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TABLE OF CONTENTS

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.1 1.2 2.0 3.0 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1

IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1 3.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3.1.1 KELSEY-HAYES EBC 2 SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . .1 3.1.2 KELSEY-HAYES EBC 325 SYSTEM DESCRIPTION . . . . . . . . . . . . . . . .2 FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 3.2.1 KELSEY-HAYES EBC 2 CONTROLLER ANTILOCK BRAKE (CAB) . . . .2 3.2.3 ABS WARNING INDICATOR AND RED BRAKE WARNING INDICATOR (EBC 2 AND EBC 325) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 3.2.4 BRAKE LAMP SWITCH CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 3.2.5 HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 3.2.6 WHEEL SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 3.2.7 4WD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 DIAGNOSTIC COMMAND MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 3.3.1 SELF-TEST AT IGNITION TURN ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 3.3.2 DRBIII DIAGNOSTIC COMMANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 THE ON-BOARD DIAGNOSTIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 3.5.1 DIAGNOSTIC TROUBLE CODES (EBC 2) . . . . . . . . . . . . . . . . . . . . . . . .5 3.5.2 DIAGNOSTIC TROUBLE CODES (EBC 325) . . . . . . . . . . . . . . . . . . . . . .5 USING THE DRBIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 DRBIII ERROR MESSAGES AND BLANK SCREEN . . . . . . . . . . . . . . . . . . . . . .5 3.7.1 DRBIII DOES NOT POWER UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 3.7.2 DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.2

3.3

3.4 3.5

3.6 3.7

4.0

DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 4.1 4.2 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 4.2.1 TECHNICIAN SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . .6 4.2.2 VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . . . . .6 4.2.3 SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 4.2.4 DRBIII SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 4.3.1 VEHICLE DAMAGE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 4.3.2 ROAD TESTING A COMPLAINT VEHICLE . . . . . . . . . . . . . . . . . . . . . . . .7 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.3

4.4 5.0 6.0 7.0

REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 BRAKES (CAB) BRAKE LAMP SWITCH CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 EXCESSIVE DUMP TIME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

i

TABLE OF CONTENTS - Continued

FOUNDATION BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 INTERMITTENT SIGNAL FROM LEFT FRONT SENSOR . . . . . . . . . . . . . . . . . . . . . . .16 NO SIGNAL FROM LEFT FRONT SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 INTERMITTENT SIGNAL FROM REAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 NO SIGNAL FROM REAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 INTERMITTENT SIGNAL FROM RIGHT FRONT SENSOR . . . . . . . . . . . . . . . . . . . . . .22 NO SIGNAL FROM RIGHT FRONT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 INTERNAL CAB FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 INTERNAL MAIN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 LEFT FRONT SENSOR OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 MISMATCHED VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 NUMBER OF TONE RING TEETH OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . .33 PUMP MOTOR FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 RAM READ/WRITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 REAR DUMP SOLENOID OPEN - EBC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 REAR DUMP SOLENOID SHORTED - EBC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 REAR ISOLATION SOLENOID OPEN - EBC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 REAR ISOLATION SOLENOID SHORTED - EBC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 REAR RESET SWITCH CLOSED - EBC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 REAR SENSOR OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 RIGHT FRONT SENSOR OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 ROM CHECKSUM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 SYSTEM CONTROL MODE TIMEOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 TIRE REVOLUTIONS PER MILE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 WATCHDOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 WHEEL SPEED MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 *ABS WARNING INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 *DRBIII NO RESPONSE MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 *REPLACING THE CONTROLLER ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . .61 *VEHICLE SPEED SIGNAL OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 VERIFICATION TESTS VERIFICATION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 8.0 COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 8.1 CONTROLLER ANTILOCK BRAKE (CAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 8.1.1 EBC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 8.1.2 EBC 325. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 8.2 DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 8.3 POWER DISTRIBUTION CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 8.4 JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 8.5 WHEEL SPEED SENSORS/TONE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 8.5.1 FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 8.5.2 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 8.6 LEFT FRONT WHEEL SPEED SENSOR CONNECTOR . . . . . . . . . . . . . . . . . . .70 8.7 RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR . . . . . . . . . . . . . . . . . .70 8.8 REAR WHEEL SPEED SENSOR CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . .70 8.9 BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 8.10 PCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 8.11 4WD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 8.12 REAR AXLE IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

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TABLE OF CONTENTS - Continued

9.0 CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 CONTROLLER ANTILOCK BRAKE C1 - BLACK 14 WAY . . . . . . . . . . . . . . . . . . . . . . .73 CONTROLLER ANTILOCK BRAKE C2 - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . .73 LEFT FRONT WHEEL SPEED SENSOR - LT. GRAY 2 WAY . . . . . . . . . . . . . . . . . . . .73 LEFT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . . .74 PUMP MOTOR CONNECTOR - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 REAR WHEEL SPEED SENSOR - BLACK 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 RIGHT FRONT WHEEL SPEED SENSOR - LT. GRAY 2 WAY . . . . . . . . . . . . . . . . . . .74 RIGHT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY . . . . . . . . . . . . .75 10.0 SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 10.1 2001 AN BODY EBC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 10.2 2000 AN BODY EBC 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

iii

NOTES

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GENERAL INFORMATION

1.0 INTRODUCTION 1.2 SIX-STEP TROUBLESHOOTING PROCEDURE

The procedures contained in this manual include all the specifications, instructions, and graphics needed to diagnose 2001 Dodge Truck Kelsey-Hayes EBC 325 Antilock Brake System (ABS) and Rear Wheel Antilock (EBC 2) System problems. The diagnostics in this manual are based on the failure condition or symptom being present at time of diagnosis. Follow the recommendations below when choosing your diagnostic path. 1. First make sure the DRBIII is communicating with the CAB. If the DRBIII displays a ``No Response'' condition, you must diagnose that first. 2. Read DTC's (diagnostic trouble codes) with the DRBIII . 3. If no DTC's are present, identify the customer complaint. 4. Once the DTC or customer complaint is identified, 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 * placed before the symptom description indicated a customer complaint. 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; carryover systems may be enhanced. READ THIS MANUAL BEFORE TRYING TO DIAGNOSE A VEHICLE DIAGNOSTIC TROUBLE CODE. It is recommended that you review the entire manual to become familiar with all new and changed diagnostic procedures. This book reflects many suggested changes from readers of past issues. 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.

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

· · · · · ·

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 EBC 2 system can be identified by the presence of a separate rear hydraulic control unit (HCU). The HCU is used to control hydraulic pressure to the REAR brakes during antilock braking. The HCU is controlled by a controller antilock brake (CAB) mounted beside the HCU. The HCU and CAB are mounted on one bracket. The EBC 325 system can be identified by the presence of the controller antilock brake (CAB) located directly on the HCU. This system uses one HCU to control the front and rear brakes. All of these components are mounted under the hood in close proximity to the master cylinder. The EBC 325 system will have a separate front wheel speed sensor wiring connector connected to the CAB.

3.0

SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION

The controller antilock brake module is used to monitor wheel speeds and modulates (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lock up during braking. The CAB also provides a vehicle speed signal (VSS) to the powertrain control module.

1.1

SYSTEM COVERAGE

3.1 3.1.1

GENERAL DESCRIPTION KELSEY-HAYES EBC 2 SYSTEM DESCRIPTION

There are two systems used on these trucks: Kelsey-Hayes EBC 2 and EBC 325 System. These systems are used on 2001 Dodge Dakota pickups. EBC 325 is a four wheel antilock braking system. EBC 2 is a two wheel rear wheel antilock braking system.

The EBC 2 is one channel, one sensor, rear wheel antilock brake system. This system has a ``passive'' rear wheel control (meaning rear brake pressure during antilock braking is provided by the master cylinder). The EBC 2 uses one HCU for control of both rear brakes.

1

GENERAL INFORMATION

SYSTEM COMPONENTS - KELSEY-HAYES EBC 2

· · · · · · · · ·

controller antilock brake (CAB) rear valve body hydraulic control unit (HCU) one wheel speed sensor/tone wheel assembly ABS warning indicator (amber) brake warning indicator (red) brake warning indicator switch 4WD switch brake lamp switch fuses and wiring

3.2.2 KELSEY-HAYES EBC 325 CONTROLLER ANTILOCK BRAKE (CAB)

The CAB is mounted directly to the hydraulic control unit and includes a microprocessor and six solenoids that control brake pressure during antilock braking. The CAB also has circuits that monitor the following: · Brake switch input is monitored to determine whether or not to prepare for possible antilock braking. · Wheel speed sensors are monitored to determine when a wheel is tending to lock up. The CAB will operate the valves in the HCU to control braking pressure during antilock braking.

3.1.2

KELSEY-HAYES EBC 325 SYSTEM DESCRIPTION

The EBC 325 system is a three channel, three sensor, four wheel antilock brake system. This system uses one HCU to control all four brakes during antilock braking.

3.2.3

ABS WARNING INDICATOR AND RED BRAKE WARNING INDICATOR (EBC 2 AND EBC 325)

SYSTEM COMPONENTS - KELSEY-HAYES EBC 325

· · · · · · · · ·

controller antilock brake (CAB) hydraulic control unit (HCU) three wheel speed sensor/tone wheel assemblies ABS warning indicator (amber) brake warning indicator (red) brake warning indicator switch 4WD switch brake lamp switch fuses and wiring

3.2 3.2.1

FUNCTIONAL OPERATION KELSEY-HAYES EBC 2 CONTROLLER ANTILOCK BRAKE (CAB)

The CAB is mounted under the hood, separately from the valve body, and has a microprocessor and circuits that: · monitor the brake switch input to tell whether or not to prepare for possible antilock braking · monitor the wheel speed sensor input to determine when a rear wheel is tending to lock up.

·

·

operate the integral control unit assembly during antilock braking based on comparing the speed sensor to information programmed in memory. detect ABS system related problems and take diagnostic action

The system is equipped with an amber ABS and a red brake warning indicator to alert the driver of a malfunction it has detected. The CAB can control the operation of both the yellow ABS warning indicator and the red brake warning indicator via PCI bus. The CAB controls the ABS warning indicator by making it do one of three things: · indicator steady for 3.4 seconds during an initial test at the beginning of an ignition cycle to function as a bulb check. · indicator steady when a system malfunction exists. · indicator flashing if a vehicle speed signal parameter is faulty or missing. The amber antilock brake system warning indicator is controlled by the vehicle's "smart" cluster. All Dodge Trucks are equipped with a smart instrument cluster that has direct control over the ABS warning indicator and red brake warning indicator. The cluster will periodically transmit a message over the PCI bus relating to diagnostics and current indicator status for the ABS and red brake indicator. The cluster will expect a periodic message back from the CAB indicating whether the indicator should be turned on or off. In the event that no signal is received from the CAB for a certain number of times, the cluster will turn on the ABS warning indicator. The indicator provides notice of system-related problems and the need to take diagnostic action. The vehicle instrument cluster has a red BRAKE warning indicator to alert the driver to the following conditions: · parking brake applied · hydraulic failure in either front or rear channel

2

GENERAL INFORMATION

·

ABS system malfunction The red brake warning indicator is controlled by the vehicle's "smart" cluster. There is a parallel path to chassis ground that will illuminate the red brake warning indicator: · through the parking brake switch contacts · through the combination valve brake warning indicator switch · through the CAB via PCI Bus The CAB can control the operation of both the yellow ABS warning indicators and the red brake warning indicator

· · ·

If the CAB is disconnected, the yellow indicator will be illuminated. If the axle type or tire size are not programmed properly, the yellow indicator will blink. If a system DTC is set, both the yellow and red indicator will be illuminated.

3.2.4

BRAKE LAMP SWITCH CIRCUIT

An input from this switch prepares the CAB for a possible antilock stop. The antilock system uses an input signal from the brake lamp switch. When the driver applies the brake pedal, the circuit voltage is 12 volts. A released brake pedal will close the switch circuit and provide 0 volts. This signal tells the CAB that the pedal is depressed.

3.2.5

HYDRAULIC CONTROL UNIT

The HCU on the EBC 2 has only a separate rear valve body. The HCU on the EBC 325 has an integral valve body for controlling the front and rear brakes. Within the HCU are solenoids, valves, check valves, and a reset switch necessary to apply and release brake pressure as required to avoid wheel lockup, keep the wheels rolling, and maintain optimum deceleration. The isolation valve(s) is/are normally open, allowing unrestricted flow from the master cylinder to the wheels. When the CAB determines antilock intervention is required, the valve closes to isolate the master cylinder hydraulic circuit. Fluid is trapped in the circuit and then prevented from reaching the wheels. The dump valve(s) is/are pulsed on and off by the CAB. This valve cycles only if the isolation valve is closed. When dump is on, it allows fluid to the low pressure accumulator for temporary storage. This causes the pressure to the wheel to decrease. When the valve is off, fluid is allowed to the wheel. The brake return check valve allows the HCU to drain faster after the ABS stop, when the brake is released.

