AM MAGAZINE SHELL - Australian Automotive Aftermarket Magazine

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TECHNICAL PAPERS 2009 Every year different products come to light, and every year new technologies are developed for use in the automotive aftermarket. Sometimes the only way to keep up with the technology is to get it right from the horse’s mouth – ask the companies making the products to tell you more. So we have... ABS Fault Diagnosis and Repair Bosch.........................................27 Century Launches New of range Deep Cycle AGM & Gel Batteries Century ......................................28 Flywheels Explained: Dual Mass and Single Mass Flywheels Exedy.........................................30 The Development of Lokring Lokring.......................................32 26 AU T O M O T I V E A F T E R M A R K E T M AG A Z I N E D E C E M B E R 2 0 0 9 www.aaaa.com.au
TECHNICAL PAPERS 2009 ABS fault diagnosis and repair Intelligent braking systems are a growing trend, with more and more vehicles on the road equipped with ABS. This steady growth is already providing workshops with increased opportunities for repairs and maintenance. Being a relatively new field there are understandably some uncertainties in the trade regarding elements of ABS servicing. Often a warning light appearing is misunderstood to mean that a part needs replacing. But this is not always the case, as there are numerous reasons why an ABS warning light may come on. If the following steps are followed carefully, the unnecessary replacement of parts which may not be faulty can be avoided. When a vehicle is presented with an ABS concern, indicated by either ABS warning lights coming on, or by the driver reporting an unexpected operating characteristic (e.g. noise, vibration, wheel lock-up, spinning wheels etc.), the following procedure needs to be followed. Procedure Firstly you need to determine whether the issues raised are actually related to the ABS system, by eliminating other possible causes. Normal operating characteristics of ABS systems In general, during normal operation the ABS makes several sounds that may seem unusual at first: - A whining sound is caused by the ABS hydraulic unit motor. - When pressure is applied to the brake pedal, the pulsation of the pedal can cause a scraping sound. - When the brakes are applied firmly, the ABS operates rapidly, applying and releasing the brakes many times per second. This repeated application and release of braking forces can cause thumping sounds and squeak for the suspension and tyres. - When the vehicle speed reaches around 10km/h, after the ignition is switched on, a thudding sound can sometimes be heard coming from the engine compartment. This is a normal sound during the ABS system self-check. For further information on Bosch ABS replacement parts for the aftermarket please contact your local Bosch distributor or call Bosch Customer Service on 1300 30 70 40. Basic brake system faults The ABS system can only operate effectively when the foundation brake system is up to standard. Issues such as unusual noises, vibration, wheel lock-up and spinning wheels can often be caused by faults within the basic brake system. Check the wheel bearing clearance, brake pad and disc wear for any issues that may be causing the initial concern. If a fault still exists after all the checks above have been completed and any issues eliminated, then it is possible there may be a fault with the ABS system. ABS system faults The most likely causes for fault codes are: a) The malfunction or physical damage of the wheel speed sensor, connector or wiring harness. b) Malfunction of the hydraulic unit (integrated with the ABS- ECU). 1 If an ABS fault is suspected, progress to the ABS diagnostic procedure, using an appropriate diagnostic tool, such as the Bosch range of KTS scan tools or FSA vehicle systems testers. 2 Work through the service instructions using the vehicle manufacturer’s workshop manuals, or Bosch ESI Service Instruction program. If any memory fault codes are displayed, refer to the fault code table for a definition and reference to the appropriate pin point test flow chart for each fault code. 3 Ensure that all memory fault codes are cleared and the vehicle is road tested prior to confirming the repair. If fault codes still exist, then the related faults are still present. Perform repair according to manufacturer’s procedure. 4 Confirm the repair by following the ABS diagnostic procedure table. If at any time the ABS or traction control warning lamp flashes or illuminates (other than the normal 3-second period after the ignition is switched on), then there is a fault in the ABS system. 5 In the event that the same fault appears, continue to follow the service instructions procedure. Repeat the same checks and if no fault is found you may need to replace the ABS modulator, ECU or assembly. 6 At the conclusion of the road test, if there are no diagnostic trouble codes (DTCs) shown, the system can be considered to be working correctly and is ready for return to the owner/driver. Often ABS work is passed on by workshops not confident doing the work themselves but it doesn’t have to be this way. With the correct diagnostic equipment, and a logical approach to fault diagnosis, ABS repairs and maintenance can easily be handled by any workshop. And now, with Bosch further supporting workshops by providing an extensive range of ABS replacement parts in the aftermarket, ABS servicing has never been easier or more accessible for the workshop. AU T O M O T I V E A F T E R M A R K E T M AG A Z I N E D E C E M B E R 2 0 0 9 27
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