Chrysler Caravan and Voyager (2003) Service Manual – Chassis

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Page 1

1.0 INTRODUCTION .........................................................1

1.1 SYSTEM COVERAGE ...............................................1

1.2 SIX-STEP TROUBLESHOOTING PROCEDURE ..........................1

2.0 IDENTIFICATION OF SYSTEM .............................................1

3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION ......................1

3.1 TEVES MARK 20e SYSTEM DESCRIPTION .............................1

3.2 TRACTION CONTROL SYSTEM (TCS) DESCRIPTION (IF EQUIPPED).......1

3.3 SYSTEM COMPONENTS.............................................2

3.3.1 ABS AND BRAKE WARNING INDICATORS......................2

3.3.2 CONTROLLER ANTILOCK BRAKE (CAB) .......................2

3.3.3 HYDRAULIC CONTROL UNIT .................................2

3.3.4 ABS SWITCHES/SENSORS...................................3

3.3.5 ABS INITIALIZATION ........................................3

3.3.6 ABS DIAGNOSTIC MODE ....................................3

3.3.7 TRACTION CONTROL OPERATION (IF EQUIPPED) ..............4

3.5 DIAGNOSTIC TROUBLE CODES ......................................4

3.6 FREEZE FRAME....................................................4

3.7 TIRE PRESSURE MONITORING SYSTEM ..............................4

3.7.1 TRAINING THE EVIC ........................................4

3.7.2 PRESSURE THRESHOLDS...................................5

3.7.2.1 CRITICAL AND NON-CRITICAL SYSTEM ALERTS................5

3.7.3 SYSTEM FAULTS...........................................5

3.7.4 SPARE WHEEL AUTO-DETECT ...............................5

3.7.5 DIAGNOSING AND CLEARING SYSTEM FAULTS ................6

3.7.6 SYSTEM TEST .............................................6

3.8 DRBIIIT ERROR MESSAGES AND BLANK SCREEN ......................6

3.8.1 DRBIIIT DOES NOT POWER UP...............................6

3.8.2 DISPLAY IS NOT VISIBLE....................................6

4.0 DISCLAIMERS, SAFETY, WARNINGS .......................................7

4.1 DISCLAIMERS......................................................7

4.2 SAFETY...........................................................7

4.2.1 TECHNICIAN SAFETY INFORMATION..........................7

4.2.2 VEHICLE PREPARATION FOR TESTING........................7

4.2.3 SERVICING SUB-ASSEMBLIES ...............................7

4.2.4 DRBIIIT SAFETY INFORMATION ..............................7

4.3 WARNINGS ........................................................8

4.3.1 VEHICLE DAMAGE WARNINGS ...............................8

4.3.2 ROAD TESTING A COMPLAINT VEHICLE.......................8

4.4 DIAGNOSIS........................................................8

5.0 REQUIRED TOOLS AND EQUIPMENT ......................................8

6.0 GLOSSARY OF TERMS...................................................9

7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ...........................11

BRAKES (CAB)

BUS SYSTEM COMMUNICATION FAILURE .................................12

Page 2

TABLE OF CONTENTS - Continued

CAB INTERNAL FAILURE ................................................14

CLUSTER LAMP FAILURE................................................16

INCORRECT TONE WHEEL FAILURE ......................................18

LEFT FRONT SENSOR CIRCUIT FAILURE ..................................19

LEFT REAR SENSOR CIRCUIT FAILURE ...................................19

RIGHT FRONT SENSOR CIRCUIT FAILURE.................................19

RIGHT REAR SENSOR CIRCUIT FAILURE ..................................19

LEFT FRONT WHEEL SPEED SIGNAL FAILURE .............................24

LEFT REAR WHEEL SPEED SIGNAL FAILURE ..............................24

RIGHT FRONT WHEEL SPEED SIGNAL FAILURE............................24

RIGHT REAR WHEEL SPEED SIGNAL FAILURE .............................24

PUMP CIRCUIT FAILURE ................................................27

SYSTEM OVER VOLTAGE................................................31

SYSTEM UNDER VOLTAGE ..............................................34

VALVE POWER FEED FAILURE ...........................................36

*BRAKE LAMP SWITCH INOPERATIVE.....................................39

*TRAC OFF INDICATOR NEVER/ALWAYS ON ...............................40

*TRAC ON INDICATOR NEVER/ALWAYS ON ................................43

COMMUNICATION

*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE ....................44

VERIFICATION TESTS

VERIFICATION TESTS...................................................46

8.0 COMPONENT LOCATIONS...............................................47

8.1 CONTROLLER ANTILOCK BRAKE (CAB) ..............................47

8.2 DATA LINK CONNECTOR ...........................................47

8.3 FUSES...........................................................47

8.4 TRACTION CONTROL SWITCH ......................................48

8.5 WHEEL SPEED SENSORS ..........................................48

8.5A WHEEL SPEED SENSOR CONNECTORS..............................49

8.6 BRAKE LAMP SWITCH .............................................50

9.0 CONNECTOR PINOUTS .................................................51

ABS PUMP MOTOR .....................................................51

BRAKE LAMP SWITCH ..................................................51

CONTROLLER ANTILOCK BRAKE .........................................52

LEFT FRONT WHEEL SPEED SENSOR ....................................52

LEFT REAR WHEEL SPEED SENSOR......................................52

RIGHT FRONT WHEEL SPEED SENSOR ...................................53

RIGHT REAR WHEEL SPEED SENSOR ....................................53

TRACTION CONTROL SWITCH ...........................................53

8.4.1 TRACTION CONTROL INDICATORS ..........................48

8.5.1 FRONT...................................................48

8.5.2 REAR....................................................49

8.5A.1 FRONT...................................................49

8.5A.2 REAR....................................................49

10.0 SCHEMATIC DIAGRAMS.................................................55

10.1 TEVES MARK 20E ANTILOCK BRAKE SYSTEM – ABS ...................55

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GENERAL INFORMATION

1.0 INTRODUCTION

The procedures contained in this manual include all the specifications, instructions, and graphics needed to diagnose the 2003 Chrysler Town & Country, Dodge Caravan, and Chrysler Voyager Mark 20e Antilock Braking System (ABS), and Mark 20e Antilocke Braking System with Traction Control. The diagnostics in this manual are based on the failure condition or symptom being present at time of diagnosis.

Please follow the recommendations below when choosing your diagnostic path.

1. First make sure the DRBIIIt is communicating

with the CAB. If the DRBIIIt displays a “No Response” condition, you must diagnose that first.

2. Read DTC’s (diagnostic trouble codes) with the

DRBIIIt.

3. If no DTC’s are present, identify the customer

complaint.

4. Once the DTC or customer complaint is identi-

fied, locate the matching test in the Table of Contents and begin to diagnose the symptom.

All component location views are in Section 8.0. All connector pinouts are in Section 9.0. All schematics are in Section 10.0.

An asterisk (*) placed before the symptom description indicates a concern with no associated DTC.

When repairs are required, refer to the appropriate service manual for the proper removal and

repair procedure.

Diagnostic procedures change every year. New diagnostic systems may be added; carry over systems may be enhanced. READ THIS MANUAL BEFORE TRYING TO DIAGNOSE A VEHICLE 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.

• verification of complaint

• verification of any related symptoms

• symptom analysis

• problem isolation

• repair of isolated problem

• verification of proper operation

2.0 IDENTIFICATION OF SYSTEM

Vehicles equipped with the Teves Mark 20e antilock brake system can be identified by the presence of the controller antilock brake module located beneath the master cylinder.

The presence of the Traction Control system is indicated by the TRAC OFF switch on top of the steering column shroud.

3.0 SYSTEM DESCRIPTION AND

FUNCTIONAL OPERATION

3.1 TEVES MARK 20e SYSTEM

DESCRIPTION

The controller antilock brake module is used to monitor wheel speeds and to modulate (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lock-up during braking.

The Teves Mark 20e system uses a diagonal split hydraulic brake system. In the standard brake mode the master cylinder primary circuit supplies pressure to the right front and left rear wheel brakes, and the secondary master cylinder circuit supplies pressure to the left front and right rear wheel brakes.

All vehicles equipped with ABS use Electronic Variable Brake Proportioning (EVPB) to balance front-to-rear braking when brakes are applied in the partial braking range.

1.1 SYSTEM COVERAGE

This diagnostic procedure manual covers the antilock braking system (ABS), and the traction control system found on: Chrysler Town and Country, Dodge Caravan, and Chrysler Voyager.

1.2 SIX-STEP TROUBLESHOOTING

PROCEDURE

Diagnosis of the controller antilock brake module is done in six basic steps:

3.2 TRACTION CONTROL SYSTEM (TCS) DESCRIPTION (IF EQUIPPED)

The main purpose of traction control is to reduce wheel slip and maintain traction at the driven wheels when road surfaces are slippery. The traction control system reduces wheel slip by braking the wheel that is losing traction. The system is designed to operate at speeds below 56 km/h (35 mph).

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GENERAL INFORMATION

3.3 SYSTEM COMPONENTS

ABS

• controller antilock brake (CAB)

• vacuum booster

• master cylinder

• ABS integrated electronic control module/

hydraulic control unit (HCU), valve block assembly: 8 valve solenoids (4 inlet valves, 4 outlet valves, 2 accumulators) 1 pump.

• 4 wheel speed sensor/tone wheel assemblies

• ABS warning indicator

• fuses and wiring harness

• fluid reservoir

ABS With Traction Control

• CAB with Traction Control programming

• HCU with two additional control valves.

• TRAC ON/OFF Switch

• TRAC/TRAC OFF indicators

3.3.1 ABS AND BRAKE WARNING INDICATORS

The amber ABS warning indicator is located in the instrument cluster. It is used to inform the driver that the antilock function has been turned off. The ABS warning indicator is controlled by the CAB. The CAB controls the lamp with a command over the PCI bus.

TheABS WarningIndicator will remainlitduring

every key cycle until a circuit or component fault is repaired and the CAB no longer detects the fault. After repairofa sensor signal faultora pump motor fault, the CAB must sense all four wheels at 25 km/h (15mph)before it will extinguish theABS and TRAC OFF Indicators.

The Instrument Cluster will illuminate the ABS Warning Indicator if it loses communication with the CAB.

The red BRAKE warning indicator is also located in the instrument cluster. It can be activated in several ways. Application of the parking brake or a low fluidsignalfrom the fluidlevelswitch located in the master cylinder reservoir will cause the indicator to come on.

3.3.2 CONTROLLER ANTILOCK BRAKE

process the information. The results are then compared to make sure that they agree. Otherwise, the CAB will turn off the antilock and turn on the ABS amber warning indicator.

The primary functions of the CAB are to:

• detect wheel locking tendencies

• control fluid pressure modulation to the brakes

during antilock stop

• monitor the system for proper operation

• manage traction control functions

• provide communication to the DRBIIIt while in

diagnostic mode

• store diagnosticinformationinnon-volatile mem-

ory

The CAB continuously monitorsthespeedofeach wheel. When a wheel locking tendency is detected, the CAB will command the appropriate valve to modulate brake fluid pressure in its hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system. The CAB continues to control pressure in individual hydraulic circuits until a wheel locking tendency is no longer present. The CAB turns on the pump motor during an antilock stop.

