Ford E-Series 2008 Workshop Manual

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SECTION 206-09: Vehicle Dynamic Systems 2008 E-Series Workshop Manual

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DIAGNOSIS AND TESTING

Procedure revision date: 08/12/2008

Anti-Lock Control — Traction Control and Stability Assist

Printable View (432 KB)

Special Tool(s)

Principles of Operation

ABS with Traction Control, Electronic Stability Control (ESC) and Roll Stability Control (RSC)

The ABS module with traction control and roll stability control (RSC) manages anti-lock braking to maintain vehicle control during deceleration and performs additional functions specific to traction control and RSC.

ABS Operation

When the ignition switch is in the RUN position, the ABS module does a preliminary electrical check and, at approximately 20 km/h (12 mph), the hydraulic pump motor is turned on for approximately 1/2 second. During this time a buzzing or humming noise may be heard and a vibration maybe felt in the brake pedal. This is a normal condition. Any malfunction of the ABS disables the stability assist and the ABS warning indicator illuminates. However, the power-assist braking system functions normally.

The ABS module monitors and compares the rotational speed of each wheel. Wheel speeds are measured by the wheel speed sensor, which electrically senses each tooth of the sensor ring as it passes through the magnetic field of the sensor. When the ABS module detects an impending wheel lock, the ABS module commands the hydraulic pump motor on and commands the hydraulic control unit (HCU) to open and close the appropriate solenoid valves to modulate the brake pressure to the individual brake caliper(s). Once the affected wheel(s) return to the desired speed, the ABS module commands the HCU to return the solenoid valves to their normal position and normal base brake operation is restored.

The ABS module must be configured when a new ABS module is installed.

Traction Control

When the drive wheels lose traction and begin to spin, with vehicle speed under 100 km/h (62 mph), the ABS module commands the hydraulic pump motor on and commands the HCU to open and close the appropriate solenoid valves to modulate the brake pressure to the brake caliper(s) while simultaneously sending a request to the PCM over the high-speed controller area network (HS-CAN) bus to reduce engine torque to maintain vehicle traction. The PCM accomplishes this by minor incremental timing changes and fewer fuel injector pulses until the ABS module ends the request. The request ends when the driven wheel speed returns to the desired speed. After the vehicle speed exceeds 100 km/h (62 mph), the traction control is accomplished only through the PCM torque control. The traction control system can be deactivated by pressing the stability/traction control switch in the instrument panel.

When the traction control system activates, any of the following can occur:

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A small deceleration or a reduction in the acceleration of the vehicle

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The traction control indicator in the instrument cluster flashes

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If the driver's foot is on the brake pedal, a vibration will be felt in the pedal much like ABS

Electronic Stability Control (ESC)

The electronic stability control (ESC) system constantly monitors the vehicle motion relative to the intended course. This is done by using sensors to compare the steering input and the yaw rate sensor with that of the actual vehicle motion. The ESC system monitors information from the throttle position (TP) sensor, the steering wheel rotation sensor (steering wheel angle and rate of change) and a yaw rate sensor (integral to the stability control sensor cluster) that measures changes in vehicle direction. If the ESC system determines from all these inputs that the vehicle is unable to travel in the intended direction, the system adjusts the brake torque at specific wheels in response to direct measurement of the vehicle motion and reduces engine torque to allow the vehicle to follow the intended course. The ESC system can be deactivated by pressing the stability/traction control switch in the instrument panel.

When the ESC system activates, any of the following can occur:

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A rumble or grinding sound much like ABS or traction control

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A small deceleration or a reduction in the acceleration of the vehicle

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The roll stability control (RSC) indicator flashes

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If the driver's foot is on the brake pedal, a vibration will be felt in the pedal much like ABS

Roll Stability Control (RSC)

The roll stability control (RSC) system constantly monitors the vehicle motion relative to the intended course. This is done by using sensors to compare the steering input and brake application with that of the actual vehicle motion. The system does not activate when the vehicle is traveling in reverse; however, the standard ABS and traction control continue to function