The Reset Switch is used on the EBC 2 system only. The switch is positioned in the HCU to monitor the master cylinder (input), rear brake (output) and accumulator pressure. During normal braking, pressure is equal for input and output and the switch remains open. During an Antilock stop the switch will close as the isolation valve is cycled and pressure becomes unequal between input and output. At the end of an ABS stop the isolation valve will open as master cylinder pressure and rear pressure equalize. The switch is used to monitor correct operation of the HCU and to set a diagnostic trouble code if incorrect pressure is detected. When the brakes are applied, fluid is forced from the master cylinder outlet ports to the HCU inlet ports. This pressure is transmitted through three normally open isolation valves inside the HCU, then through the outlet ports of the HCU to the wheels. If the CAB senses that a wheel is about to lock, based on wheel speed sensor data, it pulls the normally open isolation valve closed for that circuit. This prevents any more fluid from entering that circuit. The CAB continues to look at the sensor signal to determine if the wheel is still decelerating. If deceleration is still taking place, the normally closed dump valve for that circuit is opened. This dumps any pressure that is trapped between the normally open valve and the brake back into an accumulator. Once the affected wheel comes back up to speed, the CAB returns the valves to their normal condition allowing the affected brake to be reapplied. On the EBC 325 system, the pump and accumulators are used to provide rapid response during the reapply sequence and to minimize pedal feedback.

3.2.6

WHEEL SPEED SENSORS

The EBC 325 ABS system uses one wheel speed sensor on each front wheel, and one speed sensor mounted in the rear axle for the rear wheels. The EBC 2 used only one speed sensor mounted in the rear axle for the rear wheels. The sensor measures the wheel speed by monitoring a rotating tone wheel. The signal generated by the sensor and tone wheel is transmitted to the CAB. Each sensor has: · a magnetic/coil pick-up (speed sensor) that is mounted to a fixed component · an air gap between the tone wheel and the speed sensor assembly As the teeth of the tone wheel move through the magnetic field of the sensor, an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel.

3

GENERAL INFORMATION

The CAB monitors this signal to check for a sudden change in single or multiple wheel decelerations. If the deceleration of one or more wheels is not within a predetermined amount, the antilock module takes control. Diagnostically, the coil of wheel speed sensors have different amounts of resistance based upon the sensor type. When measured across the connector two terminals, the resistance should be: 4x4 front sensor 893-1208 ohms 4x2 front sensors 1800-2200 ohms All rear sensors 1600-2300 ohms.

3.3.1

SELF-TEST AT IGNITION TURN ON

RAM AND ROM CHECKS

Ram and Rom are the two major parts of the microprocessor in the EBC 2 and EBC 325 CAB. ROM is a permanent memory that contains the program that performs all computations, makes all logic decisions, and so forth. RAM is an erasable, rewritable memory that is used to keep track of numeric computations and logic decisions as the EBC 2 and EBC 325 control program stored in ROM is executed. The RAM and ROM are checked immediately whenever the vehicle ignition is turned on.

(NOTE: FOR ALL RESISTANCE RANGES ADD 30% TO THE VALUE FOR EXTREME HEAT, SUBTRACT 30% FOR EXTREME COLD.)

The rear wheel speed sensor, used on all vehicles have the same resistance value, but there are two different sensors. Therefore, it is important to replace the rear wheel speed sensor with the proper part. On a EBC 325 system each front wheel speed is monitored through the speed sensor mounted at the wheel end of the hub. On a EBC 325 and EBC 2 system the rear wheel speed is monitored through the speed sensor mounted in the rear axle assembly. The CAB will disable antilock control, illuminate the ABS warning indicator circuit via the PCI bus, and store diagnostic trouble codes if it detects a problem with any or all of the wheel speed sensors: · incorrect circuit resistance when checked with no vehicle movement

· ·

BULB CHECKS

At ignition turn-on, the CAB also provides the operator of the vehicle with a visual check of the amber ABS warning indicator and the red BRAKE warning indicator. When the ignition switch is turned to the RUN position, the two indicators are turned on for a few seconds. These bulb checks help confirm correct operation of both the CAB and the bulbs themselves.

SELF-TEST AT INITIAL IGNITION ON

The system undergoes a power-up self-test when the vehicle has it's initial ignition turn-on. An active self-test of the ABS system main relay, motor, and the six solenoid valves is performed. The power-up self-tests are abbreviated if the vehicle ignition switch is turned from some other position to RUN above 13 Km/h (8 mph), as might occur in restarting a stalled engine with the vehicle rolling.

incorrect sensor output during vehicle movement erratic sensor output during vehicle movement

3.3.2

DRBIII DIAGNOSTIC COMMANDS

3.2.7

4WD SWITCH

RESET MODULE

This command resets the EBC 2 and EBC 325 system as follows: it turns on both warning indicators, clears all DTC's and counters in the NVRAM, and reactivates the system. The reset module command is accepted by the CAB only if the vehicle's wheels are not rotating.

Vehicles equipped with four wheel drive (4WD) have an indicator switch mounted on the front axle assembly. This switch is closed to ground when the transfer case is shifted to four wheel drive mode and the engine is running on some vehicles. While in four wheel drive, the front and rear axles will operate together. With this input, the CAB is able to modify its operation to allow for 4WD operation. Should a need for antilock operation occur while in four wheel drive, the CAB will extend the amount of allowable dump cycles.

3.4

THE ON-BOARD DIAGNOSTIC SYSTEM

3.3

DIAGNOSTIC COMMAND MODES

The ABS system includes several self-tests that are performed every time the ignition is turned on and the vehicle is driven away. Some of the selftests occur immediately, while others do not occur until the vehicle reaches 13 Km/h (8 mph).

The brake system is monitored by the controller antilock brake (CAB). The CAB monitors critical input and output circuits within the antilock brake system of the vehicle, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances.

4

GENERAL INFORMATION

Each circuit monitored by the CAB has a corresponding trouble code assigned to it. Refer to Section 3.5 (Diagnostic Trouble Codes) below for a list and definition of trouble codes. ­ If the on-board diagnostic system senses that one of the circuits is malfunctioning, it stores the corresponding trouble code in memory. ­ If the malfunction goes away after the trouble code is stored, the trouble code will be erased after 50 key cycles, so long as no other DTC's were set within these 50 cycles. Wheel Speed Mismatch Internal CAB Fault Internal Main Relay Pump Motor Fault Excessive Dump Time RAM Read/Write ROM Checksum Watchdog System Control Mode Timeout Foundation Brake Brake Lamp Switch Circuit Number of Tone Ring Teeth Out of Range Tire Revolutions Per Mile Out of Range Mismatched VIN

3.5 3.5.1

DIAGNOSTIC TROUBLE CODES DIAGNOSTIC TROUBLE CODES (EBC 2)

The antilock brake system module may report any of the following diagnostic trouble codes: Rear Sensor Open No Signal From Rear Sensor Intermittent Signal From Rear Sensor Rear Rear Rear Rear Isolation Solenoid Open Dump Solenoid Open Isolation Solenoid Open Dump Solenoid Shorted

3.6

USING THE DRBIII

Refer to the DRBIII user's guide for instructions and assistance with reading diagnostic trouble codes, erasing trouble codes, and other DRBIII functions.

3.7

DRBIII ERROR MESSAGES AND BLANK SCREEN

Rear Reset Switch Closed Internal Main Relay Excessive Dump Time RAM Read/Write ROM Checksum Watchdog Foundation Brake Brake Lamp Switch Circuit Number of Tone Ring Teeth Out of Range Tire Revolutions per Mile Out of Range Mismatched VIN

If any of the following error messages appear on the DRBIII screen, refer to the Vehicle Communications Manual for diagnosis and repair. ­ cartridge error ­ low battery ­ ram result failure ­ high battery ­ keypad test failure If the DRBIII has a blank screen, do the following: ­ Ensure there is a good body ground at the data link connector. ­ Use the process of elimination. Sequentially substitute another cable, cartridge, and DRBIII until the condition is corrected. Under normal operation, the DRBIII will display only two error messages: ­ User-Requested WARM Boot or UserRequested COLD Boot. If the DRBIII should display any other message, record the entire display and call the Star Center. This is a sample of such an error message display:

3.5.2

DIAGNOSTIC TROUBLE CODES (EBC 325)

The antilock brake system module may report any of the following diagnostic trouble codes: Right Front Sensor Open No Signal From Right Front Sensor Intermittent Signal from Right Front Sensor Left Front Sensor Open No Signal From Left Front Sensor Intermittent Signal From Left Front Sensor Rear Sensor Open No Signal From Rear Sensor Intermittent Signal From Rear Sensor

5

GENERAL INFORMATION

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.

4.2 4.2.1

SAFETY TECHNICIAN SAFETY INFORMATION

3.7.1

DRBIII 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 and grounds to Data Link connector. A minimum of 11 volts is required to adequately power the DRBIII . If all connections are proper between the DRBIII and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRBIII may be the result of faulty cable or vehicle wiring.

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 the parking brake and block the wheels 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 an antilock brake system 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.

3.7.2

DISPLAY IS NOT VISIBLE

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

4.2.2

VEHICLE PREPARATION FOR TESTING

Make sure the vehicle being tested has a fully charged battery. If is does not, false diagnostic codes or error messages may occur.

4.2.3

SERVICING SUB-ASSEMBLIES

4.0

DISCLAIMERS, SAFETY, WARNINGS DISCLAIMERS

Some components of the antilock brake system are intended to be serviced in 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 procedures in the service manual should be serviced.

4.2.4

DRBIII SAFETY INFORMATION

4.1

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.

WARNING: EXCEEDING THE LIMITS OF THE DRBIII 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 specifications at all times.

6

GENERAL INFORMATION

· · · ·

Do not use the DRBIII 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 function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. Do not exceed the limits shown in the table below: INPUT LIMIT 0 - 500 peak volts AC 0 - 500 volts DC 0 - 1.12 megohms 0 - 10 kHz -58 - 1100°F -50 - 600°C

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

·

FUNCTION Volts Ohms (resistance)* Frequency Measured Frequency Generated Temperature

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.

* Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit.

· · ·

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

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 current, 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 DRBIII away from spark plug or coil wires to avoid measuring error from outside interference.

4.4

DIAGNOSIS

·

· · ·

1. Your diagnostic test procedure must begin with a thorough visual inspection of the ABS system components for damaged components or disconnected connectors. A visual inspection consists of physically looking for the possible cause of a malfunction. A careful and thorough visual inspection of components may quickly identify the cause of a malfunction and eliminate the need for diagnostic testing. PERFORM THE FOLLOWING VISUAL INSPECTIONS BEFORE DOING ANY DIAGNOSTIC TESTING. If a malfunction is not resolved by the visual inspection, proceed with diagnostic testing according to the instructions in the manual. See Section 8.0 (Component Locations) for pictures identifying the location of system components. Brake Fluid Level Hydraulic Control Unit Visually inspect for the proper fluid level within the fluid reservoir. Visually inspect the hydraulic assemblies for leaks and for damaged or disconnected connector. Visually inspect that all fuses are properly installed.

4.3 4.3.1

WARNING 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.

Fuses

7

GENERAL INFORMATION

Visually inspect both front wheel speed sensor connectors for damage or disconnection. Inspect the rear axle speed sensor connectors. Brake Fluid Visually inspect brake fluid Lines lines for any leaks or damage. Wheel Speed Visually inspect all three wheel Sensors speed sensors and tone wheels for any damage. Controller Visually inspect the CAB for a Antilock Brake secure mounting and the CAB (CAB) connector for damage or loose connection. Base Brake Visually inspect the condition System of the parking brake, rotors, drums, and calipers. 2. Connect the DRBIII to the data link connector. First make sure that the DRBIII is communicating with the CAB. If the DRBIII displays a ``No Response'' condition you must diagnose that first. For other DRBIII related communication problems, refer to the Vehicle Communications test in the Body Diagnostic manual. 3. With the DRBIII , read Kelsey-Hayes ABS active and stored diagnostic trouble codes and record them. If a wheel speed sensor code was present, perform the appropriate test. Using the DRBIII , either reset the module to erase all stored diagnostic trouble codes or use the erase command after reading all diagnostic trouble codes. 4. Turn ignition off, then on. a. If the diagnostic trouble code doesn't come back, refer to the diagnostic trouble code description. If the DRBIII displays diagnostic trouble codes, proceed to the appropriate diagnostic test(s) by locating the matching DTC test name in the table of contents. b. If no diagnostic trouble codes are present at this time identify the customer complaint. Proceed Wheel Speed Sensor Connectors to the appropriate test by locating the matching test in the table of contents and diagnose the symptom. 5. After repairing the customer complaint perform the System Verification Test. WARNING: Before performing any road test, verify that full braking capability is present.