The antilock brake system is constantly monitored by the CAB for proper operation. If the CAB detects a system malfunction, it can disable the antilock system and turn on the ABS warning indicator. If the antilock function is disabled, the system will revert to standard base brake system operation. The CAB inputs include the following:

• diagnostic communication

• four wheel speed sensors

• three power feeds: valve, pump, and microproces-

sor

• brake switch

• traction control switch

The CAB outputs include the following:

• ABS warning indicator actuation

• 12 volts power to wheel speed sensors

• eight valves

• ten valves with traction control

• diagnostic communication

• PCI bus communication

• traction control lamp illumination

(CAB)

The Controller Antilock Brake (CAB) is a microprocessor-based device that monitors wheel speeds and controls the antilock functions. The CAB contains two microprocessors that receive identical sensor signals and then independently

3.3.3 HYDRAULIC CONTROL UNIT

The hydraulic control unit (HCU) contains the valve block assembly, and pump/motor assembly. The HCU is attached to the CAB.

Valve Block Assembly: The valve block assembly contains valves with four inlet valves and four

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GENERAL INFORMATION

outlet valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring loaded in the closed position. During an antilock stop, these valves are cycled to maintain the proper slip ratio for each wheel. If a wheel detects slip, the inlet valve is closed to prevent and further pressure increase. Then the outlet valve is opened to release the pressure to the accumulators until the wheel is no longer slipping. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply pressure. If the wheel is decelerating within its predetermined limits (proper slip ratio), the inlet valve will close to hold the pressure constant. On vehicles which are equipped with a traction control system, there are two additional valves that isolate the master cylinder and rear wheels. During a traction control event the brakes are applied to reduce wheel slippage.

Pump Motor Assembly: The pump motor assembly provides the extra amount of fluid needed during antilock braking. The pump is supplied fluid that isreleasedto the accumulators whentheoutlet valve is opened during an antilock stop. The pump is also used to drain the accumulator circuits after the antilock stop is complete. The pump is operated by an integral electric motor. This motor is controlled by the CAB.TheCABmay turn on the pump motor when an antilock stop is detected. The pump continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump motor will run to drain the accumulators during the next drive off. The CAB monitors the pump motor operation internally.

3.3.4 ABS SWITCHES/SENSORS

Master Cylinder: The master cylinder is a standard tandem compensating port designforABS and non ABS systems. Traction control vehicles use a dual center port master cylinder. For proper traction control operation the standard master cylinder must not be used.

A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low fluid level is detected. The fluid level switch turns on the brake warning indicator by grounding the indicator circuit. This switch does not disable the ABS system.

Wheel Speed Sensors and Tone Wheels: One active wheel speed sensor (WSS) is located at each wheel and sends a small DC signal to the control module (CAB). This signal is generated when a toothed sensorring(tone wheel) passesbya stationary wheel speed sensor. The CAB converts the signals for each wheel.

Because of internal circuitry, correct wheel speed sensor function cannot be determined by a continuity or resistance check through the sensor.

The front wheelspeedsensoris attached to a boss in the steering knuckle. The tone wheel is an integral part of the front axle shaft. The rear speed sensor is mounted thoughthebearingcoverand the rear tone wheel is an integral part of the rear bearing hub. The wheel speed sensor air gap is not adjustable. Refer to the service manual for wheel speed sensor air gap and resistance specifications.

The four wheel speed sensors are serviced individually. The front tone wheels are serviced as an assembly with the outer constant velocity (C.V.) joint housing. The rear tone wheels are serviced as an assembly.

Correct antilock system operation is dependent on tone wheel speed signals from the wheel speed sensors. The vehicle’s wheels and tires should all be the same sizeandtypeto generate accurate signals. In addition, the tires should be inflated to the recommended pressure for optimum system operation. Variation in wheel and tire size or significant variations in inflation pressure can produce inaccurate wheel speed signals; however, the system will continue to function when using the correct factory mini-spare.

3.3.5 ABS INITIALIZATION

System initialization starts when the key is turned to “run”. At this point, the CAB performs a complete self-check of all electrical components in the antilock systems.

Between 8-17 km/h (5-10 mph), a dynamic test is performed. This will momentarily cycle the inlet and outlet valves, check wheel speed sensor circuitry, and run the pump motor at 25 km/h (15 mph). The CAB will try to test the pump motor. If the brake pedal is applied the test will be run at 40 km/h (24 mph) regardless of brake switch state. If, during the dynamic test, the brake pedal is applied, the driver may feel the test through brake pedal pulsations. This is a normal condition.

If any component exhibits a trouble condition during system initialization or dynamic check, the CAB will illuminate theABS warning indicator and TRAC OFF lamp if equipped.

3.3.6 ABS DIAGNOSTIC MODE

To enter diagnostic mode, a vehicle speedmustbe below 10 km/h (6 mph) and no ABS condition present. If vehicle speed is not below 10 km/h (6 mph), a “No Response” message could be displayed by the DRBIIIt. The following are characteristics of diagnostic mode:

– The amber ABS warning indicator will blink

rapidly. If a hard trouble code, such as Valve Power Feed Failure code is present, the indicator will be illuminated without blinking until the trouble condition is cleared.

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GENERAL INFORMATION

– Antilock operation is disabled. – The HCU valves cannot be actuated when the

vehicle speed is above 8 km/h (5 mph). If valve actuation isattemptedabove 8 km/h(5mph), a “No Response” message will be displayed on the DRBIIIt.

3.3.7 TRACTION CONTROL OPERATION (IF EQUIPPED)

The Controller Antilock Brake (CAB) monitors wheel speeds. If, during acceleration, the module detects front (drive) wheel slip and the brakes are not applied, the CAB will enter traction control mode. Traction control works in the following order when drive wheel slip is detected.

1. Close the (normally open) isolation valves.

2. Start pump/motor and supply volume/pressure

to front hydraulic circuits (pump runs continuously during traction control).

3. Open and close build and decay valves to main-

tain minimum wheel slip and maximum traction.

The cycling of the build and decay valves is similar to the ABS except that they work to control wheel spin by applying brakes. ABS function is to control wheel skid by releasing brakes.

Two pressure relief valves allow excess fluid volume to return to the reservoir when not used by the build/decay cycles. These are required because the pump supplies more volume than the traction control system requires.

If at any time the brake pedal is applied during a

traction control cycle, the brake lamp switch will trigger the CAB to switch off the traction control.

The traction control system will be enabled at each ignition cycle. It may be turned off by depressing the Traction Control Switch. The traction control system function lamp will illuminate “TRAC OFF” immediately upon depressing the traction control switch button. Only the “TRAC” portion of the “TRAC OFF” indicator will illuminate during a traction control event.

If the CAB calculates that the brake temperatures are high, the traction control system will become inoperative until a time-out period has elapsed. When in this thermal protection mode, the traction control “TRAC OFF” lamp will illuminate; however, a fault will not be registered.

3.5 DIAGNOSTIC TROUBLE CODES

The Controller Antilock Brake may report any of several Diagnostic Trouble Codes (DTC)s. For a list of the DTCs diagnosed in this manual, refer to the Table of Contents.

3.6 FREEZE FRAME

Freeze Frame takes a “snapshot” of specific vehicle information the instant an ABS failure is recognized and stores this information into the CAB memory. Thisinformationcan be accessed using the DRBIIIt to help diagnose the fault. Freeze Frame will capture the first time failure or only a new failure that occursduringthe current ignition cycle.

3.7 TIRE PRESSURE MONITORING

SYSTEM

If equipped with the Tire Pressure Monitoring System, each ofthevehicle’sfour wheels will have a valve stem with a pressure sensor and radio transmitter built in. Signals from the tire pressure Sensor/Transmitters are received and interpreted by the Electronic Vehicle Information Center (EVIC).

A Sensor/Transmitter in a mounted wheel will broadcast its detected pressure once per minute when the vehicle is moving faster than 32 km/h (20 mph). Each Sensor/Transmitter’s broadcast is uniquely coded so that the EVIC can determine location.

3.7.1 TRAINING THE EVIC

The EVIC can be trained to recognize the source locations of Sensor/Transmitter signals. The training procedure is given below:

1. From the Programmable Features List select

“RETRAIN TIRE SENSORS Y/N” using the EVIC MENU button. Use the STEP button to select and the MENU button to confirm “YES”. The EVIC will initiate the following procedure.

2. A display will prompt the user to: “TRAIN

DRIVER FRONT SENSOR”. At this point the user must set the left front tire Sensor/ Transmitterto learn mode by positioning a magnet (Relearn Magnet special tool 8821) over the valve stem for at least 5 seconds. The Sensor/ Transmitter in the front left tire will transmit a message indicatingtothe EVIC thatitis in learn mode. When theEVIChasreceived this message and is assured that it has learned an ID, the EVIC will request a horn chirp via a bus message and then display the next train request.

Note: The EVIC will allow 60 seconds from the first train request display to thereceipt of a unique learn ID message from the first Sensor/Transmitter and 30 seconds for each succeeding wheel. If either of these timers expires, the EVIC will abort the training procedure and revert to previous settings. The EVIC will not store one ID for

multiple locations.

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GENERAL INFORMATION

3. The EVICwillrequest the initiation ofa training sequence for each tire, one-by-one in a clockwise direction around the vehicle (Left Front, Right Front, Right Rear and Left Rear). NOTE:

1. If one or all Sensor/Transmitters cannot be trained move vehicle to avoid radio frequency interference.

2. If one Sensor/Transmitter still cannot be trained, replace it and retry.

3. If all Sensor/Transmitters still fail to train, replace the EVIC.

4. Once all tires are successfully learned, the previous set of stored IDs will be replaced by the new IDs, and the EVIC will display, “TRAINING COMPLETE” until a button is pressed.

If the vehicle is equipped with the Homelink feature and a Homelink button is pressed at any time during the training procedure, the EVIC module will immediately exit the training procedure, discard any IDs learned in the current session and perform the Homelink function. After the button is released, the module will display “RETRAIN TIRE SENSORS? NO.”

The training procedure can be stopped at any time by pressing the C/T, STEP, RESET or MENU button. When any of these buttons are pressed the EVIC will display “TRAINING ABORTED” until another button is pressed and then display “RETRAIN TIRE SENSORS? NO.”

Sensor/transmitter replacement or tire rotation will require retraining of the EVIC.

3.7.2 PRESSURE THRESHOLDS

The EVIC will monitor the tire pressure signals from the tire Sensor/Transmitters and determine if any tire has gone below the low pressure threshold or exceeded the high pressure threshold. Refer to the table below.

LOW TIRE PRESSURE THRESHOLDS

SYSTEM STATUS

INDICATOR

On 179 kPa

Off 214 kPa

HIGH TIRE PRESSURE THRESHOLDS

SYSTEM STATUS

INDICATOR

On 310 kPa

Off 276 kPa

TIRE PRESSURE

(26 PSI)

(31 PSI)

TIRE PRESSURE

(45 PSI)

(40 PSI)

3.7.2.1 CRITICAL AND NON-CRITICAL SYSTEM ALERTS

Critical:

A critical alert will be triggered when a tire pressure has gone below or above a set threshold pressure. The EVIC will request a chime and then display “X TIRE(S) LOW PRESSURE” or “X TIRES HIGH PRESSURE”. “X” will be the number of tires reporting low or high pressure.

The message will display for the duration of the current ignition cycle oruntiltheanEVIC button is pressed. If the display is removed without correcting the condition, it will reappear without a chime after 300 seconds to warn the driver of the low or high pressure condition.

