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8/14/2019 2005 Tj Chassis
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TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2 SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0 IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1
3.1 TEVES MARK 20I SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.1.1 PEDAL FEEL/VEHICLE CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . .23.1.2 SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.1.3 ABS AND BRAKE WARNING INDICATORS . . . . . . . . . . . . . . . . . . . . . .23.1.4 CONTROLLER ANTILOCK BRAKE (CAB) . . . . . . . . . . . . . . . . . . . . . . .23.1.5 HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.1.6 RELAYS/SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.1.7 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.2.1 SYSTEM INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.2.2 DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.2.3 INTERMITTENT DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . .43.3 AXLE LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.3.2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.4 USING THE DRBIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.5 DRBIII ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.5.1 DRBIII DOES NOT POWER UP (BLANK SCREEN) . . . . . . . . . . . . . .53.5.2 DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.0 DISCLAIMERS, SAFETY WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54.2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.2.1 TECHNICIAN SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .64.2.2 VEHICLE PREPARATION FOR TESTING . . . . . . . . . . . . . . . . . . . . . . . .64.2.3 SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64.2.4 DRBIII SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.3 WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64.3.1 VEHICLE DAMAGE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64.3.2 ROAD TESTING A COMPLAINT VEHICLE . . . . . . . . . . . . . . . . . . . . . . .7
4.4 DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
6.0 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
BRAKES (CAB)CAB POWER FEED CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10CONTROLLER FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13G-SWITCH NOT PROCESSABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15LEFT FRONT SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19LEFT REAR SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
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TABLE OF CONTENTS - Continued
RIGHT FRONT SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19RIGHT REAR SENSOR CIRCUIT FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19LEFT FRONT SENSOR SIGNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22LEFT REAR SENSOR SIGNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22RIGHT FRONT SENSOR SIGNAL FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22RIGHT REAR SENSOR SIGNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22PUMP MOTOR NOT WORKING PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
SYSTEM OVER VOLTAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29SYSTEM UNDER VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31*ABS WARNING INDICATOR ALWAYS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33*ABS WARNING INDICATOR INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35*BRAKE LAMP SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37*FRONT AXLE LOCK INDICATOR REMAINS FLASHING . . . . . . . . . . . . . . . . . . . . . . .38*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . . .40*REAR AXLE LOCK INDICATOR REMAINS FLASHING . . . . . . . . . . . . . . . . . . . . . . . .42*REAR AXLE LOCK INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
VERIFICATION TESTSVERIFICATION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
8.0 COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.1 CONTROLLER ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .498.2 DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .498.3 G-SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .498.4 FUSES & RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .508.5 WHEEL SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .508.6 WHEEL SPEED SENSOR CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .508.7 BRAKE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
8.7.1 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .518.7.2 BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
9.0 CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
AXLE LOCK SWITCH (OFF-ROAD PACKAGE) - 8 WAY. . . . . . . . . . . . . . . . . . . . . . . .53BRAKE LAMP SWITCH - GRAY 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53BRAKE WARNING INDICATOR SWITCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . .53C115 (OFF-ROAD PACKAGE) - BLACK (ENGINE SIDE) . . . . . . . . . . . . . . . . . . . . . . .53C115 (OFF-ROAD PACKAGE) - BLACK (FRONT FEEDBACK OVERLAY SIDE). . . . .54C116 (OFF-ROAD PACKAGE) - LT GRAY (ENGINE SIDE) . . . . . . . . . . . . . . . . . . . . . .54C116 (OFF-ROAD PACKAGE) - LT GRAY (REAR FEEDBACK OVERLAY SIDE) . . . .54CLUTCH PEDAL POSITION SWITCH (M/T) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . .54CONTROLLER ANTILOCK BRAKE - 25 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
DATA LINK CONNECTOR - BLACK 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55FRONT LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY . .56FRONT LOCKER PUMP (OFF-ROAD PACKAGE) - LT GRAY 3 WAY . . . . . . . . . . . . .56G-SWITCH (LHD) - 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56INSTRUMENT CLUSTER C1 - 12 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56INSTRUMENT CLUSTER C2 - 16 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57LEFT FRONT WHEEL SPEED SENSOR - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57LEFT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . . .57LEFT REAR WHEEL SPEED SENSOR - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58LEFT REAR WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . . . . .58
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TABLE OF CONTENTS - Continued
FUSES (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60FRONT LOCKER RELAY (IN PDC/OFF-ROAD PACKAGE). . . . . . . . . . . . . . . . . . . . . .60REAR LOCKER RELAY (IN PDC/OFF-ROAD PACKAGE) . . . . . . . . . . . . . . . . . . . . . . .60REAR LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) - BLACK 2 WAY. . . .61REAR LOCKER PUMP (OFF-ROAD PACKAGE) - LT GRAY 3 WAY . . . . . . . . . . . . . .61RIGHT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . .61RIGHT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . .62
RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . .62RIGHT REAR WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . . .62VEHICLE SPEED SENSOR - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
10.0 SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
10.1 TEVES MARK 20I CONTROLLER ANTILOCK BRAKE - ABS . . . . . . . . . . . . . . .6510.2 AXLE LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
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NOTES
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1 .0 I N T ROD UC T I ON
The procedures contained in this manual include
all the specifications, instructions, and graphics
n e ed e d t o d ia g n os e t h e 2 00 5 T J C h a s s is s ys t e m
problems: Teves Mark 20i Antilock Braking System
(ABS) and Axle Lock. The diagnostics in this man-
ual are based on the failure condition or symptom
being present at time of diagnosis.Follow the recommendations below when choos-
ing your diagnostic path.
1 . F i r s t m a k e s u r e t h e D R BI I I is communicating
w i t h t h e C A B . I f t h e D R B I I I displays a No
Response condition, you must diagnose that
first.
2. Read DTCs (diagnostic trouble codes) with th e
DRBIII.
3. If no DTCs are present, identify t he customer
complaint.
4. Once t he DTC or customer complaint is identi-
fi ed , l oca t e t h e m a t c h in g t e s t i n t h e Ta b le of Contents and begin t o diagnose the symptom.
All component location views are in Section 8.0.
All connector pinouts are in Section 9.0. All sche-
matics are in Section 10.0.
An asterisk (*) placed before the symptom de-
scription indicates a customer complaint.
When repairs a re r equired, refer t o the a ppropri-
a t e s er vice m a n u a l for t h e p r op er r e m ova l a n d
repair procedure.Diagnostic procedures change every
year. New diagnostic systems may be added; carryover
syst em s m ay b e en h an ced . R E AD T H IS M AN U AL
BEFORE TRYING TO DIAGNOSE A VEHICLE DI-
AGNOSTIC TROUBLE CODE. It is recommended
that you review the entire manual to become familiar
with all new and changed diagnostic procedures.
After using this book, if you have any comments
or recommendations, please fill out the form at the
back of the book and mail it back to us.
1. 1 SYSTEM COVERAGE
This diagnostic manual covers the Teves Mark
20i Antilock Braking System (ABS) found on the
2005 Jeep Wrangler. Diagnosis of the Axle Lock is
covered in this manual.
1. 2 SIX-STEP TROUBLESHOOTINGPROCEDURE
Diagnosis of the a ntilock brak e system is done in
six basic steps:
verification of complaint
verificat ion of any r elated symptoms
symptom analysis
problem isolation
repair of isolated problem
verification of proper operation
2 . 0 I D EN T I F I C AT I ON OFSYSTEM
Vehicles equipped with the Teves Mark 20i an-
ti lock brake system can be identified by the pres-ence of t he hydraulic contr ol unit (HCU) located
un der t he h ood nea r t he power bra ke booster. Vehi-
cles equipped with Axle Lock can be identified by
the presence of the Axle Lock Switch located on the
lower center of the instrument panel.
3 . 0 SYST EM D ESCR I PT I ON A N DFUNCTIONAL OPERATION
3.1 TEVES MARK 20I SYSTEM
DESCRIPTION
An electronic control module is used to monitor
wheel speeds and to modulate (control) hydraulic
p r e s s u r e i n e a c h b r a k e c h a n n e l t o p r e v e n t w h e e l
lock-up during braking.
During a non-ABS stop, the system functions a s a
standar d front/rear split configuration. The pri-
mary hydraulic system supplies brake fluid pres-
sure to th e front brakes, and the secondary h ydrau-
lic system supplies the rear brakes. A conventional
combination/proportioning valve is used.
D u r i n g a n A B S s t o p , t h e s y s t e m s t i l l u s e s t h e
front/rear hydraulic split; however, the brakes sys-
t e m p r e ss u r e i s f u r t h e r s p li t i n t o t h r e e con t r o l
chan nels. During ABS operation, the front wheels
are controlled independently an d are on two sepa-
r a t e con t r o l c h a n n e ls . T h e r e a r w h ee ls a r e con -
trolled together thr ough one control chann el. By
u s in g a s e pa r a t e con t r o l c h a n n e l f or e a ch fr on t
wheel, m ore steering control is maintained during
maximum braking.
Du rin g an an tilock stop, wh eel lock-up d oes not
n e ce s sa r i ly m e a n t h a t t h e w h e el h a s l ock e d, i t
m e a n s o n ly t h a t t h e w h e el i s t u r n i n g s low er t h a n
th e veh icle speed. This is called wheel s lip an d isindicated as a percentage. 0% slip means that the
wheel is r olling free an d 100% slip means tha t the
wheel is locked. The antilock system maintains an
average of approximately 20% wh eel slip.