5.0

REQUIRED TOOLS AND EQUIPMENT

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

6.0

ABS CAB CCD DLC EBC EMF HCU IC

GLOSSARY OF TERMS

antilock brake system controller antilock brake Chrysler Collision Detection data link connector electronic brake controller electromotive force (generated voltage) hydraulic control unit integrated circuit non-volatile random access memory power distribution center random access memory rear wheel antilock read only memory wheel speed sensor

NVRAM PDC RAM RWAL ROM WSS

8

7.0 DIAGNOSTIC INFORMATION AND PROCEDURES

9

BRAKES (CAB)

Symptom: BRAKE LAMP SWITCH CIRCUIT

When Monitored and Set Condition: BRAKE LAMP SWITCH CIRCUIT When Monitored: Ignition on.

Set Condition: Brake switch applied starting at ignition on, and remaining applied until 10 seconds has elapsed with the vehicle speed above 59 Km/h (37 mph).

POSSIBLE CAUSES CAB - SETTING FALSE CODE BRAKE LAMP SWITCH GROUND OPEN BRAKE LAMP SWITCH OPEN BRAKE LAMP SWITCH SENSE CIRCUIT SHORT OR OPEN CAB -- INTERNAL CONCERN

TEST 1 ACTION With the DRBIII in Inputs/Outputs, read the Brake Lamp Switch state. Press and release the brake pedal. Does the DRBIII display PRESSED and RELEASED? Yes No 2 Go To Go To 2 3 All APPLICABILITY All

Turn the ignition off. Ensure all accessories are turned off and the battery is fully charged. With the DRBIII , erase DTCs. Road test the vehicle for at least 5 minutes. Perform several antilock braking stops. Caution: Ensure braking capability is available before road testing. With the DRBIII , read DTCs. Does the original DTC recur? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

No 3

Disconnect the Brake Lamp Switch harness connector. Using a 12-volt test light connected to 12-volts, check the Brake Lamp Switch Ground circuit. Does the test light illuminate brightly ? Yes No Go To 4

All

Repair the Brake Lamp Switch Ground circuit for an open. Perform ABS VERIFICATION TEST - VER 1.

10

BRAKES (CAB)

BRAKE LAMP SWITCH CIRCUIT --

TEST 4 ACTION Disconnect the Brake Lamp Switch harness connector. With the DRBIII in Inputs/Outputs, read the Brake Lamp Switch state. Connect and disconnect a jumper wire between the Brake Lamp Switch Ground and Sense circuits. Does the DRBIII display PRESSED and RELEASED? Yes Replace the Brake Lamp Switch in accordance with the Service Information. Perform ABS VERIFICATION TEST - VER 1. Go To 5 All

Continued

APPLICABILITY All

No 5

Disconnect the CAB harness connector. Disconnect the Brake Lamp Switch harness connector. Check the Brake Lamp Switch Sense circuit for a short to voltage and for an open. Is the Brake Lamp Switch Sense circuit shorted or open? Yes Repair the Brake Lamp Switch Sense circuit for a short to voltage or an open. Perform ABS VERIFICATION TEST - VER 1. Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1.

No

11

BRAKES (CAB)

Symptom: EXCESSIVE DUMP TIME

When Monitored and Set Condition: EXCESSIVE DUMP TIME When Monitored: Brake pedal depressed (to enable antilock activity). Wheel speed below 6 km/h (4 mph). Four wheel drive sense signal input indicates vehicle is not in four wheel drive. Wheel speed history ruling out any unusual events during the preceding 15 seconds. Set Condition: The need for more that 24 dump pulses in response to the wheel (or wheels) that have gone to lock without recovering.

POSSIBLE CAUSES BRAKE SYSTEM MECHANICAL CONCERN TONE WHEEL CONCERN WIRING HARNESS CONCERN CAB INTERNAL CONCERN 4WD SWITCH SENSE CIRCUIT

TEST 1 ACTION Inspect the front and rear brakes for anything that would cause the wheel(s) to lock during braking. Is there anything mechanically wrong with the Braking System? Yes No 2 Repair the mechanical braking system as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 2 All APPLICABILITY All

Turn the ignition off. Inspect the Tone Wheel for damaged, missing teeth or looseness. Note: The Tone Wheel Teeth should be perfectly square, not bent or nicked. Is the Tone Wheel OK? Yes No Go To 3

Replace the Tone Wheel in accordance with the Service Information. Perform ABS VERIFICATION TEST - VER 1.

12

BRAKES (CAB)

EXCESSIVE DUMP TIME --

TEST 3

Continued

ACTION APPLICABILITY All

Engine Running. Raise and support the vehicle. With the DRBIII in Sensors, read the Wheel Speed Sensor signals. WARNING: BE SURE TO KEEP HANDS, FEET AND CLOTHING CLEAR OF ROTATING COMPONENTS. Allow the drive wheels to rotate. Rotate the non-driven wheels by hand. Wiggle Wheel Speed wiring harnesses. With the DRBIII in Sensors, read the Wheel Speed Sensor outputs. Is there a wheel speed dropout when a wiring harness is wiggled? Yes No Repair the wheel speed wiring harness as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 4

4

With the DRBIII in Inputs/Outputs, read the 4WD Switch Sense state. Move the 4WD selector between the 2WD and 4WD position. NOTE: 4WD mode allows additional Dump Cycles. The purpose of this test is to determine if the CAB is recognizing the 4WD mode signal. Does the display follow the selector positions? Yes No Go To 5

All

Repair the 4WD Switch Sense circuit for short or open. Perform ABS VERIFICATION TEST - VER 1. All

5

If there are no possible causes remaining, replace the HCU. View repair options. Repair Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1.

13

BRAKES (CAB)

Symptom: FOUNDATION BRAKE

When Monitored and Set Condition: FOUNDATION BRAKE When Monitored: Vehicle speed above 6 km/h (4 mph) for 2 seconds.

Set Condition: Low feedback voltage from the Brake Pressure Switch Sense circuit. The above criteria satisfied for 255 consecutive checks spaced 5 milliseconds apart (1.3 seconds total).

POSSIBLE CAUSES LOW FLUID LEVEL BRAKE PRESSURE SWITCH SENSE CIRCUIT SHORTED TO GROUND BRAKE PRESSURE SWITCH SHORTED TO GROUND CAB - INTERNAL SHORT TO GROUND FOUNDATION BRAKE INTERMITTENT DTC

TEST 1 ACTION Release the Parking Brake. Turn the ignition off. Turn the ignition on. Watch the Instrument Cluster. Does the Red Brake Warning Indicator come on and then stay on? Yes No 2 Go To Go To 2 6 All APPLICABILITY All

Turn the ignition off. Inspect the Brake Fluid Level in the Master Cylinder Reservoir. Is the Brake Fluid Level Low? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 3

3

Turn the ignition off. Disconnect the Brake Pressure Switch connector Note: Check connector - Clean/repair as necessary. Disconnect the CAB connector. Note: Check connector - Clean/repair as necessary. Turn the ignition on. Using a test light connected to 12 volts, probe the Brake Pressure Switch Sense circuit. Is the test light on? Yes No Repair the Brake Pressure Sense circuit for a short to ground. Perform ABS VERIFICATION TEST - VER 1. Go To 4 14

All

BRAKES (CAB)

FOUNDATION BRAKE --

TEST 4

Continued

ACTION APPLICABILITY All

Turn the ignition off. Disconnect the Brake Pressure Switch connector. Note: Check connector - Clean/repair as necessary. Measure the resistance of both of the Brake Pressure Switch terminals to ground. Is the resistance below 1,500 ohms at either terminal? Yes No Replace Brake Pressure Switch. Perform ABS VERIFICATION TEST - VER 1. Go To 5

5

If there are no potential causes remaining, replace the CAB. View repair options. Repair Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1.

All

6

Turn the ignition off. Visually inspect the related wiring harness. Look for any chafed, 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. Were any problems found? Yes No Repair wiring harness/connectors as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

All

15

BRAKES (CAB)

Symptom List: INTERMITTENT SIGNAL FROM LEFT FRONT SENSOR NO SIGNAL FROM LEFT FRONT SENSOR

Test Note:

All symptoms listed above are diagnosed using the same tests. The title for the tests will be INTERMITTENT SIGNAL FROM LEFT FRONT SENSOR.

When Monitored and Set Condition: INTERMITTENT SIGNAL FROM LEFT FRONT SENSOR When Monitored: Ignition turned on for at least 3.5 seconds. Average filtered speed for the two front wheels above 6 km/h (4 mph). Speed for each suspect sensor above 32 km/h (20 mph) (brake applied or ABS active) or 19 km/h (12 mph) (brake released or ABS inactive). Set Condition: There is no output signal from the sensor for 15 milliseconds (ms).

NO SIGNAL FROM LEFT FRONT SENSOR When Monitored: Wheel speed comparison is checked at drive off or every 7 milliseconds (ms). Sensor circuit continuity is checked every 7 milliseconds. Wheel speed phase length supervision is checked every 7 milliseconds. 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.

POSSIBLE CAUSES LEFT FRONT WHEEL SPEED SENSOR OR CONNECTOR DAMAGED TONE WHEEL DAMAGED LEFT FRONT WHEEL SPEED SENSOR AIR GAP OUT OF SPECIFICATION LEFT FRONT WHEEL SPEED SENSOR INOPERATIVE CAB - WON'T RESPOND TO LEFT FRONT WHEEL SPEED SENSOR SIGNAL INTERMITTENT SIGNAL DTC

16

BRAKES (CAB)

INTERMITTENT SIGNAL FROM LEFT FRONT SENSOR --

TEST 1 ACTION Turn the ignition on. Using the DRBIII , monitor the Left Front Wheel Speed Sensor while an assistant drives the vehicle. Slowly accelerate as straight as possible from a stop to 24 km/h (15 mph). With the DRBIII , monitor all wheel speed sensors. Is Left Front WSS Signal 0 km/h (0 mph) or differing from others by more than 5 km/h (3 mph)? Yes No 2 Go To Go To 2 6 All

Continued

APPLICABILITY All

Turn the ignition off. Inspect the Left Front Wheel Speed Sensor and Connector. Is the Sensor or Connector Damaged? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 3

3

Turn the ignition off. Inspect the Tone Wheel for damaged or missing teeth, cracks, or looseness. Note: The Tone Wheel Teeth should be perfectly square, not bent or nicked. Is the Tone Wheel OK? Yes No Go To 4

All

Replace the Tone Wheel. Perform ABS VERIFICATION TEST - VER 1. All

4

Turn the ignition off. Using a Feeler Gauge, measure the Wheel Speed Sensor Air Gap. NOTE: The Air Gap should be checked in at least four places on the Tone Wheel. Is the Air Gap between 0.127mm - 1.27 mm (0.005 - 0.050 ) ? Yes No Go To 5

Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. All

5

Turn the ignition off. Disconnect the CAB harness connector C2. Raise the left front wheel off the ground. Using a voltmeter in AC mode, measure the Left Front Wheel Speed Sensor (+) and (-) Circuits at the CAB connector. Spin the wheel by hand at the rate of at least 1.0 rev/sec. Measure the AC voltage of the Left Front Wheel Speed Sensor Circuits. Does the voltage go above 408 mV (2WD) or 460 mV (4WD) as the wheel is rotated? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Replace the Left Front Wheel Speed Sensor in accordance with the Service Information. Perform ABS VERIFICATION TEST - VER 1.

No

17

BRAKES (CAB)

INTERMITTENT SIGNAL FROM LEFT FRONT SENSOR --

TEST 6 ACTION Turn the ignition off. Visually inspect wheel speed sensor. Visually inspect tone wheel. Visually inspect wiring harness. 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 No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

Continued

APPLICABILITY All

18

BRAKES (CAB)

Symptom List: INTERMITTENT SIGNAL FROM REAR SENSOR NO SIGNAL FROM REAR SENSOR

Test Note:

All symptoms listed above are diagnosed using the same tests. The title for the tests will be INTERMITTENT SIGNAL FROM REAR SENSOR.

When Monitored and Set Condition: INTERMITTENT SIGNAL FROM REAR SENSOR When Monitored: Ignition turned on for at least 3.5 seconds. Average filtered speed for the wheels above 19 km/h (12 mph) (brake released or ABS inactive) or 32 km/h (20 mph) (brake applied or ABS active). Set Condition: There is no output signal from the sensor for 15 milliseconds (ms).

NO SIGNAL FROM REAR SENSOR When Monitored: Vehicle speed above 6 km/h (4 mph) for 2 seconds.

Set Condition: Low feedback voltage from the Brake Pressure Switch Sense circuit. The above criteria satisfied for 255 consecutive checks spaced 5 milliseconds apart (1.3 seconds total).

