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1. 47 CONTROLLER ANTILOCK 47 DATA LINK CONNECTOR 48 LEFT FRONT WHEEL SPEED SENSOR 48 LEFT REAR WHEEL SPEED SENSOR souk weed eee heed ee 48 RIGHT FRONT WHEEL SPEED SENSOR 49 RIGHT REAR WHEEL SPEED SENSOR vues eae 49 SCHEMATIC DIAGRAMS i565 cscs ides aceni ered Penna 51 10 1 TEVES MARK 20e CONTROLLER ANTILOCK BRAKE 51 1 0 INTRODUCTION The procedures contained in this manual include all the specifications instructions and graphics needed to diagnose the 2003 Chrysler Sebring and Dodge Stratus Mark 20e Antilock Braking System ABS The diagnostics in this manual are based on the failure condition or symptom being present at time of diagnosis Please follow the recommendations below when choosing your diagnostic path 1 First make sure the 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 identi fied locate the matching test in the Table of Contents and begin to diagnose the symptom All co
2. doar at 4 421 TECHNICIAN SAFETY 4 4 2 2 VEHICLE PREPARATION FOR 5 4 2 3 SERVICING SUB ASSEMBLIES 5 4 2 4 SAFETY INFORMATION 5 4 3 WARNINGS 0 5 4 31 VEHICLE DAMAGE 8 5 4 3 2 ROAD TESTING A COMPLAINT 5 DIAGNOSIS 6 REQUIRED TOOLS AND EQUIPMENT 6 GLOSSARY OF TERMS 6 DIAGNOSTIC INFORMATION AND PROCEDURES 9 BRAKES CAB BUS SYSTEM COMMUNICATION FAILURE 10 CAB INTERNAL FAILURE 12 CLUSTER LAMP FAILURE 0 14 INCORRECT TONE WHEEL 16 LEFT FRONT SENSOR CIRCUIT FAILURE 17 LEFT REAR SENSOR CIRCUIT 17 RIGHT FRONT SENSOR CIRCUIT 17 RIGHT REAR SENSOR CIRCUIT FAILURE noanoa anaoa oaeen 17 LEFT FRONT WHEEL SPEED SIGNAL 22 LEFT REAR WHEEL SPEED SIGNAL FAILURE 22 8 0 9 0 10 0 TABLE OF CONTENTS Continued RIGHT FRONT WHEEL SPEED SIGNAL FAILUR
3. 412 02 STEERING AUE i COLUMN Vil i N A INTERMEDIATE Ve k SHAFT BS 0 BRAKE ACCELERATOR 7 PEDAL PEDAL 7 80be4640 45 NOTES 46 9 0 CONNECTOR PINOUTS CONNECTOR PINOUTS BRAKE LAMP SWITCH CAV CIRCUIT FUNCTION 29 20 2 7L BRAKE SWITCH SENSE GRAY 1 K29 20WTIPK 2 0L 2 4L BRAKE SWITCH SIGNAL 2241 20BK 2 7L MTX GROUND 2 7241 20BK LG EXCEPT 2 7L MTX GROUND BRAKE LAMP 3 V32 20YL RD 2 7L SPEED CONTROL POWER SUPPLY SWITCH 3 V32 20YL RD 2 0L 2 4L S C SUPPLY 4 V30 20DB RD SPEED CONTROL BRAKE SWITCH OUTPUT 5 L50 16WT TN BRAKE LAMP SWITCH OUTPUT 6 A7 18RD BK FUSED CONTROLLER ANTILOCK BRAKE CAV CIRCUIT FUNCTION 1 7101 12BK GROUND B1 18YL DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL B2 20YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY D25 18YL VT PCI BUS nN gt om 6 20WT DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL 87 20WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 1 4 16 99 A20 12RD DB FUSED B g 10 20 18WT FUSED IGNITION SWITCH OUTPUT RUN H 11 12 8 13
4. 18WT OR MTX SBEC VEHICLE SPEED SENSOR SIGNAL 14 _ 15 CONTROLLER 16 7102 12BK GROUND ANTILOCK 18 1150 20WT TN BRAKE LAMP SWITCH OUTPUT 19 183 20LG DB LEFT REAR WHEEL SPEED SENSOR SIGNAL 20 20LG LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 21 22 B8 18RD DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL 23 9 20RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 24 A10 12RD DG FUSED B 47 N N E R 4 2 N N E R 4 2 BLACK LEFT FRONT WHEEL SPEED SENSOR LEFT REAR WHEEL SPEED ENSOR Nn CONNECTOR PINOUTS DATA LINK CONNECTOR CAV CIRCUIT FUNCTION 1 2 1025 20VT YL PCI BUS DLC 3 4 7305 20BK YL GROUND 5 7306 20BK VT GROUND 6 7 D21 20PK 2 7L SCI TRANSMIT 7 D21 20 2 0L 2 4L SCI TRANSMIT PCM 8 F11 20RD WT FUSED IGNITION SWITCH OUTPUT OFF RUN START 9 06 20PK LB 2 7L EATX SCI RECEIVE 9 D6 20PKILB 2 0L 2 4L SCI RECEIVE TCM EATX 10 11 12 020 20LG 2 7L SCI RECEIVE 12 1020 20LG 2 01 2 41 SCI RECEIVE PCM 13 14 15 015 20WT DG SCI TRANSMIT TCM 16 M1 20PK FUSED B LEFT FRONT WHEEL SPEED SENSOR CAV CIRCUIT FUNCTION 1 Be 2080 LEFT FRONT W
5. LEFT FRONT SENSOR CIRCUIT FAILURE When Monitored Ignition on The CAB monitors the wheel speed circuit continuously Set Condition If the CAB detects an open or shorted wheel speed sensor circuit the Diagnostic Trouble Code DTC will set LEFT REAR SENSOR CIRCUIT FAILURE When Monitored Ignition on The CAB monitors the wheel speed circuit continuously Set Condition If the CAB detects an open or shorted wheel speed sensor circuit the Diagnostic Trouble Code DTC will set RIGHT FRONT SENSOR CIRCUIT FAILURE When Monitored Ignition on The CAB monitors the wheel speed circuit continuously Set Condition If the CAB detects an open or shorted wheel speed sensor circuit the Diagnostic Trouble Code DTC will set RIGHT REAR SENSOR CIRCUIT FAILURE When Monitored Ignition on The CAB monitors the wheel speed circuit continuously Set Condition If the CAB detects an open or shorted wheel speed sensor circuit the Diagnostic Trouble Code DTC will set POSSIBLE CAUSES INTERMITTENT CONDITION WHEEL SPEED SENSOR OR CONNECTOR DAMAGE WHEEL SPEED SENSOR SIGNAL CIRCUIT FAULT WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT SHORT TO GROUND WHEEL SPEED SENSOR 12 VOLT SUPPLY CIRCUIT OPEN WHEEL SPEED SENSOR SIGNAL CIRCUIT SHORT TO GROUND WHEEL SPEED SENSOR SIGNAL CIRCUIT OPEN BRAKES CAB LEFT FRONT SENSOR CIRCUIT FAILURE Continued POSSIBLE CAUSES CAB 12 VOLT SUPPLY CIRCUIT FAULT CAB SIGNAL CIRCUIT FAULT WHEEL SPEED SENSOR 1
6. Using 12 test light connected to 12 volts probe the ground circuits at the CAB harness connector Did the test light illuminate Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the CAB Ground circuit for an open Perform ABS VERIFICATION TEST VER 1 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 Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete 36 BRAKES CAB Symptom ABS LIGHT FLASHING AFTER CAB REPLACEMENT POSSIBLE CAUSES IMPROPERLY CONFIGURED CAB ACTION APPLICABILITY Turn the ignition on All Connect the DRBIII to the Data Link Connector Select Anti lock Brakes from the main menu NOTE If DRBIII is unable to 1 0 or communicate with CAB refer to NO RESPONSE test Select Miscellaneous from menu Select Set Pinion Factor from menu Does the vehicle have unknown tires and unknown rear axle Press Enter to change will be displayed Press Enter Select the tire size that is installed on the vehicle Press Enter Select correct axle Pres
7. 1 N 5 22 Ly CONTROL ANTILOCK wes UNIT BRAKE HARNESS HCU CAB CONNECTOR DATA LINK CONNECTOR DRIVER S u SIDE KICK PANEL 2630505 43 COMPONENT LOCATIONS 8 3 FUSES SPEED CONTROL POWER DISTRIBUTION SERVO CENTER PDC FUSE gt oll 2 POWERTRAIN TRANSMISSION L T N 5 CONTROL CONTROL MODULE MODULE 80 4 3 8 4 WHEEL SPEED SENSORS 8 4 1 FRONT LEFT FRONT RIGHT FRONT ATTACHING WHEEL SPEED WHEEL SPEED ATTACHING SCREW SENSOR SCREW Wea DRIVESHAFT DRIVESHAFT OUTER STEERING STEERING KNUCKLE WHEEL KNUCKLE re 8 4 2 REAR LEFT REAR RIGHT REAR EFT RE ATTACHING WHEEL SPEED SENSOR SCREW RIGHT REAR ATTACHING WHEEL SPEED SENSOR SCREW x RIGHT REAR SHOCK ABSORBER 80be46bb SHOCK ABSORBER sooseua 44 COMPONENT LOCATIONS 8 5 WHEEL SPEED SENSOR CONNECTORS 8 5 1 FRONT 2 LEFT FRONT RIGHT FRONT N E LEFT 55 ee LEFT FRONT WHEEL SPEED SENSOR BRACKET L N 5 80be46bc 8 5 2 REAR LEFT REAR CONNECTOR a 80be4642 lt 0 227 7 VI SWITCH
8. ALL COMPONENTS ARE REASSEMBLED DURING THE TEST DRIVE DO NOT TRY TO READ THE DRBIII2 SCREEN WHILE MOTION DO NOT HANG THE FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII 4 4 DIAGNOSIS 1 A diagnostic test procedure must begin with a thorough visual inspection of the ABS system for damaged components or disconnected connec tors The brake lamps must be operational and if they are not repair them prior to continuing 2 Connect the to the data link connector which is located under the dash to the left of the steering column If the DRBIII does not power up check the power and ground supplies to the connector 3 Turn the ignition on Select Antilock Brakes If the DRBIII displays No Response condition you must diagnose that first 4 Read and record all ABS Diagnostic Trouble Codes DTC s If the CAB Power F eed Circuit diagnostic trouble code is present it must be repaired prior to addressing any other If any additional DTC s are present proceed to the appropriate test by locating the matching test in the Table of Contents and begin to diagnose the symptom 5 If there are no diagnostic trouble codes present identify the customer complaint select Inputs Outputs and read the brake switch input as you press and release the brake pedal If the display does not match the state of the pedal perform the pr