I t i s i m p or t a n t t o r e m e m be r t h a t t h e a n t i lock
brake system does not shorten the vehicle stopping
distance under all driving conditions, but provides
improved control of the vehicle while stopping.
Vehicle stopping distance is still dependent on ve-
hicle speed, weight, t ires, road surface, and other
factors.
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3. 1.1 PEDAL FEEL/VEHICLE
CHARACTERISTICS
There are several pedal feel/vehicle characteris-
tics th at ar e considered norma l for a ntilock braking
that may require further explanation.
When stopping conditions activate the ant ilock
b r a ke s, t h e d r iv er m a y fe el s om e vib r a t ion s /
p u l s a t i o n s i n t h e b r a k e p e d a l a n d m a y h e a r t h esolenoid valves clicking a nd the pump motor run -
ning. The vibrations/pulsations are caused by the
isolating, building an d d ecaying of brake fluid pr es-
s u r e w it h in t h e b r a ke lin e s. T h e A BS p r ev en t s
complete wheel lock-up, but some wheel slip is
required for t he best brak ing performa nce. This slip
may result in some tire chirping, depending on the
r oa d s u r fa ce . T h is ch i r p in g s h ou l d n ot b e i n t er -
preted as total wheel lock-up. Total wheel lock-up
leaves black tire marks on dry pavement. Antilock
braking may leave some light m arks.
At the end of an ABS stop, the ABS system may
not function below 5 Km /h (3 mph). There ma y be aslight brake pedal drop anytime the ABS is deacti-
vated.
In case of braking on a bumpy sur face, th e ABS
module may detect wheel locking t endencies du e to
wheel hop and cycle ABS. In that event the brake
pedal may pulsate with a perceived loss of deceler-
ation. ABS braking ma y also be activated at t imes
while on dry pavement with san d, gravel, or other
loose debris on the road.
It should be noted that the pulsating pedal feel
chara cteristic will not illum inate t he bra ke warn ing
indicators or set a diagnostic trouble code that is
stored in the Controller Antilock Brake (CAB).
When investigating a hard pedal feel, inspect the
sensor and tone wheel teeth for chips/broken teeth,
damaged sensor pole t ips, excessive ru nout of th e
tone wheel, or excessive gap.
3. 1.2 SYSTEM COMPONENTS
A n t i l o c k B r a k e S y s t e m
controller antilock brake (CAB)
vacuum booster
mast er cylinder (w/center valves)
hydraulic control unit (HCU)valve block a ssembly: 6 valve solenoids (3 inlet
valves, 3 outlet valves), 3
accumulators
pum p/motor a ssembly: 1 motor
2 p u m p s
G (acceleration) switch
1 proportioning valve
4 wheel speed sensor/tone wheel assemblies
ABS warning indicator
fuses and wiring harness
fluid reservoir (integral part of master cylinder
assembly)
3. 1.3 ABS AND BRAKE WARNING
INDICATORS
The amber ABS warning indicator is located in
t h e i n st r u m e n t cl u st e r. I t i s u s e d t o i n for m t h edriver tha t th e ant ilock function h as been tu rn ed off
d u e t o a s ys t e m m a l fu n c t ion . O n a T J m od e l t h e
warning indicator is controlled by the CAB and the
ABS relay. The CAB controls the indicator by di-
rectly groun ding t he ABS relay contr ol circuit. The
ABS relay grounds the indicator circuit when it is
de-energized.
The red brake warning indicator is located in the
instrument cluster. I t can be activated by applica-
tion of the parking brake, low brake fluid level or by
turn ing the ignition switch to th e sta rt position.
3. 1. 4 CONTROLLER ANTILOCK BRAKE(CAB)
T he con t r oller a n t ilock b ra k e (C AB ) is a
microprocessor-based device tha t monitors wheel
speeds and controls the antilock functions.
The primary functions of the CAB are:
monitor wheel speeds
detect wheel locking tendencies
control fluid pressure modulation to the brakes
during antilock stop operation
monitor the system for proper operation
provide communication to the DRBIII while in
diagnostic mode
contr ol t he ABS relay
store diagnostic information in non-volatile mem-
or y
The CAB continuously monitors the speed of each
wheel. When a wheel locking tendency is detected,
th e CAB will comma nd t he app ropriate valve in t he
H C U t o m od u la t e b r a ke flu id p r es su r e t o t h a t
wheel. Brake pedal position is maintained during
an antilock stop by being a closed system with the
use of three accumulators. The CAB continues to
contr ol pressure in individual hydraulic circuitsun til a wheel locking t endency is no longer pr esent.
T h e C A B t u r n s o n t h e p u m p / m o t o r d u r i n g a n a n -
tilock stop.
The a ntilock brake system is constan tly moni-
tored by the CAB for proper operation. If the CAB
d e t ect s a s ys t e m m a l fu n c t ion , i t ca n d is a b le t h e
a n t ilock s ys t em a n d t u r n on t h e A BS w a r n in g
indicator. If t he ant ilock function is disabled, the
system will revert to standard base brake system
operation.
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The CAB inpu ts include th e following:
four wheel speed sensors
brake lamp switch
ignition switch
battery voltage
diagnostic communication
G switch (acceleration switch)
The CAB outputs include the following:
six valve/solenoid drivers
pump/motor actuation
ABS warning indicator control
diagnostic communication
3.1. 5 HYDRAULIC CONTROL UNIT
The hydraulic control un it (HCU) conta ins t he
valve block assembly, three accumulators, and the
pump/motor assembly.
Va l v e B l o c k A s s e m b l y : The valve block assem-
bly contains 6 valves with three inlet valves andt h r e e ou t l et v a lv es . T h e i n le t v a lv es a r e s p r in g -
loaded in t he open position a nd t he outlet valves are
s p r in g l oa d e d i n t h e cl os e d p os it i on . D u r in g a n
antilock stop, these valves are cycled to maintain
the proper slip ratio for each channel. If a wheel
locks, the inlet valve is closed to prevent any further
pressure increase. Then the outlet valve is opened
t o r e l e a s e t h e p r e s s u r e t o t h e a c c u m u l a t o r s u n t i l
the wheel is no longer slipping. Once the wheel is no
longer slipping, the outlet valve is closed and the
i n le t v a lv e i s op e n ed t o r e a p pl y p r e s s u r e. I f t h e
wheel is decelerating within its predetermined lim-
its (proper slip ratio), both valves will close to hold
the pressure constant.
P u m p / M o t o r A s s e m b l y : T h e p u m p /m ot or a s -
sembly pr ovides t he extra amount of fluid needed
durin g ant ilock br aking. The pu mp is su pplied fluid
tha t is released to th e accum ulators when t he outlet
valve is opened during an antilock stop. The pump
is also used to drain the accumulator circuits after
the ant ilock st op is complete. The pu mp is operat ed
by a n integral electric motor. This motor is con-
trolled by the CAB. The CAB turns on the motor
when an antilock stop is detected. The pump con-
tinues to run during the an tilock stop and is tu rnedoff a p p r ox im a t e ly 3 -5 s e con d s a ft e r t h e s t op i s
com p le t e. T h e p u m p m e ch a n i s m con s is t s of t w o
opposing pistons operat ed by a n eccentr ic cam . One
piston supplies the primary hydraulic circuit . The
opposing piston supplies the secondary hydraulic
circuit . In operation, one piston draws fluid from
the accum ulators. Th e opposing piston pum ps fluid
to the valve body solenoids. The CAB monitors the
pump/motor opera tion.
A c c u m u l a t o r s : The accumulators provide tem-
porary fluid storage during a n a ntilock stop an d ar e
drained by the pump/motor.
3.1.6 RELAYS/SWITCHES
R e l a y s : The ABS Relay is located in the power
distribution center (PDC). When the relay is de-
energized, it supplies a ground to turn on the ABS
warning indicator. The ABS relay is controlled byt h e C AB . T h e C AB e n er g iz es t h e r e la y w h e n i t
receives an ignition input signal.
3.1. 7 SENSORS
Wh e e l S p e e d S e n s o r s a n d To n e Wh e e l s : On e
wheel speed sensor (WSS is located at each wheel
a n d s en d s a s m a ll AC s ign a l t o t h e C on t r olle r
Antilock Brake (CAB). This voltage is generated by
m a g n et i c i n d u ct i on w h e n a t oot h e d s e n sor r i n g
(tone wheel) passes by a st at iona ry m agnetic sensor
(wheel speed sensor). The CAB converts the AC
signals into digital signals for each wheel.The front wheel sensor is atta ched t o a boss in th e
steering knu ckle. The tone wheel is an integral par t
of t h e fr on t a x le s h a ft . T h e r e a r s p ee d s e n sor i s
mounted in t he caliper ada pter plat e (rear disc only)
a n d t h e r e a r t o n e w h e e l i s a n i n t e g r a l p a r t o f t h e
rear rotor h ub. The front wheel speed sensor air gap
is NOT adjustable. The correct front wheel speed
sensor air gap is from 0.40mm to 1.3mm (0.016 t o
0.051). P r e fe r r ed r e a r s e n sor a i r g a p f or d r u m
brak e systems is 1.1mm (0.043). Acceptable a ir ga p
range is 0.92mm to 1.275mm (0.036 to 0.050). All
wheel speed sensors have a resistance between 900
and 1300 ohms.Correct ant ilock system operation is dependent
on correct wheel speed signals from the wheel speed
sens ors. The vehicles wheels a nd t ires sh ould all be
the sa me size an d type. In addition, the tires should
be inflated to the recommended pressures for opti-
mum system operation. Varia tions in wh eel and tire
size or significant variations in inflation pressure
can produce inaccurate wheel speed signals; how-
ever, the system will continue to function when
using the mini-spare. When driven over rough road
surfaces, the rear wheel speed sensor signals may
be erratic and cause a false trouble code.