POSSIBLE CAUSES REAR WHEEL SPEED SENSOR OR CONNECTOR DAMAGED TONE WHEEL DAMAGED REAR WHEEL SPEED SENSOR AIR GAP OUT OF SPECIFICATION REAR WHEEL SPEED SENSOR INOPERATIVE CAB - WON'T RESPOND TO REAR WHEEL SPEED SENSOR SIGNAL INTERMITTENT SIGNAL DTC

TEST 1 ACTION While an assistant drives the vehicle, monitor the Wheel Speed Sensors using the DRBIII . Slowly accelerate as straight as possible from a stop to 24 km/h (15 mph). Is the Rear WSS Signal 0 Km/h (0 Mph) or differing from others by more than 5 km/h (3mph)? Yes No Go To Go To 2 6 APPLICABILITY All

19

BRAKES (CAB)

INTERMITTENT SIGNAL FROM REAR SENSOR --

TEST 2 ACTION Turn the ignition off. Inspect the Rear Wheel Speed Sensor and Connector for correct installation and for damage. Is the Sensor or Connector not seated correctly or damaged? Yes No 3 Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 3 All

Continued

APPLICABILITY All

Turn the ignition off. Inspect the Tone Wheel for damaged or missing teeth, cracks, or looseness. Note: The Tone Wheel Teeth should be perfectly square, not bent or nicked. Is the Tone Wheel OK? Yes No Go To 4

Replace the Tone Wheel. Perform ABS VERIFICATION TEST - VER 1. All

4

Turn the ignition off. Using a Feeler Gauge, measure the Wheel Speed Sensor Air Gap. NOTE: The Air Gap should be checked in at least four places on the Tone Wheel. Is the Air Gap between 0.127 mm - 1.27 mm (0.005 - 0.050 ) ? Yes No Go To 5

Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. All

5

Turn the ignition off. Disconnect the CAB harness connector C1. Set up a voltmeter to measure AC voltage on the Rear Wheel Speed Sensor Signal Circuits at the CAB connector. Raise and support the vehicle. Start the engine. WARNING: To avoid injury, keep hands, feet and clothing clear of moving parts. Put the vehicle in gear and allow the rear wheels to rotate at approximately 1.0 rev/sec. At the CAB harness connector, measure the AC voltage on the Rear Wheel Speed Sensor (+) and (-) Signal Circuits. Does the voltage go above 365 mV while the wheels are rotating? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Replace the Rear Wheel Speed Sensor in accordance with the Service Information. Perform ABS VERIFICATION TEST - VER 1.

No

20

BRAKES (CAB)

INTERMITTENT SIGNAL FROM REAR SENSOR --

TEST 6 ACTION Turn the ignition off. Visually inspect wheel speed sensor. Visually inspect tone wheel. Visually inspect wiring harness. 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 No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

Continued

APPLICABILITY All

21

BRAKES (CAB)

Symptom List: INTERMITTENT SIGNAL FROM RIGHT FRONT SENSOR NO SIGNAL FROM RIGHT FRONT SENSOR

Test Note:

All symptoms listed above are diagnosed using the same tests. The title for the tests will be INTERMITTENT SIGNAL FROM RIGHT FRONT SENSOR.

When Monitored and Set Condition: INTERMITTENT SIGNAL FROM RIGHT FRONT SENSOR When Monitored: Ignition turned on for at least 3.5 seconds. Average filtered speed for the two front wheels above 6 km/h (4 mph). Speed for each suspect sensor above 32 km/h (20 mph) (brake applied or ABS active) or 19 km/h (12 mph) (brake released or ABS inactive). Set Condition: There is no output signal from the sensor for 15 milliseconds (ms).

NO SIGNAL FROM RIGHT FRONT SENSOR When Monitored: Wheel speed comparison is checked at drive off or every 7 milliseconds (ms). Wheel speed continuity is checked every 7 milliseconds. Wheel speed phase length supervision is checked every 7 milliseconds. 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.

POSSIBLE CAUSES RIGHT FRONT WHEEL SPEED SENSOR OR CONNECTOR DAMAGED TONE WHEEL DAMAGED RIGHT FRONT WHEEL SPEED SENSOR AIR GAP OUT OF SPECIFICATION RIGHT FRONT WHEEL SPEED SENSOR INOPERATIVE CAB - WON'T RESPOND TO RIGHT FRONT WHEEL SPEED SENSOR SIGNAL INTERMITTENT SIGNAL DTC

TEST 1 ACTION While an assistant drives the vehicle, monitor the Wheel Speed Sensors using the DRBIII . Slowly accelerate as straight as possible from a stop to 24 km/h (15 mph). Is the Right Front WSS Signal 0 km/h (0 mph) or differing from others by more than 5 km/h (3 mph)? Yes No Go To Go To 2 6 APPLICABILITY All

22

BRAKES (CAB)

INTERMITTENT SIGNAL FROM RIGHT FRONT SENSOR --

TEST 2 ACTION Turn the ignition off. Inspect the Right Front Wheel Speed Sensor and Connector. Is the Sensor or Connector Damaged? Yes No 3 Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 3 All

Continued

APPLICABILITY All

Turn the ignition off. Inspect the Tone Wheel for damaged or missing teeth, cracks, or looseness. Note: The Tone Wheel Teeth should be perfectly square, not bent or nicked. Is the Tone Wheel OK? Yes No Go To 4

Replace the Tone Wheel. Perform ABS VERIFICATION TEST - VER 1. All

4

Turn the ignition off. Using a Feeler Gauge, measure the Wheel Speed Sensor Air Gap. NOTE: The Air Gap should be checked in at least four places on the Tone Wheel. Is the Air Gap between 0.42 mm - 1.71 mm (0.017 - 0.068 ) ? Yes No Go To 5

Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. All

5

Turn the ignition off. Disconnect the CAB harness connector C2. Set up a voltmeter to measure AC voltage on the Right Front Wheel Speed Sensor Signal Circuits at the CAB connector. Raise the right front wheel off the ground. Spin the wheel by hand at the rate of at least 1.0 rev/sec. Measure the AC voltage on the Right Front Wheel Speed Sensor (+) and (-) Signal Circuits. Does the voltage go above 408 mV (2WD) or 460 mV (4WD) as the wheel is rotated? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Replace the Right Front Wheel Speed Sensor. Perform ABS VERIFICATION TEST - VER 1.

No 6

Turn the ignition off. Visually inspect wheel speed sensor. Visually inspect tone wheel. Visually inspect wiring harness. 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 No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

All

23

BRAKES (CAB)

Symptom List: INTERNAL CAB FAULT INTERNAL MAIN RELAY

Test Note:

All symptoms listed above are diagnosed using the same tests. The title for the tests will be INTERNAL CAB FAULT.

When Monitored and Set Condition: INTERNAL CAB FAULT When Monitored: Ignition on. The CAB monitors the Fused B(+) circuit at all times for proper system voltage. Set Condition: If the Fused B(+) voltage is missing when the CAB detects that an internal main driver is not on , the Diagnostic Trouble Code (DTC) is set. INTERNAL MAIN RELAY When Monitored: Vehicle speed above 6 km/h (4 mph) for 2 seconds.

Set Condition: Low feedback voltage from the Brake Pressure Switch Sense circuit. The above criteria satisfied for 255 consecutive checks spaced 5 milliseconds apart (1.3 seconds total).

POSSIBLE CAUSES CONNECTOR CONCERN INTERMITTENT DTC BLOWN FUSE - FUSED B(+) CIRCUIT NO B+ SUPPLY TO FUSE FUSED B(+) CIRCUIT OPEN B(+) CIRCUIT INTERMITTENTLY SHORTED TO GROUND B(+) CIRCUIT SHORTED TO GROUND CAB - FUSED B(+) CIRCUIT OPEN CAB - FUSED B(+) CIRCUIT SHORTED TO GROUND

24

BRAKES (CAB)

INTERNAL CAB FAULT --

TEST 1

Continued

ACTION APPLICABILITY All

Turn the ignition on. With the DRBIII , erase DTC's. Turn the ignition off. Turn the ignition on. Drive the vehicle above 25 km/h (15 mph) for at least 10 seconds. Stop the vehicle. With the DRBIII , read DTC's. Does the DRBIII display CAB Power Feed Circuit DTC present right now? Yes No Go To Go To 2 11

2

Turn the ignition off. On EBC 2 systems, inspect the HCU-to-CAB connector for disconnect, pin damage, corrosion etc. Inspect the CAB harness connectors for broken, bent, pushed out, or corroded terminals. Were any problems found? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 3

All

3

Turn the ignition off. Remove and Inspect the ABS Fuse 3 in the Junction Block. Is the Fuse blown? Yes No Go To Go To 4 8

All

4

Turn the ignition off. Visually inspect the B(+) Circuit in the wiring harness from the Junction Block to the CAB. Look for any sign of an intermittent short to ground. Is the wiring harness OK? Yes No Go To 5

All

Repair the Fused B(+) Circuit Shorted to Ground. Perform ABS VERIFICATION TEST - VER 1. All

5

Turn the ignition off. Remove the ABS Fuse 3 from the Junction Block. Disconnect the CAB harness connector C1. Note: Check connector - Clean/repair as necessary. Using a test light connected to 12 volts, probe the Fused B(+) Circuit. Is the test light on? Yes No Repair the Fused B(+) Circuit Shorted to Ground. Perform ABS VERIFICATION TEST - VER 1. Go To 6

25

BRAKES (CAB)

INTERNAL CAB FAULT --

TEST 6

Continued

ACTION APPLICABILITY All

Turn the ignition off. Remove the ABS Fuse 3 from the Junction Block. The CAB must be connected for the results of this test to be valid. Using a test light connected to 12 volts, probe the Fused B(+) Circuit at the Junction Block fuse 3 terminal. Is the test light on? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Go To 7

No 7

Turn the ignition off. If there are no potential causes remaining, view repair. Repair Replace the Fuse. Perform ABS VERIFICATION TEST - VER 1.

All

8

Remove the ABS Fuse 3 from the Junction Block. Turn the ignition on. Measure the voltage of the Fused B+ supply to Fuse 3 in the Junction Block. Is the voltage above 10 volts? Yes No Go To 9

All

Repair the B+ Supply circuit for an open. Perform ABS VERIFICATION TEST - VER 1. All

9

Turn the ignition off. Remove the ABS Fuse 3 from the Junction Block. Disconnect the CAB harness connector C1. Note: Check connector - Clean/repair as necessary. Measure the resistance of the Fused B(+) circuit between Junction Block Fuse terminal 3 and the CAB connector. Is the resistance below 5 ohms? Yes No Go To 10

Repair Fused B(+) Circuit Open. Perform ABS VERIFICATION TEST - VER 1. All

10

If there are no potential causes remaining, view repair. Repair Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1.

26

BRAKES (CAB)

INTERNAL CAB FAULT --

TEST 11

Continued

ACTION APPLICABILITY All

Turn the ignition off. Visually inspect the related wiring harness. Look for any chafed, 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. Were any problems found? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

27

BRAKES (CAB)

Symptom: LEFT FRONT SENSOR OPEN

When Monitored and Set Condition: LEFT FRONT SENSOR OPEN When Monitored: milliseconds (ms). Ignition on. The CAB monitors the wheel speed circuit every 7

Set Condition: If the CAB detects an open or shorted wheel speed sensor circuit, the Diagnostic Trouble Code (DTC) will set.

POSSIBLE CAUSES LEFT FRONT WHEEL SPEED SENSOR OR CONNECTOR DAMAGE INTERMITTENT DTC LEFT FRONT WHEEL SPEED SENSOR (+) CIRCUIT SHORTED TO GROUND LEFT FRONT WHEEL SPEED SENSOR (-) CIRCUIT SHORTED TO GROUND LEFT FRONT WHEEL SPEED SENSOR SHORTED TO GROUND CAB - INTERNAL SHORT OR OPEN LEFT FRONT WHEEL SPEED SENSOR (+) CIRCUIT OPEN LEFT FRONT WHEEL SPEED SENSOR (-) CIRCUIT OPEN LEFT FRONT WHEEL SPEED SENSOR (+) CIRCUIT SHORTED TO VOLTAGE LEFT FRONT WHEEL SPEED SENSOR (-) CIRCUIT SHORTED TO VOLTAGE LEFT FRONT WHEEL SPEED SENSOR CIRCUITS SHORT TOGETHER LEFT FRONT WHEEL SPEED SENSOR RESISTANCE OUT OF SPECIFICATION

TEST 1 ACTION Turn the ignition on. With the DRBIII , read DTC's. With the DRBIII , erase DTC's. Turn the ignition off. Turn the ignition on. With the DRBIII , read DTC's. Does the DRBIII display Left Front Wheel Speed Sensor Circuit Failure DTC present right now? Yes No 2 Go To Go To 2 14 All APPLICABILITY All

Turn the ignition off. Inspect the Left Front Wheel Speed Sensor and Connector. Is the Sensor or Connector Damaged? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 3 28

BRAKES (CAB)

LEFT FRONT SENSOR OPEN --

TEST 3

Continued

APPLICABILITY All

ACTION Turn the ignition off. Disconnect the CAB C2 harness connector. Note: Check connector - Clean/repair as necessary. Measure the resistance across the Left Front Wheel Speed Sensor (+) circuit and the Left Front Wheel Speed Sensor (-) circuit at the CAB connector. Is the resistance 1800 - 2200 ohms (2WD) or 893 - 1208 ohms (4WD)? Yes No Go To Go To 4 8

4

Turn the ignition off. Disconnect the Left Front Wheel Speed Sensor Connector. Disconnect the CAB Connector C2. Measure the resistance between the Left Front Wheel Speed Sensor (+) Circuit and ground. Is the resistance below 20,000 ohms? Yes Repair the Left Front Wheel Speed Sensor (+) Circuit Short to Ground. Perform ABS VERIFICATION TEST - VER 1. Go To 5

All

No 5

Turn the ignition off. Disconnect the Left Front Wheel Speed Sensor Connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB Connector C2. Note: Check connector - Clean/repair as necessary. Measure the resistance between the Left Front Wheel Speed Sensor (-) Circuit and ground. Is the resistance below 20,000 ohms? Yes Repair the Left Front Wheel Speed Sensor (-) Circuit Short to Ground. Perform ABS VERIFICATION TEST - VER 1. Go To 6

All

No 6

Turn the ignition off. Disconnect the Left Front Wheel Speed Sensor Connector. Note: Check connector - Clean/repair as necessary. On the component, measure the resistance between both of the Left Front Wheel Speed Sensor Terminals and ground. Is the resistance below 20,000 ohms? Yes No Replace the Left Front Wheel Speed Sensor. Perform ABS VERIFICATION TEST - VER 1. Go To 7

All

7

If there are no possible causes remaining, view repair. Repair Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1.