9. Circuit Failure 15 present the indicator will be illuminated without blinking until the trouble condition is cleared Antilock operation is disabled You will be unable to actuate the valves in the valve body when the vehicle speed is above 8 km h 5 mph If valve actuation is attempted above 8 km h 5 No Response mes sage will be displayed the DRBIII 3 4 DIAGNOSTIC TROUBLE CODES The controller antilock brake may report any of the following diagnostic trouble codes CLUSTER LAMP FAILURE VALVE POWER FEED FAILURE BUS SYSTEM COMMUNICATION FAILURE GENERAL INFORMATION CAB INTERNAL FAILURE INCORRECT TONE WHEEL FAILURE LEFT FRONT SENSOR CIRCUIT FAILURE LEFT FRONT WHEEL SPEED SIGNAL FAIL URE LEFT REAR SENSOR CIRCUIT FAILURE LEFT REAR WHEEL SPEED SIGNAL FAIL URE PUMP CIRCUIT FAILURE RIGHT FRONT SENSOR CIRCUIT FAILURE RIGHT FRONT WHEEL SPEED SIGNAL FAIL URE RIGHT REAR SENSOR CIRCUIT FAILURE RIGHT REAR WHEEL SPEED SIGNAL FAIL URE SYSTEM OVER VOLTAGE SYSTEM UNDER VOLTAGE 3 5 FREEZE FRAME Freeze Frame takes snapshot of specific vehi cle information the instant an ABS failure is recog nized and stores this information into the CAB memory This information can be accessed using the DRBIII to help diagnose the fault Freeze Frame will capture the first time failure or only a new failure that occurs during the current ignition cycle 3 6 ERROR
10. The CAB HCU areon the left side beneath the air cleaner 3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 3 1 TEVES MARK 20e SYSTEM DESCRIPTION The controller antilock brake module is used to monitor wheel speeds and to modulate control hydraulic pressure in each brake channel The modulated hydraulic pressure is used to prevent wheel lock up during braking The Teves Mark 20e system uses a diagonal split hydraulic brake system In the standard brake mode the master cylinder primary circuit supplies pressure to the right front and left rear wheel brakes and the secondary master cylinder circuit supplies pressure to the left front and right rear whee brakes During and antilock stop the Mark 20e system uses four channel operation This means that each wheel brake 15 independently controlled By using separate hydraulic channel for each wheel the system is able to retain directional stability and steering control while applying maximum braking The system provides maximum braking even when road conditions vary 3 2 ABS PLUS DESCRIPTION ABS Plus operates like Traction Control except that the brake pedal must be applied for ABS Plus to be activated Also in contrast to the ABS func tion a brake is applied rather than released When the brake pedal is depressed far enough to close the brake lamp switch the Controller Antilock Brake CAB will monitor and compare the speeds of the front driven wheels When the CAB
11. detects that a wheel is turning disproportionately faster then ve hicle speed it will apply the brake at that wheel to control a possible skid and help maintain direc tional control GENERAL INFORMATION Thedriver may report the sound of the ABS pump motor running when the brake is not applied hard enought to cause an ABS event 3 3 SYSTEM COMPONENTS controller antilock brake CAB e vacuum booster master cylinder ABS integrated control unit hydraulic control unit valve block assembly 8 valve sole noids 4 inlet valves 4 outlet valves 2 accumu lators 1 motor 2 pump 4 wheel speed sensor tone wheel assemblies ABS warning indicator fuses and wiring harness fluid reservoir 3 3 1 ABS AND BRAKE WARNING LAMPS The amber ABS warning indicator is located in the instrument cluster It is used to inform the driver that the antilock function has been turned off The ABS warning indicator is controlled by the CAB If the 24 way CAB connector is not connected the BCM will not receive a message from the CAB via the PCI bus and the BCM will send a message to the instrument cluster to turn on theABS warning indicator TheABS Warning Indicator will remian lit during every key cycle until a circuit or component fault is repaired and the CAB no longer detects the fault After repair of a sensor signal fault or a pump motor fault the CAB must sense all four wheeels at 25 km h 15 mph before it will
12. extinguish the ABS Indicator The Instrument Cluster will illuminate the ABS Warning Indicator if it loses communication with the CAB The red BRAKE warning indicator is also located in the instrument cluster It can be activated in several ways Application of the parking brake or a low fluid signal from the fluid level switch located in the master cylinder reservoir will cause the indica tor to come on The status of the red BRAKE warning indicator is not monitored by the CAB 3 3 2 CONTROLLER ANTILOCK BRAKE CAB The Controller Antilock Brake CAB is a microprocessor based device that monitors wheel speeds and controls the antilock functions The CAB contains two microprocessors that receive identical sensor signals and then independently process the information The results are then com pared to make sure that they agree Otherwise the CAB will turn off the antilock system and turn on the ABS warning indicator The primary functions of the CAB are to detect wheel locking tendencies control fluid pressure modulation to the brakes during an antilock stop monitor the system for proper operation provide communication to the 2 while in diagnostic mode store diagnostic information memory TheCAB continuously monitors the speed of each wheel When a wheel locking tendency is detected the CAB will command the appropriate valve to modulate brake fluid pressure via the hydraulic control unit HCU Brake pedal po
13. for a short to ground Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB and CAB harness connector for damage 15 there any broken bent pushed out corroded or spread terminals Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No GoTo 9 Turn the ignition off Reinstall the ABS Pump fuse Disconnect the ABS Pump Motor connector Check connectors Clean repair as necessary Connect 10 gauge 40 amp fused jumper wire between the ABS Pump Fused terminal in the CAB harness connector to the ABS Pump Motor connector RED wired terminal Connect a 10 gauge jumper wire between the Ground circuit terminal in the CAB harness connector to the ABS Pump Motor connector BLACK wired terminal Did the ABS Pump Motor operate Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 GoTo 10 Turn the ignition off Disconnect the ABS Pump Motor connector Check connectors Clean repair as necessary Connect a 10 gauge 40 amp fused jumper wire between the ABS Pump Motor connector RED wired terminal and an alternate 40 amp capable B source Connect a 10 gauge jumper wire between the ABS Pump Motor connector BLACK wired terminal and ground Did the ABS Pump Motor operate Yes GoTo 11 No Replace the Hydraulic Control Unit in accordance with the Service nf
14. inflated to the recommended pressures for optimum system operation Variation in wheel and tire size or signif icant variations in inflation pressure can produce inaccurate wheel speed signals however the system will continue to function when using the mini spare 3 3 5 SYSTEM INITIALIZATION System initialization starts when the key is turned to run At this point the CAB performs a complete self check of all electrical components in the antilock systems Between 8 17 km h 5 10 mph a dynamic test is performed This will momentarily cycle the inlet and outlet valves and check wheel speed sensor circuitry At 25 km h 15 mph the CAB will try to test the pump motor If the brake pedal is applied the test will be run at 40 km h 24 mph regardless of brake switch state If during the dynamic test the brake pedal is applied brake pedal pulsations may be felt This is a normal condition If any component exhibits a trouble condition during system initialization or dynamic check the CAB will illuminate the ABS warning indicator 3 3 6 DIAGNOSTIC MODE diagnostic mode a vehicle speed must below 10 km h 6mph and no ABS condition present If vehicle speed is not below 10 km h 6 mph a No Response message could be displayed by the DRBIII The following are characteristics of diagnostic mode The amber ABS warning indicator will blink rapidly If hard trouble code such as CAB Power Feed
