Guide to replacing the Bosch 5.3 ABS pump and module

[jay8086]

Hi everybody,

This is my first guide / 'how I did mine' to changing the Bosch 5.3 ABS pump and module on my 2001 (Y) Peugeot 306 1.8 16v Meridian. Naturally I take no responsibility if you choose to follow this guide, it’s merely a how I swapped my pump write-up and as it seems reasonably common for the module / ECU to fail I thought I'd share this with you guys Hopefully it uploads ok and the pics are in the right places.

Firstly the things you will need:-

A working replacement Bosch 5.3 ABS pump
A 11mm open ended spanner
A 13mm ring or open ended spanner
Rags / tissue to soak up the break fluid
Break fluid to top up the system
Some blankets / sheets to put over the wings in case any fluids spill
A cup of coffee… make that several cups

http://imageshack.us/photo/my-images/838/dsc01585b.jpg/

I sourced my second hand pump from a scrap yard as I wanted to check the car it came from had a similar braking setup. You might also want to try places like Ebay, car breakers, people on here [parts forum], other. I was looking for another 1.8 or 2l, with discs front and back, from a similar year [found another '01 Y reg], and from a French manufactured car [ideally it would have been from another Pug but none had the same setup as mine at the scrap yard, a Citroen Xsara did]. Ideally I would have got the part number from the ABS module but I was too much of a wuss to take the pump off the car without having a replacement to hand so I went by the part number on the top of the unit around where the pipes went in the top.
You know where to get tools, rags, break fluid and coffee from, if not this guide will be way beyond you

Start disconnecting the battery, and the clip connector going to the ABS module.

http://imageshack.us/photo/my-images/17/dsc01586vs.jpg/

Once they are disconnected leave them for at least 10 mins for things to discharge etc. Make sure the disconnected battery terminal cannot make contact with the battery, I put the battery cover over the battery and the terminal on the cover but you may want to try something more secure, whatever as long as the battery doesn't reconnect.

Use the 11mm spanner to undo the pipes going to the pump. Watch where the spanner will spin round to before you rip your knuckles off Undo the pipes 1 at a time and be ready to soak up the break fluid that comes out.

http://imageshack.us/photo/my-images/220...587mm.jpg/

Wear latex gloves and have something to throw the rags into, they won't be reusable. For me the fluid was a steady ooze that looked like it was coming out of the top of the pump not out of the pipes. It should go without saying but DO NOT get break fluid on the paint, it'll strip it.
Once all the pipes are undone use the 13mm spanner to undo the nuts to the side of the ABS pump that hold it on the car. You may want to hold the pump in position as the nuts will be on tight and I didn’t like how much the pump unit twisted without being held.

http://img853.imageshack.us/img853/6489/dsc01596x.jpg/

Shift the pipes enough out of the way that you can pull the pump upwards.

http://imageshack.us/photo/my-images/444/dsc01592a.jpg/

Double check everything is out the way, including connectors, terminals, etc, and lift the pump upwards. Don’t yank it, you don’t want to screw something else in the process of fixing this. Have something to put the pump in, such as a biscuit / sweet tin. It’ll probably continue to ooze and you don’t want to be worrying about the removed part. Take care of it, if this really doesn’t work having the original pump could save time money and effort on other methods of repairs, fault fixing, etc.
Make sure it’s a compatible pump before you even start this. The scrap yard I got the pump from ‘decontaminate’ the vehicles they get in, basically they remove all fluids so it looks like this pump will have little to no fluid in it. I’m expecting this to mean the breaks will need bleeding. There are several places that describe how to bleed your brakes but I’m hoping this will be easier when my lexia 3 and pp2000 arrive
Reattach the new pump to the car by putting it in-between the bracket and using the 13mm spanner to tightly secure the nuts on each side. They need to be tight as they are the only thing holding this in place when the car is shifting around. Reconnect the pipes tightening them with the 11mm spanner, screw them in tightly but don’t strip the threads lol.
Reconnect the ABS module connector and the battery, cross your fingers and hope you didn’t get something wrong lol.

http://img37.imageshack.us/img37/9972/dsc01597v.jpg

Top up your brake fluid container. Next…bleeding the brakes.

http://img31.imageshack.us/img31/2421/dsc01598l.jpg

For me this was a completely successful repair, ABS light turned off as it should. Check the brakes, they probably need bleeding, and take it steady until you KNOW the ABS is fully working, i.e. test it in stages.
Enjoy, good luck, and be safe.

[Niall]

Just to add to this, on ph3s all the EBD modules are the same between all models so if it does pack up, any of the Bosch 5.3 units will fit and work.
Do NOT get brake fluid on the paint. Not only will it strip the paint, it will practically ruin the metal stopping you from ever painting it again (remember this for that special someone you hate. Nitromors is neutralised with water, brake fluid isn't!)
The pump should bleed its self after a few pumps so just keep a eye on the reservoir level.

[jay8086]

Also worth meantioning that when I was looking into my Bosch 5.3 setup I read that on the older Bosch 2E setup that the relays [there are 2] are seperate and not on the board inside the module. It looks worth trying to replace those first as its a quicker, easier fix. Not sure which Pugs have the 2E setup, I think the late 405's and early 306's but not sure.

[CJ_Derv]

Any idea what mine is on the Dturbo 1998 as think its packed up also

[Niall]

not sure what model but its not the 5.3. ph2s don't have EBD. Will look on auto data for you in a bit

[Kwik]

just to quell all this different abs pump thing. we all have 5.3 as the abs ecu is intergrated onto the abs pump. the difference is software versions. if we had a 5.0 the ecu would be by the dash.........

http://www.ecutesting.com/bosch_abs_pump...dules.html if you don't believe me phone them yourselves