All

29

BRAKES (CAB)

LEFT FRONT SENSOR OPEN --

TEST 8

Continued

APPLICABILITY All

ACTION Turn the ignition off. Disconnect the Left Front Wheel Speed Sensor Connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB Connector C2. Note: Check connector - Clean/repair as necessary. Measure the resistance of the wheel speed sensor (+) circuit. Is the resistance below 5 ohms? Yes No Go To 9

Repair the Left Front Wheel Speed Sensor (+) Circuit Open. Perform ABS VERIFICATION TEST - VER 1. All

9

Turn the ignition off. Disconnect the Left Front Wheel Speed Sensor Connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB Connector C2. Note: Check connector - Clean/repair as necessary. Measure the resistance of the Left Front Wheel Speed Sensor (-) circuit. Is the resistance below 5 ohms? Yes No Go To 10

Repair the Left Front Wheel Speed Sensor (-) Circuit Open. Perform ABS VERIFICATION TEST - VER 1. All

10

Turn the ignition off. Disconnect the Left Front Wheel Speed Sensor connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB connector C2. Note: Check connector - Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Left Front Wheel Speed Sensor (+) Circuit. Is the voltage above 1 volt? Yes Repair Left Front Wheel Speed Sensor (+) Circuit Shorted to Voltage. Perform ABS VERIFICATION TEST - VER 1. Go To 11

No 11

Turn the ignition off. Disconnect the Left Front Wheel Speed Sensor connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB connector C2. Note: Check connector - Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Left Front Wheel Speed Sensor (-) Circuit. Is the voltage above 1 volt? Yes No Repair Left Front Wheel Speed Sensor (-) Circuit Short to Voltage. Perform ABS VERIFICATION TEST - VER 1. Go To 12

All

30

BRAKES (CAB)

LEFT FRONT SENSOR OPEN --

TEST 12

Continued

APPLICABILITY All

ACTION Turn the ignition off. Disconnect the CAB Connector C2. Disconnect the left front wheel speed sensor harness connector. Measure the resistance through the Wheel Speed Sensor (+) and (-) circuits at the CAB harness connector. Is the resistance below 200 ohms? Yes Repair the Left Front Wheel Speed Sensor Circuits Shorted together. Perform ABS VERIFICATION TEST - VER 1. Go To 13

No 13

If there are no possible causes remaining, view repair. Repair Replace the Left Front Wheel Speed Sensor. Perform ABS VERIFICATION TEST - VER 1.

All

14

Turn the ignition off. Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or partially broken wires. Visually inspect the related wire harness component and in-line connectors. Look for broken, bent, pushed out, or corroded terminals. Refer to any Hotline letters or Technical Service Bulletins that may apply. Were any problems found? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

All

31

BRAKES (CAB)

Symptom: MISMATCHED VIN

When Monitored and Set Condition: MISMATCHED VIN When Monitored: Ignition on.

Set Condition: Vehicle line or vehicle series information transmitted from PCM does not match the expected values for two minutes. OR Vehicle line or series information not transmitted by the PCM for two minutes.

POSSIBLE CAUSES WRONG VIN PROGRAMMED IN PCM INTERMITTENT DTC INCORRECT CAB FOR VEHICLE

TEST 1 ACTION Turn the ignition on. With the DRBIII , erase DTC's. Turn the ignition off. Turn the ignition on. Wait two minutes. Did the ABS Warning Indicator come on after 2 minutes? Yes No 2 Go To Go To 2 3 All APPLICABILITY All

Turn the ignition on. With the DRBIII , read the VIN status. Compare programmed VIN with vehicle VIN. Is the correct VIN programmed in the PCM? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Program the correct VIN into the PCM. Perform ABS VERIFICATION TEST - VER 1.

No 3

Turn the ignition off. Visually inspect the related wiring harness. Look for any chafed, 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. Were any problems found? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

All

32

BRAKES (CAB)

Symptom: NUMBER OF TONE RING TEETH OUT OF RANGE

When Monitored and Set Condition: NUMBER OF TONE RING TEETH OUT OF RANGE When Monitored: Ignition on.

Set Condition: At least two of the three values for the number of tone ring teeth are not in the range between 90 and 130. (If only one value of teeth is out of range then the value of the other two will be used.) OR If all three teeth values are not in agreement.

POSSIBLE CAUSES CAB - SETTING FALSE CODE TONE RING/AXLE MISMATCH

TEST 1 ACTION Turn the ignition on. With the DRBIII , read the axle programmed into the CAB. Inspect axle in vehicle and identify it. Compare the axle programmed into the CAB, and the actual axle installed into the vehicle. Does the programmed axle match the installed axle? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Using the DRBIII , reprogram the CAB for the correct axle. Perform ABS VERIFICATION TEST - VER 1. APPLICABILITY All

No

33

BRAKES (CAB)

Symptom: PUMP MOTOR FAULT

When Monitored and Set Condition: PUMP MOTOR FAULT 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). The CAB monitors pump voltage every 7 milliseconds. 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 ABS PUMP MOTOR INTERMITTENT DTC FUSED B(+) CIRCUIT INTERMITTENTLY SHORTED TO GROUND FUSED B(+) CIRCUIT SHORTED TO GROUND CAB - FUSED B(+) CIRCUIT SHORTED TO GROUND FUSE BLOWN - PUMP MOTOR CIRCUIT NO B+ SUPPLY TO FUSE ABS PUMP MOTOR INOPERATIVE FUSED B(+) CIRCUIT OPEN GROUND CIRCUIT OPEN GROUND CIRCUIT HIGH RESISTANCE CAB - INTERNAL FAULT

TEST 1 ACTION Turn the ignition off. Reconnect all connectors. Turn the ignition on. Monitor the pump motor for continuous operation. Is the pump motor running continuously? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Go To 2 APPLICABILITY All

No

34

BRAKES (CAB)

PUMP MOTOR FAULT --

TEST 2

Continued

ACTION APPLICABILITY All

Turn the ignition on. With the DRBIII , read DTC's. With the DRBIII , erase DTC's. Turn the ignition off. Turn the ignition on. With the DRBIII , actuate the ABS pump motor. Did the Pump Motor operate when actuated? No Yes Go To Go To 3 14

3

Turn the ignition off. Remove and inspect the ABS Pump fuse 8 in the PDC. Is the Fuse blown? Yes No Go To Go To 4 8

All

4

Turn the ignition off. Visually inspect the Fused B(+) Circuit in the wiring harness from the PDC to the CAB. Look for any sign of an Intermittent Short to Ground. Is the wiring harness OK? Yes No Go To 5

All

Repair the Fused B(+) Circuit shorted to ground. Perform ABS VERIFICATION TEST - VER 1. All

5

Turn the ignition off. Remove the ABS PUMP Fuse 8 from the Power Distribution Center (PDC). Disconnect the CAB connector. Note: Check connector - Clean/repair as necessary. Using a test light connected to 12 volts, probe the Fused B (+) Circuit. Is the test light on? Yes No Repair the Fused B(+) circuit short to ground. Perform ABS VERIFICATION TEST - VER 1. Go To 6

6

Turn the ignition off. Remove the ABS PUMP Fuse 8 from the PDC. The CAB must be connected for the results of this test to be valid. Using a test light connected to 12 volts, probe the Fused B (+) circuit in the PDC. Is the test light on? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Go To 7

All

No 7

Turn the ignition off. If there are no possible causes remaining, view repair. Repair Replace the ABS Pump Motor Fuse. Perform ABS VERIFICATION TEST - VER 1.

All

35

BRAKES (CAB)

PUMP MOTOR FAULT --

TEST 8

Continued

ACTION APPLICABILITY All

Turn the ignition on. Using a 12-volt test light connected to ground, check the B+ supply to Fuse 8 in the PDC. Is the B+ supply OK? Yes No Go To 9

Repair the B+ supply for an open. Perform ABS VERIFICATION TEST - VER 1. All

9

Turn the ignition off. Disconnect Pump Motor Connector. Connect a 10 gauge jumper wire between pump motor Fused B (+) circuit and a 40 Amp Fused B (+) circuit. Connect a 10 gauge jumper wire between pump motor ground circuit and a known good body ground. Monitor Pump Motor operation. Is the pump motor running? Yes No Go To 10

Replace the ABS Pump Motor/Hydraulic Control Unit assembly. Perform ABS VERIFICATION TEST - VER 1. All

10

Turn the ignition off. Remove the ABS PUMP Fuse 8 from the Power Distribution Center (PDC). Disconnect the CAB connector. Note: Check connector - Clean/repair as necessary. Measure the resistance of the Fused B (+) circuit between the PDC Fuse Terminal and the CAB connector. Is the resistance below 10 ohms? Yes No Go To 11

Repair the Fused B(+) circuit for an open. Perform ABS VERIFICATION TEST - VER 1. All

11

Turn the ignition off. Disconnect CAB Connector C1. Note: Check connector - Clean/repair as necessary. Measure the resistance of the CAB ground circuits. Is the resistance below 1.0 ohm? Yes No Go To 12

Repair the ground circuit circuit for an open. Perform ABS VERIFICATION TEST - VER 1. All

12

Turn the ignition on. With the DRBIII , enable pump motor actuation. NOTE: Pump motor will not operate, but voltage will be applied. Measure the voltage drop across the ABS ground circuit connection, with pump motor actuation enabled. Is the voltage below 0.1 volt? Yes No Go To 13

Repair the Ground circuit for an open. Perform ABS VERIFICATION TEST - VER 1.

36

BRAKES (CAB)

PUMP MOTOR FAULT --

TEST 13

Continued

ACTION APPLICABILITY All

If there are no potential causes remaining, view repair. Repair Replace the Controller Anti-Lock Brake in accordance with the Service Information. Perform ABS VERIFICATION TEST - VER 1.

14

Turn the ignition off. Visually inspect the related wiring harness. Look for any chafed, 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. Were any problems found? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

All

37

BRAKES (CAB)

Symptom: RAM READ/WRITE

When Monitored and Set Condition: RAM READ/WRITE When Monitored: Ignition on.

Set Condition: Inability to set and subsequently recognize as being set any bit in the RAM. OR Inability to clear and subsequently recognize as being cleared any bit in the RAM.

POSSIBLE CAUSES RAM READ/WRITE DTC CONDITION PRESENT INTERMITTENT DTC

TEST 1 ACTION Turn the ignition on. With the DRBIII , erase DTC's. Turn the ignition off. Turn the ignition on. With the DRBIII , read DTC's. Is the RAM READ/WRITE DTC present? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Go To 2 All APPLICABILITY All

No 2

Turn the ignition off. Visually inspect the related wiring harness. Look for any chafed, 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. Were any problems found? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

38

BRAKES (CAB)

Symptom: REAR DUMP SOLENOID OPEN - EBC 2

When Monitored and Set Condition: REAR DUMP SOLENOID OPEN - EBC 2 When Monitored: ABS power relay closed. Valve command for the rear dump solenoid not present (not trying to turn the valve on). Set Condition: Low feedback voltage from the low side of the solenoid and the when monitored conditions have been satisfied for over 40 consecutive controller checks spaced 5 milliseconds (ms) apart.

POSSIBLE CAUSES HCU 4-WAY HARNESS OR CONNECTOR DAMAGE REAR DUMP SOLENOID OPEN CAB-- INTERNAL FAULT

TEST 1 ACTION Turn the ignition off. Disconnect the HCU harness connector. Note: Check connectors - Clean/repair as necessary. Inspect the HCU harness and connector for damage. Is there any HCU connector, terminal or harness damage? Yes No 2 Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 2 All APPLICABILITY All

Turn the ignition off. Disconnect the HCU harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance through the Rear Dump Valve Solenoid between Cavities B and D. Is the resistance between 1.0 and 2.0 ohms? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Replace the Hydraulic Control Unit (HCU). Perform ABS VERIFICATION TEST - VER 1.