15. 1 0 2 0 3 0 4 0 5 0 6 0 7 0 TABLE OF CONTENTS INTRODUCTION 1 11 SYSTEM COVERAGE 1 1 2 SIX STEP TROUBLESHOOTING PROCEDURE 1 IDENTIFICATION OF 5 5 1 SYSTEM DESCRIPTION AND FUNCTIONAL 1 3 11 TEVES MARK 20e SYSTEM 1 3 2 ABS PLUS 1 3 3 SYSTEM COMPONENTS 0 2 3 31 BRAKE WARNING 1 5 2 3 3 2 CONTROLLER ANTILOCK BRAKE 2 3 3 3 HYDRAULIC CONTROL 2 3 3 4 SWITCHES SENSORS 3 3 3 5 SYSTEM INITIALIZATION 3 3 3 6 DIAGNOSTIC MODE 3 3 4 DIAGNOSTIC TROUBLE CODES 3 35 FREEZE 4 3 6 DRBIlle ERROR MESSAGES AND BLANK 5 4 3 61 DRBIlle DOES NOT POWER UP 4 3 6 2 DISPLAY IS 4 DISCLAIMERS SAFETY 5 4 44 DISCLAIMERS deur berg 4 2 25
16. 2 VOLT SUPPLY SHORT TO GROUND WHEEL SPEED SENSOR SIGNAL CIRCUIT INOPERATIVE ACTION APPLICABILITY Turn the ignition on With the DRBIII read DTCs With the DRBIII read the Freeze Frame information With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs NOTE The CAB must sense all four wheels at 25km h 15 mph before it will extinguish the ABS indicators Does the display SENSOR CIRCUIT FAILURE Yes GoTo 2 No GoTo 13 Turn the ignition off All Inspect the CAB connector affected Wheel Speed Sensor and affected Wheel Speed Sensor connector 15 the affected Wheel Speed Sensor any of the connectors damaged Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No GoTo 3 Turn the ignition off All Disconnect the affected Wheel Speed Sensor connector Note Check connector Clean repair as necessary Turn the ignition on Measure the voltage between affected Wheel Speed Sensor 12 Volt Supply circuit and ground Is the voltage above 10 volts Yes GoTo 6 No GoTo 4 Turn the ignition off Disconnect the CAB harness connector Disconnect the affected Wheel Speed Sensor connector Using a 12 volt test light connected to 12 volts probe the affected Wheel Speed Sensor 12 Volt Supply circuit Does the test light illuminate Yes Repair theaffected Wheel Speed Sensor 12 Volt Supply circuit for a short to
17. Brake Lamp Switch Output circuit shorted or open Yes Repair the Brake Lamp Switch Output 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 nformation Perform ABS VERIFICATION TEST VER 1 Disconnect the Brake Lamp Switch harness connector All Connect jumper wire between the Brake Lamp Switch B and Brake Lamp Switch Output circuits With the DRBIII in Inputs Outputs read the Brake Lamp Switch state Does the display PRESSED Yes Replace the Brake Lamp Switch in accordance with the Service 38 COMMUNICATION Symptom NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE POSSIBLE CAUSES NO RESPONSE FROM CAB CHECK J UNCTION BLOCK FUSE GROUND CIRCUIT OPEN OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT CONTROLLER ANTILOCK BRAKE CAB MODULE PCI BUS CIRCUIT OPEN BODY CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All Note As soon as one or more module communicates with the DRB answer the question With the DRB attempt to communicate with the Airbag Control Module With the DRB attempt to communicate with the Body Control Module Was the able to 1 0 or establish communications with either of the modules Yes GoTo 2 No Refer tothe Communications category and perform the symptom Bus Communication Failure Perform ABS VERIFICATION TEST VER 1 Turn the ignition of
18. C DAMAGED CAB CAB HARNESS CONNECTOR RUNNING BATTERY VOLTAGE LOW CAB GROUND CIRCUIT OPEN FUSED IGNITION SWITCH OUTPUT RUN CIRCUIT OPEN CAB INTERNAL FAULT ACTION APPLICABILITY Turn the ignition on All With the DRBIII read With the DRBIII erase Turn the ignition off Turn the ignition on Start the engine Drive the vehicle above 16 km h 10 mph for at least 20 seconds Stop the vehicle With the DRBIII read Does the 2 display SYSTEM UNDER VOLTAGE 2 Yes GoTo 2 No GoTo 6 Engine Running Measure the battery voltage Is the battery voltage below 10 volts Yes Refer to appropriate service information for charging system testing and repair Perform ABS VERIFICATION TEST VER 1 GoTo 3 32 BRAKES CAB SYSTEM UNDER VOLTAGE Continued ACTION APPLICABILITY Turn the ignition off Disconnect the CAB harness connector Inspect the CAB and CAB harness connector for damage Is there any broken bent pushed out corroded or spread terminals Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No GoTo 4 Turn the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts probe the Ground circuits Does the test light illuminate Yes GoTo 5 No Repair the Ground circuit an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition on All Using a 12 v
19. E 22 RIGHT REAR WHEEL SPEED SIGNAL 22 PUMP CIRCUIT FAILURE corun Eko oes eit as hares 25 SYSTEM OVER 29 SYSTEM UNDER VOLIJAGE 32 VALVE POWER FEED FAILURE 34 ABS LIGHT FLASHING AFTER GAB 37 BRAKE LAMP SWITCH 25552545555 598 38 COMMUNICATION RESPONSE FROM CONTROLLER ANTILOCK 39 VERIFICATION TESTS VERIFICATION 5 555586585 eaves tens 41 COMPONENT gt gt 5 gt 5 43 81 CONTROLLER ANTILOCK BRAKE 43 8 2 DATA LINK CONNECTOR 5555 wets ex ee 43 83 FUSES 44 8 4 WHEEL SPEED SENSORS 44 8 4 1 44 842 REAR 44 8 5 WHEEL SPEED SENSOR 5 55 5 55 55565 5 45 85 1 FRONT 45 O52 45 56 BRAKE SWITCH we ewe 45 CONNECTOR PINOUTS 47 BRAKE LAMP SWITCH
20. HEEL SPEED SENSOR 12 VOLT SUPPLY 2 88 18RD DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL LEFT REAR WHEEL SPEED SENSOR CAV CIRCUIT FUNCTION 1 2016 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 20LG DB LEFT REAR WHEEL SPEED SENSOR SIGNAL 48 CONNECTOR PINOUTS s BLACK RIGHT FRONT WHEEL SPEED SENSOR 2 1 CAV CIRCUIT FUNCTION 1 7 20WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 6 20WT DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL RIGHT FRONT WHEEL SPEED SENSOR RIGHT REAR WHEEL SPEED SENSOR 2 1 CIRCUIT FUNCTION ey 1 B2 20YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 2 1 20YL DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL RIGHT REAR WHEEL SPEED SENSOR 49 N N E R NOTES 50 SCHEMATIC DIAGRAMS 10 0 SCHEMATIC DIAGRAMS 10 1 TEVES MARK 20e CONTROLLER ANTILOCK BRAKE ABS SWITCH VALVE PUMP Q 1 FUSE 22 FUSE 15 ABS JUNCTION 20A 40A FUSE4 BLOCK ABS ABS PDC 15A RD DB RD DG WT Fused B Fused B Fused Ignition Switch Output RUN WT TN Brake Lamp Switch Output RD BK Fused B 5 YL VT PCI Bus TO PCI BUS RD DB Left Front Wheel Speed Sensor Signal LF RD 12 Volt Supply CONTROLLER ANTILOCK BRAKE CAB WT DB Right Front Wheel Speed S
21. MESSAGES AND BLANK SCREEN Under normal operation the DRBIII will dis play one of only two error messages User Requested WARM Boo or Requested COLD Boot This is asample of such an error message display ver 2 14 date 26 J ul93 file key_itf cc date ul 26 1993 line 548 err 0 1 User User Requested COLD Boot Press MORE to switch between this display and the application screen Press F4 when done noting information 3 6 1 DOES NOT POWER UP If the LE D s do not light or no sound is emitted at start up check for loose cable connections or a bad cable Check the vehicle battery voltage data link connector cavity 16 A minimum of 11 volts is required to adequately power the DRBIII If connections are proper between the DRBIII and the vehicle or other devices and the vehicle battery is fully charged and inoperative DRBIII result of faulty cable or vehicle wiring 3 6 2 DISPLAY IS NOT VISABLE Low temperatures will affect the visibility of the display Adjust the contrast to compensate for this condition DISPLAY DRB m REPLACEABLE LENS Wes FUNCTION ENTER KEYS LEDs CONTRAST OO with YES key AS BACK LIGHTING QO gt with YES key KEYPAD SHIFT KEY LED 80b57566 4 0 DISCLAIMERS SAFETY WARNINGS 4 1 DISCLAIMERS All information illustrations and specifications contained in this manual are based on th
