ABS/DSC/ASC REPAIR. Although it may look like the 'black box' is pretty simple with just a bunch of solonoids...

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1 ABS/DSC/ASC REPAIR The E38's produced after 1997 can suffer from ABS failure that bungs up fault lights for ABS, ASC and Brake Warning, the lights are all orange (warning) rather than red (failure). This is due to the failure of the Bosche control unit that is strapped to the ABS pump. The fault usually shows itself when the car has got hot, all is OK one second, the next all three lights glow orange and your ABS and ASC will stop working. The fault only goes away when the car has cooled down. Although it may look like the 'black box' is pretty simple with just a bunch of solonoids......it isn't, and contains twin processors and valve-drivers construced as a hybrid circuit on a ceramic substrate. This clever stuff lives under the outer cover and is covered by a soft compound that can be easily removed. Repair of this circuit is impossible unless one of the gold wires has fallen off, and even then it requires a lot of patience: (1 of 9)6/9/2009 7:14:36 AM

2 If you use CarSoft diagnostics you may get a 'wheel sensor failure' but you will find that replacement of the wheel sensor makes no difference. You really have two choices...get a 'repair kit' from BMW (Part number ) which consists of the 'black box' and when fitted get BMW to recode the ABS controller to match the car (another 30-50). Or you can get a replacement from FAB or another breaker (usually 50 upwards and you get the ABS pump strapped to it). If you get a replacement from a breaker it is essential that it comes from the exact year and model as your car. As long as you can manage this you will NOT need to have the unit recoded. Even if you get the same part-number this does not mean that it will not need recoding. The reason for this is that (for instance) a '98 735i uses an ASC actuator whereas a '98 740i doesn't (being fly-by-wire). Both cars have the same part number on the Bosche controller. If the 735i controller was fitted to a 740i it will need recoding because the controller cannot 'find' the missing ASC actuator...carsoft will return an 'ASC valve' failure. So, enough blurb, this is how to sort it. Disconnect the battery otherwise you will need (2 of 9)6/9/2009 7:14:36 AM

3 CarSoft to reset any fault codes. Remove the pipe that leads to the airfilter housing: Then remove the top of the airfilter housing and the pipework to the MAF, all held on with clips: (3 of 9)6/9/2009 7:14:36 AM

4 Stick a broad-bladed screwdriver in the end of the ABS connector and carefully slide out the connector lock: (4 of 9)6/9/2009 7:14:36 AM

5 (5 of 9)6/9/2009 7:14:36 AM

6 The connector can now be lifted out of the way. Use a Torx 20 driver to remove the six Torx bolts that secure the controller to the ABS pump: (6 of 9)6/9/2009 7:14:36 AM

7 I found it quite easy to get to all six bolts as my driver was articulated, if you do not have an articulated driver then remove the lower part of the filter housing. The bolt marked above can be removed and a couple of jubilee clips hold the lower housing to the large diameter pipework to get easier access. Once all six bolts are removed the controller can be pulled carefully away from the pump: (7 of 9)6/9/2009 7:14:36 AM

8 ...and replacement of the new part is just a reverse of this process. In the picture above you can see that one of the brake pipes slightly interferes with the controller, push this away from the controller when fitting the new controller. Do not force the controller in place, you must align all the coils with the valve bodies and then allow it to slide into position. As long as the replacement part came from the correct car then there should be no fault lights present. If you do get an ASC warning then the controller will need recoding by BMW or someone who has the capabilities (CarSoft cannot be used to recode). All done, time for a cup of tea... (8 of 9)6/9/2009 7:14:36 AM

9 (9 of 9)6/9/2009 7:14:36 AM

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