No

39

BRAKES (CAB)

Symptom: REAR DUMP SOLENOID SHORTED - EBC 2

When Monitored and Set Condition: REAR DUMP SOLENOID SHORTED - EBC 2 When Monitored: ABS power relay closed. Valve command for rear dump solenoid present (trying to turn the valve on). Set Condition: High feedback voltage from the low side solenoid and the when monitored conditions have been satisfied for over 200 milliseconds (ms).

POSSIBLE CAUSES HCU 4-WAY HARNESS OR CONNECTOR DAMAGE REAR DUMP SOLENOID SHORTED CAB-- INTERNAL FAULT

TEST 1 ACTION Turn the ignition off. Disconnect the HCU harness connector. Note: Check connectors - Clean/repair as necessary. Inspect the HCU harness and connector for damage. Is there any HCU connector, terminal or harness damage? Yes No 2 Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 2 All APPLICABILITY All

Turn the ignition off. Disconnect the HCU harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the Rear Dump Valve Control circuit. Is the resistance below 5 ohms? Yes No Replace the Hydraulic Control Unit (HCU). Perform ABS VERIFICATION TEST - VER 1. Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1.

40

BRAKES (CAB)

Symptom: REAR ISOLATION SOLENOID OPEN - EBC 2

When Monitored and Set Condition: REAR ISOLATION SOLENOID OPEN - EBC 2 When Monitored: ABS power relay closed. Valve command for rear isolation solenoid not present (not trying to turn the valve on). Set Condition: Low feedback voltage from the low side of the solenoid and the when monitored conditions have been satisfied for over 40 consecutive controller checks spaced 5 milliseconds (ms) apart.

POSSIBLE CAUSES HCU 4-WAY HARNESS OR CONNECTOR DAMAGE REAR ISOLATION SOLENOID OPEN CAB-- INTERNAL FAULT

TEST 1 ACTION Turn the ignition off. Disconnect the HCU harness connector. Note: Check connectors - Clean/repair as necessary. Inspect the HCU harness and connector for damage. Is there any HCU connector, terminal or harness damage? Yes No 2 Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 2 All APPLICABILITY All

Turn the ignition off. Disconnect the HCU harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance through the Rear Isolation Valve Solenoid between Cavities A and D. Is the resistance between 2.5 and 5.0 ohms? Yes No Test Complete. Replace the Hydraulic Control Unit (HCU). Perform ABS VERIFICATION TEST - VER 1.

41

BRAKES (CAB)

Symptom: REAR ISOLATION SOLENOID SHORTED - EBC 2

When Monitored and Set Condition: REAR ISOLATION SOLENOID SHORTED - EBC 2 When Monitored: ABS power relay closed. Valve command for rear isolation solenoid present (trying to turn the valve on). Set Condition: High feedback voltage from the low side solenoid and the when monitored conditions have been satisfied for over 200 milliseconds (ms).

POSSIBLE CAUSES HCU 4-WAY HARNESS OR CONNECTOR DAMAGE REAR DUMP SOLENOID SHORTED CAB-- INTERNAL FAULT

TEST 1 ACTION Turn the ignition off. Disconnect the HCU harness connector. Note: Check connectors - Clean/repair as necessary. Inspect the HCU harness and connector for damage. Is there any HCU connector, terminal or harness damage? Yes No 2 Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 2 All APPLICABILITY All

Turn the ignition off. Disconnect the HCU harness connector. Note: Check connectors - Clean/repair as necessary. Measure the resistance between ground and the Rear Dump Valve Control circuit. Is the resistance below 5 ohms? Yes No Replace the Hydraulic Control Unit (HCU). Perform ABS VERIFICATION TEST - VER 1. Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1.

42

BRAKES (CAB)

Symptom: REAR RESET SWITCH CLOSED - EBC 2

When Monitored and Set Condition: REAR RESET SWITCH CLOSED - EBC 2 When Monitored: CAB not in the antilock pressure control mode.

Set Condition: Reset switch voltage low and the when monitored conditions have been satisfied for over 200 consecutive controller checks spaced 5 milliseconds (ms) apart (1.0 second total).

POSSIBLE CAUSES REAR SOLENOID DTC(S) PRESENT HCU 4-WAY HARNESS OR CONNECTOR DAMAGE MECHANICAL BRAKE CONCERN HCU INTERNAL CONCERN

TEST 1 ACTION Ignition on, engine not running. With the DRBIII , read DTC's. Are there any DTC's displayed for the Rear Solenoid Valves? Yes No 2 Perform the appropriate diagnostics test for the displayed DTC's. Perform ABS VERIFICATION TEST - VER 1. Go To 2 All APPLICABILITY All

Turn the ignition off. Disconnect the HCU harness connector. Note: Check connectors - Clean/repair as necessary. Inspect the HCU harness and connector for damage. Is there any HCU connector, terminal or harness damage? Yes No Repair the HCU 4-way harness or connector as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 3

3

Road test the vehicle and check mechanical brake operation. Check whether brakes apply and release OK. Is there a mechanical brake operation concern? Yes No Repair the mechanical brake concern. Perform ABS VERIFICATION TEST - VER 1. Replace the Hydraulic Control Unit in accordance with the Service Information. Perform ABS VERIFICATION TEST - VER 1.

All

43

BRAKES (CAB)

Symptom: REAR SENSOR OPEN

When Monitored and Set Condition: REAR SENSOR OPEN When Monitored: milliseconds (ms). Ignition on. The CAB monitors the wheel speed circuit every 7

Set Condition: If the CAB detects an open or shorted wheel speed sensor circuit, the Diagnostic Trouble Code (DTC) will set.

POSSIBLE CAUSES REAR WHEEL SPEED SENSOR OR CONNECTOR DAMAGE INTERMITTENT DTC REAR WHEEL SPEED SENSOR (+) CIRCUIT SHORTED TO GROUND REAR WHEEL SPEED SENSOR (-) CIRCUIT SHORTED TO GROUND REAR WHEEL SPEED SENSOR SHORTED TO GROUND CAB - INTERNAL SHORT OR OPEN REAR WHEEL SPEED SENSOR (+) CIRCUIT OPEN REAR WHEEL SPEED SENSOR (-) CIRCUIT OPEN REAR WHEEL SPEED SENSOR (+) CIRCUIT SHORTED TO VOLTAGE REAR WHEEL SPEED SENSOR (-) CIRCUIT SHORTED TO VOLTAGE REAR WHEEL SPEED SENSOR CIRCUITS SHORT TOGETHER REAR WHEEL SPEED SENSOR RESISTANCE OUT OF SPECIFICATION

TEST 1 Turn the ignition With the DRBIII With the DRBIII Turn the ignition Turn the ignition With the DRBIII Does the DRBIII right now? Yes No 2 ACTION on. , read DTC's. , erase DTC's. off. on. , read DTC's. display Rear Wheel Speed Sensor Circuit Failure DTC present 2 14 All APPLICABILITY All

Go To Go To

Turn the ignition off. Inspect the Rear Wheel Speed Sensor and Connector. Is the Sensor or Connector Damaged? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 3 44

BRAKES (CAB)

REAR SENSOR OPEN --

TEST 3

Continued

ACTION APPLICABILITY All

Turn the ignition off. Disconnect the CAB C1 harness connector. Note: Check connector - Clean/repair as necessary. Measure the resistance across the Rear Wheel Speed Sensor (+) and (-) circuits at the CAB connector. Is the resistance 1600 - 2300 ohms? Yes No Go To Go To 4 8

4

Turn the ignition off. Disconnect the Rear Wheel Speed Sensor Connector. Disconnect the CAB Connector C1. Measure the resistance between the Rear Wheel Speed Sensor (+) Circuit and ground. Is the resistance below 20,000 ohms? Yes No Repair the Rear Wheel Speed Sensor (+) Circuit Short to Ground. Perform ABS VERIFICATION TEST - VER 1. Go To 5

All

5

Turn the ignition off. Disconnect the Rear Wheel Speed Sensor Connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB Connector C1. Note: Check connector - Clean/repair as necessary. Measure the resistance between the Rear Wheel Speed Sensor (-) Circuit and ground. Is the resistance below 20,000 ohms? Yes No Repair the Rear Wheel Speed Sensor (-) Circuit Short to Ground. Perform ABS VERIFICATION TEST - VER 1. Go To 6

All

6

Turn the ignition off. Disconnect the Rear Wheel Speed Sensor Connector. Note: Check connector - Clean/repair as necessary. On the component, measure the resistance between both of the Rear Wheel Speed Sensor Terminals and ground. Is the resistance below 20,000 ohms? Yes Replace the Rear Wheel Speed Sensor in accordance with the Service Information. Perform ABS VERIFICATION TEST - VER 1. Go To 7

All

No 7

If there are no possible causes remaining, view repair. Repair Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1.

All

45

BRAKES (CAB)

REAR SENSOR OPEN --

TEST 8

Continued

ACTION APPLICABILITY All

Turn the ignition off. Disconnect the Rear Wheel Speed Sensor Connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB harness connector C1 . Note: Check connector - Clean/repair as necessary. Measure the resistance of the Rear Wheel Speed Sensor (+) circuit. Is the resistance below 5 ohms? Yes No Go To 9

Repair the Rear Wheel Speed Sensor (+) Circuit Open. Perform ABS VERIFICATION TEST - VER 1. All

9

Turn the ignition off. Disconnect the Rear Wheel Speed Sensor Connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB harness connector C1. Note: Check connector - Clean/repair as necessary. Measure the resistance of the Rear Wheel Speed Sensor (-) circuit. Is the resistance below 5 ohms? Yes No Go To 10

Repair the Rear Wheel Speed Sensor (-) Circuit Open. Perform ABS VERIFICATION TEST - VER 1. All

10

Turn the ignition off. Disconnect the Rear Wheel Speed Sensor harness connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB harness connector C1. Note: Check connector - Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Rear Wheel Speed Sensor (+) Circuit. Is the voltage above 1 volt? Yes No Repair Rear Wheel Speed Sensor (+) Circuit Shorted to Voltage. Perform ABS VERIFICATION TEST - VER 1. Go To 11

11

Turn the ignition off. Disconnect the Rear Wheel Speed Sensor connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB harness connector C1. Note: Check connector - Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Rear Wheel Speed Sensor (-) Circuit. Is the voltage above 1 volt? Yes No Repair Rear Wheel Speed Sensor (-) Circuit Short to Voltage. Perform ABS VERIFICATION TEST - VER 1. Go To 12

All

46

BRAKES (CAB)

REAR SENSOR OPEN --

TEST 12

Continued

ACTION APPLICABILITY All

Turn the ignition off. Disconnect the CAB harness connector C1. Disconnect the Rear Wheel Speed Sensor harness connector. Measure the resistance through the Rear Wheel Speed Sensor (+) and (-) circuits at the CAB harness connector. Is the resistance below 200 ohms? Yes No Repair the Rear Wheel Speed Sensor Circuits Shorted together. Perform ABS VERIFICATION TEST - VER 1. Go To 13

13

If there are no possible causes remaining, view repair. Repair Replace the Rear Wheel Speed Sensor in accordance with the Service Information. Perform ABS VERIFICATION TEST - VER 1.

All

14

Turn the ignition off. Visually inspect the related wiring harness. Look for any chafed, 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. Were any problems found? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

All

47

BRAKES (CAB)

Symptom: RIGHT FRONT SENSOR OPEN

When Monitored and Set Condition: RIGHT FRONT SENSOR OPEN When Monitored: milliseconds (ms). Ignition on. The CAB monitors the wheel speed circuit every 7

Set Condition: If the CAB detects an open or shorted wheel speed sensor circuit, the Diagnostic Trouble Code (DTC) will set.