22. N FAILURE Yes GoTo 2 No GoTo 4 Turn the ignition on With the DRBIII read EMIC DTCs Does the DRBIII display ABS MESSAGES RECEIVED Yes Refer to symptom ABS MESSAGES NOT RECEIVED in the BODY INSTRUMENT CLUSTER category Perform ABS VERIFICATION TEST VER 1 GoTo 3 BRAKES CAB BUS SYSTEM COMMUNICATION FAILURE Continued APPLICABILITY Turn the ignition off All Disconnect the negative battery cable Disconnect the CAB harness connector NOTE check connector Clean repair as necessary Measure the resistance of the Bus circuit between the CAB connector and the Data Link Connector DLC 15 the resistance below 5 0 ohms Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the Bus circuit for an open Perform ABS VERIFICATION TEST VER 1 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 Were any problems found Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete BRAKES CAB Symptom CAB INTERNAL FAILURE When Monitored and Set Condition CAB INTERNAL FAILURE When Monitored Ignition on The CAB monitors its internal mic
23. RCUIT INTERMITTENT SHORT TO GROUND ABS VALVE FUSED B CIRCUIT SHORT TO GROUND DAMAGED CAB CAB HARNESS CONNECTOR CAB GROUND CIRCUIT OPEN CAB INTERNAL FAULT ACTION APPLICABILITY Turn the ignition on All With the DRBIII read 5 With the DRBIII erase DTC s Turn the ignition off Turn the ignition on With the DRBIII read 5 Does the DRBIII display VALVE POWER FEED FAILURE Yes GoTo 2 No GoTo 10 Turn the ignition off Remove and Inspect the ABS Valve fuse Is the ABS Valve fuse open Yes GoTo 3 No GoTo 6 34 BRAKES CAB VALVE POWER FEED FAILURE Continued ACTION APPLICABILITY Turn the ignition off Visually inspect theABS Valve used circuit in the wiring harness Look for any sign of an intermittent short to ground Is the wiring harness OK Yes GoTo 4 No Repair the ABS Valve Fused B circuit for a short to ground Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Note Check connector Clean repair as necessary Using a test light connected to 12 volts probe the ABS Valve used circuit fuse terminal Did the test light illuminate Yes Repair the ABS Valve Fused B circuit a short to ground Perform ABS VERIFICATION TEST VER 1 No GoTo 5 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB and CAB harness connector for dam
24. TEST VER 1 No Test Complete 21 BRAKES CAB Symptom List LEFT FRONT WHEEL SPEED SIGNAL FAILURE LEFT REAR WHEEL SPEED SIGNAL FAILURE RIGHT FRONT WHEEL SPEED SIGNAL FAILURE RIGHT REAR WHEEL SPEED SIGNAL FAILURE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be LEFT FRONT WHEEL SPEED SIGNAL FAILURE When Monitored and Set Condition LEFT FRONT WHEEL SPEED SIGNAL FAILURE When Monitored Wheel speed comparison is checked and verified at drive off and continuously thereafter Set Condition If during an ABS stop the CAB commands any valve solenoid on for an extended length of time and does not see a corresponding wheel speed change the Diagnostic Trouble Code DTC is set The DTC can also set if the signal is missing or erratic LEFT REAR WHEEL SPEED SIGNAL FAILURE When Monitored Wheel speed comparison is checked and verified at drive off and continuously thereafter Set Condition If during an ABS stop the CAB commands any valve solenoid on for an extended length of time and does not see a corresponding wheel speed change the Diagnostic Trouble Code DTC is set The DTC can also set if the signal is missing or erratic RIGHT FRONT WHEEL SPEED SIGNAL FAILURE When Monitored Wheel speed comparison is checked and verified at drive off and continuously thereafter Set Condition If during an ABS stop the CAB commands any valve solenoid on for an
25. TINUOUSLY ABS PUMP FUSE ABS PUMP MOTOR INTERMITTENT DTC DAMAGED CAB CAB HARNESS CONNECTOR ABS PUMP FUSED CIRCUIT INTERMITTENT SHORT TO GROUND ABS PUMP FUSED CIRCUIT SHORT TO GROUND CAB INTERNAL FAULT ABS PUMP MOTOR INOPERATIVE ABS PUMP MOTOR OPEN ABS PUMP MOTOR B CIRCUIT OPEN ABS PUMP MOTOR GROUND CIRCUIT OPEN CAB INTERNAL FAULT ACTION APPLICABILITY Turn the ignition off All Turn the ignition on Monitor the ABS Pump Motor for continuous operation NOTE The CAB must sense ALL wheels at 25 km h 15 mph before it will extinguish the ABS indicators Is the ABS Pump Motor running continuously Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 GoTo 2 25 BRAKES CAB PUMP CIRCUIT FAILURE Continued APPLICABILITY Turn the ignition off All Turn the ignition on With the DRBIII read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII actuate the ABS Pump Motor Did the ABS Pump Motor operate Yes GoTo 3 GoTo 4 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Make sure the Pump Motor connecter is secure Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Refer to any Hotline letters o
26. ace the Instrument Cluster in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 15 BRAKES CAB Symptom INCORRECT TONE WHEEL FAILURE When Monitored and Set Condition INCORRECT TONE WHEEL FAILURE When Monitored Ignition ON Vehicle speed above 40 km h 25mph for 2 minutes Set Condition When the CAB detects an unexpected wheel speed condition caused by a tire size that does not meet vehicle specification POSSIBLE CAUSES INCORRECT TIRES ON VEHICLE INCORRECT TONE WHEEL ON VEHICLE ACTION APPLICABILITY Inspect the tire sizes on the vehicle All 15 a smaller than production tire mini spare or two mini spares installed on both front wheels Yes Replace the incorrect tire s size with production size tire s Perform ABS VERIFICATION TEST VER 1 No GoTo 2 Count the number of tone wheel teeth on both of the front driveshafts Does one or both tone wheel s have 56 or 40 teeth Yes Replace the front driveshaft s with the incorrect number of tone wheel teeth Perform ABS VERIFICATION TEST VER 1 No Test Complete BRAKES CAB Symptom List LEFT FRONT SENSOR CIRCUIT FAILURE LEFT REAR SENSOR CIRCUIT FAILURE RIGHT FRONT SENSOR CIRCUIT FAILURE RIGHT REAR SENSOR CIRCUIT FAILURE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be LEFT FRONT SENSOR CIRCUIT FAILURE When Monitored and Set Condition
27. age 15 there any broken bent pushed out corroded or spread terminals Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No GoTo 7 Turn the ignition off Using a 12 volt test light connected to ground probe the B supply at theABS Valve fuse terminal Did the test light illuminate Yes GoTo 8 No Repair the ABS Valve Fused B supply circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off All Reconnect the CAB harness connector NOTE The CAB harness connector must be reconnected for the results of this test to be valid Using a test light connected to 12 volts probe the ABS Valve used circuit fuse terminal Did the test light illuminate Yes Replace the Controller Antilock Brake in accordance with the Service nformation Perform ABS VERIFICATION TEST VER 1 Replace the ABS Valve Fused B fuse If the fuse is open make sure to check for a short to ground Perform ABS VERIFICATION TEST VER 1 35 BRAKES CAB VALVE POWER FEED FAILURE Continued ACTION APPLICABILITY Reinstall the ABS Valve fuse All Disconnect the CAB harness connector Using 12 volt test light connected to ground probe the ABS Valve used circuit at the CAB harness connector Did the test light illuminate Yes GoTo 9 No Repair the ABS Valve Fused circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off
28. connect the CAB harness connector Turn the ignition on With the DRBIII in Sensors read the ignition voltage Does the 2 display ignition voltage above 16 volts Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 GoTo 7 30 BRAKES CAB SYSTEM OVER VOLTAGE Continued APPLICABILITY Turn the ignition off All 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 Ensure the battery is fully charged Inspect the vehicle for aftermarket accessories that may exceed the Generator System output Using the wiring diagram schematic as a guide inspect the wiring and connectors Were any problems found Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete 31 BRAKES CAB Symptom SYSTEM UNDER VOLTAGE E When Monitored and Set Condition SYSTEM UNDER VOLTAGE When Monitored Ignition on The CAB monitors the Fused Ignition Switch Output circuit voltage above 10 km h 6 mph for proper system voltage Set Condition If the voltage 15 below 9 5 volts the Diagnostic Trouble Code DTC is set POSSIBLE CAUSES INTERMITTENT DT
