!Guide! Replacing/Cleaning/Bleeding ABS unit - MK7 2011

[CursedBones]

----------------------------------------------------------

-Ford Fiesta Zetec JA8  08-13

----------------------------------------------------------

Misc:
-You will NEED a scan tool that is capable of connecting to FORScan for bleeding the ABS module
-If you want to replace the computer module portion of the ABS unit then after you have installed the unit; You will need to take it to a garage that has a PMI (Programmable Module Installation) setting or module reprogramming capabilities on their scan computer. You can then complete the bleeding procedure yourself. Hopefully this will save you money as you have installed and bled the unit yourself.

----------------------------------------------------------

-Unfasten the 10mm bolt on the negative battery terminal
-Securely position the negative terminal to one side

-Unfasten the 2 10mm nuts on the battery clamp
-Remove the clamp bracket

-Unfasten the 10mm bolt on the positive battery terminal
-Securely position the positive terminal to one side

-Lift the old battery out from the battery tray

-Unbolt the 3 10mm battery tray bolts (Spray them with penetrating oil & wire brush them first)
-Unbolt the 3 T30 torx bolts that are securing the ECU to the battery tray
-Remove the battery tray

-Tightly place clingfilm over the fluid reservoir and reattach the cap to create a vacuum

-Crack off all 6 of the unions going into the ABS unit (Use mole grips so that they do not round off)

-Remove the 3 10mm bolts that are securing the ABS unit to the bulkhead & inner wheel arch panel

-Fully unfasten & pull away the brake line unions that are engaging the ABS unit (2 11mm & 4 13mm flare spanner)

-Unclip the ABS wiring connector by pulling the tab at the bottom & then pulling the plug away & up to unseat it from the unit
-Pull the ABS unit away from the car

----------------------------------------------------------

THIS NEXT SECTION IS FOR:
A) CLEANING & REUSING THE FULL ABS UNIT
B) CLEANING THE MODULE PORTION & REPLACING THE VALVE PORTION

-Remove the 4 T20 torx screws that are securing the module to the valve unit
-Pry all sides of the module with a pry tool until it separates from the valve unit

-Spray electrical cleaner on all of the solenoids & rubber O rings then clean them with a soft toothbrush (UNLESS YOU ARE REPLACING THIS VALVE PORTION OF THE UNIT WITH A BRAND NEW REPLACEMENT)
-Spray electrical cleaner inside the valves & brake line union ports & clean them out with a pipe cleaner (UNLESS YOU ARE REPLACING THIS VALVE PORTION OF THE UNIT WITH A BRAND NEW REPLACEMENT)
-Spray electrical cleaner on the 2 electrical connection mating points & clean them with a soft toothbrush
-Spray electrical cleaner inside the solenoid coils & then clean them with a pipe cleaner

-Spray everything with compressed air to help dislodge any dirt or rust
-Spray everything with electrical cleaner 1 last time & allow the cleaner to evaporate for everything to be dry

-Reassemble the module with the valve unit (Make sure that you mate them together in the correct orientation)
-Fasten down the 4 T20 torx screws until they are reasonably tight

----------------------------------------------------------

-Reposition the refurbished or brand new ABS unit on the bulkhead
-Fasten the 3 10mm bolts to the bulkhead & inner wheel arch panel @ torque them to 23Nm

-Fasten the ABS unit power connector & lock it in place

-Hand screw the 6 brake line unions & snug them up with a 11mm & 13mm flare spanner until they are reasonably tight 

-Spray brake cleaner & wipe away any brake fluid residue

-Reposition the battery try
-Refasten the 3 T30 torx bolts to re-secure the ECU to the battery tray
-Tighten the 3 10mm battery tray bolts @ 30Nm

-Place the battery back in the battery tray
-Fasten the 10mm bolt on the positive battery terminal @ 25Nm
-Fasten the 10mm bolt on the negative battery terminal @ 25Nm
-Fasten the 2 10mm nuts on the battery clamp bar @ 25Nm

----------------------------------------------------------

THIS NEXT SECTION IS FOR:
A) BLEEDING A UNIT WHERE YOU HAVE REUSED THE ORIGININAL MODULE 

-Crack off the wheel nuts on every wheel (19mm)
-Put the full car on axle stands
-Remove every wheel

-Prepare for bleeding service:
-Fill 2 water bottles with 150ml of DOT4 brake fluid and make a small hole in each lid
-Cut two 1m lengths of PVC clear hose with an ID of about 6mm & insert them into each bottle
-Cable tie each hose onto the front brake calliper bleed screws
-Top off the brake fluid reservoir as much as you can and leave the lid resting on the top

