from both a hydraulic and electrical point of view.

1) Bleed the braking circuit in the normal way using your foot or a bleeding kit.

NOTE: if, after a road test with ABS regulation, the pedal travel is not correct, bleed the hydraulic unit.

2) Bleeding the hydraulic unit

IMPORTANT: the bleeding order must be observed, beginning with the rear right brake, then the rear left, the front left and finally the front right.

a) Bleed the rear right-hand brake by bleeding the hydraulic unit secondary circuit using the diagnostic tool:

– position the bleed container and the hose, open the brake bleed screw,

– pump the brake pedal (approximately ten times),

– keep the brake pedal depressed and start the bleed command with the fault finding tool (refer to the fault finding help section),

– pump the brake pedal during the diagnostic bleed phase,

– at the end of the bleed cycle using the fault finding tool, continue to pump the brake pedal and close the brake bleed screw.

b) Follow the procedure as described in a) for the rear left brake, the front left and the front right.

c) Check the pedal travel and if it is incorrect, restart the bleeding procedure.

IMPORTANT: ensure that there is sufficient brake fluid in the tank.

Abs Esp 3520a

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