29. ctor on the Attach the red and black leads and the cable to probe adapter to the scope input cable With the DRBIII select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Set Probe to x10 Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the Bus circuit in the CAB connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts Yes Replace the Controller Antilock Brake CAB in accordance with the service information Perform ABS VERIFICATION TEST VER 1 GoTo 6 Turn the ignition off Disconnect the CAB harness connector Disconnect the BCM C3 harness connector Measure the resistance of the PCI bus circuit between the CAB connector and the BCM C3 connector 15 the resistance below 5 0 ohms Yes Replace the Body Control Module accordance with the service information Perform ABS VERIFICATION TEST VER 1 Repair the PCI Bus circuit for an open Perform ABS VERIFICATION TEST VER 1 40 VERIFICATION TESTS Verification Tests ABS VERIFICATION TEST VER 1 APPLICABILITY 1 Turn the ignition off All 2 Connect all previously disconnected components and connectors 3 Ensure all accessories are turned off and the battery is fully charge
30. d 4 Ensure that the Ignition is on and with the 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 read DTC s from ALL modules 6 If any Diagnostic Trouble Codes are present return to Symptom list and troubleshoot new or recurring symptom 7 NOTE For Sensor Signal and Pump Motor faults the CAB must sense all 4 wheels at 25 km h 15 mph before it will extinguish the ABS Indicator 8 If there are no DTC s present after turning ignition on road test the vehicle for at least 5 minutes Perform several antilock braking stops 9 Caution Ensure braking capability is available before road testing 10 Again with the DRBIII read 5 If any are present return to Symptom list 11 If there are no Diagnostic Trouble Codes present and the customer s concern longer be duplicated the repair is complete any DTC s present or is the original concern still present Yes Repair is not complete refer to appropriate symptom No Repair is complete 41 NOTES 42 COMPONENT LOCATIONS 8 0 COMPONENT LOCATIONS 8 1 CONTROLLER ANTILOCK BRAKE CAB FAN SHROUD PUMP MOTOR N 2 S lt 2
31. e any Instrument Cluster or ABS DTCs present Yes Refer to the appropriate category for the related symptoms Perform ABS VERIFICATION TEST VER 1 No GoTo 2 Turn the ignition off Perform the K ey on Bulb Check Does the ABS Warning Indicator light and then go out after a few seconds Yes GoTo 3 No Light remains after bulb check Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Indicator never comes on GoTo 4 BRAKES CAB CLUSTER LAMP FAILURE Continued ACTION APPLICABILITY NOTE The DRBIII communication with the CAB must be operational for All the result of this test to be valid Turn the ignition off Remove ABS Valve fuse Perform the K ey on Bulb Check Does the ABS Indicator remain on after the bulb check Yes Test Complete No Replace the Controller Antilock Brake in accordance with the Service nformation Perform ABS VERIFICATION TEST VER 1 NOTE The following steps will initiate the Instrument Cluster self test Turn the ignition off Press and hold the odometer reset button Turn the ignition to RUN Observe the Instrument Cluster indicators Release the odometer reset button Did the ABS Indicator illuminate during the Instrument Cluster self test Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 Repl
32. e ignition on Measure the voltage of the affected Wheel Speed Sensor 12 Volt Supply circuit in the affected Wheel Speed Sensor connector while reconnecting the sensor connector Did the affected Wheel Speed Sensor 12 Volt Supply circuit drop voltage to 0 DC volts Yes Replace the affected Wheel Speed Sensor in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 GoTo 12 Turn the ignition off Reconnect ALL affected Wheel Speed Sensor circuit connectors Turn the ignition on Measure the DC voltage of the Wheel Speed Sensor Signal circuit in the affected Wheel Speed Sensor connector Slowly rotate the wheel Does the DC voltage toggle between 1 6 volts to 8 volts Yes GoTo 13 No Replace the affected Wheel Speed Sensor in accordance with the Service nformation Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Reconnect ALL affected Wheel Speed Sensor circuit connectors 20 BRAKES CAB LEFT FRONT SENSOR CIRCUIT FAILURE Continued ACTION APPLICABILITY Turn the ignition off All 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 Repair as necessary Perform ABS VERIFICATION
33. e latest information available at the time of publication The right is reserved to make changes at any time without notice 4 2 SAFETY 4 2 1 TECHNICIAN SAFETY INFORMATION WARNING ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS CAUSES SLOWER REACTION TIME AND CAN LEAD TO SERIOUS INJURY WHEN THE ENGINE IS OPERATING KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM Set the parking brake and block the whee 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 pro tection and remove any metal jewelry such as rings watchbands or bracelets that might make an inadvertent electrical contact When diagnosing a chassis 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 safety of individuals performing diag nostic tests 4 2 2 VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery is does not false diagnostic codes or error messages may occur 4 2 3 SERVICING SUB ASSEMBLIES Some components of the chassis system are in tended to be serviced as an assembly only Attempt ing to remove or repair certain system sub components may result in
34. ecifications 15 theAir Gap OK Yes GoTo 6 No as necessary Perform ABS VERIFICATION TEST VER 1 Inspect the wheel bearings for excessive runout or clearance NOTE Refer to the appropriate service information if necessary for procedures or specifications 15 the bearing clearance OK Yes GoTo 7 No Repair as necessary Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Visually inspect brakes for locking up due to lining contamination or overheating Inspect all Components for defects which may cause a Signal DTC to set Is any Component Damaged Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Refer to symptom SENSOR CIRCUIT FAILURE for further diagnostics Perform ABS VERIFICATION TEST VER 1 Turn the ignition off 24 BRAKES CAB Symptom PUMP CIRCUIT FAILURE IE When Monitored and Set Condition PUMP CIRCUIT FAILURE When Monitored Ignition on The CAB commands the pump on at 20 km h 12 mph to check its operation if the brake switch is not applied If the brake 15 applied the test will run at 40 km h 25 mph Set Condition 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 CON
35. ensor Signal WT 12 Volt Supply RF WHEEL SPEED m 2 D LG DB Left Rear Wheel Speed Sensor Signal LG 12 Volt Supply PUMP MOTOR LR YL DB Right Rear Wheel 2 Speed Sensor Signal YL 1 12 Volt Supply 5 H E M D G R 5 8019123 NOTES 52
36. extended length of time and does not see a corresponding wheel speed change the Diagnostic Trouble Code DTC is set The DTC can also set if the signal is missing or erratic RIGHT REAR WHEEL SPEED SIGNAL FAILURE When Monitored Wheel speed comparison is checked and verified at drive off and continuously thereafter Set Condition If during an ABS stop the CAB commands any valve solenoid on for an extended length of time and does not see a corresponding wheel speed change the Diagnostic Trouble Code DTC is set The DTC can also set if the signal is missing or erratic BRAKES CAB LEFT FRONT WHEEL SPEED SIGNAL FAILURE Continued POSSIBLE CAUSES WHEEL SPEED SIGNAL FAILURE DTC PRESENT AFFECTED WHEEL SPEED SENSOR SIGNAL INOPERATIVE AFFECTED WHEEL SPEED SENSOR CONNECTOR DAMAGED AFFECTED WHEEL SPEED SENSOR TONE WHEEL DAMAGED AFFECTED WHEEL SPEED SENSOR AIR GAP FAULT WHEEL BEARING FAULT BRAKE LINING FAULT AFFECTED WHEEL SPEED SENSOR CIRCUIT ELECTRICAL FAULT ACTION APPLICABILITY Turn the ignition on All With the DRBIII read DTCs With the DRBIII read Freeze Frame information NOTE The CAB must sense ALL 4 wheels at 25 km h 15 mph before it will extinguish the ABS indicators Does the DRBIII display WHEEL SPEED SIGNAL FAILURE and SENSOR CIR CUIT FAILURE Yes Refer tothe affected Wheel Speed SENSOR CIRCUIT FAILURE for the related symptoms Perform ABS VERIFICATION TEST VER 1 GoTo 2 Turn the ig