G ( A c c e l e r a t i o n ) S w i t c h : The CAB monitorst h e a cce le r a t ion s w it ch a t a l l t i m es . T h e s w it ch
a s s em b ly con t a i n s t h r e e m e r cu r y s w it ch e s t h a t
monitor vehicle deceleration rat es (G-force). Sud-
den, rapid changes in vehicle and wheel decelera-
tion rate trigger t he switch, sending a signal t o the
CAB. The switch a ssembly responds to t hree decel-
eration rates; two for forward braking and one for
rearward braking.
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3. 2 DIAGNOSTIC TROUBLE CODES
The Teves Mar k 20i Ant ilock Bra ke Syst em (ABS)
module may report any of the following diagnostic
trouble codes:
Controller Failure
G Switch Not Processable
Left Front Sensor Circuit Failure Left Front Sensor Signal Failure
Left Rear Sensor Circuit Failure
Left Rear Sensor Signal Failure
CAB Power Feed Circuit
System Over voltage
System Under voltage
Pump Motor Not Working Properly
Right Front Sensor Circuit Failure
Right Front Sensor Signal Failure
Right Rear Sensor Circuit Failure
Right Rear Sensor Signal Failure
Diagnostic trouble codes are retained in memory
u n t i l e r a s e d u s i n g t h e D R B I I I, or aut omatically
erased after 255 key cycles.
3.2.1 SYSTEM INITIALIZATION
S ys t em in it ia liza t ion s t a r t s w h en t h e k ey is
turned to RUN. At this point, the CAB performs a
complete self-check of all electrical components in
the antilock brake systems.
At around 19 km/h (12 miles per hour), the pump
motor is briefly activated to ensure operation, and
wheel speed sensor circuitry is checked. If the brakepedal is applied when the vehicle reaches 19 km/h
(12 mph), this check will be delayed until 40 km/h
( 2 5 m p h ) . I f , d u r i n g t h e d y n a m i c t e s t , t h e b r a k e
p ed a l is a p pl ie d, t h e d r iv er m a y fe el t h e t e st
t h r o u gh b r a k e p e d a l p u l s a t ion s . T h i s i s a n or m a l
condition. Throughout the remainder of the drive
cycle, ongoing tests are performed, and the CAB
monitors ABS circuits for continuity.
If any component causes a diagnostic trouble code
during system initialization or dynamic check, the
CAB will illuminate the ABS warning indicator.
3.2.2 DIAGNOSTIC MODETo enter diagnostic mode, vehicle speed must be
below 10 km/h (6 m ph), a no response message
will be displayed by the DRBIII. The following a re
chara cteristics of diagnostic m ode:
The ABS warning indicator will f lash. If a hard
d ia g n os t ic t r ou b le cod e i s p r e se n t , s u ch a s a
Speed Sensor Circuit or Signal Failure t rouble
code or CAB P ower Feed Circuit diagnostic trou-
ble code, the indicator will be illuminated without
blinking and limited diagnostic operations only
will be a vailable u nt il the diagnostic tr ouble code
condition is corrected.
Antilock operation is disabled.
3. 2.3 INTERMITTENT DIAGNOSTIC
TROUBLE CODES
If the malfunction is not present while perform-ing a test procedure, the diagnostic procedures will
not locate the problem. In this case, the code can
on ly s u gge st a n a r e a t o i n sp ect . C h eck for t h e
following:
loose or corr oded connections
dam aged components (sensors, tone wheels espe-
cially)
damaged wiring
excessive axle shaft runout
brake system hydraulic leaks
base brake system problems, non-ABS related.If no obvious p roblems ar e foun d, era se diagn ostic
trouble codes and, with the key on, wiggle the wire
ha rness an d connectors. Recheck for codes per iodi-
cally a s you work thr ough the system. This proce-
d u r e m a y u n c ov er a n i n t er m i t t en t or d iffi cu l t t o
locate malfunction.
3.3 AXLE LOCK
3.3.1 GENERAL
For this vehicle, the Axle Lock has no dedicated
module controller. A manual switch located on theinstrument panel controls th e system. No DTCs
will occur for this system.
3.3.2 DESCRIPTION
The a xle lock h as the ability to lock the front and
rear axle differentials. The system components are
the instrument cluster, axle lock switch, front and
rear locker relays, front a nd r ear locker pu mps, an d
locker ind icat or switches. To operat e both lockers
three requirements need to be met:
1. ignition in t he ON position
2. tran sfer case ran ge sensor indicating 4 LOWr a n g e
3. vehicle speed less tha n 16km/h (10 mph)
The 16km/h (10 mph) engagement is for engage-
ment only. All axles will r emain locked if vehicle
speed does not exceed 72 km/h (45 mph).
The instrument cluster has the control logic that
monitors these requirements. If the requirements
are not met the axle lock switch will be disabled.
The axle lock switch receives the enable signals
from the instrument cluster. Any subsequent down-
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ward press of the axle lock switch will operate the
front locker relay and front locker pump. The first
downward press on the axle lock switch locks the
r e a r a x le , t h e s e con d d ow n w a r d p r e ss l ock s t h e
front axle (rear is still locked), th e th ird downward
press unlocks the front axle (rear is still locked), the
fourth downward press locks the front axle (rear
axle is st i l l locked). An upward press on the axle
lock switch at any time will unlock any axle that iscur rent ly locked.
The enabled axle lock switch energizes the locker
r e la y a n d v ol t a ge i s s e n t t o t h e l ock e r p u m p t o
supply 5 psi of air t o the a xle allowing th e differen-
tial to lock up. The axle lock indicator on the
i n st r u m e n t cl u st e r fl a sh e s d u r i n g t h e t r a n s i t ion
state. The instrument cluster is seeking lock feed-
b a ck fr om t h e l ock i n g i n di ca t or s w it ch . Wi t h a
successful lock requ est th e axle lock indicator will
be illuminated and a chime will sound.
If an a xle is engaged t he a xle lock switch r emains
enabled until all axles are unlocked, regardless if
the key is removed from the ignition switch. If theignition key is removed and either axle is locked the
instrument cluster axle lock indicator to the cor-
responding axle will flash and the chime will sound
three t imes to alert of battery discharge. Flashing
axle lock indicators will continue until axles are
unlocked. Once the axles have been locked it will
remain locked until one of the following happens:
1. an upward press of the axle lock switch for all
locked axles or downward press for front axle
only
2. tra nsfer case is shifted out of 4 LOW ran ge
3. vehicle speed exceeds 72 km/h (45 mph)
4. loss of batt ery power
3.4 USING THE DRBIII
Refer t o the DRBIII user s guide for ins tr uctions
a n d a s s is t a n ce w it h r e a d in g d ia g n os t ic t r ou b le
codes, erasing trouble codes and other DRBIII
functions.
3.5 DRBIII ERROR MESSAGES
Under normal operation, the DRBIII will dis-
play one of only two error messages:
U s e r R eq u es t e d WAR M B oot or U s e r R e-
quested COLD Boot
This is a sa mple of such an error messa ge display:
ver: 2.14date: 26 J ul93file: key_itf.ccdate: Jul 26 1993line: 548err: 0x1User-Requested COLD Boot
Press MORE to switch between this displayand the application screen.Press F4 when done noting information.
3.5.1 DRBIII DOES NOT POWER UP
(BLANK SCREEN)
If the LE Ds do not light or no soun d is emitt ed at
star t up, check for loose cable conn ections or a bad
cable. Check the vehicle battery voltage (data link
16-way conn ector cavity 16). A min imum of 11 volts
is required to adequately power the DRBIII. Also,
check for a good ground at the DLC.
I f a ll con n ect ion s a r e p r op er b et we en t h eDRBIII and the vehicle or other devices, and the
vehicle bat tery is fully charged, an d inoperative
DRBIII may be the result of faulty cable or vehicle
wiring.
3.5. 2 DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition.
4.0 DISCLAIMERS, SAFETYWARNINGS
4.1 DISCLAIMERS
All information, illustrations, and specifications
c o n t a i n e d i n t h i s m a n u a l a r e b a s e d o n t h e l a t e s t
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informat ion available at the t ime of publication.
The right is reserved to make changes at any t ime
without notice.
4.2 SAFETY
4. 2. 1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBONMONOXIDE THAT IS ODORLESS, CAUSESSLOWER REACTION TIME, AND CAN LEADTO SERIOUS INJURY. WHEN THE ENGINE ISOPERATING, KEEP SERVICE AREAS WELLVENTILATED OR ATTACH THE VEHICLEEXHAUST SYSTEM TO THE SHOP EXHAUSTREMOVAL SYSTEM.
Set th e park ing brake a nd block the wheels before
t e s t in g or r e p a ir i n g t h e v eh i cl e. I t i s e sp e ci a ll y
important to block the wheels on front-wheel drive
vehicles; the parking brake does not hold the drivewheels.
When servicing a vehicle always wear eye protec-
tion and remove any metal jewelry such as watch-
bands or bracelets th at m ight make a n inadvertent
electrical contact.
Additional safety procedures can be found in the
service ma nu al. Following th ese procedures is very
important to avoid injury.
4. 2. 2 VEHICLE PREPARATION FOR
TESTING
M a k e s u r e t h e v e h i c l e b e i n g t e s t e d h a s a f u l l ych a r g ed b a t t e r y. I f i s d oe s n ot , fa l se d ia g n os t ic
trouble codes or error messages may occur.