-Bleeding procedure:
-Plug the FORScan OBD reader into the OBD2 port & connect the vehicle (MAKE SURE THAT BOTH THE LAPTOP AND CAR HAS FULL CHARGE)
-Click on the service functions tab which has a spanner icon
-Click on ABS service bleed & press the play button in the bottom left corner of the screen
-Select ABS module & then click ok
-Remove the dust covers & crack off both front calliper bleed screws with mole grips & then loosely fasten them back up
-Open both front calliper bleed screws with a 12mm spanner (Preferably a flare spanner) 
-Press ok on the message prompt & the ABS unit will instantly start bleeding the unit 
-Without delay go to the brake fluid reservoir and start filling it right to the top. Do this until the unit has stopped pumping fluid through. You will need to start filling the system before it finishes its procedure (DON'T LET THE RESERVOIR RUN DRY)
-Quickly tighten the bleed screws & transfer the bottles to the rear wheel cylinder bleed screws

-Remove the dust covers & crack off both rear wheel cylinder bleed screws with mole grips & then loosely fasten them back up
-Open both rear wheel cylinder bleed screws with a 8mm spanner (Preferably a flare spanner) 
-Press ok on the message prompt & the ABS unit will instantly start bleeding the unit 
-Without delay go to the brake fluid reservoir and start filling it right to the top. Do this until the unit has stopped pumping fluid through. You will need to start filling the system before it finishes its procedure (DON'T LET THE RESERVOIR RUN DRY)
-Quickly tighten the bleed screws. Remove the bleed bottles & replace the dust covers

-Clean any brake fluid residue
-Apply a conservative amount of aluminium anti seize to the hat of the rotors & rear brake drum mating surface (Don't get any on the studs)
-Put all wheels back on (19mm)
-Lower the car back to the ground
-Torque all wheel nuts @ 110Nm (19mm)

----------------------------------------------------------

THIS NEXT SECTION IS FOR:
A) REPROGRAMMING & BLEEDING A UNIT WHERE YOU HAVE REPLACED THE MODULE 

-Reprogram the ABS unit:
-Now that you have installed the unit you will need to take it to a garage that has a PMI (Programmable Module Installation) setting on their scan computer.

-Prepare for bleeding service:
-Crack off the wheel nuts on every wheel (19mm)
-Put the full car on axle stands
-Remove every wheel

-Fill 2 water bottles with 150ml of DOT4 brake fluid and make a small hole in each lid
-Cut two 1m lengths of PVC clear hose with an ID of about 6mm & insert them into each bottle
-Cable tie each hose onto the front brake calliper bleed screws
-Top off the brake fluid reservoir as much as you can and leave the lid resting on the top

-Bleeding procedure
-Click on the service functions tab which has a spanner icon
-Click on ABS service bleed & press the play button in the bottom left corner of the screen
-Select ABS module & then click ok
-Remove the dust covers & crack off both front calliper bleed screws with mole grips & then loosely fasten them back up
-Open both front calliper bleed screws with a 12mm spanner (Preferably a flare spanner) 
-Press ok on the message prompt & the ABS unit will instantly start bleeding the unit 
-Without delay go to the brake fluid reservoir and start filling it right to the top. Do this until the unit has stopped pumping fluid through. You will need to start filling the system before it finishes its procedure (DON'T LET THE RESERVOIR RUN DRY)
-Quickly tighten the bleed screws & transfer the bottles to the rear wheel cylinder bleed screws

-Remove the dust covers & crack off both rear wheel cylinder bleed screws with mole grips & then loosely fasten them back up
-Open both rear wheel cylinder bleed screws with a 8mm spanner (Preferably a flare spanner) 
-Press ok on the message prompt & the ABS unit will instantly start bleeding the unit 
-Without delay go to the brake fluid reservoir and start filling it right to the top. Do this until the unit has stopped pumping fluid through. You will need to start filling the system before it finishes its procedure (DON'T LET THE RESERVOIR RUN DRY)
-Quickly tighten the bleed screws. Remove the bleed bottles & replace the dust covers

-Clean any brake fluid residue
-Apply a conservative amount of aluminium anti seize to the hat of the rotors & rear brake drum mating surface (Don't get any on the studs)
-Put all wheels back on (19mm)
-Lower the car back to the ground
-Torque all wheel nuts @ 110Nm (19mm)

----------------------------------------------------------

Useful sources:

https://www.youtube.com/watch?v=T7VQ6OwJAyc

How To Deep Clean A Hydraulic ABS Control Module Traction Control Not Working

----------------------------------------------------------

[FatHead1979]

Fantastically detailed guide, and I'll be putting it to good use in the coming weeks once I've removed the (full) ABS module from my wife's MK7 Fiesta and had it rebuilt by ECUtesting in Derby.