73III Automotive Meter 105-R0057 or equivalent

Flex Probe Kit 105-R025B or equivalent

Rotunda Active Wheel Speed Sensor Tester 105-R0110

Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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as usual. The RSC system monitors information from the wheel speed sensors, the throttle position sensor, the steering wheel rotation sensor (steering wheel angle and rate of change) and

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a roll-rate sensor (integral to the stability control sensor cluster) that measures changes in vehicle motion. If the RSC system determines from all these inputs that conditions exist for a potential roll-over event, the system adjusts the brake torque at specific wheels in response to direct measurement of the vehicle roll motion and reduces engine torque to make the vehicle more stable. By adjusting brake torque, the system can reduce the cornering forces and, therefore, the total roll moment acting on the vehicle. The RSC system can be deactivated by pressing the stability/traction control switch in the instrument panel.

When the RSC system activates, any of the following can occur:

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A rumble or grinding sound much like ABS or traction control

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A small deceleration or a reduction in the acceleration of the vehicle

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The RSC indicator flashes

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If the driver's foot is on the brake pedal, a vibration will be felt in the pedal much like ABS

Some drivers may notice a slight movement of the brake pedal when the system checks itself. The brake pedal moves when an active test of the brake booster is run. During this test a small amount of pressure is generated at the master cylinder, but no pressure is generated in the brake calipers.

Stability/Traction Control Switch

The stability/traction control switch is hard-wired to the instrument cluster module. The instrument cluster module communicates the stability/traction control switch status to the ABS module via the HS-CAN bus.

The stability/traction control switch allows the driver to control use of the ESC/RSC and traction control system. This is independent of the ABS function, which cannot be switched OFF by the driver. The ESC/RSC and traction control system status is indicated by a light in the stability/traction control switch. When the stability/traction control switch is set to OFF, the system is disabled at and below 32 km/h (20 mph). The system will automatically restore to full functionality every time the vehicle speed exceeds 32 km/h (20 mph) or when the ignition switch is cycled from OFF to RUN. However, the stability/traction control switch OFF indicator remains illuminated until the switch is pressed a second time. The ABS function continues to work as designed unless the yellow ABS warning indicator is illuminated. Normal braking function always occurs, unless the red brake warning indicator is illuminated.

Electronic Brake Distribution (EBD)

The HCU is used as an electronic proportioning valve for electronic brake distribution (EBD). The HCU controls the brake fluid pressure to the rear brakes to prevent them from applying before the front brakes. If ABS is disabled due to DTCs being present in the ABS module, EBD will also be disabled. Instrument cluster failure or a missing instrument cluster message on the HS-CAN bus will also disable EBD.

Stability Control Sensor Cluster

The sensor cluster (also called inertial module) consists of the yaw rate sensor, roll rate sensor, lateral accelerometer and longitudinal accelerometer. The lateral accelerometer measures the acceleration which corresponds to the force involved when the vehicle slides sideways. This acceleration has 2 forms. The first is the centrifugal acceleration which is generated when the vehicle travels around in a circle. The second is the acceleration due to gravity. On level ground there is no contribution from this acceleration. However, if the vehicle is parked sideways on a bank or incline, the sensor measures some lateral acceleration due to gravity even though the vehicle is not moving.

The longitudinal accelerometer measures the acceleration corresponding to the force involved when the vehicle moves forward and rearward in the horizontal plane, along the centerline of the vehicle's front and rear wheels.

The yaw rate sensor measures the relative vehicle motion about the vertical axis through its center of gravity.

The roll rate sensor measures the rate of rotation along the front to rear horizontal axis.

Steering Wheel Rotation Sensor

The steering wheel rotation sensor measures the rate of rotation of the steering wheel by monitoring the steering wheel rotation ring as it passes through the sensor gap. The steering wheel rotation sensor uses 2 signal lines to transmit information to the ABS module about whether the steering wheel is being turned left or right and how far it is being turned. The steering wheel rotation sensor does not indicate the absolute position of the steering wheel relative to straight-ahead. The stability assist system learns this position by comparing the steering wheel position with other signals and storing the position it has learned. The stability assist system confirms this position and modifies it as necessary during every new driving cycle.

