ABS M4 Kit Porsche 991 Cup
Installation Manual

11/5/2018

ABS M4 Kit Porsche 991 Cup

Table of contents | en

3

Table of contents
1Introduction

42

Content of the Kit

53

Installation of the hydraulic components

74Installation of the front wiring loom

105Installation of the inside wiring loom

15

6

Finishing the installation

22

Bosch Motorsport

Installation Manual

05.11.2018 | |4en | Introduction

1

ABS M4 Kit Porsche 991 Cup

Introduction
This instruction describes how to fit the Bosch Motorsport ABS M4 to a Porsche 991 Cup. The
manual is valid for the 991 Cup generation 1 and 2. Differences between the two models will
be mentioned in the manual.
Please also refer to the manual for the ABS M4. It is available at www.bosch-motorsport.de.

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2Content of the Kit | en5

Content of the Kit
Code letter

PartA

Mounting bracket for hydraulic module HU

BSpacer between bracket for HU and HUC

3 fuses, 40 A, 25 A, 10 A

DHydraulic module HU

E

Wheelspeed signal splitter

F

Mounting plate for yaw rate sensor

GYaw rate sensor

HFittings for brake pipes at hydraulic unit VR und HRI

Brake pressure sensor

JDummy plug M10x1

K12-position switch

LMalfunction light LED

M

Wiring loom
Bracket for fuses (not in figure)

MAG
B
DFH

KI

L

ECJ
Figure 2.1: ABS M4 components for Porsche 991 Cup

Bosch Motorsport

Installation Manual

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ABS M4 Kit Porsche 991 Cup

This instruction will also refer to the following drawing of Porsche 991 original parts.

Figure 2.2: Porsche 991 brake lines front

Required parts, not included in the kit
Your Bosch Motorsport dealer will tell you where you can get these parts.
PartUsage

1 x Brake Pipe Front Axle MC, see picture

Brake pipe to link Porsche bracket 23 to ABS

below

M4 item A labeled with HZ1.

1 x Brake Pipe Rear Axle MC, see picture

Brake pipe to link Porsche bracket 23 to ABS

below

M4 item A labeled with HZ2.

6 x Screw M6 x 10 mm, not shown

Mounting of the spacer C and the mounting
plate B to the HU

2 x Screw M6 x 10 mm, not shown

Mounting of the yaw rate sensor E to themounting plate F.

4 x Screw M3 x min 10mm with nut, notScrews to mount the diagnostic connector toshown

the fuse holder M and to mount the(Only needed in the Cup Gen 1 Kit)

intersection connector to the bulkhead.

Figure 2.3: Brake pipes, not included in the kit

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Installation of the hydraulic components | en7

Installation of the hydraulic components
Fit spacer item B to HU item D. Use 3 screws M6x10 or M6x12. Screws are not included inthe kit.

Figure 3.1: HU with spacer

Fit item B to the above described assembly. Use 3 screws M6x10. Screws are not included inthe kit.

Figure 3.2: HU with spacer and bracket

Remove the front left inner wing (plastic part).
Refer to picture “Porsche 991 brake lines front”.
Disconnect brake pipe 12, 13, 16, 19 from connector 5.
Remove the brake pipes 1, 2, 3, 4, you do not need them anymore.
Pull upwards on components 5 and 6 to remove them, you don’t need them anymore.

Figure 3.3: Original Cup parts removed

For the installation of the ABS HU assembly, push it into the rubber bushes as shown in thepicture below.

Bosch Motorsport

Installation Manual

05.11.2018 | |8en | Installation of the hydraulic components

ABS M4 Kit Porsche 991 Cup

Figure 3.4: HU pushed into bracket

Install the 2 new master cylinder brake pipes (pipes are not included in the kit) as shown inthe picture below. Connect the black 991 Cup brake pipes while also fitting the 2 steel
adapters for VR and HR. Make sure you fit the pipes into the correct port which are labeled.
V=front, H=rear, R=right, L=left

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Installation of the hydraulic components | en

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Figure 3.5: Brake pipes connected

Screw the dummy plug (item I) into the free hole of the connector for the rear axle. Fill theABS brake pressure sensor with brake fluid to avoid air in the system. Use a syringe. Install theABS brake pressure sensor in the left bore (view from the front) of the front axle connector.

Figure 3.6: ABS brake pressure sensor left installed

This is the last step of the installation of the brake hydraulics.
Bosch Motorsport

Installation Manual05.11.2018 | |10en | Installation of the front wiring loom

4ABS M4 Kit Porsche 991 Cup

Installation of the front wiring loom
Drill a hole Ø = 26 mm to feed the ABS wiring loom through the front bulkhead. Center is 50
mm to the bolt and 32 mm to the grommet. Use the connector of the loom to mark thepositions for the three additional notches for the connector. Each notch is app. Ø = 1.5 mm,file these notches out.

Figure 4.1: Position of hole in bulkhead

Use the connector to mark the correct vertical positions for the two holes for the connector
fixation and drill two holes.

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Installation of the front wiring loom | en

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Figure 4.2: Position of fixation holes, verticalFigure 4.3: ABS loom for front boot area

Connect the main connector to the ABS unit, connect pressure sensor and ABS ground cableat the same bolt as other ground cables are connected at the bulkhead nearby.