Non-Critical:

A non-critical alert with no chime will be triggered when no signal is received from a Sensor/ Transmitter or when a Sensor/Transmitter low battery condition is detected. The EVIC will display “SERVICE TIRE PRESS. SYSTEM”.

3.7.3 SYSTEM FAULTS

There are two conditions which will cause a Tire Pressure MonitoringSystemfault to beset.Allfault codes are associated with a specific wheel location.

1. If the EVIC detects a non-transmitting Sensor/

Transmitter condition, it will:

a. Store an active fault code. b. Request a chime c. Display “SERVICE TIRE PRESS. SYSTEM”

2. When the EVIC receives a Low Sensor/

Transmitter battery report from a Sensor/ Transmitter, it will

a. Store an active fault code. b. Request a chime. c. Display “SERVICE TIRE PRESS. SYS-

TEM”.

Use the DRBIIIt Inputs/Outputs function to further isolate the specific concern. The DRBIIIt can be queried to determine the status and battery condition for each Sensor/Transmitter.

3.7.4 SPARE WHEEL AUTO-DETECT

If the spare tire is mounted on the vehicle, the EVIC will:

1. detect thechangeafter 15 minutesator above 32

km/h (20 mph)

2. query driver: “SPARE TIRE IN USE?”

Use MENU button for YES and STEP button for NO. For YES the EVIC will revert to previous display and wait five hours. After five hours the EVIC will proceed as in the NO response below.

3. for a NO response, after 15 minutes, display:

“ALL 5 TIRES W/ VEHICLE? Y” Use the STEP

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GENERAL INFORMATION

button to selectYESorNOandMENU button to confirm. For a “YES” response the EVIC will display “SERVICE TIRE PRESS. SYSTEM”. For a “NO” response, the EVIC will revert to previous display and display “ALL 5 TIRES W/ VEHICLE?Y”every time the ignitioniscycledto RUN and the missing tire ID is not received.

3.7.5 DIAGNOSING AND CLEARING SYSTEM FAULTS

All Tire Pressure Monitoring System Faults are specific to one location. If a no-transmit, “LOW BATTERY”, “LOW or HIGH PRESSURE” fault is detected, the location can be determined by the DRBIIIt. The appropriate Sensor/Transmitter can then be replaced or the out-of-spec pressure condition can be corrected.

• If a single Sensor/Transmittercannotbe detected

by the EVIC, replace that Sensor/Transmitter.

• If none of the Sensor/Transmitters can be de-

tected, refer to symptoms in the EVIC section.

• If a BUCKET COUNTER test fails, and one or

more Sensor/Transmitters does not transmit, replace the affected Sensor/Transmitter.

• If none of the Sensor/Transmitter causes the

BUCKET COUNTER to advance, replace the EVIC.

• If the EVIC displays SERVICE TIRE PRESS.

SYSTEM and the DRBIIIt sees no Sensor/ Transmitterfaultorpressureoutofspecification,

1. attempt the Retrain procedure. If the display

reoccurs,

2. replace the EVIC.

3.7.6 SYSTEM TEST

Atest of the TirePressure Monitoring Systemcan be initiated in the EVIC. The test sequence is as follows:

1. Perform the RETRAIN TIRE SENSORS proce-

dure.

2. Press andholdtheRESET and STEP buttons for

five seconds.

3. The EVIC will display BUCKET COUNTERS.

4. Drive thevehicleat 32 km/h (20 mph)forat least

2 minutes.

5. The counters will increase by one each time a

Sensor/Transmitter signal is received by the EVIC.

6. Observe that the COUNTERS register at least 3

receptions for each Sensor/Transmitter.

7. Replace any Sensor/Transmitter that does not

meet specification.

8. The test will continue until any EVIC button is pressed or until the ignition is cycled to OFF.

3.8 DRBIIIT ERROR MESSAGES AND

BLANK SCREEN

Under normal operation, the DRBIIIt will dis-

play one of only two error messages:

– User-Requested WARM Boot or User-

Requested COLD Boot.

If the DRBIIIt should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display:

ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err. 0x1 User-Requested COLD boot Press MORE to switch between this display

and the application screen.

Press F4 when done noting information.

3.8.1 DRBIIIT DOES NOT POWER UP

If the LED’s do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRBIIIt.

If all connections are proper and the vehicle battery is fully charged, an inoperative DRBIIIt may be the result of faulty cable or vehicle wiring.

3.8.2 DISPLAY IS NOT VISIBLE

Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition.

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GENERAL INFORMATION

4.0 DISCLAIMERS, SAFETY, WARNINGS

4.1 DISCLAIMERS

All information, illustrations, and specifications contained in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

4.2 SAFETY

4.2.1 TECHNICIAN SAFETY INFORMATION

WARNING: ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS, CAUSES SLOWER REACTION TIME, AND CAN LEAD TO SERIOUS INJURY. WHEN THE ENGINE IS OPERATING, KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM.

Set theparkingbrake and blockthewheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the drive wheels.

When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as rings, watchbands or bracelets that might make an

inadvertent electrical contact.

When diagnosing a chassis problem, it is important to follow approved procedures where applicable. These procedures can be found in the service manual. Following these procedures is very important to the safety of individuals performing diagnostic tests.

4.2.2 VEHICLE PREPARATION FOR

TESTING

Make sure the vehicle being tested has a fully charged battery.Ifis does not, falsediagnosticcodes or error messages may occur.

4.2.3 SERVICING SUB-ASSEMBLIES

Some components of the chassis system are intended to be serviced as an assembly only.Attempting to remove or repair certain system subcomponents may result in personal injury and/or improper system operation. Only those components with approved repair and installation proceduresin the service manual should be serviced.

4.2.4 DRBIIIT SAFETY INFORMATION

WARNING: EXCEEDING THE LIMITS OF THE DRBIIIT MULTIMETER IS DANGEROUS. IT CAN EXPOSE YOU TO SERIOUS OR POSSIBLY FATAL INJURY. CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS.

• Follow the vehicle manufacturer’s service speci-

fications at all times.

• Do not use the DRBIIIt if it has been damaged.

• Do not use the test leads if the insulation is

damaged or if metal is exposed.

• To avoid electrical shock, do not touch the test

leads, tips, or the circuit being tested.

• Choose the proper range and functions for the

measurement. Do not try voltage or current measurements that may exceed the rated capacity.

• Do notexceed the limits showninthe table below:

FUNCTION INPUT LIMIT

Volts 0 - 500 peak volts AC

0 - 500 volts DC Ohms (resistance)* 0 -1.12 megohms Frequency Measured

Frequency Generated Temperature -58 - 1100°F

* Ohms cannot be measured if voltage is present.

Ohms can be measured only in a non-powered 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-

rent, make sure the meter is functioning correctly. Take a reading of a known voltage or current 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.

• When using the meter function, keep the

DRBIIIt away from spark plug or coil wires to avoid measuring error from outside interference.

0-10kHz

-50 - 600°C

Page 10

GENERAL INFORMATION

4.3 WARNINGS

4.3.1 VEHICLE DAMAGE WARNINGS

Before disconnecting any control module, make sure the ignition is ‘‘off’’. Failure to do so could damage the module.

When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation, this will damage it and eventually cause it to fail because of corrosion.

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 the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition.

WARNING: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN WHILE IN MOTION. DO NOT HANG THE DRBIIIT FROM THE REAR VIEW MIRROR OR OPERATE IT

YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIIIT.

4.4 DIAGNOSIS

1. Your diagnostictestprocedure must begin with a

thorough visual inspectionofthe system in question for damaged components or disconnected connectors. For ABS the brake lamps must be operational prior to continuing.

2. Connect the DRBIIIt to the data link connector,

which is located under the dash to the left of the steering column. If the DRBIIIt does not power up, check the power and ground supplies to the connector.

3. Turn the ignition on. Select the system in ques-

tion. If the DRBIIIt displays “No Response” condition you must diagnose that first.

4. Read and record all diagnostic trouble codes. For

ABS if the “CAB Power Feed Circuit” diagnostic trouble code is present, it must be repaired prior to addressing any other DTC’s. If any additional DTC’s are present, proceed to the appropriate

test by locating the matching test in the Table of Contents and begin to diagnose the symptom.

5. For ABS if there are no diagnostic trouble codes present, identify the customer complaint. Select “Inputs/Outputs” and read the brake switch input as you press and release the brake pedal. If the display doesnotmatchthe state of the pedal, perform the proper test by locating the matching test in the Table of Contents and begin to diagnose the symptom. If a problem exists with the yellow “ABS” warning indicator or the red “Brake” indicator exists, refer to the proper tests by locating the matching test in the Table of Contents and begin to diagnose the symptom. Read the traction control switch input as you press and release the switch. If the display does not match the state of the indicator perform the proper test by locating the matching test in the Table of Contents and begin to diagnose the symptom.

6. If no other problems are found, it will be necessary to road test the vehicle. Perform several antilock stops from above 50 Km/h (30 mph) and then repeat step 4. If any diagnostic trouble codes are present, proceed to the appropriate test.

7. The following conditions should be considered “NORMAL” operation, and no repairs should be attempted to correct them.

– Brake pedal feedback during an ABS stop

(clicking, vibrating).

– Clicking, groaning or buzzing at 25 Km/h (15

mph) or 40 Km/h (24 mph) (drive off self test). – Groaning noise during an ABS stop. – Slight brake pedal drop and pop noise when

ignition is initially turned on. – Brake pedal ratcheting down at the end of an

ABS stop.

8. If the complaint is ABS “cycling” at the end of a stop at low speeds, it may be caused by a marginal wheel speed sensor signal. The sensor air gap, tone wheel condition, and/or brakes hanging up are possible causes of this condition.

9. After a road test in which no problems were found, refer to any Technical Service Bulletins that may apply.

5.0 REQUIRED TOOLS AND

EQUIPMENT

DRBIIIt (diagnostic read-out box) jumper wires ohmmeter voltmeter test light

Page 11

6.0 GLOSSARY OF TERMS

ABS antilock brake system CAB controller antilock brake DC direct current DLC data link connector DRB diagnostic read-out box DTC diagnostic test code EVBP electronic variable brake proportion-

ing

HCU hydraulic control unit ICU integrated control unit IPM integrated power module JBLK junction block PCI programmable communication inter-

face

P/M pump motor WSS wheel speed sensor

GENERAL INFORMATION

Page 12

NOTES

Page 13

DIAGNOSTIC INFORMATION AND

7.0

PROCEDURES

Page 14

BRAKES (CAB)

Symptom:

BUS SYSTEM COMMUNICATION FAILURE

When Monitored and Set Condition:

BUS SYSTEM COMMUNICATION FAILURE

When Monitored: Ignition ON, continuously. Set Condition: When the CAB doesnot receive a message from theinstrument cluster for

10 seconds.

POSSIBLE CAUSES

INTERMITTENT CONDITION ELECTRO-MECHANICAL INSTRUMENT CLUSTER DTC PRESENT BUS CIRCUIT OPEN CAB - INTERNAL FAILURE

TEST ACTION APPLICABILITY

1 Turn the ignition on.

With the DRBIIIt, read DTCs. With the DRBIIIt, read Freeze Frame information. With the DRBIIIt, erase DTCs. Turn the ignition off. Turn the ignition on. With the DRBIIIt, read DTCs.

Does the DRBIIIt display BUS SYSTEM COMMUNICATION FAILURE?

