ABS M4 Porsche 991 Cup
Installation instructions

V 5 9/22/2017

Table of Contents

Table of contents
1 Introduction ......................................................................................................................................................... 3
2 Content of the Kit ................................................................................................................................................ 4
3 Installation of the hydraulic components ......................................................................................................... 6
4 Installation of the front wiring loom ................................................................................................................ 9
5 Installation of the inside wiring loom ............................................................................................................. 13
6 Finishing the installation .................................................................................................................................. 19

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ABS M4 Porsche Cup Installation Instructions

Bosch Motorsport

Introduction | 1

1 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 be‐tween 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‐mo‐torsport.de.

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2 | Content of the Kit

2 Content of the Kit
Code letter

Part

A

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

K

12‐position switch

LMalfunction light LED

M

Wiring loom
Bracket for fuses (not in figure)

M
AG
B
DFHKI

L

ECJ

Fig. 1: ABS M4 components for Porsche 991 Cup

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ABS M4 Porsche Cup Installation Instructions

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Content of the Kit | 2This instruction will also refer to the following drawing of Porsche 991 originalparts.

Fig. 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 pic‐
ture below

Brake pipe to link Porsche bracket 23 toABS M4 item A labeled with HZ1.

1 x Brake Pipe Rear Axle MC, see pic‐
ture below

Brake pipe to link Porsche bracket 23 toABS M4 item A labeled with HZ2.

6 x Screw M6 x 10 mm, not shown

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

2 x Screw M6 x 10 mm, not shown

Mounting of the yaw rate sensor E tothe mounting plate F.

4 x Screw M3 x min 10mm with nut, not Screws to mount the diagnostic con‐shown
nector to the fuse holder M and tomount the intersection connector to(Only needed in the Cup Gen 1 Kit)
the bulkhead.

Fig. 3: Brake pipes, not included in the kit

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3 | Installation of the hydraulic components

3 Installation of the hydraulic components
Fit spacer item B to HU item D. Use 3 screws M6x10 or M6x12. Screws are notincluded in the kit.

Fig. 4: HU with spacer

Fit item B to the above described assembly. Use 3 screws M6x10. Screws are notincluded in the kit.

Fig. 5: 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 any‐
more.

Fig. 6: Original Cup parts removed

For the installation of the ABS HU assembly, push it into the rubber bushes asshown in the picture below.

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ABS M4 Porsche Cup Installation Instructions

Bosch Motorsport

Installation of the hydraulic components | 3Fig. 7: HU pushed into bracket

Install the 2 new master cylinder brake pipes (pipes are not included in the kit)
as shown in the 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 thecorrect port which are labeled. V=front, H=rear, R=right, L=left

Fig. 8: Brake pipes connected

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

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3 | Installation of the hydraulic components

Fig. 9: ABS brake pressure sensor left installed

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

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ABS M4 Porsche Cup Installation Instructions

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Installation of the front wiring loom | 44 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 the positions for the three additional notches for the connec‐
tor. Each notch is app. Ø = 1.5 mm, file these notches out.

Fig. 10: Position of hole in bulkhead

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

Fig. 11: Position of fixation holes, vertical

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4 | Installation of the front wiring loom

Fig. 12: ABS loom for front boot area

Connect the main connector to the ABS unit, connect pressure sensor and ABS
ground cable at the same bolt as other ground cables are connected at the bulk‐
head nearby.

Fig. 13: Connection of ground cable

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

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ABS M4 Porsche Cup Installation Instructions

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Installation of the front wiring loom | 4Fig. 14: Wiring loom position at ABS exit

Install the motorsport connector at the lead‐in that goes through the fire protec‐
tion wall.

Fig. 15: Connection to the inside wiring loom

Connect wheel speed sensors:

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4 | Installation of the front wiring loom

Fig. 16: Wheel speed sensor FR connector without ABS

Disconnect the connector of the wheel speed sensors. Connect the end thatcomes from the wheel speed sensor to the ABS loom “…in”. Connect the connec‐
tor 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 splitterback to the vehicle display. Do this for all sensors.

Fig. 17: ABS loom connected

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ABS M4 Porsche Cup Installation Instructions

Bosch Motorsport

Installation of the inside wiring loom | 5

5 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 fastenernext to the driver seat on the center tunnel. Leave the fastener at its originalplace. Place the mounting plate (item F) for the yaw rate sensor on top of thefastener. Use a file to increase the width of the oval holes in the mounting plate(item F) slightly. Screw the yaw rate sensor (item G) onto the mounting plate.

Fig. 18: Yaw rate sensor (item G) on mounting plate (item F), Mounting plate on loom fas‐
tener

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

Fig. 19: Wheelspeed signal splitter with wiring loom plugged in
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5 | Installation of the inside wiring loom

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.

Fig. 20: 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 mount‐ing plate behind the ECU mounting. 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. Thewiring loom is designed to fit the MIL at this location.

Fig. 21: ABS MIL

Don’t reinstall the display before the full wiring loom installation has been com‐pleted.

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ABS M4 Porsche Cup Installation Instructions

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Installation of the inside wiring loom | 5

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 backof the console.

Fig. 22: ABS On/Off and ABS 12‐position switch

Fig. 23: Standard ABS scale (Label of rotary selector)

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

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5 | Installation of the inside wiring loom

Fig. 24: ABS loom runs from connection point upwards

Fig. 25: ABS loom fixed behind display

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ABS M4 Porsche Cup Installation Instructions

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Installation of the inside wiring loom | 5Fig. 26: 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. Plugthe connector for the YRS into the 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 cablefrom the BLS connector (output BLS signal) as in the picture below, for example
by using a quick connector. After the installation, check with RaceABS, if the ABS
receives a valid BLS Signal at a brake pressure of 2 to 5 bar on the front axle.

Fig. 27: BLS connection

Connect the main power supply for the ABS loom to the bolt for the power sup‐ply by fitting the ABS connection underneath the connector of the thick red cableas shown in the picture below.

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5 | Installation of the inside wiring loom

Fig. 28: Power supply connection

Two connectors at the ABS loom remain unused. One is the intersection for theABS CAN, the 2nd is the intersection to connect a data logger (e.g. Bosch Motor‐sport C70). They should be secured on the center tunnel.

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Bosch Motorsport

Finishing the installation | 6

6 Finishing the installation
Fix the loom tight to avoid damage due to vibrations. Reinstall parts that had tobe removed for the installation. Bleed the brake system. Check the MIL byswitching the ignition on and the ABS 12‐position switch to position 12 (ABSfunction deactivated, all signals still transmitted). The MIL must come on. Run atest 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 con‐nection of the brake pipes and the wheelspeed sensors as well as the brake pres‐sure sensor etc.
The Installation is completed.

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Bosch Engineering GmbHMotorsport
Robert-Bosch-Allee 174232 AbstattGermany
www.bosch-motorsport.com