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DSC 5.7 Pressure Sensor Fault (Advanced Level) RESOLVED

42K views 16 replies 7 participants last post by  Patlabor44  
#1 · (Edited)
Trying to figure out the problem that persists on DSC module of 325xi.

After changing brake master cylinder I got DSC trifecta fault codes - scan revealed Pressure Sensor Test Fault (Plausible Precharge Pump). I bled the system several times using pressure bleeder - the brake pedal is firm, no apparent air is in the system.

I can actuate the precharge pump - can hear it run and feel it pressing against the brake pedal.

The pressure sensor measures the hydraulic pressure once the car starts moving and achieves certain speed or engine torque, and precharge pump then charges the hydraulic system (briefly), I get DSC lights at that point, no lights are on when starting the engine.

My feeling was that there may be some air in the precharge pump itself and it does not achieve sufficient pressure for the DSC to read.

I took the car to the BMW where I was advised that DSC module is toast. I sent it out for rebuild and received it back. Upon installation the same fault persists, although the error code now is different - "Pressure Sensor Test Fault", no precharge pump plausability.

TIS reads pressure sensor data and shows hydraulic pressure from 0 bar to some 85 bar when pressing the brake pedal, so the sensor provides at least some data.

Could it be that pressure sensor failed (coincidentally) when recharging the hydraulic system?

I will try and bleed the system once again and see if I could run the precharge pump backwards to push any air back into the reservoir.

This problem is driving me nuts, I must say.
 
Discussion starter · #2 ·
One thing I forgot to mention: When installing the master cylinder I did not bench-bleed it. Initially I did, but I made a big mess trying to install it with the fluid in the reservoir, so I decided to install it dry and then bleed it. Again, the brake pedal feels firm, but who knows what the real problem is.
 
Discussion starter · #4 ·
Excellent, I will try and re-bleed it tomorrow. Unfortunately I don't have access to TIS, only the basic Rheingold, but I can activate the DSC pumps for 5 sec. - should be enough. Will follow up.
 
Discussion starter · #6 ·
I went to the garage today and tried to bleed the system again. I ran the precharge pump forward and backwards, took out the pressure sensor and put the fitting with the hose in and ran the pump to push out all the possible air. Then I re-bled the system twice. Still I get a little softness at the very top of the brake pedal and I get the DSC pressure sensor test error.

If I press the brake pedal just a little bit while activating the precharge pump I get the "normal" vibration through the chassis and I can hear the pump running. Releasing the brake pedal makes the precharge pump inaudible. This makes me think that the air bubble somewhere in the system prevents from pressurizing it to the specs and throws DSC pressure sensor test fault.

At this point I am throwing in the towel and taking the car in for the proper BMW bleed procedure.
 
Discussion starter · #8 ·
The pressure sensor reads 0 to 95 bar pressure as I am pressing the pedal - so the sensor works fine. I have a pressure bleeder and can activate the pumps separately through INPA. My problem is that that I have to do it alone and I just can't pump the brake pedals while opening the bleed nipple and activating the ABS Precharge and Return pumps. It is quite frustrating. I just want to fix it and get rid of it. Wagon is not my cup of tea anyway.
 
Discussion starter · #10 ·
After changing 3 DSC modules, 2 pressure sensors and bleeding the system numerous times the issue was resolved. The culprit was the new master brake cylinder. The fault - "DSC pressure sensor test fault" appears when the pre-charge pump fails to pressurize the system during the brief DSC system test when the brake pedal is fully released. Apparently the position of the piston seal inside the master cylinder at full idle would allow the pressure from the pump to escape into the reservoir, causing the pressure sensor test fault. I replaced the master cylinder again, bled the system and everything works as it should.

I must stress that this problem was extremely difficult to resolve. Numerous BMW techs with GT1 and Autologics were telling me that the fault is DSC module related 100%, I was driving eBay sellers and ABSMasters crazy. Nobody thought that my master cylinder theory was plausible and they thought I was nuts.

Back to normal driving now.