Yes → Go To 2 No → Go To 4

2 Turn the ignition on.

With the DRBIIIt, read EMIC DTCs. Does the DRBIIIt display NO ABS MESSAGE RECEIVED?

Yes → Refer to symptom NOABS MESSAGE RECEIVED in the BODY/

No → Go To 3

All

INSTRUMENT CLUSTER category. Perform ABS VERIFICATION TEST - VER 1.

Page 15

BRAKES (CAB)

BUS SYSTEM COMMUNICATION FAILURE — Continued

TEST ACTION APPLICABILITY

3 Turn the ignition off.

Disconnect the negative (-) battery cable. Disconnect the CAB harness connector.

NOTE: check connector - Clean/repair as necessary.

Measure the resistance of the Bus circuit between the CAB connector and the Data Link Connector (DLC). Is the resistance below 5.0 ohms?

Yes → Replace the Controller Antilock Brake in accordance with the

Service Information. Perform ABS VERIFICATION TEST - VER 1.

No → Repair the Bus circuit for an open.

Perform ABS VERIFICATION TEST - VER 1.

All

4 Turn the ignition off.

Yes → Repair as necessary.

No → Test Complete.

All

Perform ABS VERIFICATION TEST - VER 1.

Page 16

BRAKES (CAB)

Symptom:

CAB INTERNAL FAILURE

When Monitored and Set Condition:

CAB INTERNAL FAILURE

When Monitored: Ignition on. The CAB monitors its internal microprocessors for correct operation.

Set Condition: If the CAB detects an internal fault, the DTC is set.

POSSIBLE CAUSES

INTERMITTENT DTC DAMAGED CAB/CAB HARNESS CONNECTOR CAB - GROUND CIRCUIT OPEN ABS VALVE FUSED B(+) CIRCUIT OPEN ABS PUMP FUSED B(+) CIRCUIT OPEN CAB - INTERNAL FAULT

TEST ACTION APPLICABILITY

1 Turn the ignition on.

With the DRBIIIt, read DTCs. With the DRBIIIt, erase DTCs.

Turn the ignition off. Turn the ignition on. With the DRBIIIt, read DTCs. Does the DRBIIIt display CAB INTERNAL FAILURE?

Yes → Go To 2 No → Go To 6

2 Turn the ignition off.

Disconnect the CAB harness connector. Inspect the CAB/CAB harness connector for damage. Is ther any broken, bent, pushed out, corroded or spread terminals?

Yes → Repair as necessary.

No → Go To 3

All

Perform ABS VERIFICATION TEST - VER 1.

3 Turn the ignition off.

Disconnect the CAB harness connector. Using a 12-volt test light connected to 12-volts, probe the CAB harness connector ground circuits. Did the test light illuminate?

Yes → Go To 4 No → Repair the CAB Ground circuit for an open.

Perform ABS VERIFICATION TEST - VER 1.

All

Page 17

BRAKES (CAB)

CAB INTERNAL FAILURE — Continued

TEST ACTION APPLICABILITY

4 Turn the ignition off.

Using a12-volt testlight connected toground, probetheABSValve FusedB(+) circuit at the CAB harness connector. Did the test light illuminate?

Yes → Go To 5 No → Repair the ABS Valve Fused B(+) circuit for an open.

Perform ABS VERIFICATION TEST - VER 1.

All

5 Turn the ignition off.

Using a 12-volt test light connected to ground, probe the ABS Pump Fused B(+) circuit at the CAB harness connector. Did the test light illuminate?

Yes → Replace the Controller Antilock Brake in accordance with the

No → Repair the ABS Pump Fused B(+) circuit for an open.

6 Turn the ignition off.

Yes → Repair as necessary.

No → Test Complete.

All

Service Information. Perform ABS VERIFICATION TEST - VER 1.

Perform ABS VERIFICATION TEST - VER 1.

All

Perform ABS VERIFICATION TEST - VER 1.

Page 18

BRAKES (CAB)

Symptom:

CLUSTER LAMP FAILURE

When Monitored and Set Condition:

CLUSTER LAMP FAILURE

When Monitored: Key ON. After Key-ON bulb check. Set Condition: When the instrument cluster informs the CAB that the cluster cannot

turn on the ABS Lamp.

POSSIBLE CAUSES

INSTRUMENT CLUSTER OR ABS DTC PRESENT INSTRUMENT CLUSTER CAB--NO DTC SIGNAL TO THE INSTRUMENT CLUSTER CAB -- PERMANENT FAULT SIGNAL CAB--NO KEY-ON BULB CHECK SIGNAL

TEST ACTION APPLICABILITY

1 Turn the ignition on.

With the DRBIIIt, read DTCs. Are there any Instrument Cluster or ABS DTCs present?

Yes → Refer to the appropriate category for the related symptom(s).

No → Go To 2

2 Turn the ignition off.

Perform the Key-on Bulb Check. Does the ABS Warning Indicator light and then go out after a few seconds?

Yes → Go To 3 No. Light remains after bulb check.

No. Indicator never comes on.

All

Perform ABS VERIFICATION TEST - VER 1.

All

Replace the Controller Antilock Brake in accordance with the Service Information. Perform ABS VERIFICATION TEST - VER 1.

Go To 4

Page 19

BRAKES (CAB)

CLUSTER LAMP FAILURE — Continued

TEST ACTION APPLICABILITY

3 NOTE: The DRBIIIt communication with the CAB must be operational for

the result of this test to be valid.

Turn the ignition off. Remove ABS Valve fuse. Perform the Key-on Bulb Check. Does the ABS Indicator remain on after the bulb check?

Yes → Test Complete. No → Replace the Controller Antilock Brake in accordance with the

Service Information. Perform ABS VERIFICATION TEST - VER 1.

All

4 NOTE: The following steps will initiate the Instrument Cluster self test.

Turn the ignition off. Press and hold the odometer reset button. Turn the ignition to RUN. Observe the Instrument Cluster indicators. Release the odometer reset button. Did the ABS Indicator illuminate during the Instrument Cluster self test?

Yes → Replace the Controller Antilock Brake in accordance with the

No → Replace the Instrument Cluster in accordance with the Service

All

Service Information. Perform ABS VERIFICATION TEST - VER 1.

Information. Perform ABS VERIFICATION TEST - VER 1.

Page 20

BRAKES (CAB)

Symptom:

INCORRECT TONE WHEEL FAILURE

When Monitored and Set Condition:

INCORRECT TONE WHEEL FAILURE

When Monitored: Ignition ON. Vehicle speed above 40 km/h (25 mph) for 2 minutes. Set Condition: When the CAB detects an unexpected wheel speed condition caused by a

tire size that does not meet vehicle specification.

POSSIBLE CAUSES

INCORRECT TIRES ON VEHICLE INCORRECT TONE WHEEL ON VEHICLE

TEST ACTION APPLICABILITY

1 Inspect the tire sizes on the vehicle.

Is a smaller than production tire, mini spare, or two mini spares installed on both front wheels?

Yes → Replace the incorrect tire(s) size with production size tire(s).

No → Go To 2

2 Count the number of tone wheel teeth on both of the front driveshafts.

Does one or both tone wheel(s) have (56 or 40) teeth?

Yes → Replace the front driveshaft(s) with the incorrect number of tone

No → Test Complete.

All

Perform ABS VERIFICATION TEST - VER 1.

All

wheel teeth. Perform ABS VERIFICATION TEST - VER 1.

Page 21

BRAKES (CAB)

Symptom List:

LEFT FRONT SENSOR CIRCUIT FAILURE LEFT REAR SENSOR CIRCUIT FAILURE RIGHT FRONT SENSOR CIRCUIT FAILURE RIGHT REAR SENSOR CIRCUIT FAILURE

Test Note: All symptoms listed above are diagnosed using the same tests.

The title for the tests will be LEFT FRONT SENSOR CIRCUIT FAILURE.

When Monitored and Set Condition:

LEFT FRONT SENSOR CIRCUIT FAILURE

When Monitored: Ignition on. The CAB monitors the wheel speed circuit 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 Monitored: Ignition on. The CAB monitors the wheel speed circuit 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 FAILURE

When Monitored: Ignition on. The CAB monitors the wheel speed circuit continuously.

INTERMITTENT CONDITION WHEEL SPEED SENSOR OR CONNECTOR DAMAGE

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 Monitored: Ignition on. The CAB monitors the wheel speed circuit continuously. Set Condition: If the CAB detects an open or shorted wheel speed sensor circuit, the

Diagnostic Trouble Code (DTC) will set.

POSSIBLE CAUSES

WHEEL SPEED SENSOR SIGNAL CIRCUIT FAULT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT SHORT TO GROUND WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT OPEN WHEEL SPEED SENSOR SIGNAL CIRCUIT SHORT TO GROUND WHEEL SPEED SENSOR SIGNAL CIRCUIT OPEN

Page 22

BRAKES (CAB)

LEFT FRONT SENSOR CIRCUIT FAILURE — Continued

POSSIBLE CAUSES

CAB - 12 VOLT SUPPLY CIRCUIT FAULT CAB - SIGNAL CIRCUIT FAULT WHEEL SPEED SENSOR 12 VOLT SUPPLY SHORT TO GROUND WHEEL SPEED SENSOR SIGNAL CIRCUIT INOPERATIVE

TEST ACTION APPLICABILITY

1 Turn the ignition on.

With the DRBIIIt, read DTCs. With the DRBIIIt, read the Freeze Frame information. With the DRBIIIt, erase DTCs. Turn the ignition off. Turn the ignition on. With the DRBIIIt, read DTCs.

NOTE: The CAB mustsense all four wheels at 25km/h(15 mph) before it will extinguish the ABS indicators.

Does the DRBIIIt display SENSOR CIRCUIT FAILURE?

All

Yes → Go To 2 No → Go To 13

2 Turn the ignition off.

Inspect the CAB connector, affected Wheel Speed Sensor, and affected Wheel Speed Sensor connector. Is the affected Wheel Speed Sensor or any of the connectors damaged?

Yes → Repair as necessary.

No → Go To 3

3 Turn the ignition off.

Disconnect the affected Wheel Speed Sensor connector.

Note: Check connector - Clean/repair as necessary.

Turn the ignition on. Measure thevoltage between affected WheelSpeed Sensor 12VoltSupply circuit and ground. Is the voltage above 10 volts?

Yes → Go To 6 No → Go To 4

4 Turn the ignition off.

Disconnect the CAB harness connector. Disconnect the affected Wheel Speed Sensor connector. Using a 12-volt test light connected to 12-volts, probe the affected Wheel Speed Sensor 12 Volt Supply circuit. Does the test light illuminate?

All

Perform ABS VERIFICATION TEST - VER 1.

All

Yes → Repair theaffected Wheel Speed Sensor 12 Volt Supply circuit for

a short to ground. Perform ABS VERIFICATION TEST - VER 1.

No → Go To 5

Page 23

BRAKES (CAB)

LEFT FRONT SENSOR CIRCUIT FAILURE — Continued

TEST ACTION APPLICABILITY

5 Turn the ignition off.

Disconnect the CAB harness connector. Disconnect the affected Wheel Speed Sensor connector. Connect a jumper wire between affected Wheel Speed Sensor 12 Volt Supply circuit and ground. Using a 12-volt test light connected to 12-volts, probe the affected Wheel Speed Sensor 12 Volt Supply circuit. Does the test light illuminate?

Yes → Go To 6 No → Repair the affected Wheel Speed Sensor 12 Volt Supply circuit for

an open. Perform ABS VERIFICATION TEST - VER 1.

