How To Repair Abs Control Module 08 G6

Anti-lock braking organization (ABS 8.0 and ABS eight.0 ESP)

General

From MY 2004, the Corsa-C, in all engine variants, volition be fitted with the new anti-lock braking organisation, ABS 8.0.

ABS 8.0 is a modular system, with 8 solenoid valves. In its basic form it is the same every bit ABS 5.three and is also available with ESP as an choice.

With the introduction of ABS 8.0 ESP, Opel vehicles will, for the kickoff time, exist taking the "braking system temperature" parameter into account in the braking system control strategy.

By measuring the temperature in the hydraulic unit, a map can be calculated to make up one's mind whether there is a risk of the braking system overheating, for example, on downhill runs.

The ABS control unit/hydraulic unit associates has been modified. The weight of the ABS command unit/hydraulic unit has been reduced by 25% by using mod microprocessor technology. At the same fourth dimension, the exterior dimensions have been changed, thus reducing the volume of the assembly by 30% compared with ABS 5.3.

Thanks to its horizontal installation position in the Corsa-C, the ABS control unit of measurement can be detached from the hydraulic unit whilst yet installed.

ABS control unit of measurement/hydraulic unit assembly

1. ABS control unit 2. Hydraulic unit

From an appearance point of view, the ABS 8.0 and ABS 8.0/ESP do not just differ in size.

The bore of the hydraulic connections on the ABS control unit of measurement coming from the chief cylinder is smaller on the ABS viii.0 than on the ABS 8.0/ESP.

The electrical connection on the ABS command unit is a 26-pin connexion on the ABS 8.0 and a 46-pin connection on the ABS 8.0/ESP.

Dimensions and weight

The weight of the ABS 8.0 also varies depending on the version.

	ABS 8.0 (XS engine)	ABS v.3
Dimensions
Width x top x length	(118 x 80.3 ten 113.6) mm	(84 10 118 x 170) mm
Book	one.ane litres	i.seven litres
Weight	ane.half-dozen kg	2.6 kg

	ESP 8.0/ESP (S/50 engine)	ABS 5.3 TCS/ESP
Dimensions
Width x elevation x length	118 x 103 ten 132.v) mm	84 x 138 x 183 mm
Volume	1.seven litres	ii.1 litres
Weight	2.3 kg	3.two kg

Versions i Fifty engine 3 XS engine 2 Due south engine 4 L engine

Installation location

The ABS command unit/hydraulic unit assembly is installed horizontally (1) in the Corsa-C. The motor of the hydraulic unit of measurement is installed with its shaft in a horizontal position and the connections of the individual restriction circuits face upwards. The advantage of this installation position is that the ABS control unit of measurement tin be removed for assembly or repair work without having to remove the entire associates.

Exploded diagram

1 Pump motor fastening bolt (x2) 8 ABS command unit 2 Pump motor 9 ABS command unit cover 3 Guide sleeve x ABS command unit fastening commodities (x4) 4 Pump/valve housing 11 Pressure level sensor (only ABS 8.0/ESP) v Outlet valves (x4) 12 USV valve (x2) 6 Inlet valves (x4) 13 ASV/HSV valve (x2) 7 Printed excursion board with semiconductor relay 14 Pressure control valve (x2)

ABS control unit

The control unit of the ABS 8.0 is based on the latest pulse line and chip technology and is designed to connect to four active or 4 passive cycle sensors. Agile wheel sensors are used on the Corsa-C. The regulation and control function of ABS 8.0 is safeguarded by two dissever microprocessors (1). Each of these microprocessors tin exist reprogrammed. The individual components of the ABS control unit are not replaceable. If there is a fault, the entire ABS control unit has to exist replaced. The pump motor in the hydraulic unit of ABS 8.0 is actuated via the pump housing. The solenoid valves to the hydraulic unit are actuated by magnet coils. These magnet coils are connected directly with the semiconductor relay in the ABS control unit and are therefore incorporated into the ABS control unit. The ABS control unit of measurement is connected to the hydraulic unit via four fastening bolts (4) and can be detached and removed from the hydraulic unit in the vehicle.

•  Service:
For repair piece of work it is possible to replace the ABS command unit and the hydraulic unit separately.

The hydraulic unit is supplied "pre-filled" from the Service department. The seal of the ABS control unit is not bachelor separately. If there is a leak between the hydraulic unit of measurement and the ABS command unit of measurement, the entire ABS control unit/hydraulic unit must exist replaced.

