Bosch ABS M5 Kit Porsche 991 Cup User manual

ABS M5 Kit Porsche 991 Cup
Installation Manual
Version 1.0 05/04/2019

Content
ii/16 ABS_M5_Kit_Porsche_991_Cup_Installation_Instruction Bosch Motorsport
Content
1 Introduction .................................................................................................................................................................... 3
2 Content of the Porsche 991 ABS M5 Kit ...................................................................................................................... 4
3 Required Parts................................................................................................................................................................. 6
4 Installation of the ABS M5 Kit....................................................................................................................................... 7
4.1 Installation of the hydraulic parts .................................................................................................................................................................. 7
4.2 Installation of wiring loom and electrical components ......................................................................................................................... 9
4.3 Finishing the installation.................................................................................................................................................................................... 15

Introduction | 1
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1 Introduction
This Installation Manual describes how to fit the Bosch Motorsport ABS M5 into a Porsche
991 Cup car. The manual is valid for the 991 Cup generations 1 and 2. Differences
between these two models will be mentioned in this manual.
Please also refer to the ABS M5 Operation Manual. It is available at www.bosch-
motorsport.com.

2 | Content of the Porsche 991 ABS M5 Kit
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2 Content of the Porsche 991 ABS M5 Kit
F
A
C
D
E
B
H
G
I
J
K
Illustration1: ABS M5 Porsche 991 Kit Parts (Image shows not all parts of the Kit)
Item Description
A Mounting bracket for Hydraulic Module HU
B Brackets for fuses
C Hydraulic module HU
D Wheelspeed signal splitter
E Mounting plate for Yaw rate sensor
F Yaw rate sensor
G Fittings for brake pipes at hydraulic unit VR und HR
H 2 brake pressure sensors
I 12-position switch
J Malfunction light LED
K Wiring loom
w/o image 3 fuses, 40 A, 25 A, 10 A
This instruction will also refer to the following drawing of Porsche 991 original parts.

Content of the Porsche 991 ABS M5 Kit | 2
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Pos. Description Pc. Part no.
1
2
3
4
5
6
7
8
9
10
11
13
12
14
15
16
17
18
19
20
21
22
23
Brake-line rear right
Brake-line front left
Brake-line front right
Brake-line rear left
Connector
Bracket for connector
Fillister screw MS6X12
Rubber element
Bracket for distributor
Torx screw M8X20
Hex screw M6X25
Brake-line front left
Brake-line front right
Bracket
Bracket
Brake-line rear left short
Brake-line rear left long
Bracket
Brake-line rear right short
Brake-line rear right long
Bracket
Bracket
Connector
1
1
1
1
1
1
2
3
1
1
1
1
1
1
5
1
1
2
1
1
1
6
2
991.355.316.8A
991.355.327.8A
991.355.326.8A
991.355.315.8A
991.355.650.8A
991.355.135.8A
999.218.011.03
7P0.614.177
991.355.033.01
900.385.001.01
N .909.995.02
991.355.175.03
991.355.176.8A
991.355.512.01
999.651.409.40
991.355.315.03
991.355.177.80
8K0.611.797.D
991.355.316.03
991.355.179.80
991.355.507.01
991.355.512.01
991.355.657.8A
R
R
R
R
R
R
R
R
R
R
R
06-05-00
Illustration2: Porsche 991 brake lines front
Two further brake pipes are required for the installation. Please contact your dealer for
that.
Illustration3: Brake Pipes (not included in the Kit)
This brake pipes replace the pipes 1 to 4. The brake pipes link Porsche bracket 23 to both
ABS M5 connections, labeled with MC1 and MC2 on the hydraulic module.

3 | Required Parts
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3 Required Parts
Part Usage Quantity
Brake Pipe Front Axle MC Brake pipe to link Porsche bracket 23 to ABS
M5 item A labeled with MC1.
1
Brake Pipe Rear Axle MC Brake pipe to link Porsche bracket 23 to ABS
M5 item A labeled with MC2.
1

Installation of the ABS M5 Kit | 4
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4 Installation of the ABS M5 Kit
4.1 Installation of the hydraulic parts
Fit the mounting bracket item A to HU. Use the M10x1 screw, which comes with the kit.
Illustration4: HU with Bracket
Remove the front left inner wing (plastic part).
Refer to picture “Porsche brake parts” in the previous chapter Content of the Porsche 991
ABS M5 Kit [}4]. Disconnect brake pipe 12, 13, 16, 19 from connector 5.
Remove the brake pipes 1, 2, 3, 4, as they are no longer needed. Pull upwards on com-
ponents 5 and 6 to remove these. These are no longer needed.
Illustration5: Original Cup parts removed
For the installation of the ABS HU assembly, push this into the rubber bushes as shown in
the following picture below.

4 | Installation of the ABS M5 Kit
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Illustration6: HU pushed into bracket
Attention: This picture is outdated and will be renewed soon.
Install the two new master cylinder brake pipes – pipes are not included – as shown in
the following picture. Connect the black 991 Cup brake pipes while also fitting the two
steel adapters for VR and HR. Make sure you fit the pipes into the correct port which are
labeled: F=front, R=rear, R=right, L=left.
Illustration7: Brake pipes connected
Attention: This picture is outdated and will be renewed soon.
Prime the ABS brake pressure sensor with a syringe and install one of them on each brake
circuit connector. This is the last step of the installation of the brake hydraulics.
Illustration8: ABS brake pressure sensors installed

Installation of the ABS M5 Kit | 4
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4.2 Installation of wiring loom and electrical
components
Now install the two-piece ABS wiring loom.
Installation of the front wiring loom
Drill a hole of d = 26 mm to feed the ABS wiring loom through the front bulk head. The
center is 50 mm to the bolt and 32 mm to the grommet. Use the connector of the loom to
mark the positions for the three additional notches for the connector. Each notch has ap-
proximately a diameter of ca. 1.5 mm. File these notches out.
Mark the correct vertical positions for the two holes for the connector fixation and drill
two holes.
Illustration9: Position of hole in bulk head
Illustration10: Position of fixation holes, vertical

4 | Installation of the ABS M5 Kit
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Illustration11: Connection of ground cable
The installation of the front wiring loom starts from the ABS connector.
Connect the main connector to the ABS unit.
Connect the pressure sensors. Pay attention, to connect the correct brake circuit.
Connect the ABS ground cable at the same bolt as other ground cables are connected at
the bulkhead nearby. The loom is designed to run underneath the black transversal beam
to the right. Mount the connector to connect to the inside loom into the bulkhead by us-
ing the delivered nutplate.
Connect the wheel speed sensors: Disconnect the connector of the wheel speed sensor.
Connect the end that comes from the wheel to the ABS loom “…in”. Connect the con-
nector that runs into the vehicle chassis loom to the ABS loom connector “…out”. By doing
this, the wheel speed signal is fed to the ABS and from the signal splitter back to the
vehicle display. Repeat this for front left.
Illustration12: ABS loom for front boot area