4. 2.3 SERVICING SUB-ASSEMBLIES
Some components of the antilock brake system
are intended to be serviced in assembly only. At-
tempting to remove or repair certain system sub-
components may result in personal injury and/or
improper system opera tion. On ly those component s
with appr oved repair a nd inst allation pr ocedures in
the service manual should be serviced.
4.2.4 DRBIII SAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THEDRBIII MULTIMETER IS DANGEROUS. ITCAN EXPOSE YOU TO SERIOUS ORPOSSIBLY FATAL INJURY. CAREFULLYREAD AND UNDERSTAND THE CAUTIONSAND THE SPECIFICATION LIMITS.
Follow t he vehicle m an ufacturer s service speci-
fications at all times.
Do not use th e DRBIII if i t ha s been dam aged.
D o n ot u s e t h e t e st le a ds if t h e in s u la t ion is
damaged or if metal is exposed.
To a void electrical shock, do n ot touch the test
leads, tips or the circuit being tested.
C h oos e t h e p r op e r r a n g e a n d fu n c t ion for t h e
measurement. Do not try voltage or current mea-
surements that may exceed the rated capacity. Do not exceed the limits shown in the table below:
F U N CTION IN P U T LIMIT
Volt s 0 - 500 pea k volt s AC
0 - 500 volts DC
O h m s (r e si st a n ce )* 0 - 1 .1 2 m e goh m s
Frequency Measured
Frequency Generated
0 - 1 0 k H z
Tem per a t u r e -50 - 600C
-58 - 1100F
* Ohms cannot be measured if voltage is present.O h m s ca n b e m e a su r e d on l y i n a n on -p ow er e d
circuit.
Voltage between any terminal and ground must
not exceed 500v DC or 500v peak AC.
Use caution when measuring voltage above 25v
DC or 25v AC.
Use the low current shunt to measure circuits up
to 10A. Use the high current clamp to measure
circuits exceeding 10A.
When testing for the presence of voltage or cur-
r e n t , m a k e s u r e t h e m e t e r i s f u n ct i on i n g c or -
r e ct l y. Ta k e a r e a d in g of a k n ow n v ol t a ge orcurrent before accepting a zero reading.
When measuring current, connect the meter in
series with the load.
Disconnect the live test lead before disconnecting
the common test lead.
Wh en u sin g t h e m et er fu n ct ion , k eep t h e
DRBIII away from spark plug or coil wires to
avoid m easur ing error from outside inter ference.
4.3 WARNING
4. 3.1 VEHICLE DAMAGE WARNINGS
Before disconnecting any control module, make
s u r e t h e i gn i t ion i s O F F . F a i l u r e t o d o s o c ou l d
damage t he m odule.
When t esting voltage or continu ity at an y control
module, use the terminal side (not the wire end) of
the connector. Do not pierce wire insulation; this
will damage i t and eventually cause i t to fail be-
cause of corrosion.
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Be careful when performing electrical tests so as
to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a
second code could be set, making diagnosis of the
original problem more difficult.
4.3. 2 ROAD TESTING A COMPLAINT
VEHICLE
Some complaints will require a test drive as part
of th e r epair verificat ion procedure. The purp ose of
the test drive is to try to duplicate the diagnostic
code or symptom condition.
NOTE: After the repair of pump or speedsignal DTCs, the vehicle must be driven at 25km/h (15 mph) to clear the DTC from the CAB.
WARNING: BEFORE ROAD TESTING AVEHICLE, BE SURE THAT ALLCOMPONENTS ARE REASSEMBLED.
DURING THE TEST DRIVE, DO NOT TRY TOREAD THE DRBIII SCREEN WHILE INMOTION. DO NOT HANG THE DRB FROMTHE REAR VIEW MIRROR OR OPERATE ITYOURSELF. HAVE AN ASSISTANTAVAILABLE TO OPERATE THE DRBIII.
4.4 DIAGNOSIS
1. Your diagnostic test pr ocedure mu st begin with a
thorough visual inspection of the ABS for dam-
aged components or disconnected connectors.
T h e b r a k e l a m p s m u s t b e o p e r a t i o n a l p r i o r t ocontinuing.
2. Connect the DRBIII to the data link connector
located under the dash. If the DRBIII does not
power up, check the power and ground supplies
to t he conn ector.
3. Select Ant ilock Br ak es. Tur n t he ign ition on. If
t h e D RB I II disp lays No Resp onse, per form
the proper test .
4 . R ea d a n d r e cor d a l l A BS d ia g n os t ic t r ou b le
codes. If t he CAB P ower Feed Circuit tr ouble
cod e i s p r e se n t , i t m u s t b e r e p a i r ed p r ior t o
addressing any other DTCs. If any additionalcod e s a r e p r e se n t , p r oce ed t o t h e a p p r op r ia t e
test.
5. If there ar e no diagnostic trouble codes present,
s e le ct I n p u t s /O u t p u t s a n d r e a d t h e b r a k e
switch input a s you press and release th e brake
pedal. If the display does not m atch t he st ate of
the pedal, perform the appr opriat e test. Read th e
G-Switch stat us, with the vehicle on a level
su rfa ce, both swit ches sh ould r ead CLOSE D. If
the st atu s is not correct, perform t he appr opriate
test. If a problem with the ABS warning indica-
tor exists, refer to th e a ppropriate t est .
6. If no other problem are found, i t will be neces-
s a r y t o r o a d t e s t t h e v eh i cl e. T H E D R B I II
MU ST N OT B E CON NE CTE D TO TH E
D ATA L IN K C ON N E C T OR WH E N R O AD
T E S TI N G F O R P R O P E R A N TI LO CK O P -
E R AT IO N . T HE S YS T E M I S D I S AB L E D
WH I LE I N D I AG N OS T I C M OD E . Performseveral antilock stops from above 50 Km/h (30
m p h ) a n d t h e n r e p e a t s t e p s 2 , 3 , a n d 4 . I f a n y
diagnostic trouble codes are present, proceed to
the appropriate test .
7. The following conditions should be considered
NORMAL operat ion, a nd no r epair s sh ould be
attempted to correct them.
B r a ke p ed a l fe ed ba ck d u r in g a n AB S s t op
(clicking, vibrat ing)
Clicking, groaning or buzzing at 10 Km/h (6
mph) (drive off self test)
Groaning noise during a n ABS stop
S li gh t b r a k e p e d a l d r op a n d p op n oi se w h e n
ignition is initially turned on
Brake pedal ratcheting down at the end of an
ABS stop
8. If the complaint is ABS cycling at t he end of a
s t op a t low s pe ed s, it m a y b e c a us ed b y a
marginal wheel speed sensor signal. The sensor
a i r g a p , t on e w h e el con d it i on , a n d /or b r a k e s
ha nging up ar e possible cau ses of this condition.
9 . A ft e r a r oa d t e s t i n w h i ch n o p r o bl em s w er e
found, refer to any Technical Service Bulletinsthat may a pply.
5 . 0 R EQU I RED T OOL S A N DEQUIPMENT
DRBIII (diagnostic read-out box)
jumper wires
ohmmeter
voltmetertest lamp
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7 .0
DIAGNOSTI C I NFORM ATI ON AND
PROCEDURES
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S y m p t o m :
CAB POWER FEED CIRCUIT
W h e n M o n i t o r e d a n d S e t C o n d i t i o n :
CAB POWER FEED CIRCUIT
When Monitored: Ignition on. The CAB monitors t he F used B(+) circuit a t all times for
proper system voltage.
Set Condition: If the F used B(+) voltage is missing when the CAB detects th at a n intern al
main driver is not on, the Diagnostic Trouble Code (DTC) is set.
P O S S I B L E C A U S E S
INTERMITTENT DTC
B(+) CIRCUIT SHORTED TO GROUND
BLOWN FUSE - FUSED B(+) CIRCUIT
CAB - FUSED B(+) CIRCUIT SHORTED TO GROUND
FUSED B(+) CIRCUIT OPEN
NO B+ SUP PLY TO FUSE
CAB - FUSED B(+) CIRCUIT OPEN
TES T ACTION AP P LICAB ILITY
1 Tu r n t h e ign it ion on .
With the DRBIII, era se DTCs.Turn the ignition off.
Turn the ignition on.
Drive the vehicle above 25 km/h (15 mph) for at least 10 seconds.
Stop th e vehicle.
With the DRBIII, read DTCs.
Does the DRBIII display CAB Power Feed Circuit DTC present right now?
All
Yes G o To 2
N o Go To 9
2 Tu r n t h e ig ni t ion off.
Rem ove and Ins pect F us e 12 in the P D C.
Is the F us e blow n?
All
Yes G o To 3
N o Go To 6
10
BRAKES (CAB)
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TES T ACTION AP P LICAB ILITY
3 Tu r n t h e ig ni t ion off.
Remove Fuse 12 from the PDC.
Disconnect the CAB h arn ess connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .Using a test light connected to 12 volts, probe the Fused B(+) Circuit.
Does the test light illuminate brightly?
All
Yes Repair the Fused B(+) Circuit Shorted to Ground.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 4
4 Tu r n t h e ig ni t ion off.
Remove Fuse 12 from the PDC.
The CAB must be connected for the results of this test to be valid.
Using a test light connected to 12 volts, probe the Fused B+ circuit at the PDC fuse
term inal.
Does the test light illuminate brightly?