Atmospheric condition for replacing the ABS control unit:

• The ABS control unit should just be replaced with a new one if the unambiguous diagnosis consequence "ABS control unit of measurement fault" (when diagnosing with Tech ii and error code "Faulty control unit" is present) is obtained or if there is visible damage to the housing or the connector of the ABS control unit.
• If the ABS control unit of measurement is detached from the hydraulic unit whilst even so in situ, ensure that the surrounding area is kept clean as even the smallest amount of dirt in the hydraulic unit of measurement'south valves tin can cause malfunctions.
• Under no circumstances must the cover of the ABS control unit be pushed in. This will cause harm to the ABS control unit that will non be visible from the outside. When installing just agree the ABS control unit on the outside border of the housing. Practice not use force when installing the unit.
• Nether no circumstances should the ABS control unit of measurement be attached to the hydraulic unit with fastening screws. This will cause damage to the ABS control unit and/or the hydraulic unit.
• The components of ABS eight.0, particularly in connection with the ABS control unit/hydraulic unit assembly, should only exist replaced by specialist personnel with the appropriate specialist knowledge of the conditions for replacement and the Service Instruction.
• Only the new parts specified in the electronic parts catalogue should exist used equally replacement parts.

Hydraulic unit of measurement

When installed, the hydraulic unit is continued with the ABS control unit of measurement. On the version with ESP, the pressure sensor is no longer on the outside of the hydraulic unit of measurement, like on ABS 5.3 TC/ESP but instead is incorporated into the hydraulic unit of measurement. The individual components of the hydraulic unit cannot exist replaced or repaired. If there is a fault, either the entire hydraulic unit or the entire ABS command unit/hydraulic unit assembly has to be replaced.

The hydraulic unit's hydraulic connections to the primary cylinder are spaced differently for the ABS 8.0 and ABS eight.0/ESP versions. The diameters of the hydraulic connections also differ on the 2 versions. Information technology is therefore impossible to install the wrong version of the hydraulic unit of measurement.

The spring contact pins located on the side facing the ABS control unit must not exist touched because of possible electrostatic discharge. Neither should measurements exist taken at them. The jump contact pins cannot exist replaced separately. Besides, to prevent impairment, the hard gold surface of the contact pins should non exist mechanically machined or treated with liquids such as contact spray.

No measurements should be taken at the connector contacts for the pump motor either. The contacts cannot exist replaced and are led in the lower section of the hydraulic unit through the valve block to the ABS control unit.

Pressure and temperature sensor - ABS 8.0 ESP

Unlike on the ABS v.3 TC/ESP, the pressure sensor on the ABS 8.0 ESP is no longer on the outside of the hydraulic unit of measurement, but incorporated into the hydraulic unit of measurement instead. The electric connection to the ABS control unit of measurement is achieved using gilded coated bound contact pins. The pressure level sensor is attached to the hydraulic unit using a self-locking machinery (1) and cannot exist removed. The sensor is sealed off past means of the conical surface (two). The pressure sensor likewise incorporates a temperature sensor. The temperature sensor measures the temperature of the hydraulic unit of measurement. This information is used in the ABS control unit of measurement to assess the load on the braking arrangement past means of characteristic curves. For instance, the system assesses whether the braking system is about to overheat as a result of driving downhill. When driving downhill, the braking process causes the brake discs to heat up so much that the heat that is generated in the brake discs is transmitted via the brake calliper to the brake fluid. As a outcome, the temperature in the hydraulic unit rises as well.

The pressure and temperature sensor has the following backdrop for all ABS control units:

• Selftest function
• Full self-diagnosis office with detection of sensitivity and offset errors
• 2 analogue outputs for force per unit area
• 2 digital outputs for temperature

Technical information for the pressure level sensor

Pressure sensor measuring range:	(0 ... 250) bar
Temperature sensor measuring range	(-40 ...+120) °C
Power supply:	five V DC

•  Service: The pressure level sensor cannot exist replaced individually. Similar the spring contacts (1), the contact plate for the pressure sensor in the ABS control unit has a hard gold surface. It must non exist mechanically machined. The position of the pressure sensor must not exist inverse (due east.one thousand. by twisting). Neither should the sensor housing be subjected to mechanical loads, otherwise non-visible damage may occur. If there is a fault with the pressure sensor (apart from leaks), the entire hydraulic unit of measurement must be replaced. If there are still faults with the pressure sensor when the organisation goes back into functioning, the ABS control unit volition have to be replaced as well. If there is evidence of brake fluid loss at the pressure sensor, the unabridged ABS control unit/hydraulic unit of measurement associates will have to exist replaced as impairment to the ABS control unit by brake fluid tin can no longer be ruled out in this example.