POSSIBLE CAUSES RIGHT FRONT WHEEL SPEED SENSOR OR CONNECTOR DAMAGE INTERMITTENT DTC RIGHT FRONT WHEEL SPEED SENSOR (+) CIRCUIT SHORTED TO GROUND RIGHT FRONT WHEEL SPEED SENSOR (-) CIRCUIT SHORTED TO GROUND RIGHT FRONT WHEEL SPEED SENSOR - SHORT TO GROUND CAB - INTERNAL SHORT OR OPEN RIGHT FRONT WHEEL SPEED SENSOR (+) CIRCUIT OPEN RIGHT FRONT WHEEL SPEED SENSOR (-) CIRCUIT OPEN RIGHT FRONT WHEEL SPEED SENSOR (+) CIRCUIT SHORTED TO VOLTAGE RIGHT FRONT WHEEL SPEED SENSOR (-) CIRCUIT SHORTED TO VOLTAGE RIGHT FRONT WHEEL SPEED SENSOR CIRCUITS SHORT TOGETHER RIGHT FRONT WHEEL SPEED SENSOR RESISTANCE OUT OF SPECIFICATION

TEST 1 Turn With With Turn Turn With Does the the the the the the the ignition DRBIII DRBIII ignition ignition DRBIII DRBIII Yes No 2 ACTION on. , read DTC's. , erase DTC's. off. on. , read DTC's. display RF Wheel Speed Sensor Circuit Failure DTC? 2 14 All APPLICABILITY All

Go To Go To

Turn the ignition off. Inspect the Right Front Wheel Speed Sensor and Connector. Is the Sensor or Connector Damaged? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Go To 3

48

BRAKES (CAB)

RIGHT FRONT SENSOR OPEN --

TEST 3

Continued

APPLICABILITY All

ACTION Turn the ignition off. Disconnect the CAB harness connector C2. Note: Check connector - Clean/repair as necessary. Measure the resistance across the Right Front Wheel Speed Sensor (+) and (-) circuits at the CAB connector. Is the resistance between 1000 - 1250 ohms for 2WD and 945 - 1155 ohms for 4WD? Yes No Go To Go To 4 8

4

Turn the ignition off. Disconnect the Right Front Wheel Speed Sensor Connector. Disconnect the CAB harness connector C2. Measure the resistance between the Right Front Wheel Speed Sensor (+) Circuit and ground. Is the resistance below 20,000 ohms? Yes Repair the Right Front Wheel Speed Sensor (+) circuit Short to Ground. Perform ABS VERIFICATION TEST - VER 1. Go To 5

All

No 5

Turn the ignition off. Disconnect the Right Front Wheel Speed Sensor harness connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB harness connector C2. Note: Check connector - Clean/repair as necessary. Measure the resistance between the Right Front Wheel Speed Sensor (-) circuit and ground. Is the resistance below 20,000 ohms? Yes Repair the Right Front Wheel Speed Sensor (-) Circuit Short to Ground. Perform ABS VERIFICATION TEST - VER 1. Go To 6

All

No 6

Turn the ignition off. Disconnect the Right Front Wheel Speed Sensor harness connector. Note: Check connector - Clean/repair as necessary. On the sensor, measure the resistance between ground and both of the Right Front Wheel Speed Sensor terminals. Is the resistance below 20,000 ohms? Yes No Replace the Right Front Wheel Speed Sensor. Perform ABS VERIFICATION TEST - VER 1. Go To 7

All

7

If there are no possible causes remaining, view repair. Repair Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1.

All

49

BRAKES (CAB)

RIGHT FRONT SENSOR OPEN --

TEST 8

Continued

APPLICABILITY All

ACTION Turn the ignition off. Disconnect the Right Front Wheel Speed Sensor Connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB harness connector C2. Note: Check connector - Clean/repair as necessary. Measure the resistance of the wheel speed sensor (+) circuit. Is the resistance below 5 ohms? Yes No Go To 9

Repair the Right Front Wheel Speed Sensor (+) Circuit Open. Perform ABS VERIFICATION TEST - VER 1. All

9

Turn the ignition off. Disconnect the Right Front Wheel Speed Sensor Connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB harness connector C2. Note: Check connector - Clean/repair as necessary. Measure the resistance of the Right Front Wheel Speed Sensor (-) circuit. Is the resistance below 5 ohms? Yes No Go To 10

Repair the Right Front Wheel Speed Sensor (-) Circuit Open. Perform ABS VERIFICATION TEST - VER 1. All

10

Turn the ignition off. Disconnect the Right Front Wheel Speed Sensor harness connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB harness connector C2. Note: Check connector - Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Right Front Wheel Speed Sensor (+) Circuit. Is the voltage above 1 volt? Yes Repair Right Front Wheel Speed Sensor (+) Circuit Shorted to Voltage. Perform ABS VERIFICATION TEST - VER 1. Go To 11

No 11

Turn the ignition off. Disconnect the Right Front Wheel Speed Sensor harness connector. Note: Check connector - Clean/repair as necessary. Disconnect the CAB harness connector C2. Note: Check connector - Clean/repair as necessary. Turn the ignition on. Measure the voltage of the Right Front Wheel Speed Sensor (-) Circuit. Is the voltage above 1 volt? Yes Repair Right Front Wheel Speed Sensor (-) Circuit Short to Voltage. Perform ABS VERIFICATION TEST - VER 1. Go To 12

All

No

50

BRAKES (CAB)

RIGHT FRONT SENSOR OPEN --

TEST 12

Continued

APPLICABILITY All

ACTION Turn the ignition off. Disconnect the CAB harness connector C2. Disconnect the Right Front Wheel Speed Sensor harness connector. Measure the resistance through the Wheel Speed Sensor (+) and (-) circuits at the CAB harness connector. Is the resistance below 200 ohms? Yes Repair the Right Front Wheel Speed Sensor Circuits Shorted together. Perform ABS VERIFICATION TEST - VER 1. Go To 13

No 13

If there are no possible causes remaining, view repair. Repair Replace the Right Front Wheel Speed Sensor. Perform ABS VERIFICATION TEST - VER 1.

All

14

Turn the ignition off. Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or partially broken wires. Visually inspect the related wire harness component and in-line connectors. Look for broken, bent, pushed out, or corroded terminals. Refer to any Hotline letters or Technical Service Bulletins that may apply. Were any problems found? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

All

51

BRAKES (CAB)

Symptom: ROM CHECKSUM

When Monitored and Set Condition: ROM CHECKSUM When Monitored: Ignition on.

Set Condition: Sum of all the storage bytes in the CAB's ROM not equal to the original sum stored in ROM.

POSSIBLE CAUSES ROM CHECKSUM DTC CONDITION PRESENT INTERMITTENT DTC

TEST 1 Turn the ignition on. With the DRBIII , erase DTC's. Turn the ignition off. Turn the ignition on. With the DRBIII , read DTC's. Is the ROM CHECKSUM DTC set? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Go To 2 All ACTION APPLICABILITY All

No 2

Turn the ignition off. Visually inspect the related wiring harness. Look for any chafed, 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. Were any problems found? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

52

BRAKES (CAB)

Symptom: SYSTEM CONTROL MODE TIMEOUT

When Monitored and Set Condition: SYSTEM CONTROL MODE TIMEOUT When Monitored: for 2 seconds. Vehicle in antilock control mode. Vehicle speed above 6 km/h (4 mph)

Set Condition: When monitored conditions have been satisfied for 120 consecutive controller checks spaced 1 second apart.

POSSIBLE CAUSES CAB - NO RESPONSE TO INPUT BRAKE LAMP SWITCH BRAKE LAMP SWITCH SENSE CIRCUIT CAB INTERNAL FAULT

TEST 1 ACTION With the DRBIII in Inputs/Outputs, read the Brake Lamp Switch state. Apply and release the brake pedal. Does the DRBIII follow the pedal position? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Go To 2 All APPLICABILITY All

No 2

Turn the ignition off. Apply and release the brake pedal. Observe the brake lamps. Do the brake lamps operate OK? Yes No Go To 3

Refer to Service information for the related symptom(s). Perform ABS VERIFICATION TEST - VER 1.

53

BRAKES (CAB)

SYSTEM CONTROL MODE TIMEOUT --

TEST 3 ACTION Turn the ignition off. Disconnect the CAB connector. Note: Check connector - Clean/repair as necessary. Turn the ignition on. Apply and release the brake pedal. Check Brake Lamp Switch Sense for ground with pedal released and open with pedal applied. Does the Brake Lamp Switch Sense circuit change state as specified? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Repair the Brake Lamp Switch Sense circuit for a short to battery, ground or for an open. Perform ABS VERIFICATION TEST - VER 1.

Continued

APPLICABILITY All

No

54

BRAKES (CAB)

Symptom: TIRE REVOLUTIONS PER MILE OUT OF RANGE

When Monitored and Set Condition: TIRE REVOLUTIONS PER MILE OUT OF RANGE When Monitored: Ignition on.

Set Condition: Two of the three values for the tire revolutions per mile are not in the range between 400 and 900. If only one value of tire revolutions per mile is out of range, value of the other two will be used. When this DTC is set, ABS warning indicator flashes.

POSSIBLE CAUSES INCORRECT TIRES PROGRAMMED INTO CAB INTERMITTENT DTC CAB INTERNAL FAULT

TEST 1 ACTION Turn the ignition on. Observe the ABS Warning Indicator. Is the ABS Warning Indicator Flashing? Yes No 2 Go To Go To 2 3 All APPLICABILITY All

Inspect all four of the tire sizes on the vehicle. NOTE: Non-production size tire cannot be programmed into the CAB. The production Powertrain, with the production size tires is the only emissions certified configuration that is available for reprogramming. Turn the ignition on. With the DRBIII , read the tire size that is programmed into the CAB. Does the DRBIII displayed tire size match the actual tire size on the vehicle? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Reprogram the tire size. Make sure that the ignition is on throughout the entire reprogramming procedure. Perform ABS VERIFICATION TEST - VER 1.

No

55

BRAKES (CAB)

TIRE REVOLUTIONS PER MILE OUT OF RANGE --

TEST 3 ACTION Turn the ignition off. Visually inspect the related wiring harness. Look for any chafed, 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. Were any problems found? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

Continued

APPLICABILITY All

56

BRAKES (CAB)

Symptom: WATCHDOG

When Monitored and Set Condition: WATCHDOG When Monitored: Ignition on.

Set Condition: High feedback voltage from the low side of both the isolation and dump solenoids in the middle of a ABS bulb check, (at start up) for 23 consecutive checks spaced 5 milliseconds apart.

POSSIBLE CAUSES WATCHDOG DTC CONDITION PRESENT INTERMITTENT DTC

TEST 1 Turn the ignition on. With the DRBIII , erase DTC's. Turn the ignition off. Turn the ignition on. With the DRBIII , read DTC's. Is the WATCHDOG DTC present? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Go To 2 All ACTION APPLICABILITY All

No 2

Turn the ignition off. Visually inspect the related wiring harness. Look for any chafed, 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. Were any problems found? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

57

BRAKES (CAB)

Symptom: WHEEL SPEED MISMATCH

When Monitored and Set Condition: WHEEL SPEED MISMATCH When Monitored: 1500 Series Vehicles When Monitored: Vehicle speed greater than 20 km/h (12 mph). No evidence of drivetrain spin up in the last 5 seconds. Open sensor DTC not present. ABS not inhibited. ABS not in active control mode. 2500 and 3500 Series Vehicles When Monitored: Vehicle speed greater than 16 km/h (10 mph) but less than 64 km/h (40 mph). No evidence of drivetrain acceleration or deceleration. Open sensor DTC not present. ABS not inhibited. ABS not in active control mode. Set Condition: 1500 Series Vehicles: When compared to the other wheels, one wheel is 20% different. OR Three wheel speeds differing from each other by more than 12%. All criteria above met for 12 seconds. 2500 and 3500 Series Vehicles: Three wheel speeds differing from each other by more than 13%. All criteria above met for 12 seconds.

POSSIBLE CAUSES WHEEL SPEED MISMATCH DTC CONDITION PRESENT INCORRECT TONE WHEEL CAB INTERNAL FAULT

TEST 1 ACTION Turn the ignition off. Inspect all four tire sizes on vehicle. Are any of the tires/wheels significantly different in size? Yes Correct as necessary. All of the tires and wheels must be of uniform size. Perform ABS VERIFICATION TEST - VER 1. Go To 2 All APPLICABILITY All

No 2

Turn the ignition off. Count number of teeth on the suspect Tone Wheel. Does the suspect tone wheel match the non-suspect tone wheels? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Replace the tone wheel. Perform ABS VERIFICATION TEST - VER 1.

No

58

BRAKES (CAB)

Symptom: *ABS WARNING INDICATOR

POSSIBLE CAUSES CLUSTER DTC PRESENT INSTRUMENT CLUSTER BULB CONCERN CAB DTC PRESENT INSTRUMENT CLUSTER INTERNAL CONCERN

TEST 1 ACTION Turn the ignition on. With the DRBIII , read DTCs. Are there any Instrument Cluster DTCs present? Yes Refer to the INSTRUMENT CLUSTER category for the related symptom(s). Perform ABS VERIFICATION TEST - VER 1. Go To 2 All APPLICABILITY All

No 2

Turn the ignition off. Observe the instrument cluster indicators. Turn the ignition on. Did the ABS Indicator illuminate for several seconds? Yes No Go To 3

Replace the Instrument Cluster in accordance with the Service Information. Perform ABS VERIFICATION TEST - VER 1. All

3

Turn the ignition on. NOTE: The DRBIII communication with the CAB must be operational for the result of this test to be valid. With the DRBIII , read DTCs. Are there any CAB DTCs present? Yes No Refer to BRAKES category for the related symptom(s). Perform ABS VERIFICATION TEST - VER 1. Go To 4

4

If there are no possible causes remaining, view repair. Repair Replace the Instrument Cluster in accordance with the Service Information. Perform ABS VERIFICATION TEST - VER 1.

