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ABS relay cover removal

Mark Elder

PCGB Member
Member
Anyone know how to remove this plastic cover to get at these relays?

Following on from the other thread on my ABS/ABD my Durametric cable tells me I have two ABS faults (front left sensor and "valve relay"). According to a post on Renlist corrosion on contacts of the relays is a common problem and so is finding the secret trick to opening the cover to get at the relays!

IMG_4025.jpg


Above picture is looking at the relay box (which is opposite side of spare wheel from battery). Spare wheel removed to take photo.

Anyone on here know how to open the box? It looks like it probably slides upwards but it will not budge and I can't see any latches or tabs. The actual controller box (to the left of the photo) slides upward easily.

Thanks
 
You've probably found out how to do it by now, Mark, but if not, it's quite easy. If you grip the cover with one finger down the back, and squeeze gently, you should unhook the single, central latch, and the cover can then be wriggled up. It then stops against the diagonal bodywork pressing to the right and can't be removed! You have to pull the whole assembly gently outwards as soon as the latch is free, so that it clears the fixed pressing. There's enough flexibility in the relay back plate to do so.

These pics may help.

Stuck against the pressing:
993%20ABS%20cover%2020150426_132124_resized_zpstgy4kr2e.jpg


The cover:
993%20ABS%20cover%2020150426_133412_resized_zps2wjhxgsn.jpg


The relays:
993%20ABS%20relays%2020150426_133259_resized_zpsaphkq2og.jpg


I wonder why I have only two relays? Anyway good luck.
 
I wonder why I have only two relays? Anyway good luck.

Other options for different spec cars or extra space for add-ons, perhaps?
Maybe they thought about certain things with the 993, though the cover removal scenario beggars belief[8|], i.e. that once cover unclipped it fouls on another part of the car.
 
And getting it back on is even more difficult, as you have to get the cover onto the back plate at both ends while keeping the curve in the back plate. I can't believe that's really how a workshop would do it. I suspect the little plastic clip holding the back plate onto the body panel is designed to be sacrificed and replaced.
 
Hi Richard

I suspect that you only have two relays as I don't think C2's have ABD as standard.

C4's & TT's have the ABD as standard, so I suspect the two relays you have are for ABS and the missing two are for the (optional on C2's) ABD?

Anton
 
Richard - thanks for the detailed reply and pictures - no I'd not yet succeeded - will try your technique tonight. . .
 
I'm sure you're right Anton. That thought occurred to me this morning when I saw Mark's avatar and remembered he has a C4, though that has only 3 relays, according to his pic at the start of the thread. Perhaps the TT has the 4th. Anyway 2 seems to be enough for me - I had replacement discs fitted FOC recently, as the ones I bought the car with had suffered badly over 3 years of nil use, and during the bedding-in process, the ABS was triggered and worked perfectly! [:D] Thanks, Kenny Dunn, you behaved impeccably in sorting them out.

And for Mark and others tempted to try my solution, just be aware that the cover will almost certainly get scraped along the top right corner unless you devise a way of protecting it. Nothing serious but mine is no longer pristine, so no point in trying for the concours prize! [:(]
 
I must admit that was my solution-those hammer rivets are used all over my BMW & generally can be removed & reused by using a sharp bradawl to pick out the center pin.
 
Well I finally managed to remove the cover - Richard, thanks again, could not have done it without your photo showing the plastic hook on the back of the cover. Squeezing did not work for me, but in the end I was ready to break the plastic rivet and then realized the whole thing is quite flexible and it can be bent outward enough to get a flat bladed screwdriver down the back to push the plastic hook out of it's home. Phew!

Cleaned all the relay contacts and reassembled - now the relay fault has gone - good!

Still have the front/left sensor fault so I'll need to get Brian Miller to replace that.
 

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