ABS Module Calibration

If installing a new ABS module, HCU, steering wheel rotation sensor or stability control sensor cluster, the calibration procedure must be carried out. The calibration procedure is required for the ABS module to learn the "zero-position" of the various ESC/RSC sensors and components.

To calibrate the ABS module, connect the scan tool and carry out the Interactive Vehicle Dynamics (IVD) Initialization sequence.

If a DTC is logged for any component of the ESC/RSC system, the DTC must be cleared or repaired before carrying out the initialization sequence. The need to calibrate the ABS module is also indicated by the RSC indicator on the instrument cluster module flashing once every 2 seconds. The indicator flashes after clearing the DTCs that are associated with the RSC system. If a DTC is retrieved after calibration, refer to the ABS Module DTC Chart in this section.

When carrying out the initialization sequence for the ABS module, the vehicle must be on a level surface, must not be moving and the ignition switch must be in the RUN position.

When carrying out the initialization sequence for the ABS module after installing a new steering wheel rotation sensor, the ignition switch must be in the RUN position with the engine running and the steering wheel must be rotated back and forth from lock position to lock position.

Inspection and Verification

Identifying the Brake System

Two ABS systems are available for this vehicle: standard ABS and ABS enhanced with traction control and stability assist. ABS with traction control and stability assist may also be called electronic stability control (ESC), roll stability control (RSC), AdvanceTrac®, or interactive vehicle dynamics (IVD) by the scan tool and other service publications.

Vehicles that are equipped with traction control and stability assist can be identified by the presence of individual left and right rear wheel speed sensors.

Vehicles with standard ABS can be identified by the absence of rear wheel speed sensors.

If the vehicle is equipped with standard ABS, refer to Anti-Lock Control in this section to continue diagnosis of this system.

1. Verify the customer concern.

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2. Verify the stop lamps operate correctly by pressing and releasing the brake pedal with the ignition switch in the OFF position. If the stoplamps do not operate correctly, refer to

Steering wheel rotation sensor ring

Central junction box (CJB) fuse(s):

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Section 417-01. If the stoplamps operate correctly, proceed to the next step.

3. Verify the base brake system operates correctly. If any concerns are present, address them before continuing with any ABS concerns. Refer to Section 206-00. If the base brake system operates correctly, proceed to the next step.

4. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical

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Base brake system

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Hydraulic control unit (HCU)

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Tire pressure

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Tire size or mismatched tires

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Wheel speed sensor ring

5. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

6. NOTE: Make sure to use the latest scan tool software release.

If the cause is not visually evident, connect the scan tool to the data link connector (DLC).

7. NOTE: The vehicle communication module (VCM) LED prove out confirms power and ground from the DLC are provided to the VCM.

If the scan tool does not communicate with the VCM:

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check the VCM connection to the vehicle.

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check the scan tool connection to the VCM.

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refer to Section 418-00, No Power To The Scan Tool, to diagnose no communication with the scan tool.

8. If the scan tool does not communicate with the vehicle:

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verify the ignition key is in the ON position.

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verify the scan tool operation with a known good vehicle.

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refer to Section 418-00 to diagnose no response from the PCM.

9. Carry out the network test.

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If the scan tool responds with no communication for one or more modules, refer to Section 418-00.

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If the network test passes, retrieve and record continuous memory DTCs.

10. Clear the continuous DTCs and carry out the self-test diagnostics for the ABS module and the instrument cluster.

11. If the DTCs retrieved are related to the concern, go to the ABS Module DTC Chart or the Instrument Cluster DTC Chart. For all other DTCs, refer to Section 419-10.

12. If no DTCs related to the concern are retrieved, GO to Symptom Chart.

ABS Module DTC Chart

DTC Description Source Action

B1104 Steering Angle Sensor Signal

Error

B1317 Battery Voltage High ABS

B1318 Battery Voltage Low ABS

B1342 ECU is Faulted ABS

B211B Satellite ECU (Stability Control

Sensor Cluster) is Faulted

B2900 VIN Mismatch ABS

C1095 ABS Hydraulic Pump Motor

Circuit Failure

C1096 ABS Hydraulic Pump Motor

Circuit Open

C1115 ABS Power Relay Output Short

Circuit to Battery

C1145 RF Wheel Speed Sensor Input ABS GO to Pinpoint Test I.