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Installation Manual

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ABS M4 Kit Porsche 991 Cup

Figure 4.4: Connection of ground cable

The loom is designed to run underneath the black transversal beam to the right.

Figure 4.5: Wiring loom position at ABS exit

Install the motorsport connector at the lead-in that goes through the fire protection wall.

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Figure 4.6: Connection to the inside wiring loom

Connect wheel speed sensors:

Figure 4.7: Wheel speed sensor FR connector without ABSBosch Motorsport

Installation Manual

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en | Installation of the front wiring loom

ABS M4 Kit Porsche 991 Cup

Disconnect the connector of the wheel speed sensors. Connect the end that comes from thewheel speed sensor to the ABS loom “…in”. Connect the connector 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. Do this for all sensors.

Figure 4.8: ABS loom connected

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Installation of the inside wiring loom | en15

Installation of the inside wiring loom
At first the parts of the ABS Kit for inside the car shall be installed.
Install the Yaw rate sensor (item G). Remove the screws from the loom fastener next to thedriver seat on the center tunnel. Leave the fastener at its original place. Place the mounting
plate (item F) for the yaw rate sensor on top of the fastener. Use a file to increase the width ofthe oval holes in the mounting plate (item F) slightly. Screw the yaw rate sensor (item G) onto
the mounting plate.

Figure 5.1: Yaw rate sensor (item G) on mounting plate (item F), Mounting plate on loom fastener

Install the wheelspeed signal splitter (item K), as shown on the picture in the front area on thetunnel, using velcrotape. This device duplicates the wheelspeed signal and provides it to theABS unit as well as to the display. There is no change to the display configuration required.

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en | Installation of the inside wiring loom

ABS M4 Kit Porsche 991 Cup

Figure 5.2: Wheelspeed signal splitter with wiring loom plugged in

Install the bracket for the fuses and the ABS diagnostic plug.
On the Cup Gen 1, the bracket is fitted at the glove box area. You will find two fixation points
for it as shown in the picture.
Left fuse: 10 A; middle fuse 25 A; right fuse 40 A.

Figure 5.3: Bracket with fuses and hole for ABS diagnostic plug on the Cup Gen 1

On the Cup Gen 2, the fuse mounting uses the same fixation points as the fire extinguisher
ECU mounting. Dismount the ECU mounting and place the mounting plate behind the ECUmounting. Fix both mountings at the fixation points. Turn the mounting, so that the fuses face
the center tunnel.
Remove the driver display. Fit the ABS warning light (MIL) above the display. The wiring loom
is designed to fit the MIL at this location.

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Figure 5.4: ABS MIL

Don’t reinstall the display before the full wiring loom installation has been completed.
Install the ABS 12-position switch (plus the corresponding sticker) and the ABS On/Off switch
in the center console. The required holes are indicated on the back of the console.

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ABS M4 Kit Porsche 991 Cup

Figure 5.5: ABS On/Off and ABS 12-position switch

Figure 5.6: Standard ABS scale (Label of rotary selector)

Fit the 2nd part of the ABS loom inside the car. The loom runs from the hole upwards behindthe display (dismounted) and after that downwards behind the center console continuing on
top of the center tunnel. Feed the loom underneath all the existing fixation points on thecenter tunnel.

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Figure 5.7: ABS loom runs from connection point upwards

Figure 5.8: ABS loom fixed behind display

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Installation Manual

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en | Installation of the inside wiring loom

ABS M4 Kit Porsche 991 Cup

Figure 5.9: ABS loom on top of center tunnel

Fit the Diagnostic connector into the empty hole of the bracket for the fuses. Connect the On/Off switch, as well as the 12-position switch to the loom. Plug the connector for the YRS intothe sensor. Plug in the connectors for the wheel speed sensors as described above.
Connect the open-end cable for the brake light switch (BLS) to the white cable from the BLS
connector (output BLS signal) as in the picture below, for example by using a quickconnector. After the installation, check with RaceABS, if the ABS receives a valid BLS Signal ata brake pressure of 2 to 5 bar on the front axle.

Figure 5.10: BLS connectionConnect the main power supply for the ABS loom to the bolt for the power supply by fitting
the ABS connection underneath the connector of the thick red cable as shown in the picture
below.
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Installation of the inside wiring loom | en

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Figure 5.11: Power supply connection

Two connectors at the ABS loom remain unused. One is the intersection for the ABS CAN, the2nd is the intersection to connect a data logger (e.g. Bosch Motorsport C70). They should besecured on the center tunnel.

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Installation Manual

05.11.2018 | |22en | Finishing the installation

6ABS M4 Kit Porsche 991 CupFinishing the installation
Fix the loom tight to avoid damage due to vibrations. Reinstall parts that had to be removed
for the installation. Bleed the brake system. Check the MIL by switching the ignition on and
the ABS 12-position switch to position 12 (ABS function deactivated, all signals stilltransmitted). The MIL must come on. Run a test to make sure the ABS is operational. If you
have an MSA-box available, run the Bosch Motorsport Software RaceABS to check all sensor
signals, correct connection of the brake pipes and the wheelspeed sensors as well as thebrake pressure sensor etc.
The Installation is completed.

05.11.2018 | |Installation Manual

Bosch MotorsportBosch Engineering GmbH
Motorsport
Robert-Bosch-Allee 174232 AbstattGermany
www.bosch-motorsport.com© Bosch Engineering GmbH, 2018