All
Yes Replace t he Controller Antilock Bra ke in accordance w ith the
Service Informa tion.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 5
5 Tu r n t h e i gn it i on off.
If there are no potential caus es rem aining, view repair .
All
Continue
Replace the Fuse.
Perform ABS VERIFICATION TEST - VER 1.
6 Tu r n t h e i gn it i on off.
Remove Fuse 12 from the PDC.
Disconnect the CAB h arn ess connector.N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
M eas ure the res istance of the F us ed B+ circuit betw een the P D C fus e term inal and
the CAB connector.
Is the resistance below 5 ohms?
All
Yes G o To 7
N o Repair the Fused B+ circuit for an open.
Perform ABS VERIFICATION TEST - VER 1.
7 R em ov e F u s e 1 2 fr om t h e P DC .
Turn the ignition on.
M eas ure the voltage of the F us ed B+ s upply to F us e 12 in the P D C.
Is the voltage above 10 volts?
All
Yes G o To 8
N o Repair the B+ Supply circuit for an open.
Perform ABS VERIFICATION TEST - VER 1.
8 If t h er e a r e n o pot en t ia l ca u ses r em a in in g, view r epa ir. All
Repair
Replace t he Controller Antilock Brak e in accordance w ith the
Service Informa tion.
Perform ABS VERIFICATION TE ST - VER 1.
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CAB POWER FEED CIRCUIT C o n t i n u e d
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TES T ACTION AP P LICAB ILITY
9 Tu r n t h e ig ni t ion off.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect th e r elated wire har ness connectors. Look for broken, bent, pu shedout, or corroded t ermina ls.
Refer to any Hotline letters or Technical Service Bulletins that may apply.
Were a ny pr oblems found?
All
Yes Repair as necessary.
Perform ABS VERIFICATION TE ST - VER 1.
N o Test Complete.
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BRAKES (CAB)
CAB POWER FEED CIRCUIT C o n t i n u e d
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S y m p t o m :
CONTROLLER FAILURE
W h e n M o n i t o r e d a n d S e t C o n d i t i o n :
CONTROLLER FAILURE
When Monitored: Ignition on. The CAB monitors its int ern al microprocessors for correct
operation.
Set Condition: If the CAB detects a n interna l fault , the DTC is set .
P O S S I B L E C A U S E S
GROUND AND POWER CONNECTIONS
GROUND CIRCUIT HIGH RESISTANCE
GROUND CIRCUIT INTERFE RENCE
CAB - INTE RNAL FAILURE
TES T ACTION AP P LICAB ILITY
1 Inspect for non-factory wiring tha t may interfere with CAB power or ground circuits.
Disconnect the CAB h arn ess connector.
Inspect the CAB wiring harness for incorrect routing and damage.
Inspect the CAB harness and component connectors for corrosion and damage.
Were an y concerns found?
All
Yes Repair as necessary.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 2
2 Tu r n t h e ig ni t ion off.
Disconnect the CAB h arn ess connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Measure the resistance of the CAB ground circuits to body ground.
Is the resistance below 1.0 ohm?
All
Yes G o To 3
N o Repair the Ground circuit high resistance.
Perform ABS VERIFICATION TEST - VER 1.
3 Tu r n t h e i gn it i on off.
Disconnect the CAB h arn ess connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Turn the ignition on.
Turn on a ll accessories.
Measure the voltage of the Ground circuit.
Is the voltage below 1.0 volts?
All
Yes G o To 4
N o Repair as necessary. Unsplice any accessories connected to t he
CAB ground circuit. Reroute and shield any high voltage cables
away from the CAB ground circuit.
Perform ABS VERIFICATION TEST - VER 1.
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TES T ACTION AP P LICAB ILITY
4 If t h er e a r e n o possible ca u ses r em a in in g, view r epa ir. All
Repair
Replace the CAB.
Perform ABS VERIFICATION TEST - VER 1.
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BRAKES (CAB)
CONTROLLER FAILURE C o n t i n u e d
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S y m p t o m :
G-SWITCH NOT PROCESSABLE
W h e n M o n i t o r e d a n d S e t C o n d i t i o n :
G-SWITCH NOT PR OCESSABLE
When M onitored: Ignition on. The CAB sends a test signal out to the G-switch and
monitors the sense circuits #1 and #2.
Set Condition: If the sense circuits ar e open for 2 minu tes while driving or a n otherwise
improper signal is detected a t any time, th e Diagnostic Trouble Code (DTC) is set.
P O S S I B L E C A U S E S
G-SWITCH TEST SIGNAL CIRCUIT OPEN
INTERMITTENT DTC
G-SWITCH TEST SIGNAL OR SENSE CIRCUIT SHORT TO VOLTAGE OR GROUND
G-SWITCH SIGNAL CIRCUIT INTERNAL OPEN
CAB - TEST SIGNAL CIRCUIT OPEN
G-SWITCH #1 SENSE CIRCUIT OPE N
G-SWITCH #1 SENSE SWITCH OPEN
CAB - #1 SENSE CIRCUIT OPEN
G-SWITCH #2 SENSE CIRCUIT OPE N
G-SWITCH #2 SENSE SWITCH OPEN
CAB - #2 SENSE CIRCUIT OPEN
TES T ACTION AP P LICAB ILITY
1 Tu r n t h e ign it ion on .
With the DRBIII, read the s tatus of the G -S w itch interna l s w itches .
What is the status of both of the G-Switches?
All
Both G-Switches are closed.
G o To 2
Both G-Switches are open.
G o To 3
Only the #1 G-Switch is open.
G o To 7
Only the #2 G-Switch is open.
G o To 1 0
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TES T ACTION AP P LICAB ILITY
2 Tu r n t h e ig ni t ion off.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect th e r elated wire har ness connectors. Look for broken, bent, pu shedout, or corroded t ermina ls.
Refer to any Hotline letters or Technical Service Bulletins that may apply.
Were a ny pr oblems found?
All
Yes Repair as necessary.
Perform ABS VERIFICATION TE ST - VER 1.
N o Test Complete.
3 Tu r n t h e ig ni t ion off.
Disconnect the CAB connector.
C h e c k c o n n e c t o r - C l e a n /r e p a i r a s n e c e s s a r y .
Disconnect the G-Switch Sensor Connector.
N O TE : C h e c k c o n n e c t o r - C l e a n / re p a i r a s n e c e s s a r y.
Measure the resistance of the G-Switch Test Signal circuit.Is the resistance below 5 ohms?
All
Yes G o To 4
N o Repair the G-Switch Test Signal Circuit Open.
Perform ABS VERIFICATION TEST - VER 1.
4 Tu r n t h e i gn it i on off.
Disconnect the CAB Connector.
C h e c k c o n n e c t o r - C l e a n /r e p a i r a s n e c e s s a r y .
Disconnect the G-Switch Sensor Connector.
C h e c k c o n n e c t o r - C l e a n /r e p a i r a s n e c e s s a r y .
Turn the ignition on.
Using a 12-volt t est light connected t o ground, check th e Test Signa l an d both Sen se
circuits.Using a 12-volt test light connected to 12-volts, check the Test Signal and both Sense
circuits.
C AU T IO N : T h e t e s t l i g h t s h o u l d n o t l i g h t a t a n y t e s t p o i n t .
D oes the tes t l ight i l lum inate at any t es t point?
All
Yes Repair the G -S w itch Tes t S ignal or S ens e circuit for a s hort to
voltage or ground.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 5
5 Tu r n t h e i gn it i on off.
Disconnect the G-Switch Connector.
C h e c k c o n n e c t o r - C l e a n /r e p a i r a s n e c e s s a r y .
Remove G-Switch from vehicle.While holding the G-Switch level, measure the resistance of the G-Switch Test Signal
circuit a nd the G-Switch #1 Sense circuit in th e G-Switch connector.
Is the resistance below 5 ohms?
All
Yes G o To 6
N o Replace G-Switch.
Perform ABS VERIFICATION TEST - VER 1.
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BRAKES (CAB)
G-SWITCH NOT PROCESSABLE C o n t i n u e d
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TES T ACTION AP P LICAB ILITY
6 If t h er e a r e n o pot en t ia l ca u ses r em a in in g, view r epa ir. All
Repair
Replace the CAB.
Perform ABS VERIFICATION TEST - VER 1.
7 Tu r n t h e ig ni t ion off.
Disconnect the CAB Connector.
N o t e : Ch e c k c o n n e c t o r - C l e a n /r e p a i r a s n e c e s s a r y.
Disconnect the G-Switch Sensor Connector.
Measure the resistance of the G-Switch #1 Sense Circuit.
Is the resistance below 5 ohms?
All
Yes G o To 8
N o Repair the G-Switch #1 Sense circuit open.
Perform ABS VERIFICATION TEST - VER 1.
8 Tu r n t h e ig ni t ion off.
C h e c k c o n n e c t o r - C l e a n /r e p a i r a s n e c e s s a r y .Remove G-Switch from vehicle.
While holding the G-Switch level, measure the resistance of the G-Switch Test Signal
circuit a nd the G-Switch #1 Sense circuit in the G-Switch connector.
Is the resistance below 5 ohms?
All
Yes G o To 9
N o Replace G-Switch Assembly.
Perform ABS VERIFICATION TEST - VER 1.
9 If t h er e a r e n o pot en t ia l ca u ses r em a in in g, view r epa ir. All
Repair
Replace t he CAB.
Perform ABS VERIFICATION TEST - VER 1.
1 0 Tu r n t h e i gn it i on off.
Disconnect the CAB Connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Disconnect the G-Switch Connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Measure the resistance of the G-Switch #2 Sense Circuit.
