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45 01 01 Psm/Abs Check Using The Piwis Tester - As of My 2005 (All Models)
45 01 01 Psm/Abs Check Using The Piwis Tester - As of My 2005 (All Models)
45 01 01 Psm/Abs Check Using The Piwis Tester - As of My 2005 (All Models)
BRAKES
TEST OVERVIEW
Test overview
Microsoft
Thursday, September 24, 2009 8:37:44
8:37:40 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
Procedure: If work has been done on the hydraulic unit -D- , the speed sensors and the wire harness or if the
hydraulic unit -D- is replaced, an ABS/PSM test (system check) must be performed using the PIWIS Tester!
This is the case, for example, after accident repairs! This prevents any confusion of electrical or hydraulic lines
and ensures faultless operation of the system! See Fig. 1.
If certain brake lines are replaced, e. g. at the intermediate piece in the front left wheel housing -E- , a swap test
must also be performed (in the Checks/Tests menu)! Unintentional bending of the brake lines could lead to
incorrect hydraulic allocation despite the markings (FL = front left, FR = front right, RL = rear left, RR = rear
right)! See Fig. 1.
If a fault is displayed during operation (when no assembly work was carried out beforehand), diagnosis and
fault finding are also carried out using the PIWIS Tester! To do this, select the PSM system and read out the
fault memory there! The fault can then be located using the appropriate menus (Drive links, Actual values,
Checks/Tests)!
1. PIWIS Tester P 9718 must be connected to the vehicle, then start it. Switch on ignition and press >> to
continue.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
The PIWIS Tester 9718 is connected to the vehicle via a diagnostic socket. The diagnosis socket is located
inside the vehicle in the vicinity of the driver's A-pillar below the instrument panel.
Information
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 3 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
The brake components (brake booster, brake master cylinder, hydraulic unit) are installed under the luggage
compartment cover -2- . See Fig. 3.
Remove hydraulic unit -D- together with the support and the four brake lines, which are fitted on the
intermediate piece -E- . See Fig. 4.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 4 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
C - Brake booster
D - Hydraulic unit
E - Intermediate piece
PRELIMINARY WORK
Preliminary work
1. Remove cover over hydraulic unit (front luggage compartment cover) Refer to 70 30 19 Removing and
installing front luggage compartment cover - as of MY 2005 (All Models) . Refer to 70 30 19 Removing
and installing rear luggage compartment cover - as of MY 2006 (Cayman S, Cayman S RHD) .
There are two types of luggage compartment covers -1- (drawings below). See Fig. 5.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 5 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
1.1. Hold down brake pedal with pedal holder so that the brake fluid (in the reservoir) does not drain
completely.
1.2. Loosen the brake lines -1- on the brake master cylinder. See Fig. 7.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 6 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
1.3. Loosen the brake lines -2- from the hydraulic unit -D- on the intermediate piece -E- . See Fig. 7.
1.4. Close the brake lines and connections with suitable plugs.
1.5. Release control unit connector on the hydraulic unit and pull it off. Cover the plug connection and
connector (to shield them from brake fluid or water).
1.6. Loosen support on hydraulic unit -Arrows- (3-point mount). See Fig. 7.
NOTE: First connect the electric plug connections on the hydraulic unit. This will
protect the plug connections from brake fluid or water.
After bleeding, check the assignment of the brake lines to the correct brake
callipers. Carry out a swap test using the PIWIS Tester.
1. Install hydraulic unit -D- . Observe tightening torques Refer to 47 Tightening torques for brake hydraulics
- as of MY 2005 (All Models) . See Fig. 8.
1.1. Insert hydraulic unit with support and tighten fastening nuts -Arrows- (3-point mount). See Fig. 8.
1.2. Connect control unit connector to hydraulic unit and lock it.
1.3. Fit the brake lines -1- in the correct position on the brake master cylinder. HZ 1 = Brake master cylinder
push-rod circuit (close to fastening flange). HZ 2 = Intermediate piston circuit. See Fig. 8.
1.4. Fit brake lines -2- in correct position. Observe marking on the hydraulic unit -D- and intermediate piece -E-
. RL = rear left/RR = rear right/FR = front right/FL = front left. See Fig. 8.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 7 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
NOTE: First bleed the brake system in the normal way - with the bleeding device at the
reservoir and approx. 2.0 bar pressure (primary circuit).
Then, use the PIWIS Tester to bleed the brakes as well (secondary circuit). Only
necessary if the hydraulic unit was replaced and if brake pedal travel is
excessive after bleeding in the normal way (primary circuit). The process is
menu-driven. Always observe the specified sequence rear left, front left, front
right, rear right.
To bleed the secondary circuit, the bleeding device remains connected to the
brake fluid reservoir. Bleeding pressure is approx. 2.0 bar.
Throughout the entire bleeding process, the brake pedal must be operated
cyclically (keep depressed for 2 to 3 seconds, then release slowly). After
operating the pedal for the last time, hold the brake pedal down and close the
bleeder valve.