ABS control unit of measurement wiring harness plug

The plug connection on the ABS control unit is a 26-pin connector (ane) for the ABS eight.0 and a 46-pivot connector (2) for the ABS eight.0 ESP. For both variants, the wiring harness connector contains 4 power contacts with individual core seal. The size of the power contacts is (2.8 x 0.viii) mm.

ABS 8.0 also has 22 indicate contacts (42 for ABS 8.0 ESP), size (0.63 x 0.63) mm. The bespeak contacts are protected in the ABS command unit connector past a silicon seal.

After connecting them. the wiring harness connectors are locked past inserting the plastic pivot.

Pin assignment - ABS control unit for ABS 8.0

Pivot Assignment Pin Assignment ane Earth xiv Engine control unit 2 Battery + (concluding 30) 15 Can passenger vehicle: With MTA: Signal line to MTA Without MTA: Bespeak line to BCM three Battery + (final 30) sixteen Not assigned 4 Globe 17 Rear left wheel sensor 5 Front correct wheel sensor eighteen Ignition + (last xv) 6 Forepart right bike sensor 19 Rear correct wheel sensor seven Rear left wheel sensor xx Brake calorie-free switch eight Rear right bike sensor 21 Not assigned 9 Front left wheel sensor 22 Trunk Control Module (BCM, Tin can bus) 10 Front end left bike sensor 23 Instrument cluster 11 Diagnostics connector 24 Non assigned 12 Not assigned 25 Engine control unit 13 Not assigned 26 CAN bus: With MTA: Indicate line to MTA Without MTA: Point line to BCM

Pin consignment - ABS command unit for ABS 8.0 ESP

Pivot	Assignment	Pin	Assignment
one	Earth	24	Not assigned
2	Battery + (last xxx)	25	CAN motorcoach: Signal line - yaw rate and steering angle sensor Likewise: With MTA: MTA point line Without MTA: BCM signal line
3	Battery + (terminal 30)	26	Not assigned
4	Earth	27	Rear left bike sensor
v	Front right bicycle sensor	28	Ignition + (final 15)
6	Front right wheel sensor	29	Rear right bicycle sensor
seven	Rear left cycle sensor	30	Brake light switch
8	Rear right wheel sensor	31	Not assigned
9	Front end left wheel sensor	32	Torso Command Module (BCM, Tin bus)
10	Forepart left bicycle sensor	33	Not assigned
11	Diagnostics connector	34	Not assigned
12	Non assigned	35	Engine control unit
13	Not assigned	36	Not assigned
14	Engine control unit	37	Non assigned
15	Not assigned	38	Not assigned
xvi	Non assigned	39	Not assigned
17	Non assigned	xl	Not assigned
eighteen	Not assigned	41	Non assigned
xix	Not assigned	42	Instrument cluster
twenty	Not assigned	43	Not assigned
21	Not assigned	44	Not assigned
22	Not assigned	45	Tin can bus: Signal line - yaw rate and steering angle sensor Too: With MTA: MTA point line Without MTA: BCM signal line
23	Not assigned	46	Not assigned

Hydraulic system diagram - ABS 8.0

1 Front correct inlet valve 7 Rear right outlet valve 2 Rear left inlet valve 8 Rear right brake 3 Rear correct inlet valve 9 Rear left brake iv Front end left inlet valve x Rear left outlet valve 5 Front end left brake 11 Forepart right outlet valve 6 Front left outlet valve 12 Front right restriction

Haemorrhage the ABS eight.0 and ABS 8.0 ESP braking systems

Like on the Astra-G, the ABS 8.0 hydraulic system is bled in the post-obit sequence: rear right, rear left, front right, front left. The brake haemorrhage equipment bachelor from the "Service" department must exist used for this purpose.

The brake fluid goes into the reservoir and is pushed by the access pressure of the brake haemorrhage equipment through the master cylinder and the hydraulic unit into the wheel brake cylinder. The drain screw of the brake circuit being bled (hither the front end left excursion) is opened. All other bleed screws are airtight.