All

6 Turn the ignition off.

Disconnect the affected Wheel Speed Sensor connector.

NOTE: Check connector - Clean/repair as necessary.

Turn the ignition on. Measure thevoltage between affectedWheel Speed SensorSignal circuit andground. Is the voltage above 1 volt?

Yes → Repair the affected Wheel Speed Sensor Signal circuit for a short

No → Go To 7

7 Turn the ignition off.

Disconnect the CAB harness connector. Disconnect the affected Wheel Speed Sensor connector. Using a 12-volt test light connected to 12-volts, probe the affected Wheel Speed Sensor Signal circuit.

Does the test light illuminate?

Yes → Repair the affected Wheel Speed Sensor Signal circuit for a short

No → Go To 8

8 Turn the ignition off.

Disconnect the CAB harness connector. Disconnect the affected Wheel Speed Sensor connector. Connect a jumper wire between affected Wheel Speed Sensor Signal circuit and ground. Using a 12-volt test light connected to 12-volts, probe the affected Wheel Speed Sensor Signal circuit. Does the test light illuminate?

All

to voltage. Perform ABS VERIFICATION TEST - VER 1.

All

to ground. Perform ABS VERIFICATION TEST - VER 1.

All

Yes → Go To 9 No → Repair the affectedWheel SpeedSensor Signal circuitfor anopen.

Perform ABS VERIFICATION TEST - VER 1.

Page 24

BRAKES (CAB)

LEFT FRONT SENSOR CIRCUIT FAILURE — Continued

TEST ACTION APPLICABILITY

9 Turn the ignition off.

Remove the CAB harness strain relief to access wires. Reconnect the CAB harness connector. Turn the ignition on. Measure thevoltage between affected WheelSpeed Sensor 12VoltSupply circuit and ground. Is the voltage above 10 volts?

Yes → Go To 10 No → Replace the Controller Antilock Brake in accordance with the

Service Information. Perform ABS VERIFICATION TEST - VER 1.

All

10 Turn the ignition off.

Yes → Go To 11 No → Replace the Controller Antilock Brake in accordance with the

11 Turn the ignition off.

Reconnect ALL affected Wheel Speed Sensor circuit connectors. Disconnect the affected Wheel Speed Sensor connector. Turn the ignition on. Measure the voltage oftheaffected Wheel Speed Sensor 12 Volt Supply circuit in the

affected Wheel Speed Sensor connector while reconnecting the sensor connector. Did the affected Wheel Speed Sensor 12 Volt Supply circuit drop voltage to 0 DC volts?

Yes → Replace the affected Wheel Speed Sensor in accordance with the

No → Go To 12

All

Service Information. Perform ABS VERIFICATION TEST - VER 1.

All

Service Information. Perform ABS VERIFICATION TEST - VER 1.

12 Turn the ignition off.

Reconnect ALL affected Wheel Speed Sensor circuit connectors. Turn the ignition on. Measure the DC voltage of the Wheel Speed Sensor Signal circuit in the affected Wheel Speed Sensor connector. Slowly rotate the wheel. Does the DC voltage toggle between 1.6 volts to .8 volts?

Yes → Go To 13 No → Replace the affected Wheel Speed Sensor in accordance with the

Service Information. Perform ABS VERIFICATION TEST - VER 1.

All

Page 25

BRAKES (CAB)

LEFT FRONT SENSOR CIRCUIT FAILURE — Continued

TEST ACTION APPLICABILITY

13 Turn the ignition off.

Yes → Repair as necessary.

Perform ABS VERIFICATION TEST - VER 1.

No → Test Complete.

All

Page 26

BRAKES (CAB)

Symptom List:

LEFT FRONT WHEEL SPEED SIGNAL FAILURE LEFT REAR WHEEL SPEED SIGNAL FAILURE RIGHT FRONT WHEEL SPEED SIGNAL FAILURE RIGHT REAR WHEEL SPEED SIGNAL FAILURE

Test Note: All symptoms listed above are diagnosed using the same tests.

The title for the tests will be LEFT FRONT WHEEL SPEED SIGNAL FAILURE.

When Monitored and Set Condition:

LEFT FRONT WHEEL SPEED SIGNAL FAILURE

When Monitored: Wheel speed are checked and verified at drive off and continuously thereafter.

Set Condition: If, during an ABS stop, the CAB commands any valve solenoid on for an extended length of time, and does not see a corresponding wheel speed change, the Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or erratic.

LEFT REAR WHEEL SPEED SIGNAL FAILURE

When Monitored: Wheel speed are checked and verified at drive off and continuously thereafter.

Set Condition: If, during an ABS stop, the CAB commands any valve solenoid on for an

extended length of time, and does not see a corresponding wheel speed change, the Diagnostic Trouble Code (DTC) is set. The DTC can also set if the signal is missing or erratic.

RIGHT FRONT WHEEL SPEED SIGNAL FAILURE

When Monitored: Wheel speed are checked and verified at drive off and continuously thereafter.

RIGHT REAR WHEEL SPEED SIGNAL FAILURE

When Monitored: Wheel speed are checked and verified at drive off and continuously thereafter.

Page 27

BRAKES (CAB)

LEFT FRONT WHEEL SPEED SIGNAL FAILURE — Continued

POSSIBLE CAUSES

WHEEL SPEED SIGNAL FAILURE DTC PRESENT AFFECTED WHEEL SPEED SENSOR SIGNAL INOPERATIVE AFFECTED WHEEL SPEED SENSOR CONNECTOR DAMAGED AFFECTED WHEEL SPEED SENSOR TONE WHEEL DAMAGED AFFECTED WHEEL SPEED SENSOR AIR GAP FAULT WHEEL BEARING FAULT BRAKE LINING FAULT AFFECTED WHEEL SPEED SENSOR CIRCUIT ELECTRICAL FAULT

TEST ACTION APPLICABILITY

1 Turn the ignition on.

With the DRBIIIt, read DTCs. With the DRBIIIt, read Freeze Frame information.

NOTE: The CAB must sense ALL 4 wheels at 25 km/h (15 mph) before it will extinguish the ABS indicators.

Does the DRBIIIt display WHEEL SPEED/SIGNAL FAILURE and SENSOR CIRCUIT FAILURE?

All

Yes → Refer to the affected Wheel Speed SENSOR CIRCUIT FAILURE

No → Go To 2

2 Turn the ignition on.

With theDRBIIIt in Sensors, monitorALL the WheelSpeed Sensor Signals while an assistant drives the vehicle. Slowly accelerate as straight as possible from a stop to 24 km/h (15 mph). Is the affected Wheel Speed Signal showing 0 km/h (0 mph)?

Yes → Go To 3 No → The condition is not present at this time. Monitor DRBIIIt

3 Turn the ignition off.

Inspect the CAB connector, affected Wheel Speed Sensor, and affected Wheel Speed Sensor connector. Is the Wheel Speed Sensor or any connector damaged?

Yes → Repair as necessary.

No → Go To 4

for the related symptom(s). Perform ABS VERIFICATION TEST - VER 1.

All

parameters while wiggling the related wiring harness. Refer to any Technical Service Bulletins(TSB) that may apply. Visually inspect the related wiring harness and connector terminals. Perform ABS VERIFICATION TEST - VER 1.

All

Perform ABS VERIFICATION TEST - VER 1.

Page 28

BRAKES (CAB)

LEFT FRONT WHEEL SPEED SIGNAL FAILURE — Continued

TEST ACTION APPLICABILITY

4 Turn ignition off.

Inspect the affected Tone Wheel for damaged, missing teeth, cracks, or looseness.

NOTE: TheToneWheel teethshould be perfectlysquare, notbent, or nicked.

Is the affected Tone Wheel OK?

Yes → Go To 5 No → Replace the Tone Wheel in accordance with the Service Informa-

tion. Perform ABS VERIFICATION TEST - VER 1.

All

5 Turn the ignition off.

Using a Feeler Gauge, measure the affected Wheel Speed Sensor Air Gap.

NOTE: Refer to the appropriate service information, if necessary, for procedures or specifications.

Is the Air Gap OK?

Yes → Go To 6 No → Repair as necessary.

6 Turn the ignition off.

Inspect the wheel bearings for excessive runout or clearance.

NOTE: Refer to the appropriate service information, if necessary, for procedures or specifications.

Is the bearing clearance OK ?

Yes → Go To 7 No → Repair as necessary.

7 Turn the ignition off.

Visually inspect brakes for locking up due to lining contamination or overheating. Inspect all Components for defects which may cause a Signal DTC to set. Is any Component Damaged?

Yes → Repair as necessary.

All

Perform ABS VERIFICATION TEST - VER 1.

All

Perform ABS VERIFICATION TEST - VER 1.

All

Perform ABS VERIFICATION TEST - VER 1.

No → Refer to symptom SENSOR CIRCUIT FAILURE for further

diagnostics. Perform ABS VERIFICATION TEST - VER 1.

Page 29

Symptom:

PUMP CIRCUIT FAILURE

When Monitored and Set Condition:

PUMP CIRCUIT FAILURE

When Monitored: Ignition on. The CAB commands the pump on at 20 km/h (12 mph) to check its operation, if the brake switch is not applied. If the brake is applied, the test will run at 40 km/h (25 mph).

Set Condition: The DTC is stored when the CAB detects: 1) Improper voltage decay after the pump was turned off. 2) Pump not energized by the CAB, but voltage is present for 3.5 seconds. 3) Pump is turned on by the CAB, but without sufficient voltage to operate it.

POSSIBLE CAUSES

CAB - PUMP MOTOR RUNNING CONTINUOUSLY

BRAKES (CAB)

ABS PUMP FUSE ABS PUMP MOTOR INTERMITTENT DTC DAMAGED CAB/CAB HARNESS CONNECTOR ABS PUMP FUSED B(+) CIRCUIT INTERMITTENT SHORT TO GROUND ABS PUMP FUSED B(+) CIRCUIT SHORT TO GROUND CAB - INTERNAL FAULT ABS PUMP MOTOR INOPERATIVE

ABS PUMP MOTOR OPEN ABS PUMP MOTOR B(+) CIRCUIT OPEN ABS PUMP MOTOR GROUND CIRCUIT OPEN CAB - INTERNAL FAULT

TEST ACTION APPLICABILITY

1 Turn the ignition off.

Turn the ignition on. Monitor the ABS Pump Motor for continuous operation.

NOTE: The CAB must sense ALL wheels at 25 km/h (15 mph) before it will extinguish the ABS indicators.

Is the ABS Pump Motor running continuously?

All

Yes → Replace the Controller Antilock Brake in accordance with the

Service Information. Perform ABS VERIFICATION TEST - VER 1.

No → Go To 2

Page 30

BRAKES (CAB)

PUMP CIRCUIT FAILURE — Continued

TEST ACTION APPLICABILITY

2 Turn the ignition off.

Turn the ignition on. With the DRBIIIt, read DTCs. With the DRBIIIt, erase DTCs. Turn the ignition off. Turn the ignition on. With the DRBIIIt, actuate the ABS Pump Motor. Did the ABS Pump Motor operate?

Yes → Go To 3 No → Go To 4

All

3 Turn the ignition off.

Visually inspectthe related wiring harness. Look foranychafed, pierced, pinched, or partially broken wires. Make sure the Pump Motor connecter is secure. Visually inspect the related wire harness 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?

Yes → Repair as necessary.

No → Test Complete.

