1.0 INTRODUCTION
Th e pr ocedu res con t ain ed in t h is m a nu a l in clu de
all t h e specifica t ion s, inst r u ction s, an d gr a ph ics
needed t o dia gn ose t he Spr int er Cha ssis syst em
pr oblem s: Bosch 5.7 ABS/E SP /TCS (ASR) Br a k in g
Syst em . Th e dia gn ost ics in t h is m an u a l a r e ba sed
on t h e fa ilu re con dition or sym pt om being presen t
at t im e of dia gn osis.
Plea se follow th e r ecom men da tion s below wh en
choosin g you r dia gn ost ic pa t h.
1. F ir st m a k e su r e t h e DRBI II" is com mu n ica t in g
wit h t he veh icle syst em bein g dia gn osed. If th e
DRBII I" displa ys a ‘‘N o Respon se’’ con dition , you
mu st diagn ose th a t fir st .
2. Rea d DTC’s (dia gn ost ic trou ble codes) wit h th e
DRBII I".
3. If n o DTC’s are pr esen t, iden t ify t h e cust omer
compla in t .
4. On ce t he DTC or cu st omer compla in t is iden -
tified loca t e t h e m a t ch in g t est in the Table of
Con t ent s a n d begin t o dia gn ose th e system .
All com pon ent loca t ion views a re in Sect ion 8.0.
All con nect or pin out s a r e in Sect ion 9.0. All sch e-
ma t ics a r e in Sect ion 10.0.
Wh en r epa ir s a re requ ired, r efer t o th e appropr i-
at e ser vice ma n ua l for th e pr oper r em ova l a n d
repa ir pr ocedu r e.
Dia gn ost ic pr ocedu r es ch a nge ever y yea r. N ew
dia gn ost ic syst em s ma y be added; ca r ryover sys-
tem s ma ybe en h an ced. READ TH IS MANUAL BE -
FORE TRYIN G TO DIAGN OSE A VEH ICLE DI-
AGNOSTIC TROUBLE CODE . It is r ecom men ded
th a t you review th e en t ir e m an u al t o becom e fa m il-
ia r wit h all new a n d ch a nged dia gnost ic pr ocedu res.
Th is m a nu a l r eflect s m a n y su ggest ed cha nges
from r ea der s of pa st issu es. Aft er usin g t h is m a n -
ua l, if you h ave a n y com men t s or recom m enda t ion s,
plea se fill ou t t he for m at t h e ba ck of th e ma n ua l
an d m a il it ba ck.
1.1 S Y S T EM COV ER AGE
Th is dia gn ost ic pr ocedu re ma n ua l cover s th e An -
tilock Br a king System (ABS), th e E lect r onic Sta bil-
it y P r ogr a m (ESP ) an d t h e Tra ct ion Con t r ol Syst em
(TCS) fou n d on th e Spr in t er.
1.2 SIX-STEP TROUBLESHOOTING
PROCEDURE
Dia gn osis of t h e An t ilock Br a ke System s is don e
in s ix bas ic s te p s :
• Ver ifica tion of compla in t
• Ver ifica tion of an y relat ed sympt om s
• Sym pt om a na lysis
• Pr oblem isola t ion
• Repa ir of isola ted problem
• Ver ifica tion of pr oper oper at ion
2.0 INDENTIFICATION OF
SY ST EM
Th e Bosch 5.7 syst em ca n be iden t ified by th e 42
wa y Con t r oller An t ilock Bra ke (CAB), Hydr au lic
Con t r ol Un it (HCU) a nd P u mp Mot or being a n
in t egr a l elect ron ic/h ydr au lic u n it m oun t ed below
th e Ma st er Cylin der wit h fou r Wh eel Speed Sen -
sor s, on e a t ea ch wh eel.
Veh icles wit h th e Tra ct ion Con t rol Syst em (TCS/
ASR) can be iden tified by th e pr esence of t h e
Tra ct ion Con t rol Syst em Swit ch (TCCS) locat ed on
th e cent er in st ru m en t pa n el.
Veh icles wit h Elect ron ic St a bilit y P r ogr a m (ESP )
can be iden t ified by t h e pr esen ce of t h e St eer in g
Angle Sen sor an d t h e La ter a l Acceler a tion /Ya w
Sensor.
3.0 SYSTEM DESCRIPTION AND
FU N CT I ON AL OPERAT I ON
3.1 ES P
Th e ESP syst em con sist s of t h e electr on ic con t r ol/
hydr a u lic u nit , st eer in g a n gle sen sor, la t er a l
acceler a t ion /ya w sen sor a nd wh eel speed sen sor s.
Wh en th e veh icle is in a t u r n, t h e ESP looks at th e
st eer ing wh eel a ngle sen sor valu e an d mon it or s t h e
wh eel speed of th e in n er an d ou t er wh eels t o en su re
th e va lues ar e pla usible. Th e st eer in g a n gle sen sor
also m ea su r es t he speed at wh ich t h e st eer in g
wh eel is t u r n ed .
Th e E SP con t r ol m odu le is ver y sim ila r to t he
ABS/ASR modu le. Th e ESP is compr ised of severa l
oth er syst em s, n a mely t he HBA, ABS, TCS (ASR),
EBD and F ZR systems.
3.2 ABS
Th e Con tr oller An tilock Br a k e (CAB) is u sed t o
mon it or wh eel speeds an d m odu la t es (cont rols) h y-
dr au lic pr essu re in ea ch br ake cha n nel. Th e m odu -
late d hyd raulic p re s s ure is us e d to pre vent w he el
lock up du r in g bra k in g a n d main ta in veh icle st a bil-
it y. Th e CAB a lso pr ovides a veh icle speed sign a l
(VSS) t o t h e E lect r onic Con tr ol Modu le (E CM).
Du r in g a n on-ABS st op, th e system fun ct ion s a s a
st an da r d br a k ing syst em . Th e CAB u ses specia l
sor twa r e t ha t mon it or s th e wh eel speed(s) an d
wh en cer ta in crit er ia a r e m et , t h e soft wa r e will
1
GEN ERAL I N FORM AT I ON
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