37. f Remove and inspect fuse in the junction block 15 the fuse open Yes Check the Fused Ignition Switch Output circuit for a short to ground refer to the wiring diagrams located in the service information Replace Fuse 4 Perform ABS VERIFICATION TEST VER 1 No GoTo 3 Turn the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts probe both ground circuits Is the test light illuminated for both circuits Yes GoTo 4 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VER 1 39 COMMUNICATION NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE Continued ACTION APPLICABILITY Turn the ignition off All NOTE Ensure fuse 4 is installed in the junction block Disconnect the CAB harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the Fused Ignition Switch Output circuit Is the test light illuminated Yes GoTo 5 Repair the Fused Ignition Switch Output circuit for an open Perform ABS VERIFICATION TEST VER 1 Note Ensure there is PCI Bus communication with other modules on the vehicle before proceeding If not refer to the symptom list from the menu and repair as necessary Disconnect the CAB harness connector Use Scope input cable CH 7058 Cable to Probe adapter CH 7062 and the red and black test probes Connect the scope input cable to the channel one conne
38. ground Perform ABS VERIFICATION TEST VER 1 GoTo 5 BRAKES CAB LEFT FRONT SENSOR CIRCUIT FAILURE Continued ACTION APPLICABILITY Turn the ignition off Disconnect the CAB harness connector Disconnect the affected Wheel Speed Sensor connector Connect a jumper wire between affected Wheel Speed Sensor 12 Volt Supply circuit and ground Using a 12 volt test light connected to 12 volts probe the affected Wheel Speed Sensor 12 Volt Supply circuit Does the test light illuminate Yes GoTo 6 Repair the affected Whee Speed Sensor 12 Volt Supply circuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off All Disconnect the affected Wheel Speed Sensor connector NOTE Check connector Clean repair as necessary Turn the ignition on Measure the voltage between affected Wheel Speed Sensor Signal circuit and ground 15 the voltage above 1 volt Yes Repair the affected Wheel Speed Sensor Signal circuit for a short to voltage Perform ABS VERIFICATION TEST VER 1 GoTo 7 Turn the ignition off Disconnect the CAB harness connector Disconnect the affected Wheel Speed Sensor connector Using a 12 volt test light connected to 12 volts probe the affected Wheel Speed Sensor Signal circuit Does the test light illuminate Yes Repair the affected Wheel Speed Sensor Signal circuit for a short to ground Perform ABS VERIFICATION TEST VER 1 GoTo 8 Turn the ignition off Disc
39. he CAB detects slip the inlet valve is closed to prevent any further pressure increase If necessary the outlet valve is opened to release the pressure to the accumulators until the wheel is no longer slipping Once the wheel is no longer slipping the outlet valve is closed and the inlet valve is opened to reapply pressure If the wheel is decelerating within its predetermined lim its proper slip ratio the inlet valve will close to hold the pressure constant Pump Motor Assembly The pump motor as sembly provides the extra amount of fluid needed during antilock braking The pump is supplied fluid that is released tothe accumulators when the outlet valve 15 opened during and antilock stop The pump is also used to drain the accumulator circuits after the antilock stop is complete The pump is operated by an integral electric motor This motor is con trolled by the CAB The CAB will turn on the pump motor when an antilock stop is detected The pump continues to run during the antilock stop and is turned off after the stop is complete Under some conditions the pump motor will run to drain the accumulators during the next drive off The CAB monitors the pump motor operation internally 3 3 4 SWITCHES SENSORS Master Cylinder A fluid level switch is located in the master cylinder fluid reservoir The switch closes when a fluid level is detected The fluid level switch turns on the brake warning indicator by grounding the indicator circ
40. mponent location views are in Section 8 0 All connector pinouts are in Section 9 0 All sche matics in Section 10 0 An placed before the symptom description indi cated a customer complaint When repairs are required refer to the appropri ate service manual for the proper removal and repair procedure Diagnostic procedures change every year New diag nostic systems may be added carryover systems may be enhanced READ THIS MANUAL BEFORE TRY ING TO DIAGNOSE A VEHICLE CODE It is recom mended that you review the entire manual to become familiar with all new and changed diagnostic proce dures After using this book if you have any comments or recommendations please fill out the form at the back of the book and mail it back to us 1 1 SYSTEM COVERAGE This diagnostic procedure manual covers the an tilock braking system ABS system found on the Chrysler Sebring and Dodge Stratus 1 2 SIX STEP TROUBLESHOOTING PROCEDURE Diagnosis of the controller antilock brake module is done in six basic steps verification of complaint verification of any related symptoms symptom analysis problem isolation GENERAL INFORMATION repair of isolated problem verification of proper operation 2 0 IDENTIFICATION OF SYSTEM Vehicles equipped with the Teves Mark 20e an tilock brake system can be identified by the pres ence of the controller antilock brake module located along with HCU
41. nition on With the DRBIII in Sensors monitor ALL the Wheel Speed Sensor Signals while an assistant drives the vehicle Slowly accelerate as straight as possible from a stop to 24 km h 15 mph Is the affected Wheel Speed Signal showing 0 km h 0 mph Yes GoTo 3 No The condition is not present at this time Monitor DRBIII parameters while wiggling the related wiring harness Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness and connector terminals Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Inspect the CAB connector affected Wheel Speed Sensor and affected Wheel Speed Sensor connector 15 the Wheel Speed Sensor any connector damaged Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 GoTo 4 23 BRAKES CAB LEFT FRONT WHEEL SPEED SIGNAL FAILURE Continued ACTION APPLICABILITY Turn ignition off Inspect the affected Tone Wheel for damaged missing teeth cracks or looseness NOTE The Tone Wheel teeth should be perfectly square not bend or nicked 15 the affected Tone Wheel OK Yes GoTo 5 No Replace the Tone Wheel in accordance with the Service Informa tion Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Using a Feeler Gauge measure the affected Wheel Speed Sensor Air Gap NOTE Refer to the appropriate service information if necessary for procedures or sp
42. ohmmeter voltmeter test light 6 0 GLOSSARY OF TERMS ABS antilock brake system BCM body control module CAB controller antilock brake DC direct current DLC data link connector DRBIII diagnostic read out box DTC diagnostic trouble code EDW electrical distribution wir ing EMI electro magnetic interfer ence EVBP electronic variable brake proportioning HCU hydraulic control unit BLK junction block LF left front LR left rear programmable communica tion interface PDC power distribution center P M pump motor GENERAL INFORMATION RF right front RR right rear RFI radio frequency interfer WSS wheel speed sensor ence NOTES 7 0 DIAGNOSTIC INFORMATION AND PROCEDURES BRAKES CAB Symptom BUS SYSTEM COMMUNICATION FAILURE When Monitored and Set Condition BUS SYSTEM COMMUNICATION FAILURE When Monitored Ignition ON continuously Set Condition When the CAB does not receive a message from the instrument cluster for 10 seconds POSSIBLE CAUSES INTERMITTENT CONDITION ELECTRO MECHANICAL INSTRUMENT CLUSTER DTC PRESENT BUS CIRCUIT OPEN CAB INTERNAL FAILURE ACTION APPLICABILITY Turn the ignition on All With the read DTCs With the DRBIII read Freeze Frame information With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Does the DRBIII display BUS SYSTEM COMMUNICATIO