4 Turn the ignition off.

Remove and inspect the ABS Pump fuse. Is the ABS Pump fuse open?

Yes → Go To 5 No → Go To 8

5 Turn the ignition off.

Visually inspect the ABS Pump Fused B(+) circuit in the wiring harness. Look for any sign of an intermittent short to ground. Is the wiring harness OK?

Yes → Go To 6 No → Repair the ABS Pump Fused B(+) circuit for a short to ground.

All

Perform ABS VERIFICATION TEST - VER 1.

All

Perform ABS VERIFICATION TEST - VER 1.

6 Turn the ignition off.

Disconnect the CAB harness connector. Check connectors - Clean/repair as necessary. Using a 12-volt test light connected to 12-volts, probe the ABS Pump Fused B(+) circuit fuse terminal. Does the test light illuminate?

Yes → Repair the ABS Pump Fused B(+) circuit for a short to ground.

Perform ABS VERIFICATION TEST - VER 1.

No → Go To 7

All

Page 31

BRAKES (CAB)

PUMP CIRCUIT FAILURE — Continued

TEST ACTION APPLICABILITY

7 Turn the ignition off.

Reconnect the CAB harness connector. Using a 12-volt test light connected to 12-volts, probe the ABS Pump Fused B(+) circuit fuse terminal. Does the test light illuminate?

Yes → Replace the Controller Antilock Brake in accordance with the

Service Information. Perform ABS VERIFICATION TEST - VER 1.

No → Replace theABS Pump fuse.If thefuse is openmake sureto check

for a short to ground. Perform ABS VERIFICATION TEST - VER 1.

All

8 Turn the ignition off.

Disconnect the CAB harness connector. Inspect the CAB and CAB harness connector for damage. Is there any broken, bent, pushed out, corroded, or spread terminals?

Yes → Repair as necessary.

No → Go To 9

9 Turn the ignition off.

Reinstall the ABS Pump fuse. Disconnect the ABS Pump Motor connector. Check connectors - Clean/repair as necessary. Connect a 10 gauge 40 amp fused jumper wire between the ABS Pump Fused B(+) terminal inthe CAB harnessconnector to theABS PumpMotor connector REDwired terminal. Connect a 10 gauge jumper wire between the Ground circuit terminal in the CAB harness connector to the ABS Pump Motor connector BLACK wired terminal.

Did the ABS Pump Motor operate?

Yes → Replace the Controller Antilock Brake in accordance with the

No → Go To 10

10 Turn the ignition off.

Disconnect the ABS Pump Motor connector. Check connectors - Clean/repair as necessary. Connect a 10 gauge 40 amp fused jumper wire between the ABS Pump Motor connector RED wired terminal and an alternate 40 amp capable B(+) source. Connect a 10 gauge jumper wire between the ABS Pump Motor connector BLACK wired terminal and ground Did the ABS Pump Motor operate?

All

Perform ABS VERIFICATION TEST - VER 1.

All

Service Information. Perform ABS VERIFICATION TEST - VER 1.

All

Yes → Go To 11 No → Replace the Hydraulic Control Unit in accordance with the

Service Information. Perform ABS VERIFICATION TEST - VER 1.

Page 32

BRAKES (CAB)

PUMP CIRCUIT FAILURE — Continued

TEST ACTION APPLICABILITY

11 Turn the ignition off.

Disconnect the ABS Pump Motor connector. Check connectors - Clean/repair as necessary. Connect a 10 gauge 40 amp fused jumper wire between the ABS Pump Fused B(+) terminal inthe CAB harnessconnector to theABS PumpMotor connector REDwired terminal. Connect a 10 gauge jumper wire between the ABS Pump Motor connector BLACK wired terminal and ground. Did the ABS Pump Motor operate?

Yes → Repair the ABS Pump Motor Fused B(+) circuit for an open.

Perform ABS VERIFICATION TEST - VER 1.

No → Repair the ABS Pump Motor Ground circuit for an open.

Perform ABS VERIFICATION TEST - VER 1.

All

Page 33

Symptom:

SYSTEM OVER VOLTAGE

When Monitored and Set Condition:

SYSTEM OVER VOLTAGE

When Monitored: Ignition on. The CAB monitors the Fused B(+) circuit at all times for proper system voltage.

Set Condition: If the voltage is above 16.5 volts, the Diagnostic TroubleCode(DTC)isset.

POSSIBLE CAUSES

INTERMITTENT DTC BATTERY CHARGER CONNECTED FUSED IGNITION SWITCH OUTPUT (RUN) CIRCUIT HIGH

BRAKES (CAB)

DAMAGED CAB/CAB HARNESS CONNECTOR CAB - GROUND CIRCUIT OPEN CAB - INTERNAL FAULT

TEST ACTION APPLICABILITY

1 Turn the ignition on.

With the DRBIIIt, read DTC’s. With the DRBIIIt, erase DTC’s.

Turn the ignition off. Turn the ignition on. Start the engine. With the DRBIIIt, read DTC’s. Does the DRBIIIt display SYSTEM OVER VOLTAGE?

Yes → Go To 2 No → Go To 7

2 Is a battery charger connected to the vehicle? All

Yes → Ensure the battery is fully charged.

No → Go To 3

All

Perform ABS VERIFICATION TEST - VER 1.

Page 34

BRAKES (CAB)

SYSTEM OVER VOLTAGE — Continued

TEST ACTION APPLICABILITY

3 Turn the ignition off.

Disconnect the CAB connector.

Note: Check connector - Clean/repair as necessary.

Start the engine. Raise engine speed above 1,800 RPM’s Measure the voltage between Fused Ignition Switch Output (RUN) circuit and ground. Is the voltage above 16.5 volts ?

Yes → Refer to appropriate service information for Charging System

testing and repair. Perform ABS VERIFICATION TEST - VER 1.

No → Go To 4

All

4 Turn the ignition off.

Disconnect the CAB connector.

Note: Check connector - Clean/repair as necessary.

Inspect the CAB and CAB harness connector for damage. Is there any broken, bent, pushed out, corroded, or spread terminals?

Yes → Repair as necessary.

No → Go To 5

5 Turn the ignition off.

Disconnect the CAB connector.

Note: Check connector - Clean/repair as necessary.

Using a 12-volt test light connected to 12-volts, probe the Ground circuits. Does the test light illuminate?

Yes → Go To 6

6 Turn the ignition off.

Reconnect the CAB harness connector. Turn the ignition on. With the DRBIIIt in Sensors, read the ignition voltage. Does the DRBIIIt display ignition voltage above 16 volts?

No → Repair the Ground circuit for an open.

Yes → Replace the Controller Antilock Brake in accordance with the

All

Perform ABS VERIFICATION TEST - VER 1.

All

Perform ABS VERIFICATION TEST - VER 1.

All

Service Information. Perform ABS VERIFICATION TEST - VER 1.

No → Go To 7

Page 35

BRAKES (CAB)

SYSTEM OVER VOLTAGE — Continued

TEST ACTION APPLICABILITY

7 Turn the ignition off.

Visually inspectthe related wiring harness. Look foranychafed, pierced, pinched, or partially broken wires. Visually inspect the related wire harness connectors. Look for broken, bent, pushed out, or corroded terminals. Refer to any Hotline letters or Technical Service Bulletins that may apply. Ensure the battery is fully charged. Inspect the vehicle for aftermarket accessories that may exceed the Generator System output. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors. Were any problems found?

Yes → Repair as necessary.

Perform ABS VERIFICATION TEST - VER 1.

No → Test Complete.

All

Page 36

BRAKES (CAB)

Symptom:

SYSTEM UNDER VOLTAGE

When Monitored and Set Condition:

SYSTEM UNDER VOLTAGE

When Monitored: Ignition on. The CAB monitors the Fused Ignition Switch Output circuit voltage above 10 km/h (6 mph) for proper system voltage.

Set Condition: If the voltage is below 9.5 volts, the Diagnostic Trouble Code (DTC) is set.

POSSIBLE CAUSES

INTERMITTENT DTC DAMAGED CAB/CAB HARNESS CONNECTOR RUNNING BATTERY VOLTAGE LOW CAB - GROUND CIRCUIT OPEN FUSED IGNITION SWITCH OUTPUT (RUN) CIRCUIT OPEN CAB - INTERNAL FAULT

TEST ACTION APPLICABILITY

1 Turn the ignition on.

With the DRBIIIt, read DTC’s. With the DRBIIIt, erase DTC’s.

Turn the ignition off. Turn the ignition on. Start the engine. Drive the vehicle above 16 km/h (10 mph) for at least 20 seconds. Stop the vehicle With the DRBIIIt, read DTC’s. Does the DRBIIIt display SYSTEM UNDER VOLTAGE ?

Yes → Go To 2 No → Go To 6

2 Engine Running.

Measure the battery voltage. Is the battery voltage below 10 volts?

Yes → Refer to appropriate service information for charging system

All

testing and repair. Perform ABS VERIFICATION TEST - VER 1.

No → Go To 3

Page 37

BRAKES (CAB)

SYSTEM UNDER VOLTAGE — Continued

TEST ACTION APPLICABILITY

3 Turn the ignition off.

Disconnect the CAB harness connector. Inspect the CAB and CAB harness connector for damage. Is there any broken, bent, pushed out, corroded, or spread terminals?

Yes → Repair as necessary.

Perform ABS VERIFICATION TEST - VER 1.

No → Go To 4

All

4 Turn the ignition off.

Disconnect the CAB harness connector. Using a 12-volt test light connected to 12-volts, probe the Ground circuits. Does the test light illuminate?

Yes → Go To 5 No → Repair the Ground circuit for an open.

5 Turn the ignition on.

Using a 12-volt test light connected to ground, probe the Fused Ignition Switch Output (RUN) circuit. Does the test light illuminate?

Yes → Replace the Controller Antilock Brake in accordance with the

No → Repair the Fused Ignition Switch Output (RUN) circuit for an

6 Turn the ignition off.

All

Perform ABS VERIFICATION TEST - VER 1.

All

Service Information. Perform ABS VERIFICATION TEST - VER 1.

open. Perform ABS VERIFICATION TEST - VER 1.

All

Yes → Repair as necessary.

Perform ABS VERIFICATION TEST - VER 1.

No → Test Complete.

Page 38

BRAKES (CAB)

Symptom:

VALVE POWER FEED FAILURE

When Monitored and Set Condition:

VALVE POWER FEED FAILURE

When Monitored: Ignition ON. ABS Power Relay closed. Valve command for a particular solenoid not present.

Set Condition: Low feedback voltage from the low side of all the solenoids.

POSSIBLE CAUSES

INTERMITTENT DTC ABS VALVE FUSE ABS VALVE FUSED B(+) SUPPLY CIRCUIT OPEN ABS VALVE FUSED B(+) CIRCUIT OPEN ABS VALVE FUSED B(+) CIRCUIT INTERMITTENT SHORT TO GROUND ABS VALVE FUSED B(+) CIRCUIT SHORT TO GROUND DAMAGED CAB/CAB HARNESS CONNECTOR CAB - GROUND CIRCUIT OPEN CAB - INTERNAL FAULT

TEST ACTION APPLICABILITY

1 Turn the ignition on.

With the DRBIIIt, read DTC’s. With the DRBIIIt, erase DTC’s. Turn the ignition off. Turn the ignition on. With the DRBIIIt, read DTC’s. Does the DRBIIIt display VALVE POWER FEED FAILURE?