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ABS module

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Battery junction box (BJB) fuse(s):

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11 (40A)

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16 (40A)

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Brake pedal position (BPP) switch

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2 (10A)

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22 (15A)

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Stability control sensor cluster

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Stability/traction control switch

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Steering wheel rotation sensor

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Traction control switch

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Wheel speed sensor

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Wiring, terminals or connectors

ABS

GO to Pinpoint Test K.

Module

GO to Pinpoint Test G.

Module

GO to Pinpoint Test G.

Module

NOTE: If other DTCs are present, REPAIR them before installing a new component.

Module

CLEAR the DTCs. CARRY OUT the self-test and RETRIEVE the DTCs. If DTC is retrieved again, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. Using the scan tool, CARRY OUT the IVD Initialization sequence. CLEAR the DTCs. CARRY OUT the self-test with the brake pedal not applied.

ABS

CHECK the stability control sensor cluster electrical connector and wiring for water intrusion. REPAIR as necessary. If OK, INSTALL a

Module

new sensor cluster. REFER to Stability Control Sensor Cluster in this section. CLEAR the DTCs. CARRY OUT the self-test with the brake pedal not applied.

GO to Pinpoint Test R.

Module

ABS

GO to Pinpoint Test H.

Module

ABS

GO to Pinpoint Test H.

Module

ABS

NOTE: If other DTCs are present, REPAIR them before installing a new component.

Module

CLEAR all DTCs. TEST DRIVE the vehicle above 32 km/h (20 mph) and CARRY OUT at least one ABS stop. RETRIEVE the DTCs. If DTC C1115 is retrieved again, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. Using

the scan tool, CARRY OUT the IVD Initialization sequence. CLEAR the DTCs. CARRY OUT the self-test with the brake pedal not applied.

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Circuit Failure Module

ABS Outlet Valve Coil LF Circuit

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C1155 LF Wheel Speed Sensor Input

Circuit Failure

C1165 RR Wheel Speed Sensor Input

Circuit Failure

C1175 LR Wheel Speed Sensor Input

Circuit Failure

C1185 ABS Power Relay Output

Circuit Failure

C1194

Failure

C1198 ABS Inlet Valve Coil LF Circuit

Failure

C1210 ABS Outlet Valve Coil RF

Circuit Failure

C1214 ABS Inlet Valve Coil RF Circuit

Failure

C1222 Wheel Speed Mismatch ABS

C1233 LF Wheel Speed Input Signal

Missing

C1234 RF Wheel Speed Input Signal

Missing

C1235 RR Wheel Speed Input Signal

Missing

C1236 LR Wheel Speed Input Signal

Missing

C1242 ABS Outlet Valve Coil LR

Circuit Failure

C1246 ABS Outlet Valve Coil RR

Circuit Failure

C1250 ABS Inlet Valve Coil LR Circuit

Failure

C1254 ABS Inlet Valve Coil RR Circuit

Failure

C1277 Steering Wheel Angle 1 and 2

Circuit Failure

C1278 Steering Wheel Angle 1 and 2

Signal Faulted

C1279 Yaw Rate Sensor Circuit Failure ABS

C1280 Yaw Rate Sensor Signal Fault ABS

C1281 Lateral Accelerometer Circuit

Failure

C1282 Lateral Accelerometer Signal

Fault

C1288 Pressure Transducer

Main/Primary Input Circuit Failure

C1329 ABS Outlet Valve Coil RF

Circuit Excessive Temperature

C1330 ABS Outlet Valve Coil LR

Circuit Excessive Temperature

C1331 ABS Outlet Valve Coil RR

Circuit Excessive Temperature

C1332

Excessive Temperature

C1333 ABS Inlet Valve Coil LR Circuit

Excessive Temperature

C1334 ABS Inlet Valve Coil LF Circuit

Excessive Temperature

C1335 ABS Inlet Valve Coil RF Circuit

Excessive Temperature

C1336 ABS Inlet Valve Coil RR Circuit

Excessive Temperature

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

ABS

Module

GO to Pinpoint Test I.