Is the resistance below 5 ohms?
All
Yes G o To 11
N o Repair the G-Switch #2 Sense Circuit Open.
Perform ABS VERIFICATION TEST - VER 1.
11 Tu r n t h e i gn i t ion off.Disconnect the G-Switch connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Remove the G-Switch from vehicle.
While holding the G-Switch level, measure the resistance of the G-Switch Test Signal
circuit a nd the G-Switch #2 Sense circuit in th e G-Switch connector.
Is the resistance below 5 ohms?
All
Yes G o To 1 2
N o Replace the G-Switch Assembly.
Perform ABS VERIFICATION TEST - VER 1.
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BRAKES (CAB)
G-SWITCH NOT PROCESSABLE C o n t i n u e d
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TES T ACTION AP P LICAB ILITY
12 If t h er e a r e n o pot en t ia l ca u ses r em a in in g, view r epa ir. All
Repair
Replace the CAB.
Perform ABS VERIFICATION TEST - VER 1.
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BRAKES (CAB)
G-SWITCH NOT PROCESSABLE C o n t i n u e d
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S y m p t o m L i s t :
LEFT FRONT SENSOR CIRCUIT FAILURE
LEFT REAR SEN SOR CIRCUIT FAILURE
RIGHT FRONT S ENS OR CIRCUIT FAILURE
RIGHT REAR S ENS OR CIRCUIT FAILURE
Te s t N o t e : Al l s y m p t o m s l i s t e d a b o v e a r e d i a g n o s e d u s i n g t h e s a m e te s t s .
The title for the tests will be LEFT FRONT SENSOR CIRCUIT
FAILURE.
W h e n M o n i t o r e d a n d S e t C o n d i t i o n :
LEFT FRONT SENSOR CIRCUIT FAILURE
When M onitored: Ignition on. The CAB m onitors the Wheel Speed Sensor circuits
continuously.
Set Condition: If the CAB detects an open or shorted wheel speed sensor circuit , the
Diagnostic Trouble Code (DTC) will set .
LEFT REAR SENSOR CIRCUIT FAILURE
When M onitored: Ignition on. The CAB m onitors the Wheel Speed Sensor circuits
continuously.
Set Condition: If the CAB detects an open or shorted wheel speed sensor circuit , the
Diagnostic Trouble Code (DTC) will set .
RIGHT FRONT SENSOR CIRCUIT FAILUREWhen M onitored: Ignition on. The CAB m onitors the Wheel Speed Sensor circuits
continuously.
Set Condition: If the CAB detects an open or shorted wheel speed sensor circuit , the
Diagnostic Trouble Code (DTC) will set .
RIGHT REAR SENSOR CIRCUIT FAILURE
When M onitored: Ignition on. The CAB m onitors the Wheel Speed Sensor circuits
continuously.
Set Condition: If the CAB detects an open or shorted Wheel speed sensor circuit , the
Diagnostic Trouble Code (DTC) will set .
P O S S I B L E C A U S E S
SENSOR OR CONNECTOR DAMAGE
INTERMITTENT DTC
WHEEL SPEED SENSOR OPEN OR SHORTED TO GROUND
WHEEL SPEED SENSOR (+) OR (-) CIRCUIT SHORTED TO VOLTAGE
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P O S S I B L E C A U S E S
WHEEL SPEE D SE NSOR (+) OR (-) CIRCUIT SH ORTED TO GROUND
WHEEL SPEED SENSOR CIRCUITS SHORTED TOGETHER
SPEED SENSOR (+) OR (-) CIRCUIT OPEN
CAB - INTERNAL SHORT OR OPEN
TES T ACTION AP P LICAB ILITY
1 Tu r n t h e ign it ion on .
With the DRBIII, read DTCs.
With the DRBIII, era se DTCs.
Turn the ignition off.
Turn the ignition on.
With the DRBIII, read DTCs.
Does the DRBIII display a Wheel Speed Sensor Circuit Failure DTC?
All
Yes G o To 2
N o Go To 9
2 Tu r n t h e ig ni t ion off.
Inspect t he a ffected Wheel Speed Sensor a nd Connector.
Is the Sensor or Connector Damaged?
All
Yes Repair as necessary.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 3
3 Tu r n t h e ig ni t ion off.
Disconnect the affected Wheel Speed Sensor connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
M eas ure the res is tance acros s the W heel S peed S ens or (+) and (-) circuits at theSensor side of the connector.
Measure t he resista nce between ground an d th e (+) and (-) circuits on the Sen sor side
of the connector.
Is the S ens or res istance 900 to 1300 ohm s and res istance to ground m ore tha n 15k
ohms?
All
Yes G o To 4
N o Repair t he short or replace the Wheel Speed Sensor, as n ecessary.
Perform ABS VERIFICATION TEST - VER 1.
4 Tu r n t h e i gn it i on off.
Disconnect the affected Wheel Speed Sensor connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Disconnect the CAB connector.N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Turn the ignition on.
Measure the voltage of the Wheel Speed Sensor (+) and (-) circuits.
Is the voltage above 1 volt at either circuit?
All
Yes Repair the Wheel Speed Sensor circuit for a short to voltage.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 5
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LEFT FRONT SENSOR CIRCUIT FAILURE C o n t i n u e d
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TES T ACTION AP P LICAB ILITY
5 Tu r n t h e ig ni t ion off.
Disconnect the affected Wheel Speed Sen sor Connector.
Disconnect the CAB Connector.
M eas ure the res is tance betw een the W heel S peed S ens or (+) and (-) circuits andground.
Is t he r esistance below 15,000 ohms for either circuit?
All
Yes Repair the Wheel Speed Sensor circuit short to ground.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 6
6 Tu r n t h e ig ni t ion off.
Disconnect the CAB Connector.
Disconnect the affected Wheel Speed Sen sor ha rness connector.
M eas ure th e r es is tance th rough the W heel S peed S ens or (+) and (-) circuits at the
CAB har ness connector.
Is the resistance below 200 ohms?
All
Yes Repair the Wheel Speed Sensor circuits shorted together.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 7
7 Tu r n t h e i gn it i on off.
Disconnect the affected Wheel Speed Sen sor Connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Disconnect the CAB Connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Measure the resistance of the Wheel Speed Sensor (+) and (-) circuits.
Is the resistance below 5 ohms for both circuits?
All
Yes G o To 8
N o Repair t he Wheel Speed Sensor (+) or (-) circuit for an open.Perform ABS VERIFICATION TEST - VER 1.
8 If t h er e a r e n o possible ca u ses r em a in in g, view r epa ir. All
Repair
Replace t he Controller Antilock Brak e in accordance w ith the
Service Informa tion.
Perform ABS VERIFICATION TE ST - VER 1.
9 Tu r n t h e i gn it i on off.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wire harness component and in-line connectors. Look for
broken, bent, pushed out, or corroded terminals.
Refer to any Hotline letters or Technical Service Bulletins that may apply.
Were any problems found?
All
Yes Repair as necessary.
Perform ABS VERIFICATION TE ST - VER 1.
N o Test Complete.
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BRAKES (CAB)
LEFT FRONT SENSOR CIRCUIT FAILURE C o n t i n u e d
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S y m p t o m L i s t :
LEFT FRONT SENSOR SIGNAL FAILURE
LEFT REAR SEN SOR SIGNAL FAILURE
RIGHT FRONT S ENS OR S IGNAL FAILURE
RIGHT REAR S ENS OR S IGNAL FAILURE
Te s t N o t e : Al l s y m p t o m s l i s t e d a b o v e a r e d i a g n o s e d u s i n g t h e s a m e te s t s .
T he t i t l e f o r t he t e s t s w i l l be L E F T F R O N T SE N SO R SI GN A L
FAILURE.
W h e n M o n i t o r e d a n d S e t C o n d i t i o n :
LEFT FRONT SENSOR SIGNAL FAILURE
When M onitored: Wheel speed com parison is checked at drive off a nd continuously
thereafter.
Set Condition: If, during a n ABS stop, the CAB comma nds a ny valve solenoid on for an
extended length of t im e, a nd does not see a corresponding wheel speed change, th e
Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or
erratic.
LEFT REAR SENSOR SIGNAL FAILURE
When M onitored: Wheel speed com parison is checked at drive off a nd continuously
thereafter.
Set Condition: If, during a n ABS stop, the CAB comma nds a ny valve solenoid on for an
extended length of t im e, a nd does not see a corresponding wheel speed change, th eDiagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or
erratic.
RIGHT FRONT SENSOR SIGNAL FAILURE
When M onitored: Wheel speed com parison is checked at drive off a nd continuously
thereafter.
Set Condition: If, during a n ABS stop, the CAB comma nds a ny valve solenoid on for an
extended length of t im e, a nd does not see a corresponding wheel speed change, th e
Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or
erratic.
RIGHT REAR SENSOR SIGNAL FAILURE
When M onitored: Wheel speed com parison is checked at drive off a nd continuously
thereafter.
Set Condition: If, during a n ABS stop, the CAB comma nds a ny valve solenoid on for an
extended length of t im e, a nd does not see a corresponding wheel speed change, th e
Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or
erratic.
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P O S S I B L E C A U S E S
SPEE D SE NSOR OR CONNECTOR DAMAGED
TONE WHEEL DAMAGED
WHEEL SP EED SENSOR AIR GAP OUT OF SPECIFICATION
WHEEL BEARING EXCESS RUNOUT
WHEEL SPEE D SE NSOR INOPERATIVE
CAB - CANT READ WHE EL SP EE D SE NSOR SIGN AL
INTERMITTENT SIGNAL DTC
TES T ACTION AP P LICAB ILITY
1 Tu r n t h e ign it ion on .Using the DRBIII, monitor all Wheel Speed Sensors while an assistant drives the
vehicle.