Yes → Go To 2 No → Go To 10

2 Turn the ignition off.

Remove and Inspect the ABS Valve fuse. Is the ABS Valve fuse open?

All

Yes → Go To 3 No → Go To 6

Page 39

BRAKES (CAB)

VALVE POWER FEED FAILURE — Continued

TEST ACTION APPLICABILITY

3 Turn the ignition off.

Visuallyinspect the ABSValveFused B(+) circuit inthe wiring harness. Lookfor any sign of an intermittent short to ground. Is the wiring harness OK?

Yes → Go To 4 No → Repair the ABS Valve Fused B(+) circuit for a short to ground.

Perform ABS VERIFICATION TEST - VER 1.

All

4 Turn the ignition off.

Disconnect the CAB harness connector.

Note: Check connector - Clean/repair as necessary.

Using a test light connected to 12 volts, probe theABS Valve Fused B(+) circuit fuse terminal. Did the test light illuminate?

Yes → Repair the ABS Valve Fused B(+) circuit for a short to ground.

No → Go To 5

5 Turn the ignition off.

Reconnect the CAB harness connector.

NOTE: The CAB harness connector must be reconnected for the results of this test to be valid.

Using a test light connected to 12 volts, probe theABS Valve Fused B(+) circuit fuse terminal. Did the test light illuminate?

Yes → Replace the Controller Antilock Brake in accordance with the

6 Turn the ignition off.

Disconnect the CAB harness connector. Inspect the CAB and CAB harness connector for damage. Is there any broken, bent, pushed out, corroded or spread terminals?

No → Replace the ABS Valve Fused B(+) fuse. If the fuse is open make

All

Perform ABS VERIFICATION TEST - VER 1.

All

Service Information. Perform ABS VERIFICATION TEST - VER 1.

sure to check for a short to ground. Perform ABS VERIFICATION TEST - VER 1.

All

Yes → Repair as necessary.

Perform ABS VERIFICATION TEST - VER 1.

No → Go To 7

7 Turn the ignition off.

Using a12-volt testlight connected toground, probethe B(+) supplyat theABS Valve fuse terminal. Did the test light illuminate?

Yes → Go To 8 No → Repair the ABS Valve Fused B(+) supply circuit for an open.

Perform ABS VERIFICATION TEST - VER 1.

All

Page 40

BRAKES (CAB)

VALVE POWER FEED FAILURE — Continued

TEST ACTION APPLICABILITY

8 Reinstall the ABS Valve fuse.

Disconnect the CAB harness connector. Using a12-volt testlight connected toground, probetheABSValve FusedB(+) circuit at the CAB harness connector. Did the test light illuminate?

Yes → Go To 9 No → Repair the ABS Valve Fused B(+) circuit for an open.

Perform ABS VERIFICATION TEST - VER 1.

All

9 Turn the ignition off.

Using a 12-volt test light connectedto 12-volts, probe the ground circuits at the CAB harness connector. Did the test light illuminate?

Yes → Replace the Controller Antilock Brake in accordance with the

No → Repair the CAB Ground circuit for an open.

10 Turn the ignition off.

Yes → Repair as necessary.

No → Test Complete.

All

Service Information. Perform ABS VERIFICATION TEST - VER 1.

Perform ABS VERIFICATION TEST - VER 1.

All

Perform ABS VERIFICATION TEST - VER 1.

Page 41

BRAKES (CAB)

Symptom:

*BRAKE LAMP SWITCH INOPERATIVE

POSSIBLE CAUSES

CHECK BRAKE LAMP SWITCH OUTPUT BRAKE LAMP SWITCH B+ OPEN BRAKE LAMP SWITCH OPEN BRAKE LAMP SWITCH OUTPUT CIRCUIT SHORT OR OPEN CAB -- INTERNAL OPEN

TEST ACTION APPLICABILITY

1 With the DRBIIIt in Inputs/Outputs, read the Brake Lamp Switch state.

Press and release the brake pedal. Does the DRBIIIt display PRESSED and RELEASED?

All

Yes → The Brake Lamp Switch is OK.

No → Go To 2

2 Disconnect the Brake Lamp Switch harness connector.

Using a 12-volt test light connected to ground, check the Brake Lamp Switch Fused B+ circuit. Does the test light illuminate brightly ?

Yes → Go To 3 No → Repair the Brake Lamp Switch Fused B+ circuit for an open.

3 Disconnect the Brake Lamp Switch harness connector.

Connect a jumper wire between theBrake Lamp Switch B+ and Brake Lamp Switch Output circuits. With the DRBIIIt in Inputs/Outputs, read the Brake Lamp Switch state. Does the DRBIIIt display PRESSED?

Yes → Replace the Brake Lamp Switch in accordance with the Service

No → Go To 4

4 Disconnect the CAB harness connector.

Disconnect the Brake Lamp Switch harness connector. Check the Brake Lamp Switch Output circuit for a short to voltage and for an open. Is the Brake Lamp Switch Output circuit shorted or open?

Perform ABS VERIFICATION TEST - VER 1.

All

Perform ABS VERIFICATION TEST - VER 1.

All

Information. Perform ABS VERIFICATION TEST - VER 1.

All

Yes → Repair the Brake Lamp Switch Output circuit for a short to

voltage or an open. Perform ABS VERIFICATION TEST - VER 1.

No → Replace the Controller Antilock Brake in accordance with the

Service Information. Perform ABS VERIFICATION TEST - VER 1.

Page 42

BRAKES (CAB)

Symptom:

*TRAC OFF INDICATOR NEVER/ALWAYS ON

POSSIBLE CAUSES

TRAC OFF SW GROUND OPEN TRAC OFF SWITCH OPEN TRAC OFF SWITCH SENSE CIRCUIT SHORT TO B+ OR OPEN BCM -- NO TRAC OFF MESSAGE CLUSTER INTERNAL FAULT-- TRAC OFF INDICATOR INOPERATIVE CLUSTER-PERMANENT TRAC OFF INDICATOR TRAC OFF SWITCH INTERNAL SHORT TRAC OFF SWITCH SENSE CIRCUIT SHORT TO GROUND BCM -- PERMANENT TRAC OFF MESSAGE

TEST ACTION APPLICABILITY

1 Note: If any DTC’s are present, they must be repaired prior to performing

this test.

Turn the ignition off. Turn the ignition on. Observe the TRAC OFF indicator. Did the TRAC OFF indicator come on for several seconds then go out?

Yes → Go To 2 No. TRAC OFF Indicator does not come on.

No. TRAC OFF Indicator does not go out.

2 Disconnect the TRAC OFF Switch harness connector.

Using a 12-volt testlight connected to 12-volts, check the TRAC OFFSwitch Ground circuit. Does the test light illuminate?

Yes → Go To 3 No → Repair the TRAC OFF Switch Ground circuit for an open.

3 Turn the ignition off.

Disconnect the TRAC OFF Switch harness connector. Turn the ignition on. Connect and disconnect a jumper wire between TRAC OFF Switch Ground and TRAC OFF Switch Sense circuits. Does the TRAC OFF Indicator light and then go out?

All

Go To 5

Go To 6

All

Perform ABS VERIFICATION TEST - VER 1.

All

Yes → Replace the TRAC OFF switch.

Perform ABS VERIFICATION TEST - VER 1.

No → Go To 4

Page 43

BRAKES (CAB)

*TRAC OFF INDICATOR NEVER/ALWAYS ON — Continued

TEST ACTION APPLICABILITY

4 Turn the ignition off.

Disconnect the TRAC OFF Switch harness connector. Disconnect the CAB harness connector. Turn the ignition on. Check the TRAC OFF Switch Sense circuit for short to B+ and for an open. Is the Sense circuit shorted or open?

Yes → Repair the TRAC OFF Switch Sense circuit for a short to battery

or for an open. Perform ABS VERIFICATION TEST - VER 1.

No → Replace the Body Control Module in accordance with the Service

Information. Perform ABS VERIFICATION TEST - VER 1.

All

5 Turn the ignition off.

NOTE: The purpose of this test is to perform the Instrument Cluster self test.

Depress and hold the Odometer Reset Button. Turn the Key from OFF to ON and then back to OFF. Release the Odometer Reset Button. Do the Instrument Cluster Indicators and Gauges activate and deactivate?

Yes → Replace the Body Control Module in accordance with the Service

No → Replace the Instrument Cluster in accordance with the Service

6 NOTE: The purpose of this test is to perform the Instrument Cluster self

test.

Yes → Go To 7 No → Replace the Instrument Cluster in accordance with the Service

All

Information. Perform ABS VERIFICATION TEST - VER 1.

All

Information. Perform ABS VERIFICATION TEST - VER 1.

7 Turn the ignition off.

Disconnect the TRAC OFF Switch harness connector. Turn the ignition on. Does the TRAC OFF Indicator light and then go out?

Yes → Replace the TRAC OFF switch.

Perform ABS VERIFICATION TEST - VER 1.

No → Go To 8

All

Page 44

BRAKES (CAB)

*TRAC OFF INDICATOR NEVER/ALWAYS ON — Continued

TEST ACTION APPLICABILITY

8 Turn the ignition off.

Disconnect the TRAC OFF Switch harness connector. Disconnect the BCM C4 harness connector. Check the TRAC OFF Switch Sense circuit for short to ground. Is the Sense circuit shorted to ground?

Yes → Repair the TRAC OFF SwitchSense circuit for a short to ground.

Perform ABS VERIFICATION TEST - VER 1.

No → Replace the Body Control Module in accordance with the Service

Information. Perform ABS VERIFICATION TEST - VER 1.

All

Page 45

BRAKES (CAB)

Symptom:

*TRAC ON INDICATOR NEVER/ALWAYS ON

POSSIBLE CAUSES

CAB -- INTERNAL FAULT CHECK TRACTION CONTROL SYSTEM CLUSTER FAILS SELF TEST CAB - NO TRAC MESSAGE

TEST ACTION APPLICABILITY

1 NOTE: The DRBIIIt must be able to communicate with the CAB prior to

performing this test. NOTE: Note: If any CAB DTC’s are present, they must be repaired prior to performing this test.

Perform the KEY-ON bulb test. Did the TRAC Indicator illuminate and then go out?

All

Yes → Go To 2 No → Go To 3

2 Make surethe TractionControl system hasnot been deactivatedwith the TRACOFF

switch.

NOTE: The purpose of this test is to determine if the Traction Control system is operating.

With the DRBIIIt in Inputs/Outputs, read the ABS Pump Motor voltage state. Accelerate sufficient to cause drive wheel slip. Does the TRACIndicator illuminate and the DRBIIIt displayapproximately 9 volts?

3 NOTE: The purpose of this test is to perform the Instrument Cluster self

test.

Yes → The traction control system is functioning normally.

No → Replace the Controller Antilock Brake in accordance with the

Yes → Replace the Controller Antilock Brake in accordance with the

All

Perform ABS VERIFICATION TEST - VER 1.

Service Information. Perform ABS VERIFICATION TEST - VER 1.

All

Service Information. Perform ABS VERIFICATION TEST - VER 1.

No → Replace the Instrument Cluster in accordance with the Service

Information. Perform ABS VERIFICATION TEST - VER 1.

Page 46

COMMUNICATION

Symptom:

*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE

POSSIBLE CAUSES

NO RESPONSE FROM CAB GROUND CIRCUIT OPEN OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN PCI BUS CIRCUIT CONTROLLER ANTILOCK BRAKE

TEST ACTION APPLICABILITY

1 Turn the ignition on.

Note: As soon as one or more module communicates with the DRB, answer the question.