43. olt test light connected to ground probe the Fused Ignition Switch Output RUN circuit Does the test light illuminate Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 Repair the Fused Ignition Switch Output RUN circuit for an open Perform ABS VERIFICATION TEST VER 1 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 Ensure the battery is fully charged Inspect the vehicle for aftermarket accessories that may exceed the Generator System output Using the wiring diagram schematic as a guide inspect the wiring and connectors Were any problems found Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete 33 BRAKES CAB Symptom VALVE POWER FEED FAILURE When Monitored and Set Condition VALVE POWER FEED FAILURE When Monitored Ignition ON The CAB checks it s microprocessors for correct operation continuously Set Condition If the CAB detects an internal fault the DTC is set POSSIBLE CAUSES INTERMITTENT DTC ABS VALVE FUSE ABS VALVE FUSED B SUPPLY CIRCUIT OPEN ABS VALVE FUSED B CIRCUIT OPEN ABS VALVE FUSED B CI
44. onnect the CAB harness connector Disconnect the affected Wheel Speed Sensor connector Connect a jumper wire between affected Wheel Speed Sensor Signal circuit and ground Using a 12 volt test light connected to 12 volts probe the affected Wheel Speed Sensor Signal circuit Does the test light illuminate Yes GoTo 9 No Repair the affected Wheel Speed Sensor Signal circuit for an open Perform ABS VERIFICATION TEST VER 1 BRAKES CAB LEFT FRONT SENSOR CIRCUIT FAILURE Continued ACTION APPLICABILITY Turn the ignition off Remove the CAB harness strain relief to access wires Reconnect the CAB harness connector Turn the ignition on Measure the voltage between affected Wheel Speed Sensor 12 Volt Supply circuit and ground 15 the voltage above 10 volts Yes GoTo 10 No Replace the Controller Antilock Brake in accordance with the Service nformation Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Remove the CAB harness strain relief to access wires Reconnect the CAB harness connector Turn the ignition on Measure the voltage between affected Wheel Speed Sensor 12 Volt Supply circuit and affected Wheel Speed Sensor Signal circuit 15 the voltage above 10 volts Yes GoTo 11 No Replace the Controller Antilock Brake in accordance with the Service nformation Perform ABS VERIFICATION TEST VER 1 Disconnect the affected Wheel Speed Sensor connector Turn th
45. oper test by locating the matching test in the Table of Contents and begin to diagnose the symptom If a problem exists with the ABS warning indicator or the red Brake warning indicator exists perform the proper tests by locating the matching test in the Table of Con tents and begin to diagnose the symptom 6 If no other problems are found it will be neces sary to road test the vehicle Perform several antilock stops from above 50 K m h 30 mph then repeat step 4 If any diagnostic trouble codes are present proceed to the appropriate test 7 The following conditions should be considered NORMAL operation and no repairs should be attempted to correct them Brake pedal feedback during an ABS stop clicking vibrating Clicking groaning or buzzing at 25 Km h 15 mph or 40 Km h 24 mph drive off self test Groaning noise during an ABS stop Slight brake pedal drop and pop noise when ignition is initially turned on Brake pedal ratcheting down at the end of an ABS stop 8 If the complaint is ABS cycling at the end of a stop at low speeds it may be caused by a marginal wheel speed sensor signal The sensor air gap tone wheel condition and or brakes hanging up are possible causes of this condition 9 After a road test in which no problems were found refer to any Technical Service Bulletins that may apply 5 0 REQUIRED TOOLS AND EQUIPMENT DRBIII diagnostic read out box jumper wires
46. ormation Perform ABS VERIFICATION TEST VER 1 27 BRAKES CAB PUMP CIRCUIT FAILURE Continued APPLICABILITY Turn the ignition off All Disconnect the ABS Pump Motor connector Check connectors Clean repair as necessary Connect 10 gauge 40 amp fused jumper wire between the ABS Pump Fused terminal in the CAB harness connector to the ABS Pump Motor connector RED wired terminal Connect a 10 gauge jumper wire between the ABS Pump Motor connector BLACK wired terminal and ground Did the ABS Pump Motor operate Yes Repair the ABS Pump Motor Fused circuit an open Perform ABS VERIFICATION TEST VER 1 No Repair the ABS Pump Motor Ground circuit for an open Perform ABS VERIFICATION TEST VER 1 28 BRAKES CAB Symptom SYSTEM OVER VOLTAGE When Monitored and Set Condition SYSTEM OVER VOLTAGE When Monitored Ignition on The CAB monitors the Fused circuit at all times for proper system voltage Set Condition Ifthe voltage is above 16 5 volts the Diagnostic Trouble Code DTC is set POSSIBLE CAUSES INTERMITTENT DTC BATTERY CHARGER CONNECTED FUSED IGNITION SWITCH OUTPUT RUN CIRCUIT HIGH DAMAGED CAB CAB HARNESS CONNECTOR CAB GROUND CIRCUIT OPEN CAB INTERNAL FAULT APPLICABILITY Turn the ignition on All With the DRBIII read With the DRBIII erase Turn the ignition off Turn the ignition on Star
47. 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 WARNING EXCEEDING THE LIMITS OF THE DRBIII MULTIMETER IS DANGEROUS CAN EXPOSE YOU TO SERIOUS OR POSSIBLY FATAL INJURY CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS e Follow the vehicle manufacturer s service speci fications at all times Do not use the DRBIII if it has been damaged Do not use the test leads if the insulation 15 damaged or if metal is exposed e To avoid electrical shock do not touch the test leads tips or the circuit being tested e Choose the proper range and functions for the measurement Do not try voltage or current mea surement that may exceed the rated capacity Donot exceed the limits shown in the table below FUNCTION INPUT LIMIT Volts 0 500 peak volts AC 0 500 volts DC Ohms resistance 0 1 12 megohms GENERAL INFORMATION Frequency Measured 0 10 2 Frequency Generated Temperature 58 1100 F 50 600 C Ohms cannot be measured if voltage is present Ohms can be measured only in a non powered circuit Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC e Use caution when measuring voltage above 25v DC 25 Usethe low current shunt to measure circuits up to 10A Use the high c
48. r Technical Service Bulletins that may apply Were any problems found Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete Turn the ignition off Remove and inspect the ABS Pump fuse Is the ABS Pump fuse open Yes GoTo 5 No GoTo 8 Turn the ignition off Visually inspect the ABS Pump Fused circuit in the wiring harness Look for any sign of an intermittent short to ground Is the wiring harness OK Yes GoTo 6 No Repair the ABS Pump Fused B circuit for a short to ground Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Disconnect the CAB harness connector Check connectors Clean repair as necessary Using 12 volt test light connected to 12 volts probe the ABS Pump Fused circuit fuse terminal Does the test light illuminate Yes Repair the ABS Pump Fused B circuit for a short to ground Perform ABS VERIFICATION TEST VER 1 No GoTo 7 26 BRAKES CAB PUMP CIRCUIT FAILURE Continued APPLICABILITY Turn the ignition off All Reconnect the CAB harness connector Using a 12 test light connected to 12 volts probe the ABS Pump Fused circuit fuse terminal Does the test light illuminate Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 Replace theABS Pump fuse the fuse is open make sure to check
49. rcuit for an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Using 12 volt test light connected to ground probe the ABS Pump Fused circuit at the CAB harness connector Did the test light illuminate Yes Replace the Controller Antilock Brake in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the ABS Pump Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 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 Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete BRAKES CAB Symptom CLUSTER LAMP FAILURE aaa N When Monitored and Set Condition CLUSTER LAMP FAILURE When Monitored Key ON After Key ON bulb check Set Condition When the instrument cluster informs the CAB that the cluster cannot turn on the ABS Lamp POSSIBLE CAUSES INSTRUMENT CLUSTER OR ABS DTC PRESENT INSTRUMENT CLUSTER CAB NO DTC SIGNAL TO THE INSTRUMENT CLUSTER CAB PERMANENT FAULT SIGNAL CAB NO KEY ON BULB CHECK SIGNAL APPLICABILITY Turn the ignition on All With the DRBIII read DTCs Are ther
