Solution for swapping E46 XI ABS Module
Edit: although I wrote this for the Xi dsc5.7 abs unit you can use the same processes for the e46 asc/abs systems.
Ok so I started this thread to find a solution to swapping the Bosch DSC 5.7 ABS module that is in the XI models of the e46. My daughters 325xi had the dreaded tri-fecta of lights on the cluster. ABS, Brake and DSC all lit up. The error scanning the ABS with PA Soft was [023] Incorrect Coding - ABS/ASC module is faulty. In other words the Bosch DSC 5.7 module was shot (electronically). I picked one up from a donor car for $100.
Here's my resolve. This is not a full DIY as I don't have time right now. I did this with the battery disconnected. The module will swap easily enough. There are 6 pipe fittings connected to the module that will need connected.
The ABS Module for the XI e46 is in the "drug bin" - this is the sectioned off area in front of the passenger side under the hood. It is called the drug bin as it is empty on the RWD e46 and folk stuff things in it. On the RWD the abs module is completely different and located on the opposite side of the engine in the same area as the brake booster (on the driver side).
The location and removal replacement of the module description below is specific to the Xi model, however the process of coding your VIN to the new module, steering angle calibration, and clearing errors is the same for all models.
1. Disconnect the two electrical harnesses that connect to the ABS module. The one closest to the engine is the pressure sensor connector. It just squeezes off by pressing the tab. The second is the big one with about 40 wires that connects to the base of the Bosch DMC 5.7 ABS unit. At the front of this connection is a pull out tray - I used a small flathead screwdriver to pry it out about half inch so I could get my fingers on it to pull it out the rest. It pulls out toward the front of the car. Once that is pulled out you can lift the connector up off the pins. Tuck these away or wrap in a rag so you don't drip brake fluid on them.
2. Disconnect the 2x10mm bolts that hold the abs module to the support bracket. 1 at the firewall side and the other underneath the module bolted into the aluminium block. Tip When you go to put the lower bolt back on the donor module there are multiple holes on the bracket and it is difficult to locate the right hole and then turn into the ABS module block. When you remove the unit make a note of the hole the bolt was in and tape the others up - trust me it will save time. Then after you have the new one in place just peel the tape off. For me I didn't and finding the correct hole and lining up the thread on the block for the lower bolt was the worst part of this whole job.
3. Make sure that you have topped off the brake fluid reservoir so as it doesn't run dry during this entire procedure.
4. Disconnect the 6 pipe fittings - do the outer two on top last as they will leak the most.
5. Wear gloves - you will get it on your hands.
6. Replace old ABS module with the good donor. Reconnect fittings. Put the two 10mm bolts back that hold the module.
7. Bleed brakes at all four wheels. Start at back passenger, then rear driver, front driver, finishing at front passenger. You will actually see the air bubbles bleed out from disconnecting the lines. You might need a pint of brake fluid total. I also cleaned the four wheel sensors while I had the wheels off as they also feed the abs module data.
8. Connect both harnesses at the abs module. Connect battery - Code the new ABS module to the vehicle using NCS Expert and the instructions in the attached PDF. The directions are for the 2wd e39 but the process is exactly the same. Basically you have NCS expert take the VIN from an existing module and you have it write that VIN (and other FA data) to your donor module.
9. Use INPA or PA Soft to clear any remaining errors. The error that will remain should be "097 Steering Angle Calibration Adjustment Necessary" This is normal as the vehicle sees the donor module as a new module and resets the stored steering angle values for the old module to zero. You need to recalibrate the steering angle sensor.
10. Line up your steering wheel to the position that is exactly straight ( as best as you can tell - this is not a wheel alignment so it is not critical to the nth degree) Adjust the steering angle sensor and save values to the DSC module. Now this sounds simple enough except that neither PA Soft nor most versions of INPA (I was using 5.02) have this capability. If you have access to GT1 then you can do it. However there is an older full version of INPA that has this function available under F8 Special Tests -> Steering Angle Adjustment E46.
As you can see from the screen shot in addition to NCS Expert, Ediabas and INPA, a few other diagnostic tools (NCS Plant, WinELDI etc.) get installed with this version of the BMW Standard Tools.
Download the version of INPA with the
Special Tests for E46 - Including
Steering Angle Sensor Calibration
This version has a hoard of functions that I had not yet seen via my INPA and although older is more suited to maintaining our aging e46.
You will get this full version of INPA here
The package is an NRG file. You will need
ISO Workshop (free edition - linked) to create the install directory (image) or disk.
The file is 347,183 Kb
Here's the link:
Single NRG file for the complete BMW Standard Tools Suite
11. Do the steering angle adjustment via INPA Special Tests. - Daughter is at work with the Xi so when she brings the car back I'll add a couple more pics and details to the final piece. - See next post.
Also when I get more time I'll put in more detail but if you're reading this cause your in the middle of the job the info you need is already here.
Attachments: (EDIT: I've run out of forum space so I only left the essential attachments)
PDF - Using NCS Expert to recode VIN to donor ABS Module
PDF - The Bosch DSC 5.7 ABS Module information - although from Renault it works the same as the e46 xi and this has the best information for explaining how the system works.
PDF - Explaining the different ASC/DSC/ABS systems on the e46 (The Renault PDF has more module detail)
Screenshots of the different version of INPA /Toolkit that has the Special Test for recalibrating the steering angle sensor.