NOTE: REPAIR all other DTCs prior to diagnosing this one.

CLEAR all DTCs. RETRIEVE DTCs. If the DTC is retrieve again, INSTALL a new ABS module. REFER to Anti-Lock Brake System

(ABS) Module in this section. Using the scan tool, CARRY OUT the IVD Initialization sequence. CLEAR the DTCs. CARRY OUT the

self-test with the brake pedal not applied. CLEAR all DTCs. DRIVE the vehicle. RETRIEVE the DTCs. If multiple coil DTCs are retrieved, GO to Pinpoint Test G. If only DTC

C1194 is retrieved, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. Using the scan tool, CARRY OUT the IVD Initialization sequence. CLEAR the DTCs. CARRY OUT the self-test with the brake pedal not applied.

CLEAR all DTCs. DRIVE the vehicle. RETRIEVE the DTCs. If multiple coil DTCs are retrieved, GO to Pinpoint Test G. If only DTC C1198 is retrieved, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. Using the scan tool, CARRY OUT the IVD Initialization sequence. CLEAR the DTCs. CARRY OUT the self-test with the brake pedal not applied.

CLEAR all DTCs. DRIVE the vehicle. RETRIEVE the DTCs. If multiple coil DTCs are retrieved, GO to Pinpoint Test G. If only DTC C1210 is retrieved, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. Using the scan tool, CARRY OUT the IVD Initialization sequence. CLEAR the DTCs. CARRY OUT the self-test with the brake pedal not applied.

CLEAR all DTCs. DRIVE the vehicle. RETRIEVE the DTCs. If multiple coil DTCs are retrieved, GO to Pinpoint Test G. If only DTC C1214 is retrieved, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. Using the scan tool, CARRY OUT the IVD Initialization sequence. CLEAR the DTCs. CARRY OUT the self-test with the brake pedal not applied.

GO to Pinpoint Test J.

CLEAR all DTCs. DRIVE the vehicle. RETRIEVE the DTCs. If multiple coil DTCs are retrieved, GO to Pinpoint Test G. If only DTC C1242 is retrieved, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. Using the scan tool, CARRY OUT the IVD Initialization sequence. CLEAR the DTCs. CARRY OUT the self-test with the brake pedal not applied.

CLEAR all DTCs. DRIVE the vehicle. RETRIEVE the DTCs. If multiple coil DTCs are retrieved, GO to Pinpoint Test G. If only DTC C1246 is retrieved, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. Using the scan tool, CARRY OUT the IVD Initialization sequence. CLEAR the DTCs. CARRY OUT the self-test with the brake pedal not applied.

CLEAR all DTCs. DRIVE the vehicle. RETRIEVE the DTCs. If multiple coil DTCs are retrieved, GO to Pinpoint Test G. If only DTC C1250 is retrieved, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. Using the scan tool, CARRY OUT the IVD Initialization sequence. CLEAR the DTCs. CARRY OUT the self-test with the brake pedal not applied.

CLEAR all DTCs. DRIVE the vehicle. RETRIEVE the DTCs. If multiple coil DTCs are retrieved, GO to Pinpoint Test G. If only DTC C1254 is retrieved, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. Using the scan tool, CARRY OUT the IVD Initialization sequence. CLEAR the DTCs. CARRY OUT the self-test with the brake pedal not applied.

GO to Pinpoint Test K.

GO to Pinpoint Test L.

GO to Pinpoint Test M.

CLEAR all DTCs. DRIVE the vehicle. RETRIEVE the DTCs. If the DTC is retrieved again, INSTALL a new ABS module. REFER to

Anti-Lock Brake System (ABS) Module in this section. Using the scan tool, CARRY OUT the IVD Initialization sequence. CLEAR the

DTCs. CARRY OUT the self-test with the brake pedal not applied. CLEAR all DTCs. DRIVE the vehicle. RETRIEVE the DTCs. If the DTC is retrieved again, INSTALL a new ABS module. REFER to