E36 MK60 ABS Installation Guide
MK60 ABS installation notes for E36 chassis using stock ABS location
MK60 ABS unit
E46 wheel speed sensors (w/ blue plugs)
2x Pressure sensors
DSC Sensor (commonly called “Yaw sensor”)
2x M10 tube joiner https://www.fcpeuro.com/products/bmw-intermediate-piece-m10x1-34326757282
2x M12 tube joiner https://www.fcpeuro.com/products?keywords=34326757285
2x Tee fittings for pressure sensors http://store.fedhillusa.com/tm204.aspx
10x M12x1.0 flare nut for 3/16” tube http://store.fedhillusa.com/m63.aspx
6x M10x1.0 flare nut for 3/16” tube http://store.fedhillusa.com/m13.aspx
Assorted butt and ring terminals as required
2x 20A fuses
1x 5A fuse
Pressure Connection Labels
V = Front
H = Rear
VL = Front Left
VR = Front Right
HL = Rear Left
HR = Rear Right
Brake Line Notes
Lines required are as follows:
Master cylinder front (V) circuit outlet to pressure tee fitting; 3/16” tube M10x1.0 DIN to M12x1.0 45 deg
Master cylinder rear (H) circuit outlet to pressure tee fitting; 3/16” tube M10x1.0 DIN to M12x1.0 45 deg
Front circuit pressure tee fitting to MK60; 3/16” tube M12x1.0 45 deg to M12x1.0 DIN
Rear circuit pressure tee fitting to MK60; 3/16” tube M12x1.0 45 deg to M12x1.0 DIN
Front Left (VL) MK60 outlet to chassis hardline; 3/16” tube M12x1.0 DIN to M10x1.0 DIN
Front Right (VR) MK60 outlet to chassis hardline; 3/16” tube M10x1.0 DIN to M12x1.0 DIN
Rear Left (HL) MK60 outlet to chassis hardline; 3/16” tube M12x1.0 DIN to M10x1.0 DIN
Rear Right (HR) MK60 outlet to chassis hardline; 3/16” tube M10x1.0 DIN to M12x.10 DIN
NOTE: outlet at front of brake master cylinder (labeled “H”) is rear circuit and outlet at back of master cylinder (labeled “V”) is front circuit.
Harness Routing Notes
WARNING: Never try to pull the wheel speed sensor connectors from the wheel speed sensor plugs by the wires! The wires will come out before the plug does. Always use small pliers on the edge of the connector while depressing the tabs to remove.
These notes assume the MK60 unit has been installed in the location where the E36 factory MK20 was installed using a fabricated bracket.
Front left wheel speed: route similar to factory installation by tracing back from the existing E36 sensor
Front right wheel speed: route cable across rear of engine bay then forward to the opening currently being used by the E36 sensor
Rear left/right wheel speed sensor: route across the engine bay and thru available opening/grommet in firewall trying to avoid being adjacent to battery cable. Route to rear seat pan and thru rear seat bulkhead to hole in trunk floor ahead of the spare tire well. Run left and right rear sensor runs along the factory path using clips or zip ties to the wheel speed sensors. Be mindful of rotating components (like axles) in that area.
Diag port: Route across engine bay and thru same opening used by rear wheel speed wire and place diag port as desired.
DSC: Route across engine bay and thru same opening used by rear wheel speed wires. Install the sensor oriented as shown using a BMW bracket or custom fabricated bracket. I’ve found using the hat sections that support the passenger seat works well.
ABS expansion: Route across engine bay and thru same opening used by rear wheel speed wire. Notes in “ABS Expansion” section below for more details.
Power: Route across engine bay and thru same opening used by rear wheel speed wire. Notes in “ABS Power” section below for more details.
Ground: Use nut on front left shock tower for chassis ground.
The ABS Expansion plug contains wires for LED Warning Light and brake pedal switch.
LED Warning Light
A warning light can be connected to the purple/white and purple wires to provide visual indication of an ABS fault. Purple/White wire is the voltage to the LED and purple is ground.
The MK60 requires a “notification” when the brake pedal has been depressed in order to know when to monitor and regular wheel slip as required. The proper signals are GROUND when the pedal is NOT pressed and open circuit when the pedal is pressed. This signal is provided by the yellow/white wire.
The best way I’ve found of accomplishing this is splicing into the switched voltage side of the brake pedal switch that is located near the top of the brake pedal arm in the driver footwell area. Use this switched voltage to trigger the DPDT relay which should be wired as follows:
Pin 30: Yellow/black, yellow/white or yellow brake switch
Pin 85: Ground
Pin 86: Switched power brake pedal switch
Pin 87A: Ground
Small spade connectors work well here.
The MK60 requires 3 power inputs to operate. All 3 wires are provided for in a pigtail from a 3-pin DT connector. The two larger gauge wires should be connected to 20A power that is constant when the car is on (IE Kill Switch in “ON” position) and the smaller wire should be connected to 5A power and can be switched if you desire to be able to turn the ABS system off while driving.
Brake Line Plumbing
The brake line fitting sizes between the E36 and the E46 are not the same nor are the outputs oriented in such a way that the MK60 can be directly connected to your car’s existing hard lines.
With the ABS pump oriented as shown on a bracket similar to this one short patch lines can be made to connect the MK60 to the existing chassis hard lines. All outlets on the MK60 that are M10x1.0 go to chassis hard lines that are M12x1.0 and vice versa. Therefore short patch lines need to be M10x1.0 flare nuts on one end and M12x1.0 flare nuts on the other. The tube joiners referenced in the opening can be used to join the patch lines to the chassis hard lines.
Pressure Sensor installation
The pressure sensors are required to make best use of the MK60’s capabilities and should be installed. These sensors monitor the outlet pressure of the front and rear lines from the master cylinder and need to be installed upstream of the MK60.
Note that the pressure sensors are SAE flare which is not the convention for BMW’s. The hardlines to and from the tee fittings must be made with the standard DIN bubble flare on one end and the SAE flare on the other to ensure proper sealing.
It is recommended that you use a factory type tool to follow the BMW bleed routine to remove air from the lines and MK60 unit prior to first use. I can recommend tools or provide these as required.