SWB a5 m08 Final

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ASE 5 - Brakes

Module 8

Bosch ABS

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Acknowledgements

General Motors, the IAGMASEP Association Board of Directors, and Raytheon

Professional Services, GM's training partner for GM's Service Technical College wish to

thank all of the people who contributed to the GM ASEP/BSEP curriculum development

project 2002-3. This project would not have been possible without the tireless efforts of

many people. We acknowledge:

The IAGMASEP Association members for agreeing to tackle this large project to

create the curriculum for the GM ASEP/BSEP schools.

The IAGMASEP Curriculum team for leading the members to a single vision and

implementation.

Direct contributors within Raytheon Professional Services for their support of

translating a good idea into reality. Specifically, we thank:

Chris Mason and Vince Williams, for their leadership, guidance, and support.

Media and Graphics department under Mary McClain and in particular, Cheryl

Squicciarini, Diana Pajewski, Lesley McCowey, Jeremy Pawelek, & Nancy

DeSantis.

For his help on the Brakes curriculum volume, Subject Matter Expert, John

Fisher, for his wealth of knowledge.

Finally, we wish to recognize the individual instructors and staffs of the GM ASEP/BSEPColleges for their contribution for reformatting existing General Motors training material,

adding critical technical content and the sharing of their expertise in the GM product.

Separate committees worked on each of the eight curriculum areas. For the work on this

volume, we thank the members of the Brakes committee:

George Behrens, Monroe Community College

Lorenza Dickerson, J. Sargeant Reynolds Community College

Tim McCluskey, Dakota County Technical College

Wayne Musser, Harrisburg Area Community College

Vince Williams, Raytheon

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Contents

Module 8 Bosch ABS

Acknowledgements .......................................................................................... 2Exercise #1 ..................................................................................................................... 4

Exercise #2 ..................................................................................................................... 5

Exercise #3 ..................................................................................................................... 7

Exercise #4 ..................................................................................................................... 9

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2002 General Motors Corporation

All Rights Reserved

ASE 5- Brakes

Module 8 -

Bosch ABS

8-4

Student WorkbooIntroduction

This workbook is designed to help you to gain a working knowledge of the

operation, diagnosis and repair of the Bosch 5 Series ABS systems used

in General Motor's cars. Toward that purpose, we will be assigning you a

number of different exercises that will test your ability to diagnose these

vehicles.

Exercise #1Vehicle needed:

Current or recent production GM car with Bosch 5 Series ABS

brakes.

Tools needed:

Tech 2

Techline terminal.

Activity to accomplish: Using the Tech 2, access the ABS system data

and perform a snap shot of that data. Then, accessing the Techline

terminal, download the snapshot data from the Tech 2 to the terminal.Choose 5 data parameters and graph those parameters out and then print

the graph. Fill out the following information as you perform these steps in

the exercise.

Vehicle information:

Model Year ________________________

Make of car ________________________

Model of car _______________________

Type of system (check one) ________ ABS ________ ABS/TCS

Connect the Tech 2 to the car and program the scan tool.

List the Tech 2 Screens that you used to access the ABS data. Be

specific!

_________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

List the data parameters you chose.

__________________________________________________________________________________________________________________

_________________________________________________________

_________________________________________________________

Show you instructor the graph that you printed and have them initial this

worksheet. Instructor's initials _______________

Ask you instructor for further instructions.

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ASE 5- Brakes

Module 8 -

Bosch ABS

8-5

Student WorkbooExercise #2

Vehicle needed:

Current or recent production General Motors car equipped with a Bosch 5

Series ABS system. This vehicle should have a "bugged" component or

circuit installed in the ABS system for the student to diagnose.

Tools needed:

Tech 2

Techline terminal

J-39200 DVOM or equivalent

J-39700 or J-39700-A Break out box

J-39700-15 adapter cable (as needed)


J-39700-10A adapter cable (as needed)


J-41247 Brake Pressure Modulator Valve Break out box (as needed)

Activity to accomplish: Using the Tech 2, Techline terminal and special

tools, you are to diagnose the root cause of the customer complaint. Be

prepared to explain your diagnosis to your instructor.

Fill out the following information as you investigate the customer concern.

Model year _________________________

Make of car ________________________

Model of car _______________________

Type of system (check one) ___________ ABS __________ ABS/TCS

Connect the Tech 2 to the car and program the scan tool.