Slowly accelerate as straight as possible from a stop to 24 km/h (15 mph).
Note the DRBIII Wheel Speed Sensor readings.
Is one wheel speed signal zero or differing from others by m ore tha n 5 km/h (3 mph)?
All
Yes G o To 2
N o Go To 7
2 Tu r n t h e ig ni t ion off.
Inspect the Wheel Speed Sensor and Connector at the affected wheel.
Is the Sensor or Connector Damaged?
All
Yes Repair as neces s ary. The CA B m us t s ens e all four w heels a t 25
km/h (15 m ph) before it will extinguish the ABS In dicat or.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 3
3 Tu r n t h e ig ni t ion off.
At the affected wheel, inspect the Tone Wheel for dama ged or missing teet h, cracks,
or looseness.
N o t e : T h e To n e W h e e l Te e t h s h o u l d b e p e r f e c t l y s q u a r e , n o t b e n t o r n i c k e d .
Is the Tone Wheel OK?
All
Yes G o To 4
N o Replace the Tone Wheel. The CAB must sense all four wheels at
25 km/h (15 mph ) before it will extinguish t he ABS Indicator.
Perform ABS VERIFICATION TEST - VER 1.
4 Tu r n t h e i gn it i on off.
Using a Feeler Gauge, measure the Wheel Speed Sensor Air Gap.
N O TE : T h e Ai r G a p s h o u l d b e c h e c k e d i n a t l e a s t f o u r p l a c e s o n t h e T o n e
Wh eel.
Is the Air Gap between 0.42 mm - 1.71 mm (0.017 - 0.068) ?
All
Yes G o To 5
N o Repair as neces s ary. The CA B m us t s ens e all four w heels a t 25
km/h (15 mph ) before it will extinguish the ABS In dicat or.
Perform ABS VERIFICATION TEST - VER 1.
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LEFT FRONT SENSOR SIGNAL FAILURE C o n t i n u e d
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TES T ACTION AP P LICAB ILITY
5 Tu r n t h e ig ni t ion off.
Inspect the wheel bearing for excessive runout or clearance.
N o t e : R e f e r t o t h e a p p r o p r i a t e s e r v i c e i n f o r m a t i o n , i f n e c e s s a r y , f o r p r o c e -
d u r e s o r s p e c i f i c a t i o n s .Is the bearing run out O K ?
All
Yes G o To 6
N o Repair as neces s ary. The CA B m us t s ens e all four w heels a t 25
km/h (15 mph ) before it will extinguish the ABS In dicat or.
Perform ABS VERIFICATION TEST - VER 1.
6 Tu r n t h e ig ni t ion off.
Raise the affected wheel off the ground.
Disconnect the Wheel Speed Sensor connector a t the affected wheel.
S et up an A C voltm eter t o read t he output of the W heel S peed S ens or.
Q uickly rotate the w heel by s pinning the t ire by han d.
Measure the Wheel Speed Sensor AC voltage output.
Does the voltage go above 650 millivolts as the wheel is rotated?
All
Yes Replace t he Controller Antilock Bra ke in accordance w ith the
Service Informa tion.
Perform ABS VERIFICATION TE ST - VER 1.
N o Replace the Wheel Speed Sensor in accordance with the Service
Information. The CAB must sense all four wheels at 25 km/h (15
mph) before it will extinguish the ABS In dicator.
Perform ABS VERIFICATION TEST - VER 1.
7 Tu r n t h e i gn it i on off.
Visually inspect th e a ffected Wheel Speed Sensor for correct installat ion.
Visually inspect t he Tone Wheel for looseness and correct installat ion.
Visually inspect the wiring ha rness for loose or interm ittent connections.
Visually inspect mechan ical brake components.Inspect for conditions that may cause lockup or drag.
Inspect for seized caliper or wheel cylinder piston.
Inspect all component s for a condition which ma y cause a Wheel Speed Signal DTC
to s et.
Is any Component Damaged?
All
Yes Repair as neces s ary. The CA B m us t s ens e all four w heels a t 25
km/h (15 m ph) before it will extinguish the ABS In dicat or.
Perform ABS VERIFICATION TE ST - VER 1.
N o Test Complete.
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BRAKES (CAB)
LEFT FRONT SENSOR SIGNAL FAILURE C o n t i n u e d
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S y m p t o m :
PUMP MOTOR NOT WORKING PROPERLY
W h e n M o n i t o r e d a n d S e t C o n d i t i o n :
PU MP MOTOR NOT WORKING PR OPERLY
When Monitored: Ignition on. The CAB comma nds th e pump on at 20 km/h (12 mph) to
check its operation, if the brake switch is not applied. If the driver has their foot on the
b r a ke , t h e t e st w ill r u n a t 4 0 k m /h (2 5 m p h ). T he C AB m on it or s p u mp volt a ge
continuously.
Set Condition: The DTC is stored when t he CAB detects: 1) Impr oper volta ge decay after
the pump was turned off. 2) Pump not energized by the CAB, but voltage is present for 3.5
seconds. 3) Pum p is t ur ned on by the CAB, but their is insufficient volta ge to operat e it.
P O S S I B L E C A U S E S
ABS PUMP MOTOR INTERMITTENT DTC
FUSED B(+) CIRCUIT INTERMITTENTLY SHORTED TO GROUND
FUSED B(+) CIRCUIT SHORTED TO GROUND
CAB - FUSED B(+) CIRCUIT SHORTED TO GROUND
FUSE BLOWN - PUMP MOTOR CIRCUIT
NO B+ SUP PLY TO FUSE
ABS PUMP MOTOR INOPERATIVE
FUSED B(+) CIRCUIT OPEN
GROUND CIRCUIT OPE N
GROUND CIRCUIT HIGH RESISTANCE
CAB - INTERNAL FAULT
TES T ACTION AP P LICAB ILITY
1 Tu r n t h e ign it ion on .
With the DRBIII, read DTCs.
With the DRBIII, era se DTCs.
Turn the ignition off.
Turn the ignition on.
With the DRBIII, actuate the A BS pum p m otor.D id th e P um p M otor operate w hen actuated?
All
N o Go To 2
Yes G o To 1 3
2 Tu r n t h e ig ni t ion off.
Rem ove and ins pect the A BS P um p fus e in the P D C.
Is the F us e blow n?
All
Yes G o To 3
N o Go To 7
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TES T ACTION AP P LICAB ILITY
3 Tu r n t h e ig ni t ion off.
Make sure the Pump Motor connector is secure.
Vis ually ins pect the F us ed B(+) Circuit in t he w iring ha rnes s from the P D C to the
CAB. Look for any sign of an Intermittent Short to Ground.Is the w iring har nes s O K ?
All
Yes G o To 4
N o Repair the Fused B(+) Circuit shorted to ground. The CAB must
sense all four wheels at 25 km/h (15 mph) before it will extinguish
the ABS In dicat or.
Perform ABS VERIFICATION TEST - VER 1.
4 Tu r n t h e ig ni t ion off.
Remove ABS PUMP Fuse 8 from the Power Distribution Center (PDC).
Disconnect the CAB connector.
Make sure the Pump Motor connector is secure.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Using a test light connected to 12 volts, probe the Fused B (+) Circuit.Is the t es t l ight on?
All
Yes Repair the F us ed B(+) circuit s hort to ground. The CA B m us t
sense all four wheels at 25 km/h (15 mph) before it will extinguish
the ABS Indicator.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 5
5 Tu r n t h e i gn it i on off.
Remove ABS PUMP Fuse 12 from the PDC.
The CAB must be connected for the results of this test to be valid.
Using a test light connected to 12 volts, probe the Fused B (+) circuit in the PDC.
Is the t es t l ight on?
All
Yes Replace t he Controller Antilock Bra ke in accordance w ith the
Service Informa tion.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 6
6 Tu r n t h e i gn it i on off.
Make sure the Pump Motor connector is secure
If there ar e no potential caus es rem a ining, replace th e F u s e.
If there are no possible causes remaining, view repair.
All
Repair
Replace th e ABS Pu mp Motor Fuse. The CAB must sense all four
w heels at 25 km /h (15 m ph) before it w ill extinguis h the A BS
Indicator.Perform ABS VERIFICATION TE ST - VER 1.
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TES T ACTION AP P LICAB ILITY
7 Tu r n t h e ig ni t ion off.
Remove ABS PUMP Fuse #12 from the Power Distribution Center (PDC).
Disconnect the CAB connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .M eas ure the res istance of the F u s ed B (+) circuit betw een t he P D C F us e Term inal
and the CAB connector.
Is the resistance below 10 ohms?
All
Yes G o To 8
N o Repair the Fused B(+) circuit for an open. The CAB must sense all
four wheels at 25 km/h (15 mph) before it will extinguish the ABS
Indicator.
Perform ABS VERIFICATION TEST - VER 1.
8 Tu r n t h e ign it ion on .
Using a 12-volt test light connected t o ground, check t he B+ supply to Fu se 12 in th e
PDC.
Is the B+ s upply O K ?
All
Yes G o To 9
N o Repair the B+ s upply for an open. The CAB m u s t s ens e all four
w heels at 25 km /h (15 m ph) before it w ill extinguis h the A BS
Indicator.
Perform ABS VERIFICATION TEST - VER 1.