50. roprocessors for correct operation Set Condition If the CAB detects an internal fault the DTC is set POSSIBLE CAUSES INTERMITTENT DTC DAMAGED CAB CAB HARNESS CONNECTOR CAB GROUND CIRCUIT OPEN ABS VALVE FUSED B CIRCUIT OPEN ABS PUMP FUSED B CIRCUIT OPEN CAB INTERNAL FAULT ACTION APPLICABILITY Turn the ignition on All With the DRBIII read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Does the display CAB INTERNAL FAILURE Yes GoTo 2 No GoTo 6 Turn the ignition off Disconnect the CAB harness connector Inspect the CAB CAB harness connector for damage 15 ther any broken bent pushed out corroded or spread terminals Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No GoTo 3 Turn the ignition off Disconnect the CAB harness connector Using a 12 volt test light connected to 12 volts probe the CAB harness connector ground circuits Did the test light illuminate Yes GoTo 4 No Repair the CAB Ground circuit for an open Perform ABS VERIFICATION TEST VER 1 BRAKES CAB CAB INTERNAL FAILURE Continued ACTION APPLICABILITY Turn the ignition off All Usinga 12 volt test light connected to ground probe the ABS Valve used circuit at the CAB harness connector Did the test light illuminate Yes GoTo 5 No Repair the ABS Valve Fused B ci
51. s Enter The tire size and axle selected will be displayed Press Enter to accept these values Programming Successful will be displayed Does the DRBIII display PROGRAMMING SUCCESSFUL Yes Test Complete No Ensure DRBIII software is current and retry on a known good vehicle Communicate with other modules refer to symptom s Perform ABS VERIFICATION TEST VER 1 37 BRAKES CAB Symptom BRAKE LAMP SWITCH INOPERATIVE POSSIBLE CAUSES CHECK BRAKE LAMP SWITCH OUTPUT BRAKE LAMP SWITCH B OPEN BRAKE LAMP SWITCH OPEN BRAKE LAMP SWITCH OUTPUT CIRCUIT SHORT OR OPEN CAB INTERNAL OPEN ACTION APPLICABILITY 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 The Brake Lamp Switch is Perform ABS VERIFICATION TEST VER 1 No GoTo 2 Disconnect the Brake Lamp Switch harness connector Using a 12 volt test light connected to ground check the Brake Lamp Switch Fused B circuit Does the test light illuminate brightly Yes GoTo 3 No Repair the Brake Lamp Switch Fused B circuit an open Perform ABS VERIFICATION TEST VER 1 Information Perform ABS VERIFICATION TEST VER 1 GoTo 4 Disconnect the CAB harness connector Disconnect the Brake Lamp Switch harness connector Check the Brake Lamp Switch Output circuit for a short to voltage and for an open Is the
52. sition is main tained during an antilock stop by being a closed system with the use of 2 accumulators The CAB continues to control pressure in individual hydrau lic Gircuits until a wheel locking tendency is longer present The CAB turns on the pump motor during an antilock stop The antilock brake system 15 constantly monitored by the CAB for proper operation If the CAB detects a system malfunction it can disable the antilock system and turn on the ABS warning indicator If the antilock function is disabled the system will revert to standard base brake system operation The CAB inputs include the following diagnostic communication four wheel speed sensors ignition switch fused B brake switch non volatile The CAB outputs include the following ABS warning indicator actuation ABS pump control eight valve control signals diagnostic communication body controller communication 3 3 3 HYDRAULIC CONTROL UNIT The hydraulic control unit HCU contains the valve block assembly and pump motor assembly TheHCU andthe CAB are mounted as an assembly and are not separately serviceable Valve Block Assembly The valve block assem bly contains valves with four inlet valves and four outlet valves The inlet valves are spring loaded in the open position and the outlet valves are spring loaded in the closed position During an antilock stop these valves are cycled to maintain the proper slip ratio for each wheel If t
53. t the engine With the DRBIII read 5 Does the DRBIII display SYSTEM OVER VOLTAGE Yes GoTo 2 No GoTo 7 15 a battery charger connected to the vehicle Yes Ensure the battery is fully charged Perform ABS VERIFICATION TEST VER 1 No GoTo 3 29 BRAKES CAB SYSTEM OVER VOLTAGE Continued ACTION APPLICABILITY Turn the ignition off Disconnect the CAB connector Note Check connector Clean repair as necessary Start the engine Raise engine speed above 1 800 5 Measure the voltage between Fused Ignition Switch Output RUN circuit and ground 15 the voltage above 16 5 volts Yes Refer to appropriate service information for Charging System testing and repair Perform ABS VERIFICATION TEST VER 1 GoTo 4 Turn the ignition off All Disconnect the CAB connector Note Check connector Clean repair as necessary Inspect the CAB and CAB harness connector for damage 15 there any broken bent pushed out corroded or spread terminals Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No GoTo 5 Turn the ignition off Disconnect the CAB connector Note Check connector Clean repair as necessary Using a 12 volt test light connected to 12 volts probe the Ground circuits Does the test light illuminate Yes GoTo 6 No Repair the Ground circuit an open Perform ABS VERIFICATION TEST VER 1 Turn the ignition off Re
54. uit in the Instrument Cluster This switch does not disable the ABS sys tem Wheel Speed Sensors and Tone Wheels One Wheel Speed Sensor WSS is located at each wheel Each sensor sends a small digital signal to the control module CAB The CAB sends 12 volts to the sensor The sensor has an internal magneto resistance bridge that alters the voltage and amper age of the signal circuit This voltage and amperage is changed by magnetic induction when a toothed sensor ring tone wheel passes by a stationary magnetic sensor wheel speed sensor The CAB measures the voltage and amperage of the digital signals for each wheel The front wheel speed sensor is attached to a boss the steering knuckle tone wheel is integral part of the front axle shaft The rear sensors are mounted to the rear disc adapters The rear tone wheels are pressed on the rear hub The wheel speed sensor air gap is not adjustable Refer to Service Manual for wheel speed sensor air gap specifications The four wheel speed sensors are serviced indi vidually The front tone wheels are serviced as an assembly with the outer joint housing tone wheels are serviced as an assembly GENERAL INFORMATION Correct antilock system operation is dependent on tone wheel speed signals from the wheel speed sensors The vehicle s wheels and tires should all be the same size and type to generate accurate signals In addition the tires should be
55. urrent clamp to measure circuits exceeding 10A e When testing for the presence of voltage or cur rent make sure the meter is functioning cor rectly Take a reading of a known voltage or current before accepting a zero reading e When measuring current connect the meter in series with the load Disconnect the live test lead before disconnecting the common test lead e When using the meter function keep the DRBIII away from spark plug or coil wires to avoid measuring error from outside interference 4 3 WARNINGS 4 3 1 VEHICLE DAMAGE WARNINGS Before disconnecting any control module make sure the ignition is off Failure to do so could damage the module When testing voltage or continuity at any control module use the terminal side not the wire end of the connector Do not probe a wire through the insulation this will damage it and eventually cause it to fail because of corrosion Be careful when performing electrical tests so as to prevent accidental shorting of terminals Such mistakes can damage fuses or components Also a second code could be set making diagnosis of the original problem more difficult 4 3 2 ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition GENERAL INFORMATION WARNING BEFORE ROAD TESTING A VEHICLE BE SURE THAT

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