While the brakes are being bled, the initial pressure tin exist additional, thereby improving results, by operating the pedal. The respective brake circuits must exist bled until the brake fluid comes out without whatever bubbles or foam. The bleed operation is repeated in the same manner on the other iii wheels.

The following hydraulic diagram of the ABS 8.0 shows a normal bleed performance beingness carried out on the front left brake circuit.

one Master cylinder 5 Rear correct outlet valve two Front left inlet valve vi Rear correct restriction 3 Front left restriction seven Rear right inlet valve iv Front end left outlet valve

Electric data

Software:
Echo switch-on voltage after ignition ON	(ix.7 ± 0.iii) V
Undervoltage switch-off during regulation	(eight.nine...ix.6) V
Undervoltage switch-off exterior regulation menstruum	(9.2 ... 9.9) V
Overvoltage switch-off	(16.viii ± 0.5)Five
Hardware:
Upper close-off threshold	(nineteen.9...23.five) V
Upper cut-in threshold	(20.vii ± 1.seven) Five
Lower shut-off threshold	(vi.9...7.8) V
Lower switch-on threshold	(7.v ± 0.4 5
Overvoltage resistance of entire organisation
with ignition ON, no operation	< 18 V
Duration	1 h
at ambience temperature	(23 ± 5) °C
Jump starting time of unabridged system
Overvoltage	< 24 V
Duration	five min
at ambience temperature	(23 ± 5) °C

Hydraulic data

Pump commitment rate per circuit in ABS performance
	at a voltage at the pump motor of		(x ± 0.1) Five
		with pump motor XS	> one.1 cm 3 /s
		with pump motor S	> 1.5 cm three /s
		with pump motor L	> 2.ii cm three /s
	at a voltage at the pump motor of		(12 ± 0.1) V
		with pump motor XS	> 1.8 cm iii /s
		with pump motor S	> 2.2 cm 3 /s
		with pump motor L	> 3.0 cm 3 /south
Pressure data:
	Permissible operating pressure level		<200 bar
	Maximum permissible pressure peaks during pump performance in chief circuit		< 250 bar
Minimum pressure level upward to outer leak in the
	main circuit		350 bar
	Secondary circuit		150 bar

Wiring diagram - ABS 8.0

Component	Description	Component	Description
BCM	Bodywork Control Module	Control units
DIAG	Diagnostics connector	A15	Bodywork Control Module
ECC	Electronic climate control	A38	ABS control unit of measurement
EMP	Radio	Sensors
EPS	Electric power steering	B52L	Forepart left wheel speed sensor
GID	Graphic Info Display	B52R	Front right wheel speed sensor
MID	Multi Info Display	B76L	Rear left wheel speed sensor
MTA	Automated-shift manual manual	B76R	Rear right bicycle speed sensor
NAV	Navigation organisation	Wiring harness connector
PBV	Corsa-C Combo	X1	Instrument panel and front torso
SLS	Brake light switch	X14	Left-hand body
TID	Triple Info Display	X20	Rear left trunk
TM	Telematics	X20.1	Rear left body
WEG	Distance signal	X46	Front end body and bodywork control module
XNL	Xenon headlamps	X80	Rear left body

Wiring diagram - ABS 8.0 ESP

Component	Description	Component	Description
BCM	Bodywork Control Module	Sensors
DIAG	Diagnostics connector	B52L	Front left cycle speed sensor
EMP	Radio	B52R	Front right bicycle speed sensor
EPS	Electrical ability steering	B76L	Rear left wheel speed sensor
GID	Graphic Info Display	B76R	Rear right cycle speed sensor
MID	Multi Info Brandish	B84	Yaw rate sensor
MTA	Automatic-shift manual transmission	B161	Steering bending sensor
NAV	Navigation system	Wiring harness connector
PBV	Corsa-C Combo	X1	Instrument panel and forepart body
SLS	Brake light switch	X14	Left-paw body
TID	Triple Info Brandish	X20	Rear left trunk
XNL	Xenon headlamps	X20.ane	Rear left trunk
Control units		X46	Front body and bodywork command module
A15	Bodywork Control Module	X80	Rear left body
A38	ABS control unit	X91	Musical instrument console and contact unit
		X116	Contact unit

Source: https://workshop-manuals.com/vauxhall/corsa-c/h__brakes/abs_8/description_and_operation/anti-lock_braking_system_(abs_8.0_and_abs_8.0_esp)/

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