List the Tech 2 screens that you used to access the ABS data. Be

specific!

_________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

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ASE 5- Brakes

Module 8 -

Bosch ABS

8-6

Student WorkbooList the Tech 2 screens that you used to determine if any ABS DTC's are

stored in the EBCM.

_________________________________________________________

_________________________________________________________

_________________________________________________________

List the DTC's that you retrieved from the EBCM with the Tech 2.

_________________________________________________________

_________________________________________________________

_________________________________________________________

List the document numbers from the Techline terminal that relate to the

DTC's.

_________________________________________________________

_________________________________________________________

_________________________________________________________

Using the needed diagnostic tools, perform the necessary procedures as

directed by the DTC chart(s). Record your step numbers and readings

below.

_________________________________________________________

_________________________________________________________

_________________________________________________________

Based on your diagnostic procedures and testing, what is the root cause

of the customer concern?

_________________________________________________________

_________________________________________________________

_________________________________________________________

Show your instructor the completed worksheet and answer any questions

that they may have. Have your instructor initial this worksheet.

Instructor's initials _______________

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ASE 5- Brakes

Module 8 -

Bosch ABS

8-7


Vehicle needed:

None

Tools needed:

Techline terminal

Activity to accomplish: Using the Techline terminal, access the following

information requested in the worksheet. Make sure that you use

document numbers for Techline information. Use the vehicle information

provided by your instructor.

Vehicle information:

Model Year _________________________

Make of car ________________________

Model of car _______________________

Type of system (check one) ________ ABS _________ ABS/TCS

Which Bosch system does this vehicle use? ______________________

Doc # ______________________________

What is meant by DRP? _______________________________

Doc # ______________________________

How many hydraulic channels does this ABS system have? __________

Doc # ______________________________What DTC number relates to an open right front speed sensor circuit?

________________________________________________________

Doc # ______________________________

How many solenoid valves are used in this system? ______________

Doc # ______________________________

What is the recommended brake fluid for this ABS application?

_______________________________________________________

Doc # ______________________________

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ASE 5- Brakes

Module 8 -

Bosch ABS

8-8

Student WorkbooIs brake intervention part of the traction control system of this vehicle?

________________________________________________________

Doc # ______________________________

List the steps for bleeding the brake system after replacing the BPMV.

_________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

Doc # ______________________________

Show your instructor you completed worksheet. If all answers are correct,have your instructor initial this worksheet. Instructor's initials _________

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All Rights Reserved

ASE 5- Brakes

Module 8 -

Bosch ABS

8-9


Vehicle needed:

Current or recent production General Motors car equipped with a Bosch 5

Series ABS system. This system should be free of any "bugs" for this

exercise.

Tools needed:

Tech 2

Techline terminal

J-39200 DVOM or equivalent

J-39700 or J-39700-A Break out box

J-39700- appropriate adapter cable for vehicle

Activity to accomplish: Using the Tech 2, access the wheel speed

sensor data. Carefully lift the vehicle on a hoist or use jacks and jack

stands to raise the tires off of the ground. Rotate each wheel by hand and

read the data displayed on the Tech 2. Record the data below.

Right front WSS ____________________

Left front WSS _____________________

Right rear WSS _____________________

Left rear WSS ______________________

Now, using the break out box, connect into the ABS harness at the EBCM.

Access the directions for the procedure in the Techline terminal and record

the directions below.

_________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

Doc # ______________________________

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All Rights Reserved

ASE 5- Brakes

Module 8 -

Bosch ABS

8-10

Student WorkbooWith the break out box correctly connected, measure both the resistance

and A/C voltage of each wheel speed sensor and record the data below.

Right front WSS resistance __________________________________

Right front WSS A/C voltage _________________________________

Left front WSS resistance __________________________________

Left front WSS A/C voltage __________________________________Right rear WSS resistance ___________________________________

Right rear WSS A/C voltage __________________________________

Left rear WSS resistance ____________________________________

Left rear WSS A/C voltage ___________________________________

Are these reading within specifications? ____________________

If not, why not?

Doc # ______________________________

Show your instructor the data that you retrieved and have them initial this

worksheet. Instructor's initials ____________

SWB a5 m08 Final

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