9 Tu r n t h e i gn it i on off.
Disconnect Pump Motor Connector.
Connect a 10 gauge jumper wire between pump motor Fused B (+) circuit and a 40
Amp Fused B (+) circuit.
Connect a 10 gauge jumper wire between pump motor ground circuit and a known
good body ground.
Monitor Pump Motor operation.Is the pum p m otor ru nning?
All
Yes G o To 1 0
N o Replace t he Controller Antilock Brake in accordance w ith the
Service Information. The CAB must sense all four wheels at 25
km/h (15 mph ) before it will extinguish the ABS In dicat or.
Perform ABS VERIFICATION TEST - VER 1.
1 0 Tu r n t h e i gn it i on off.
Disconnect CAB Connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Measure the resistance of the CAB ground circuits.
Is the resistance below 1.0 ohm?
All
Yes G o To 11
N o Repair the ground circuit for an open. The CA B m us t s ens e all
four wheels at 25 km/h (15 mph) before it will extinguish the ABS
Indicator.
Perform ABS VERIFICATION TEST - VER 1.
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TES T ACTION AP P LICAB ILITY
11 M a k e s u r e t h e P u m p M ot or con n e ct or is se cu r e .
Turn the ignition on.
With the DRBIII, enable pum p m otor actuation.
N O TE : P u m p m o t o r w i l l n o t o p e r a t e , b u t v o l t a g e w i l l b e a p p l i e d .Measure the voltage drop across the ABS ground circuit connection, with pump motor
actuation enabled.
Is t he voltage below 0.1 volt?
All
Yes G o To 1 2
N o Repair the G round circuit for an open. The CA B m us t s ens e all
four wheels at 25 km/h (15 mph) before it will extinguish the ABS
Indicator.
Perform ABS VERIFICATION TEST - VER 1.
12 If t h er e a r e n o possible ca u ses r em a in in g, view r epa ir. All
Repair
Replace the Controller Anti-Lock Brake in accordance with the
S ervice Inform at ion. The CAB m us t s ens e all four w heels at 25
km/h (15 m ph) before it will extinguish th e ABS In dicator.
Perform ABS VERIFICATION TEST - VER 1.
1 3 Tu r n t h e ig ni t ion off.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Make sure the Pump Motor connecter is secure.
Visually inspect th e relat ed wire h ar ness connectors. Look for broken, bent, pu shed
out, or corroded t ermina ls.
Refer to any Hotline letters or Technical Service Bulletins that may apply.
Were a ny pr oblems found?
All
Yes Repair as neces s ary. The CA B m us t s ens e all four w heels a t 25
km/h (15 m ph) before it will extinguish the ABS In dicat or.Perform ABS VERIFICATION TE ST - VER 1.
N o Test Complete.
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S y m p t o m :
SYSTEM OVER VOLTAGE
W h e n M o n i t o r e d a n d S e t C o n d i t i o n :
SYSTEM OVER VOLTAGE
When Monitored: Ignition on. The CAB monitors t he F used B(+) circuit a t all times for
proper system voltage.
Set Condition: If the volta ge is above 16.5 volts, th e Diagnostic Trouble Code (DTC) is set.
P O S S I B L E C A U S E S
BATTERY OVERCHARGED
FUSED IGNITION SWITCH OUTPUT HIGH
GROUND CIRCUIT OPE N
CAB - INTERNAL FAULT
INTERMITTENT DTC
TES T ACTION AP P LICAB ILITY
1 Tu r n t h e ign it ion on .
With the DRBIII, era se DTCs.
Turn the ignition off.
Turn the ignition on.
S tart the engine.
With the DRBIII
, read DTCs.Does the DRBIII display System Overvoltage DTC?
All
Yes G o To 2
N o Go To 6
2 Tu r n t h e ig ni t ion off.
Inspect for battery charger connected to battery.
Is a battery charger connected to the batt ery?
All
Yes Charge battery to proper level. D is connect the battery charger.
Clear DTCs.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 3
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3 Tu r n t h e ig ni t ion off.
Disconnect the CAB connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
S tart the engine.Raise en gine RP Ms a bove 1,800.
M eas ure th e batt ery voltage.
Is t he voltage a bove 16.5 volts ?
All
Yes Refer to appropriate s ervice inform ation for charging s ystem
tes ting and repair.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 4
4 Tu r n t h e ig ni t ion off.
Disconnect the CAB connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Measure the resistance of the ground circuits.
Is the resistance below 1.0 ohm?
All
Yes G o To 5
N o Repair the Ground circuit for an open.
Perform ABS VERIFICATION TEST - VER 1.
5 If t h er e a r e n o pot en t ia l ca u ses r em a in in g, view r epa ir. All
Repair
Replace t he Contr oller Antilock Bra ke.
Perform ABS VERIFICATION TEST - VER 1.
6 Tu r n t h e ig ni t ion off.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect th e relat ed wire h arn ess connectors. Look for broken, bent, push ed
out, or corroded t ermina ls.
Refer to any Hotline letters or Technical Service Bulletins that may apply.
Were a ny pr oblems found?
All
Yes Repair as necessary.
Perform ABS VERIFICATION TE ST - VER 1.
N o Test Complete.
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S y m p t o m :
SYSTEM UNDER VOLTAGE
W h e n M o n i t o r e d a n d S e t C o n d i t i o n :
SYSTEM UNDER VOLTAGE
When Monitored: Ignition on. The CAB monitors the Fused Ignition Switch Output for
proper system voltage.
Set Condition: If the volta ge is below 9.5 volts, th e Diagnostic Trouble Code (DTC) is set.
P O S S I B L E C A U S E S
BATTERY VOLTAGE LOW
INTERMITTENT DTC
FUSED IGNITION SWITCH OUTPUT CIRCUIT H IGH RESISTANCE
GROUND CIRCUIT OPE N
CAB - INTERNAL FAULT
TES T ACTION AP P LICAB ILITY
1 Tu r n t h e ign it ion on .
With the DRBIII, era se DTCs.
Turn the ignition off.
Turn the ignition on.
S tart the engine.
Drive the vehicle above 16 km/h (10 mph) for at least 20 seconds.Stop the vehicle
With the DRBIII, read DTCs.
Does the DRBIII display System Un dervoltage DTC?
All
Yes G o To 2
N o Go To 6
2 E ngin e Ru nn in g.
M eas ure th e batt ery voltage.
Is the battery voltage below 10 volts?
All
Yes Refer to appropriate s ervice inform ation for charging s ystem
tes ting and repair.
Perform ABS VERIFICATION TE ST - VER 1.
N o Go To 3
3 Tu r n t h e ig ni t ion off.
Disconnect the CAB connector.
N o t e : Ch e c k c o n n e c t o r - C le a n / r e p a i r a s n e c e s s a r y .
Measure the resistance of the ground circuits.
Is the resistance below 1.0 ohm?
All
Yes G o To 4
N o Repair the Ground circuit for an open.
Perform ABS VERIFICATION TEST - VER 1.
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4 D is con n e ct t h e C AB h a r n e s s con n e ct or .
Turn the ignition on.
Measure the voltage of the Fused Ignition Switch circuit.
Is the voltage above 10 volts?
All
Yes G o To 5
N o Repair the Fused Ignition Switch Output Circuit for high resis-
tance
Perform ABS VERIFICATION TEST - VER 1.
5 If t h er e a r e n o pot en t ia l ca u ses r em a in in g, view r epa ir. All
Repair
Replace t he Contr oller Antilock Bra ke.
Perform ABS VERIFICATION TEST - VER 1.
6 Tu r n t h e ig ni t ion off.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.Visually inspect th e relat ed wire h ar ness connectors. Look for broken, bent, pu shed
out, or corroded t ermina ls.
Refer to any Hotline letters or Technical Service Bulletins that may apply.
Were a ny pr oblems found?
All
Yes Repair as necessary.
Perform ABS VERIFICATION TE ST - VER 1.
N o Test Complete.
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S y m p t o m :
*ABS WARNING INDICATOR ALWAYS ON
P O S S I B L E C A U S E S
ABS RELAY STUCK
ABS RELAY FUSED B+ CIRCUIT OPEN
ABS RELAY CONTROL CIRCUIT OPEN
CAB INTERNAL OPEN
ABS INDICATOR DRIVER SHORT TO GROUND
INSTRUMENT CLUSTER CONCERN
TES T ACTION AP P LICAB ILITY
1 R em ov e t h e AB S r e la y fr om P D C.Perform the key-on bulb test.
Does the ABS Indicator light and remain lit?
All
Yes G o To 2
N o Go To 3
2 D is con n e ct t h e I n s t r u m e n t C lu s t e r C 2 h a r n e s s con n e ct or .
Remove the ABS relay from the PDC.
Using a 12-volt test light connected to 12-volts, check the ABS Warning Indicator
Driver circuit.
Does the test light illuminate?
All
Yes Repair the ABS Indicator circuit for a short to ground. The CAB
may have to sense all four wheels at 25 km/h (15 mph) before itwill extinguish the ABS Indicator.
Perform ABS VERIFICATION TE ST - VER 1.
N o Refer to symptom list for pr oblems related t o Instru ment Cluster.
The CAB may have to sense all four wheels at 25 km/h (15 mph)
before it will extinguish the ABS Indicator.
Perform ABS VERIFICATION TEST - VER 1.
3 I n s t a ll a s u bs t it u t e r el a y i n p la ce of t h e AB S r e la y.
Perform the key-on bulb check.
Does t he ABS Warn ing Indicator operat e OK?
All
Yes Replace th e A