With the DRB, attempt to communicate with the Airbag Control Module (ACM). With the DRB, attempt to communicate with the Body Control Module (BCM). Was the DRB able to I/D or establish communications with either of the modules?

All

Yes → Go To 2 No → Refer to the Communications category and perform the symptom

2 Turn the ignition off.

Disconnect the CAB harness connector. Using a 12-volt test light connected to 12-volts, probe both ground circuits. Is the test light illuminated for each circuit?

Yes → Go To 3 No → Repair the ground circuit(s) for an open.

3 Turn the ignition off.

Disconnect the CAB harness connector. Turn the ignition on. Using a 12-volt test light connected to ground, probe the Fused Ignition Switch Output circuit. Is the test light illuminated?

Yes → Go To 4 No → Repair the Fused Ignition Switch Output circuit for an open.

PCI Bus Communication Failure. Perform ABS VERIFICATION TEST - VER 1.

All

Perform ABS VERIFICATION TEST - VER 1.

All

Perform ABS VERIFICATION TEST - VER 1.

Page 47

COMMUNICATION

*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE — Continued

TEST ACTION APPLICABILITY

4 Note: Ensure there is PCI Bus communication with other modules on the

vehicle before proceeding. If not, refer to the symptom list from the menu and repair as necessary.

Disconnect the CAB harness connector. Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and black test probes. Connect the scope input cable to the channel one connector on the DRB. Attach the red and black leads and the cable to probe adapter to the scope input cable. With the DRBIIIt select Pep Module Tools. Select lab scope. Select Live Data. Select 12 volt square wave. Press F2 for Scope. Press F2 and use the down arrow to set voltage range to 20 volts. Set Probe to x10. Press F2 again when complete. Connect the Black lead to the chassis ground. Connect the Red lead to the PCI Bus circuit in the CAB connector. Turn the ignition on. Observe the voltage display on the DRB Lab Scope. Does the voltage pulse from 0 to approximately 7.5 volts?

All

Yes → Go To 5 No → Repair the PCI Bus circuit for an open.

5 If there are no possible causes remaining, view repair. All

Repair

Perform ABS VERIFICATION TEST - VER 1.

Replace the Controller Antilock Brake in accordance with the Service Information. Perform ABS VERIFICATION TEST - VER 1.

Page 48

VERIFICATION TESTS

Verification Tests

ABS VERIFICATION TEST - VER 1 APPLICABILITY

1. Turn the ignition off.

2. Connect all previously disconnected components and connectors.

3. Ensure all accessories are turned off and the battery is fully charged.

4. Ensure thatthe Ignition is on, andwith the DRBIII, erase allDiagnostic Trouble Codesfrom ALL modules. Start the engine and allow it to run for 2 minutes and fully operate the system that was malfunctioning.

5. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIII, read DTC’s from ALL modules.

6. If any Diagnostic Trouble Codes are present, return to Symptom list and troubleshoot new or recurring symptom.

7. NOTE: For Sensor Signal and Pump Motor faults, the CAB must sense all 4 wheels at 25 km/h (15 mph) before it will extinguish the ABS Indicator.

8. If there are no DTC’s present after turning ignition on, road test the vehicle for at least 5 minutes. Perform several antilock braking stops.

9. Caution: Ensure braking capability is available before road testing.

10. Again, with the DRBIIIt read DTC’s. If any DTC’s are present, return to Symptom list.

11.If there areno Diagnostic Trouble Codes (DTC’s)present, and thecustomer’s concern can no longer be duplicated, the repair is complete. Are any DTC’s present or is the original concern still present?

All

Yes → Repair is not complete, refer to appropriate symptom. No → Repair is complete.

Page 49

8.0 COMPONENT LOCATIONS

8.1 CONTROLLER ANTILOCK BRAKE (CAB)

8.2 DATA LINK CONNECTOR

COMPONENT LOCATIONS

C O

P O N

E N

L O

I O N

8.3 FUSES

Page 50

COMPONENT LOCATIONS

C O

8.4 TRACTION CONTROL SWITCH

P O N

E N

L O

I O N

8.4.1 TRACTION CONTROL INDICATORS

8.5 WHEEL SPEED SENSORS

8.5.1 FRONT

Page 51

8.5.2 REAR

8.5A WHEEL SPEED SENSOR CONNECTORS

8.5A.1 FRONT

COMPONENT LOCATIONS

C O M

P O N

E N

L O

I O N

8.5A.2 REAR

Page 52

COMPONENT LOCATIONS

8.6 BRAKE LAMP SWITCH

P O N

E N

L O

I O N

Page 53

9.0 CONNECTOR PINOUTS

CONNECTOR PINOUTS

CAV CIRCUIT FUNCTION

ABS PUMP MOTOR

1 TN GROUND 2 RD PUMP/MOTOR RELAY OUTPUT

BRAKE LAMP SWITCH

CAV CIRCUIT FUNCTION

1 A103 18GY/RD FUSED B(+) 2 L50 18WT/TN (GAS) BRAKE LAMP SWITCH OUTPUT 2 L50 18WT/TN (DIESEL) PRIMARY BRAKE SWITCH SIGNAL 3 V30 20VT/WT (GAS) SPEED CONTROL BRAKE SWITCH OUTPUT 4 V32 20VT/YL (GAS) SPEED CONTROL ON/OFF SWITCH SENSE 5 Z429 20BK/OR GROUND 6 B29 20DG/WT SECONDARY BRAKE SWITCH SIGNAL

C O N N

T O

I N O U

T S

Page 54

CONNECTOR PINOUTS

O N N

CAV CIRCUIT FUNCTION

1 Z107 12BK/DG GROUND 2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL 3 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 4- 5 D25 18WT/VT PCI BUS 6 B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL 7 B7 18DG/VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 8- -

9 A111 12DG/RD FUSED B(+) 10 F500 18DG/PK FUSED IGNITION SWITCH OUTPUT (RUN) 11 - 12 - 13 - 14 - 15 - 16 Z127 12BK/DG GROUND 17 - 18 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 19 B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR SIGNAL

E C T

20 B4 18DG/GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 21 - 22 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL 23 B9 18DG/LG (EXCEPT

3.3L/3.8L) 23 B9 18DG/WT (3.3L/3.8L) LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 24 A107 12TN/RD FUSED B(+)

CONTROLLER ANTILOCK BRAKE

LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY

O U

T S

CAV CIRCUIT FUNCTION

1 B9 18DG/LG (EXCEPT

3.3L/3.8L)

1 B9 18DG/WT (3.3L/3.8L) LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL

CAV CIRCUIT FUNCTION

1 B4 18DG/GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR SIGNAL

LEFT FRONT WHEEL SPEED SENSOR

LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY

LEFT REAR WHEEL SPEED SENSOR

Page 55

CONNECTOR PINOUTS

CAV CIRCUIT FUNCTION

RIGHT FRONT WHEEL SPEED SENSOR

1 B7 18DG/VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL

RIGHT REAR WHEEL SPEED SENSOR

CAV CIRCUIT FUNCTION

1 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL

TRACTION CONTROL SWITCH

CAV CIRCUIT FUNCTION

1 B27 20DG/WT TRACTION CONTROL SWITCH SENSE 2 Z427 20BK/WT GROUND

C O N N

T O

I N O U

T S

Page 56

NOTES

Page 57

10.0 SCHEMATIC DIAGRAMS

10.1 TEVES MARK 20E ANTILOCK BRAKE SYSTEM – ABS

SCHEMATIC DIAGRAMS

S C

A T

R A

Page 58

NOTES

Chrysler Caravan and Voyager (2003) Service Manual – Chassis

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 IDENTIFICATION OF SYSTEM

1.1 SYSTEM COVERAGE

3.2 TRACTION CONTROL SYSTEM (TCS) DESCRIPTION (IF EQUIPPED)

3.3 SYSTEM COMPONENTS

• controller antilock brake (CAB)

3.3.1 ABS AND BRAKE WARNING INDICATORS

3.3.3 HYDRAULIC CONTROL UNIT

3.3.4 ABS SWITCHES/SENSORS

3.3.5 ABS INITIALIZATION

3.3.6 ABS DIAGNOSTIC MODE

3.3.7 TRACTION CONTROL OPERATION (IF EQUIPPED)

3.5 DIAGNOSTIC TROUBLE CODES

3.6 FREEZE FRAME

3.7.1 TRAINING THE EVIC

3.7.2 PRESSURE THRESHOLDS

3.7.2.1 CRITICAL AND NON-CRITICAL SYSTEM ALERTS

3.7.3 SYSTEM FAULTS

3.7.4 SPARE WHEEL AUTO-DETECT

3.7.5 DIAGNOSING AND CLEARING SYSTEM FAULTS

3.7.6 SYSTEM TEST

3.8.2 DISPLAY IS NOT VISIBLE

4.0 DISCLAIMERS, SAFETY, WARNINGS

4.1 DISCLAIMERS

4.2 SAFETY

4.2.1 TECHNICIAN SAFETY INFORMATION

4.2.3 SERVICING SUB-ASSEMBLIES

4.3 WARNINGS

4.3.1 VEHICLE DAMAGE WARNINGS

4.4 DIAGNOSIS

6.0 GLOSSARY OF TERMS

BRAKES (CAB)

BUS SYSTEM COMMUNICATION FAILURE

CAB INTERNAL FAILURE

CLUSTER LAMP FAILURE

INCORRECT TONE WHEEL FAILURE

LEFT FRONT SENSOR CIRCUIT FAILURE

LEFT REAR SENSOR CIRCUIT FAILURE

RIGHT FRONT SENSOR CIRCUIT FAILURE

RIGHT REAR SENSOR CIRCUIT FAILURE

LEFT FRONT WHEEL SPEED SIGNAL FAILURE

LEFT REAR WHEEL SPEED SIGNAL FAILURE

RIGHT FRONT WHEEL SPEED SIGNAL FAILURE

RIGHT REAR WHEEL SPEED SIGNAL FAILURE

PUMP CIRCUIT FAILURE

SYSTEM OVER VOLTAGE

SYSTEM UNDER VOLTAGE

VALVE POWER FEED FAILURE

*BRAKE LAMP SWITCH INOPERATIVE

*TRAC OFF INDICATOR NEVER/ALWAYS ON

*TRAC ON INDICATOR NEVER/ALWAYS ON

COMMUNICATION

*NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE

VERIFICATION TESTS

Verification Tests

8.0 COMPONENT LOCATIONS

8.1 CONTROLLER ANTILOCK BRAKE (CAB)

8.2 DATA LINK CONNECTOR

8.3 FUSES

8.4 TRACTION CONTROL SWITCH

8.4.1 TRACTION CONTROL INDICATORS

8.5 WHEEL SPEED SENSORS

8.5.1 FRONT

8.5.2 REAR

8.5A WHEEL SPEED SENSOR CONNECTORS

8.5A.1 FRONT

8.5A.2 REAR

8.6 BRAKE LAMP SWITCH

9.0 CONNECTOR PINOUTS

ABS PUMP MOTOR

BRAKE LAMP SWITCH

CONTROLLER ANTILOCK BRAKE

LEFT FRONT WHEEL SPEED SENSOR

LEFT REAR WHEEL SPEED SENSOR

RIGHT FRONT WHEEL SPEED SENSOR