All

59

BRAKES (CAB)

Symptom: *DRBIII NO RESPONSE MESSAGE

POSSIBLE CAUSES CHECK COMMUNICATION TO MIC CAB-- INTERNAL FAULT

TEST 1 ACTION Turn the ignition on. With the DRBIII , attempt to communicate with the MIC Was the DRB able to I/D or communicate with the MIC? Yes No Go To 2 APPLICABILITY All

Refer to the Communication category and perform the symptom Bus +/- Signals Open from the Controller Anti-Lock Brake. Perform ABS VERIFICATION TEST - VER 1. All

2

With the DRB, erase DTC's. Turn the ignition on and wait approximately 1 minute. With the DRB, read DTC's. Did this DTC reset? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information. Perform ABS VERIFICATION TEST - VER 1. Test Complete.

No

60

BRAKES (CAB)

Symptom: *REPLACING THE CONTROLLER ANTILOCK BRAKE

POSSIBLE CAUSES REPLACING THE CAB

TEST 1 ACTION Note: You must call STAR to recieve a new CAB. Note: Failure to properly program the replacement CAB will result in a blinking ABS indicator. Turn the ignition off. Replace the CAB. With the DRBIII , check the Tire Size and Rear Axle Type. If the DRBIII display's the Tire size and Axle ratio, use the DRBIII select: MISC then MODULE REPLACEMENT. If the DRBIII does not display Tire Size and Rear Axle Type, use the DRBIII select: MISC then SET PINION FACTOR. Inspect rear tires to determine tire sizes. Note: If the vehicle does not have production size tires listed on the DRBIII menu screen, install Production Size tires on the vehicle. Determine which rear axle type, not the axle ratio, is used on this vehicle. NOTE: To identify the proper axle on the vehicle, refer to Component Location in Chassis Diagnostic Procedures or Service Information on MDS2. Ignition on, engine not running. With the DRBIII , program the correct tire size and rear axle type. Road test the vehicle above 48 Km/h (30 mph) for at least two minutes. Check for any DTC's. Did any DTC's set during the road test? Yes No 2 Refer to the Symptom List for further diagnostic tests. Perform ABS VERIFICATION TEST - VER 1. Go To 2 All APPLICABILITY All

Turn the ignition off. Connect all previously disconnected components and connectors. Ensure all accessories are turned off and the battery is fully charged. Ensure that the Ignition is on, and with the DRBIII, erase all Diagnostic Trouble Codes from ALL modules. Start the engine and allow it to run for 2 minutes and fully operate the system that was malfunctioning. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIII, read DTC's from ALL modules. If any Diagnostic Trouble Codes are present, return to Symptom list and troubleshoot new or recurring symptom. 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. Caution: Ensure braking capability is available before road testing. Again, with the DRBIII read DTC's. If any DTC's are present, return to Symptom list. If there are no Diagnostic Trouble Codes (DTC's) present, and the customer's concern can no longer be duplicated, the repair is complete. Are any DTC's present or is the original concern still present? Yes No Test Complete. Test Complete. 61

BRAKES (CAB)

Symptom: *VEHICLE SPEED SIGNAL OUTPUT

POSSIBLE CAUSES CONTROLLER ANTILOCK BRAKE DTC'S PRESENT INTERMITTENT VEHICLE SPEED SIGNAL VEHICLE SPEED SIGNAL CIRCUIT SHORTED OR OPEN CAB- NO SPEED SIGNAL OUTPUT PCM- CAN'T READ VEHICLE SPEED SIGNAL

TEST 1 ACTION Turn the ignition on. With the DRB III read DTC's. Is the Good Trip Counter for P-0500 displayed and Equal to 0? Yes No 2 Go To Go To 2 6 All APPLICABILITY All

Turn the ignition on. With the DRBIII , read DTCs. Check for Controller Antilock Brake DTC's. Are any CAB DTC's present? Yes No Repair all Controller Antilock Brake DTC's before proceeding. Go To 3

3

Turn the ignition off. Disconnect the Powertrain Control Module harness connectors. Disconnect the CAB connector. Check the Vehicle Speed Signal circuit for a short to B+, short to ground and for an open. Is the Vehicle Speed Signal circuit OK? Yes No Go To 4

All

Repair the open Vehicle Speed Signal circuit for a short or an open. Perform ABS VERIFICATION TEST - VER 1. All

4

Turn ignition off. Disconnect the CAB connector. Connect a jumper wire to the Vehicle Speed Signal circuit in the CAB harness connector. Turn ignition on. Quickly and repeatedly tap the jumper wire to ground. With the DRBIII read the Vehicle Speed Signal display. Is the DRBIII reading Vehicle Speed above 0 MPH? Yes Replace the Controller Antilock Brake in accordance with the Service Information. Refer to the symptom *Replacing the Controller Antilock Brake for additional information.. Perform ABS VERIFICATION TEST - VER 1. Go To 5

No

62

BRAKES (CAB)

*VEHICLE SPEED SIGNAL OUTPUT --

TEST 5 ACTION If there are no possible causes remaining, view repair. Repair Replace the Powertrain Control Module in accordance with the Service Information. Perform POWERTRAIN VERIFICATION TEST VER - 5. 6 At this time, the conditions required to set the DTC are not present. NOTE: Use the Freeze Frame Data to help duplicate the conditions that set the DTC. Pay particular attention to the DTC set conditions, such as, VSS, MAP, ECT, and Load. Note: Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or partially broken wires. Note: Visually inspect the related wire harness connectors. Look for broken, bent, pushed out, or corroded terminals. Note: Refer to any technical service bulletins that may apply. Were any problems found? Yes No Repair as necessary. Perform ABS VERIFICATION TEST - VER 1. Test Complete. All

Continued

APPLICABILITY All

63

VERIFICATION TESTS

Verification Tests

ABS VERIFICATION TEST - VER 1 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 that the Ignition is on, and with the DRBIII, erase all Diagnostic Trouble Codes from 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. 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. 8. Caution: Ensure braking capability is available before road testing. 9. Again, with the DRBIII read DTC's. If any DTC's are present, return to Symptom list. 10. If there are no Diagnostic Trouble Codes (DTC's) present, and the customer's concern can no longer be duplicated, the repair is complete. Are any DTC's present or is the original concern still present? Yes No Repair is not complete, refer to appropriate symptom. Repair is complete. APPLICABILITY All

64

VERIFICATION TESTS

Verification Tests --

Continued

APPLICABILITY All

POWERTRAIN VERIFICATION TEST VER - 5 1. Inspect the vehicle to ensure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary. 2. If any existing diagnostic trouble codes have not been repaired, go to Symptom List and follow path specified. 3. Connect the DRBIII to the data link connector. 4. Ensure the fuel tank has at least a quarter tank of fuel. Turn off all accessories. 5. Perform steps 6 through 8 if the PCM has been replaced. Then proceed with the verification. If the PCM has not been replaced skip those steps and continue verification. 6. If PCM has been changed and correct VIN and mileage have not been programmed, a DTC will be set in ABS and Air bag modules. In addition, if vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key data must be updated to enable start. 7. For ABS and Air Bag systems: Enter correct VIN and Mileage in PCM. Erase codes in ABS and Air Bag modules. 8. For SKIM theft alarm: Connect DRBIII to data link conn. Go to Theft Alarm, SKIM, Misc. and place SKIM in secured access mode, by using the appropriate PIN code for this vehicle. Select Update Secret Key data. Data will be transferred from SKIM to PCM. 9. If a Comprehensive Component DTC was repaired, perform steps 10-13. If a Major OBDII Monitor DTC was repaired skip those steps and continue verification. 10. After the ignition has been off for at least 10 seconds, restart the vehicle and run 2 minutes. 11. If the Good Trip counter changed to one or more and there are no new DTC's, the repair was successful and is now complete. Erase DTC's and disconnect the DRBIII . 12. If the repaired DTC has reset, the repair is not complete. Check for any related TSB's or flash updates and return to the Symptom list. 13. If another DTC has set, return to the Symptom List and follow the path specified for that DTC. 14. With the DRBIII , monitor the appropriate pre-test enabling conditions until all conditions have been met. Once the conditions have been met, switch screen to the appropriate OBDII monitor, (Audible beeps when the monitor is running). 15. If the monitor ran, and the Good Trip counter changed to one or more, the repair was successful and is now complete. Erase DTC's and disconnect the DRBIII . 16. If the repaired OBDII trouble code has reset or was seen in the monitor while on the road test, the repair is not complete. Check for any related technical service bulletins or flash updates and return to Symptom List. 17. If another DTC has set, return to the Symptom List and follow the path specified for that DTC.

65

NOTES

66

COMPONENT LOCATIONS

8.0 8.1 8.1.1 COMPONENT LOCATIONS CONTROLLER ANTILOCK BRAKE (CAB) EBC 2

C O M P O N E N T L O C A T I O N S

8.1.2

EBC 325

67

C O M P O N E N T L O C A T I O N S

COMPONENT LOCATIONS

8.2 DATA LINK CONNECTOR

8.3

POWER DISTRIBUTION CENTER

8.4

JUNCTION BLOCK

68

COMPONENT LOCATIONS

8.5 WHEEL SPEED SENSORS/TONE WHEELS 8.5.1 FRONT

2WD TYPICAL TONE WHEEL

C O M P O N E N T L O C A T I O N S

8.5.2

REAR

REAR TONE WHEEL

69

C O M P O N E N T L O C A T I O N S

COMPONENT LOCATIONS

8.6 LEFT FRONT WHEEL SPEED SENSOR CONNECTOR

8.7

RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR

8.8

REAR WHEEL SPEED SENSOR CONNECTOR

70

COMPONENT LOCATIONS

8.9 BRAKE LAMP SWITCH

C O M P O N E N T L O C A T I O N S

8.10

PCM

8.11

4WD SWITCH

71

C O M P O N E N T L O C A T I O N S

COMPONENT LOCATIONS

8.12 REAR AXLE IDENTIFICATION

72

CONNECTOR PINOUTS

9.0 CONNECTOR PINOUTS

CONTROLLER ANTILOCK BRAKE C1 - BLACK 14 WAY

CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 G7 18WT/OR Z19 12BK/PK A10 12RD/DG Z19 12BK/PK A10 12RD/DG B114 20WT/VT V40 18WT/PK B10 20BR/WT D25 18VT/YL A20 20RD/DB GROUND FUSED B(+) REAR WHEEL SPEED SENSOR (-) BRAKE LAMP SWITCH SENSE BRAKE PRESSURE SWITCH SENSE VEHICLE SPEED SENSOR SIGNAL GROUND FUSED B(+) CIRCUIT B113 20RD/VT PCI BUS FUSED IGNITION SWITCH OUTPUT (RUN) FUNCTION REAR WHEEL SPEED SENSOR (+) -

CONTROLLER ANTILOCK BRAKE C2 - BLACK 4 WAY

CAV 1 2 3 4 B9 20RD B8 20RD/GY B6 20WT/DB B7 20WT CIRCUIT FUNCTION LEFT FRONT WHEEL SPEED SENSOR (+) LEFT FRONT WHEEL SPEED SENSOR (-) RIGHT FRONT WHEEL SPEED SENSOR (-) RIGHT FRONT WHEEL SPEED SENSOR (+)

C O N N E C T O R P I N O U T S

LEFT FRONT WHEEL SPEED SENSOR - LT. GRAY 2 WAY

CAV 1 2 B9 20RD CIRCUIT B8 20RD/GY FUNCTION LEFT FRONT WHEEL SPEED SENSOR (-) LEFT FRONT WHEEL SPEED SENSOR (+)

73

CONNECTOR PINOUTS

LEFT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY

CAV 1 2 BK BK CIRCUIT WHEEL SPEED SENSOR (-) WHEEL SPEED SENSOR (-) FUNCTION

PUMP MOTOR CONNECTOR - 2 WAY

CAV CIRCUIT RD BK PUMP MOTOR CONTROL GROUND FUNCTION

C O N N E C T O R P I N O U T S

1 2

REAR WHEEL SPEED SENSOR - BLACK 2 WAY

CAV 1 2 CIRCUIT B114 20WT/VT B113 20RD/VT FUNCTION REAR WHEEL SPEED SENSOR (-) REAR WHEEL SPEED SENSOR (+)

RIGHT FRONT WHEEL SPEED SENSOR - LT. GRAY 2 WAY

CAV 1 2 B7 20WT CIRCUIT B6 20WT/DB FUNCTION RIGHT FRONT WHEEL SPEED SENSOR (-) RIGHT FRONT WHEEL SPEED SENSOR (+)

74

CONNECTOR PINOUTS

RIGHT FRONT WHEEL SPEED SENSOR (SENSOR SIDE) - 2 WAY

CAV 1 2 BK BK CIRCUIT WHEEL SPEEED SENSOR (-) WHEEL SPEEED SENSOR (+) FUNCTION

C O N N E C T O R P I N O U T S

75

NOTES

76

SCHEMATIC DIAGRAMS

10.0 10.1 SCHEMATIC DIAGRAMS 2001 AN BODY EBC 2

S C H E M A T I C D I A G R A M S

77

SCHEMATIC DIAGRAMS

10.2 2000 AN BODY EBC 325

S C H E M A T I C D I A G R A M S

78

Information

daimler-chrysler

82 pages

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