2. Bleed the brake system and adjust the brake-fluid level. Refer to 47 01 07 Bleeding the brake system - as of
MY 2005 (All Models) .
3. When replacing the hydraulic unit, code the control unit (manual transmission/Tiptronic).
SUBSEQUENT WORK
Subsequent work
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 8 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
Install cover over hydraulic unit (luggage compartment cover) -1- , Refer to 70 30 19 Removing and installing
front luggage compartment cover - as of MY 2005 (All Models) . Refer to 70 30 19 Removing and
installing rear luggage compartment cover - as of MY 2006 (Cayman S, Cayman S RHD) . See Fig. 9.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 9 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
Information
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 10 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
Removing
1. Move the left seat back and adjust the steering wheel upwards.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 11 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
Unscrew screw -2- and take off cover -1- . See Fig. 12.
Unscrew screws -1- (the screws -1- can only be accessed using a 1/4-inch tool). Pull off plug connection and
take out rotation-rate sensor. See Fig. 13.
Installing
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 12 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
Subsequent work
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 13 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
1. After installing the rotation-rate sensor, read out the PSM fault memory with the PIWIS Tester (diagnostic
tester) and erase it. Carry out a static test. Then start the engine. The PSM-related lights in the instrument cluster
must go out when the engine is running. Read out the PSM fault memory again. There must not be any stored
faults.
--> The steering-angle sensor must be initialized (taught) whenever the battery is disconnected.
NOTE: The steering-angle sensor is integrated into the steering column switch
and records the movements of the steering wheel (steering wheel angle)
using light switches. The data is transmitted to the PSM control unit via
the CAN bus.
During initialization, the steering-angle sensor learns its current position
(straight-ahead position).
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 14 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
2. Start engine.
3. From the straight-ahead position, turn steering wheel approx. 20° to the left and 20° to the right (past straight-
ahead position).
4. Drive the vehicle straight ahead for at least three seconds at a speed above 6 km/h (3.7 mph).
After successful initialization, the stored fault code is erased from the fault memory. The PSM indicator light in
the instrument cluster goes out.
After initialization has been completed, the battery must not be disconnected, the relevant fuse must not be
removed and there must not be undervoltage. Otherwise, initialization will have to be carried out again.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 15 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
The steering angle sensor must be calibrated using the menu with PIWIS tester under the specified test
conditions:
1. Switch on ignition.
2. Turn wheels or steering wheel to straight-ahead position. In the straight-ahead position, the steering wheel
must deviate by no more than ± 2.0° from the horizontal position (steering center position).
3. Before calibrating, first turn the steering wheel from the straight-ahead position approx. 20° to the left and
20° to the right (past straight-ahead position).
4. Turn wheels or steering wheel to straight-ahead position and calibrate the steering-angle sensor. To calibrate,
you must enter the security code in the actual values menu.
Information
The steering-angle sensor is integrated into the steering-column switch. The steering angle is recorded in the
airbag contact unit (spring).
Only replace the steering-angle sensor together with the airbag contact unit (spring) and electronic unit.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 16 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
C - Wiper switch
F - Electronic unit
PRELIMINARY WORK
Preliminary work
1. Remove airbag unit --> 69 58 19 REMOVING AND INSTALLING DRIVER'S AIRBAG UNIT - AS OF
MY 2005 (ALL MODELS) .
Removing
CAUTION: Malfunction
Unscrew screws -1- and unclip cable clamp -2- . See Fig. 18.
Move steering-wheel adjustment lever to a vertical position and remove lower steering-column panel -3- . See
Fig. 18.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 18 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
Unclip upper steering-column panel -4- , see -Arrows- , and disconnect electric plug connection. See Fig. 18,
Fig. 19.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 19 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
Unscrew screw -1- , unclip cable guide -2- , pull out electric plug connections and remove steering-column
switch. See Fig. 20.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 20 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
NOTE: Ensure that arrow -A- on the rotor is positioned between the markings -B- of the
arrows -C- on the airbag contact unit and that the locking element -D- is
engaged.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 21 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
Unclip airbag contact unit (spring) -Arrows- and carefully remove it. See Fig. 22.
Replacing
The steering-angle sensor can only be replaced together with the airbag contact unit -E- and electronic
unit -F-. See Fig. 23.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 22 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
C - Wiper switch
F - Electronic unit
Replace the airbag contact unit (spring)/steering-angle sensor -E- and electronic unit -F- . See Fig. 23.
Installing
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 23 © 2005 Mitchell Repair Information Company, LLC.
2007 Porsche Boxster
BRAKES Anti-Lock Brake System (ABS)
SUBSEQUENT WORK
Subsequent work
2. Install airbag unit --> 69 58 19 REMOVING AND INSTALLING DRIVER'S AIRBAG UNIT - AS OF
MY 2005 (ALL MODELS) .
3. Initialize and calibrate steering-angle sensor --> 456000 Initializing and calibrating steering-angle sensor.
Microsoft
Thursday, September 24, 2009 8:37:40 AM Page 24 © 2005 Mitchell Repair Information Company, LLC.